FOREWORD/INDEX 【0-0】
FOREWORD/INDEX DINLI 270 cc QUAD Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Dinli Metal Industrial Co., Ltd.. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.
FOREWORD/INDEX Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area.
FOREWORD/INDEX △WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.
FOREWORD/INDEX CHAPTER INDEX CHAPTER1 GENERAL CHAPTER2 WHEELS/TIRES CHAPTER3 BRAKE CHAPTER4 SUSPENSION CHAPTER5 FRAME CHAPTER6 ENGINE CHAPTER7 ELECTRICAL CHAPTER8 APPENDIX 【0-4】
FOREWORD/INDEX 【0-5】
GENERAL INFORMATION GENERAL INFORMATION Table of Contents Before Servicing------------------------------------------------------------------------------------------------1-2 Model Identifications----------------------------------------------------------------------------------------- 1-5 General Specifications-----------------------------------------------------------------------------------------1-6 Periodic Maintenance Chart---------------------------------------------------------------------------------
GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a quad, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.
GENERAL INFORMATION (7) Edges Watch for sharp edges, as they could cause injury through careless handing, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over. (8) High-Flash Point Solvent A high-Flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent.
GENERAL INFORMATION (15) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubrication film. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubrication quality and may contain forging particles that act as abrasives; therefore, make sure to wipe it off and apply fresh grease or oil.
GENERAL INFORMATION Model Identification Engine serial number Vehicle identification number ENGINE SERIAL NUMBER (Ex. 13G6500xxx) VEHICLE IDENTIFICATION (ex. RKWAJ74C45Txxxxxx) Whenever corresponding with Dinli about a particular issues, the engine number and serial number are important for vehicle identification.
GENERAL INFORMATION General Specification NOTE: Specifications subject to change without notice. Model DL-801 Engine 4-stroke, DOHC Bore and stroke ψ72.7 x 63.0 mm Compression ratio 12.0 Displacement 261.
GENERAL INFORMATION CHASSIS Frame Steel Overall length 1682 mm Overall width 1060 mm Overall height 1082 mm Seat height 810 mm Wheel base 1176 mm Front tire 21 x 7 – 10 Rear tire 20 x 11 – 9 Recommended cold tire pressure (front/rear) 30kpa/ 30kpa Turning radius (Inner Radius of Tire) 1650 Fuse 15A Loading limit (Incl. rider, cargo, etc….
GENERAL INFORMATION Periodic Maintenance Chart Perform a Pre-Ride inspection before every ride and at schedule maintenance periods. C=Clean R=Replace L=Lubricate I=Inspect, Verify, Clean, Adjust, Lubricate, Replace if necessary.
WHEELS/TIRES Wheels/Tires Table of Contents Specifications---------------------------------------------------------------------------------------------------2-2 Wheel Alignment-----------------------------------------------------------------------------------------------2-3 Steering Centering Inspection----------------------------------------------------------------------------2-3 Steering Centering Adjustment--------------------------------------------------------------------------2-3 Toe-in Inspection---
WHEELS/TIRES Specifications Item Standard Service Limit Wheel Alignment: Toe-in 2WD 25~40 mm --- Tires: Standard tire: Front AT 21×7-10 Rear MAXXIS M-971-1, Tubeless AT 20×11-9 38N --- MAXXIS M-972-2, Tubeless 35 kPa (0.35 kgf/cm2,5.0psi) 35 kPa (0.35 kgf/cm2,5.0psi) ----- 250 kPa (2.
WHEELS/TIRES Wheel Alignment Toe-in is the amount that the front wheels are closer together in front than at the rear at the axle height. When there is toe-in, the distance A (Rear) is the greater than B (Front) as shown. The purpose of toe-in is to prevent the front wheels from getting out of parallel at any time, and to prevent any slipping or scuffing action between the tires and the ground, if ton-in is incorrect, the front wheels will be dragged along the ground, scuffing and wearing the tread knobs.
WHEELS/TIRES ●Repeat the straightedge procedure on the other side of the vehicle, now the front wheels are parallel to each other and to the center line of the vehicle. ●Go on to the Toe-in Inspection procedure. Toe-in Inspection ●Support the vehicle on a stand or the jack so that the front wheels are off the ground. ●Apply a heavy coat of the chalk near the center of the front tires. ●Using a needle nose scriber, mark a thin mark near the center of the chalk coating while turning the wheel.
WHEELS/TIRES ●Check the toe-in. ●Tighten: Torque - Tie-Rod Adjusting Sleeve Locknuts: 33 N-m (3.4 kgf-m, 45 ft-lb) ●Test ride the vehicle. Wheels (Rims) Wheel Removal ●Loosen the wheel nuts [A] ●Support the vehicle on a stand or the jack so that the wheels are off the ground. ●Take off the wheel nuts and remove the wheel. Wheel Installation ●Check the tire rotation mark [A] on the tire, and install the wheel accordingly. NOTE ○The direction of the tire rotation is shown by an arrow on the tire sidewall.
WHEELS/TIRES Wheel (Rim) Inspection ●Examine both sides of the rim for dents [A]. If the rim is dented, replace it. ●If the tire is removed, inspect the air sealing surfaces [A] of the rim for scratches or nicks. Smooth the sealing surfaces with fine emery cloth if necessary Wheel (Rim) Replacement ●Remove the wheel (see Wheel Removal) ●Disassemble the tire from the rim (see Tire Removal). ○Remove the air valve and discard it. CAUTION Replace the air valve whenever the tire is replaced.
WHEELS/TIRES CAUTION Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the tire. ●Remove the tire from the rim using a suitable commercially available tire changer. NOTE ○The tires cannot be removed with hand tools because they fit the rims tightly. Tire Installation ●Inspect the rim (see Wheel (Rim) Inspection). ●Replace the air valve with a new one. CAUTION Replace the air with whenever the tire is replaced. Do not reuse the air valve.
WHEELS/TIRES ●Support the wheel rim [A] on a suitable stand [B] to prevent the tire from slipping off. ●Inflate the tire until the tire beads seat on the rim. Maximum Tire Air Pressure ( to seat beads when cold ) Front and Rear: 250kpa (2.5 kgf-cm2, 36 psi ) △WARNING Do not inflate the tire to more than the maximum tire air pressure. Over inflation can explode the tire with possibility of injury and loss of line.
WHEELS/TIRES Front Hub Removal ●Remove the cotter pin [A] and loosen the axle nut [B]. ●Remove the wheel (see Wheel Removal). ●Remove the caliper by taking off the mounting bolts [C], and let the caliper hang free. ●Remove the axle nut and pull off the front hub brake disc. ●Separate the brake disc from the front hub. Front Hub Installation ●Grease:: Seal Front Spindle ●Tighten: Torque - Front Spindle Nut: 145 N-m (15.
WHEELS/TIRES Rear Hub Rear Hub Installation ●Grease the axle spindle. ●Apply non-permanent locking agent: Rear Axle Nuts [A] ●Tighten: Torque - Rear Axle Nut: 265 N-m (27.0 kgf-m, 195ft-lb) ●Insert a new cotter pin [B] and bend it over the nut. Rear Hub Disassembly/Assembly ●Do not press the hub bolts [A] out. ★If any hub bolt is damaged, replace the hub [B] and bolts as a nut.
BRAKE Brake Table of Contents Brake Fluid-----------------------------------------------------------------------------------------------------3-2 Brake Fluid Recommendation-------------------------------------------------------------------------3-2 Brake Fluid Level Inspection--------------------------------------------------------------------------3-3 Brake Fluid Change-------------------------------------------------------------------------------------3-3 Brake Line Air Breeding--------------------------
BRAKE Brake Fluid △WARNING When working with the disc brake, observe the precautions listed below. 1.Never reuse old brake fluid. 2.Do not use fluid from a container that has been left unsealed or that has or that has been open for a long time. 3.Do not mix two types and brand of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake parts to deteriorate. 4.
BRAKE Brake Fluid Level Inspection ●Position the reservoir horizontal, and check that the fluid level in the reservoir is higher than the lower level line. ★If the fluid level is lower than the lower level line, check for fluid leakage of the brake line, and add the fluid as follow. ○Removal the reservoir cap, and fill the reservoir to the upper level line [A] in the reservoir with the same type and brand of the fluid that is already in the reservoir. And then install the reservoir cap.
BRAKE △WARNING Do not mix two brand of fluid. Change the brake fluid in the brake line completely if the fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified. ●Tighten: Torque - Bleed Valve: 5.4 N-m (0.55 kg-m, 48 in-lb) ●Apply the brake lever forcefully for a few second, and check for fluid leakage around the fittings.
BRAKE NOTE ○If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line. ○If the brake level action still feels soft or "spongy", tap the brake hose from bottom to top and air will rise up to part of the hose. Slowly pump the brake level in the same manner as above. ●Tighten: Torque - Bleed Valves: 5.4 N-m (0.
BRAKE △WARNING Do not attempt to drive the vehicle until a full brake level is obtained by pumping the brake level until the pads are against each dis. The brakes will not function on the first application of the level if this is not done. Caliper Removal ●Removal the front wheel (see Wheels/Tires chapter). ●Loose the banjo bolt [A] at the brake hose lower end, and tighten it loosely. ●Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.
BRAKE Brake Pad Removal ●Remove the front wheel (see Wheels/Tires chapter). ●Remove the caliper (see Caliper Removal) ●Push the anti-rattle spring [A], remove the pads [B] [C]. Brake Pad Installation ●Push the caliper piston in by hand as far as it will go. ●Be sure that the anti-rattle spring is in place. ●Install the pads ●Tighten: Torque - Pad Mounting Bolts:18N-m(1.8kg-m,13.
BRAKE Disc Cleaning Poor braking can be caused by oil on a disc. Oil on a disc must be cleaned off with an oil cleaning fluid such as trichloroethylene or acetone. △WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods. Be sure to heed the fluid manufacturer's warnings.
BRAKE Disc Runout ●Jack up the vehicle so that the wheels are off the ground. ●Remove the front wheels and turn the handlebar fully to one side. ●Set up a dial gauge against the disc [A], and measure the disc runout. ★ If the runout exceeds the service limit, replace the disc. Disc Runout Standard: TIR 0.2 mm or less Service Limit: TIR 0.3 mm Brake Hose Inspection ●The high pressure inside the brake line can cause fluid to leak or the hose to burst if the line is not properly maintained.
BRAKE Brake Pedal Position Inspection ●Check that the brake pedal [A] is in the correct position as shown. [B] step Pedal Position [C] Standard: 49.8 ~ 54.8 mm above footrest ★ If it is correct, adjust the brake pedal position. Brake Pedal Position Adjustment ●Remove the brake pedal (see Brake Pedal Removal). ●Loosen the nut [A], and turn the bracket [B] until pedal is correctly positioned. ●Tighten the nut [A]. ●Check the brake pedal free play (see Brake Pedal Free Play Inspection).
BRAKE Caliper Removal ●Removal the Rear wheel (see Wheels/Tires chapter). ●Loose the banjo bolt [A] at the brake hose lower end, and tighten it loosely. ●Unscrew the caliper mounting bolts [B], and detach the caliper from the disc. ●Unscrew the banjo bolt and remove the brake hose from the caliper. CAUTION Immediately wash away any brake fluid that spills.
BRAKE Rear Brake Pads Removal ●Remove the caliper (see Caliper Removal) ●Remove the Cir-clip [A] and bolt [B] ●Remove: Anti-rattle Spring [C] Brake Pads [D] Brake Pad Installation ●Check the lining thickness (see Brake Pad Wear Inspection). ●Push the caliper piston in by hand as far as it will go. ●Be sure that the anti-rattle spring is in place. ●Install the pads. ○Be careful not mix it up inboard pads with the out board pad. ●Tighten: Torque - Pad Mounting Bolts:18N-m(1.8kg.m,13.0ft.
BRAKE Master Cylinder Removal ●Remove the master cylinder joint [A] and the banjo bolt [B] at the brake hose lower end, and tighten it loosely. ●Remove the brake hose [C]. ●Loose the master cylinder mounting bolts [D]. CAUTION Brake fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately. ●Remove: Fastener [A] Hose [B] Reservoir [C] Master Cylinder Installation ●Use a new flat washer on each side of the brake hose fitting, and tighten the banjo bolt.
BRAKE Brake Disc Removal ●Remove the rear caliper, unscrew the banjo bolt and remove the brake hose from the caliper. ●Loose the brake disc mounting bolts [A] and nut [B]. ●Support the vehicle. ●Remove the rear wheel (see Wheel Removal). ●Remove the disc. Brake Disc Installation ●The disc must be installed with the marked side [A] facing toward the steering knuckle. ●Tighten: Non-permanent Locking Agent - Disc Mounting Bolts Torque - Disc Mounting Bolts:37N-m(3.
SUSPENSION/STEERING Suspension & Steering Table of Contents Shock Absorbers------------------------------------------------------------------------------------------------4-2 Front Shock Absorber Removal------------------------------------------------------------------------4-2 Front Shock Absorber Installation---------------------------------------------------------------------4-2 Front Shock Absorber Inspection----------------------------------------------------------------------4-2 Front Shock Absorber
SUSPENSION/STEERING Front Shock Absorber Removal ●While supporting the vehicle to up with the jack. ●Remove: Front Shock Absorber Mounting Bolt and Nut [A] Front Shock Absorber [B] Front Shock Absorber Installation ●Insert the shock absorber into the bracket [C]. ●Tighten: Torque - Mounting Bolts and Nuts: 47 N-m (4.8 kgf-m, 35 ft-lb) ●While supporting the vehicle to down with the jack.
SUSPENSION/STEERING Rear Shock Absorber Preload Adjustment ●See the Front Shock Absorber Preload Adjustment Suspension Arm Removal ●Remove: Front Wheel (see Wheels/Tires chapter) Front Hub (see Wheels/Tires chapter) Cotter Pin, Nut and Bolt [A] Tie-Rod End [B] Front Shock Absorber Mounting Bolts [C] Suspension Arm Pivot Bolts [D] Suspension Arm Installation ●Tighten: Torque – Suspension Arm Pivot Bolts: 88 N-m (9.0 kgf-m, 65 ft-lb) Steering Knuckle Joint Nut: 42 N-m (4.
SUSPENSION/STEERING Suspension Arm Assembly ●When installing the rubber bushing into the arm, lubricate the outer surface of the bushings with a soap and water solution. CAUTION Do not lubricate the rubber bushings with engine oil or petroleum distillates because they will deteriorate the rubbers. ●Position the bushings in the suspension arm as shown using a suitable bearing driver in the bearing driver set.
SUSPENSION/STEERING Steering Stem Removal ●Remove: Speedometer Bracket Bolts [A] Speedometer Bracket [B] Handlebar Holder Bolts [C] Handlebar [D] Front Cover (see Frame Chapter) ●Remove: Steering Clamp Bolts [A] Steering Clamp Support Plate [B] Steering Clamp [C] Tie-Rod End Nuts [D] Steering Stem Cotter Pin [E] and Nut [F] Washer [G] CAUTION Do not loosen the locknut at the ends of the tie-rod adjusting sleeve, or the toe-in of the front wheels will be changed. ●Pull the steering stem out of the frame.
SUSPENSION/STEERING Steering Stem Installation ●Lubricate the steering stem clamp, grease seals, (see Steering Lubrication). ●Install the grease seals [A] facing the end [B] rearward to prevent the entry of dirt. ●Install the steering stem clamps on both grease seals fit into the groves on the steering stem clamps [C]. ●Tighten: Torque – Bottom End Nut: 29 N-m (3.0 kgf-m, 22 ft-lb) Bearing Housing Bolts: 20 N-m (2.0 kgf-m, 14.5 ft-lb) Clamp Allen Bolts: 25 N-m (2.5 kgf-m, 18.
SUSPENSION/STEERING Steering Knuckle Installation ●Clean the sealing surface [A] and the hole [B]. ●Grease the sealing surface. ●Tighten: Torque – Suspension Arm Pivot Bolts: 88 N-m (9.0 kgf-m, 65 ft-lb) Steering Knuckle Joint Nut: 42 N-m (4.3 kgf-m, 35 ft-lb) Front Shock Absorber Clamp Nut: 52 N-m (5.3 kgf-m, 38 ft-.lb) Tie-Rod End Nut: 47 N-m (4.8 kgf-m, 35 ft-lb) Tie-Rod Removal ●Remove: Tie-Rod End Nuts [A] Tie-Rod [B] CAUTION When removing the tie-rod, be careful not to bend it.
SUSPENSION/STEERING CAUTION Do not remove the grease seal. It is packed with grease. Tie-Rod End Installation ●Install the tie-rod ends so that the tie-rod has the correct length [A], and the both visible thread length [B] make equal. Tie-Rod Length Standard: 385 mm ●Tighten: Torque – Tie-Rod adjusting Sleeve Locknut: 27 N-m (2.8 kgf-m, 20 ft-lb) Steering Inspection ●Turn the handlebar left and right, and check the steering action.
SUSPENSION/STEERING Steering Lubrication ●Lubricate the steering stem clamps. ○Remove the steering stem (see Steering Stem Removal). ○Wipe all the old grease off the steering stem, and clamps, and out of the grease seals. ○Apply grease to the steering stem [A], grease seal lips and mating surface [B] of the clamp, and pack the grooves [C] in the clamp with grease. Steering Stem Clamp Inspection ●Inspect the steering stem clamps [A]. ★ If roughness, excessive play, or seizure is found, replace both clamps.
SUSPENSION/STEERING Handlebar Removal ●Remove: Throttle Switch (see Steering Stem Removal) Front Brake Master Cylinder Left-hand Switch Housing Handlebar Cover Screw Handlebar Cover ●Remove: Handlebar Holder Bolts [A] Handlebar Holders [B] Handlebar [C] Handlebar Installation ●Install the handlebar so that the angle of the handlebar matches the angle of the steering stem as shown. ●Tighten the holder rear bolts first [A] and then the front bolts [B]. Torque – Handlebar Holder Bolts: 27 N-m (2.
FRAME Frame Table of Contents Seat---------------------------------------------------------------------------------------------------------------5-2 Seat Removal-----------------------------------------------------------------------------------------------5-2 Seat Installation--------------------------------------------------------------------------------------------5-2 Front and Rear Fenders----------------------------------------------------------------------------------------5-3 Front Cover Removal-----
FRAME Seat Seat Removal ● To remove the seat [A] by pulling the seat latch lever [B] up and then pulling the seat up to the rear. Seat Installation ● Slip the seat hook [A] under the brace [B] on the frame, and put the stoppers [C] into the holes on the frame. ● Push down the rear parts of the seat until the lock clicks.
FRAME Front and Rear Fenders Front Fender Removal ● Remove: Handlebar Cover [A] (see Handlebar Removal) Handlebar [B] Fuel Tank Cap ● Remove: Front Fender Screws [A]*2 Front Fender Bolts [B]*2 [C]*6 Front Fender Front Fender Installation ● Please reverse the Removal steps to install.
FRAME Rear Fender Removal ● Remove: Air Cleaner Cover [A] Air Cleaner [B] ● Remove: Battery [A] CDI Unit [B] Fuse [C] Starter Relay [D] Rear Fender Bolts [E] Rear Fender Bracket [F] Rear Fender Rear Fender Installation ● Please reverse the Removal steps to install.
FRAME Radiator Removal ● Remove: Water Tube [A], [B] and [C] Connector [D] Fan Connector Radiator Bolts [E] *2 Radiator ● Remove: Radiator Cover Bolts [A]*4 Radiator Protector [B] Radiator Installation ● Please reverse the Removal steps to install.
FRAME Headlight Holder Removal ● Remove: Handlebar (see Handlebar Removal) Front Fender (see Front Fender Removal) Headlight Holder Screw [A] Headlight Bolts and Screw [B] Headlight Holder 【5-6】
ENGINE Engine Table of Contents ENGINE REMOVAL-----------------------------------------------------------------------------------------6-2 CYLINDER HEAD/VALVES-------------------------------------------------------------------------------6-6 SERVICE INFORMATION----------------------------------------------------------------------------6-6 CYLINDER HEAD COVER---------------------------------------------------------------------------6-7 CAMSHAFT/CAMSHAFT HOLDER------------------------------------------------
ENGINE ENGINE REMOVAL ● ● ● ● Drain engine oil and transmission oil. Remove frame covers (Refer to the “Frame” chapter). Remove the carburetor. Remove the Exhaust Pipe. Torque Value: Engine Oil Drain Plug Exhaust Pipe Nut 1.5kgf-m 1.8 – 2.2kgf-m ● Disconnect the water hose from water pump cover. ● Remove the bolt at the thermostat and disconnect the thermo sensor wire, then disconnect the thermostat from the cylinder head.
ENGINE ● Disconnect the speedometer cable. ● Remove the three bolts at the drive sprocket cover and then remove the drive sprocket cover. ● Remove the two bolts on the drive sprocket. ● Remove the drive sprocket and washer. ● Slide the rubber sleeve back to expose the starter motor wire nut. ● Remove the starter motor wire nut for disconnect the starter motor wire.
ENGINE Remove the A.C.Generator, pulser and gear change switch couplers. ● Disconnect the spark plug cap. ● Unscrew the clamp and then disconnect the outlet hose from the left crankcase cover. ● Unscrew the clamp and then disconnect the inlet hose from the left crankcase cover. ● Remove the left foot step and the left foot holder (refer to “Frame” chapter). ● Remove the drive select lever.
ENGINE ● Remove the three bolts and nuts for remove the left and right engine brackets. ● Remove the engine assembly to the left side of the machine.
ENGINE CYLINDER HEAD COVER REMOVAL ● Remove the four bolts at the cylinder head cover and then remove the cylinder head cover. INSTALLATION ● Install a new cylinder head cover O-ring and install the cylinder head cover. ● Install and tighten the cylinder head cover bolts. Torque: 0.8_ 1.2kgf-m NOTE: Be sure to install the O-ring into the groove properly. CAMSHAFT/CAMSHAFT HOLDER REMOVAL ● Remove the cylinder head cover.
ENGINE ● Remove the four camshaft holder nuts and washers. NOTE: Diagonally loosen the cylinder head nuts in 2 or 3 times. ● Remove the camshaft holder and dowel pins. ● Remove the camshaft gear from the cam chain and remove the camshaft. CAMSHAFT HOLDER DISASSEMBLY ● Take out the valve rocker arm shafts. ● Remove the valve rocker arms and arm shafts. Torque Valves Adjuster Nut 1.4 – 1.
ENGINE CAMSHAFT HOLDER INSPECTION ● Inspect the camshaft holder for wear or damage. ● Inspect the rocker arm shaft for blue discoloration or grooves. ● If any defects are found, replace the rocker arm shaft with a new one and then inspect lubrication system. ● Inspect the rocker arm bore, cam lobe contact surface and adjuster surface for wear/pitting/scratches/blue discoloration. If any defects are found, replace the rocker arm shaft with a new one and then inspect the lubrication system.
ENGINE CYLINDER HEAD REMOVE ● Remove the camshaft. (Refer to the “Camshaft Remove” section ) ● Remove the carburetor and exhaust muffler.. ● Remove the two bolts and then remove the carburetor intake manifold as show. ● Remove the clip to disconnect the thermostat (Remember to drain the water in the hoses first) ● Remove the bolt to disconnect the thermostat. ● Remove the two cylinder head bolts. ● Remove the cylinder head.
ENGINE VALVE /VALVE GUIDE INSPECTION ● Inspect each valve for bending, burning, scratches or abnormal stem wear. If any defects are found, replace the valve with a new one. Check valve movement in the guide. ● Measure each valve stem O.D. ● Measure each valve guide I.D. ● Subtract each valve stem O.D. from the corresponding guide I.D. to obtain the stem-to-guide clearance. Service limits: IN : 5.420mm replace if over EX: 5.
ENGINE ASSEMBLY ● Install the valve spring seats and oil seal. NOTE: Be sure to install new oil seal. ● Lubricate each valve with engine oil and insert the valves into the valve guides. ● Install the valve springs and retainers. ● Compress the valve springs using the valve spring compressor, then install the valve cotters. NOTE: When assembling, a valve spring compressor must be used. Install the cotters with the pointed ends facing down from the upper side of the cylinder head.
ENGINE CYLINDER/PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder and piston can be serviced with the engine installed in the frame. After disassembly, clean the removed parts and dry them with compressed air before inspection. SPECIFICATIONS Cylinder Piston, piston ring I.D. Warpage Cylindricity True roundness Ring-to-groove clearance Ring end gap Top Second Top Second Oil ring Piston O.D. Piston O.D. measuring position Piston-to-cylinder clearance Piston pin hold I.D. Piston pin O.D.
ENGINE CYLINDER/PISTON REMOVAL ● Remove the cylinder head. (Refer to “Cylinder Head/Valves”) ● Remove the two dowel pins, cylinder head gasket and cam chain guide. ● Disconnect the water hose. ● Remove the cylinder ● Remove the cylinder gasket and dowel pins. ● Clean any gasket material from the cylinder surface. NOTE: Be careful not to drop foreign matters into the crankcase. ● Remove the piston pin clip. NOTE: Be careful to keep the piston pin clip from falling into the crankcase.
ENGINE INSPECTION ● Inspect the piston, piston pin and piston rings. ● Remove the piston rings. NOTE: Take care not to damage or break the piston rings during removal. ● Clean carbon deposits from the piston ring grooves. ● Inspect the piston wall for wear/scratches/damage. If any defects are found, replace the piston with a new one. Install the piston rings onto the piston and measure the piston ring-to-groove clearance. Service Limits: Top: 0.09mm replace if over 2nd: 0.
ENGINE ● Measure the piston pin O.D. Service Limit: ψ17.06mm replace if below ● Measure the piston O.D. NOTE: Take measurement at 10mm from the bottom and 90 to the piston pin hole. Service Limit: ψ72.60mm replace if below ● Measure the piston-to-piston pin clearance. Service Limit: 0.025mm replace if over CYLINDER INSPECTION ● Inspect the cylinder bore for wear or damage. ● Measure the cylinder I.D. at three levels of top, middle and bottom at 90° to the piston pin (in both X and Y directions).
ENGINE PISTON RING INSTALLATION ● Install the piston rings onto the piston. ● Apply engine oil to each piston ring. NOTE: Be careful not to damage or break the piston and piston rings. All rings should be installed with the markings facing up. After installing the rings, they should rotate freely without sticking. ● Measure the connecting rod small end I.D. Service Limit: ψ17.05mm replace if over ● Measure the connecting rod to piston pin clearance. Service Limit: 0.
ENGINE PISTON INSTALLATION ● Remove any gasket material from the crankcase surface. NOTE: Be careful not to drop foreign matters into the crankcase. ● Install the piston, piston pin and a new piston pin clip. NOTE: Position the piston “IN” mark on the intake valve side. Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase. CYLINDER INSTALLATION ● Install the dowel pins and a new cylinder gasket on the crankcase.
ENGINE DRIVE AND DRIVEN PULLEYS SERVICE INFORMATION GENERAL INSTRUCTIONS The drive pulley, clutch and driven pulley can be serviced with the engine installed in the frame. Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley. SPECIFICATIONS Item Movable drive face bushing I.D. Drive face collar O.D. Drive belt width Clutch lining thickness Clutch outer I.D. Driven face spring free length Weight roller O.
ENGINE LEFT CRANKCASE COVER REMOVAL ● Loosen the drive belt air inlet and outlet hose band screws and disconnect them from the left crankcase cover. ● Remove the left crankcase cover bolts and left crankcase cover. ● Remove the gasket and dowel pins. INSPECTION ● Inspect the bearing for allow play in the left crankcase cover or the bearing turns roughly – Replace. INSTALLATION ● Install the dowel pins and new gasket. ● Reverse the “LEFT CRANKCASE COVER REMOVAL” procedures.
ENGINE DRIVE PULLEY REMOVAL ● Remove the left crankcase cover. (Refer to the “LEFT CRANKCASE COVER REMOVAL” section) ● Hold the drive pulley using a universal holder and remove the drive face nut and washer. ● Remove the drive pulley. ● Remove the movable drive face assembly and drive pulley collar. DISASSEMBLY ● Remove the ramp plate. ● Remove the six weight rollers. INSPECTION ● Check each weight roller for wear or damage. ● Measure each weight roller O.D. Service Limit: ψ22mm replace if below.
ENGINE ● Measure the movable drive face bushing I.D. Service Limit: ψ27.06mm replace if over ASSEMBLY ● Install the weight rollers into the movable drive face. ● Install the ramp plate. ● Check the drive pulley collar for wear or damage. ● Measure the O.D. of the drive pulley collar sliding surface. Service Limit: ψ26.94mm replace if below INSTALLATION ● Install the drive pulley face assembly and collar. ● Reverse the Removal procedure to install the drive pulley, wash and nut.
ENGINE CLUTCH/DRIVEN PULLEY REMOVAL ● Remove the left crankcase cover. (Refer to “LEFT CRANKCASE COVER REMOVAL”) ● Remove the drive pulley. (Refer to “DRIVE PULLEY REMOVAL” ) ● Remove the o-ring, nut, washer and clutch outer. ● Remove the clutch/driven pulley and drive belt. SUGGESTION: If the clutch/driven pulley is damaged, please replace the whole clutch/driven Assy. to make sure the engine functioning well.
ENGINE FINAL REDUCTION/TRANSMISSION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS The transmission system can be serviced with the engine installed in the frame. When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. SPECIFICATIONS Specified Oil: GEAR OIL SAE ??# Oil Capacity: At change : At disassembly : 0.8 liter 0.78 liter TORQUE VALUES Transmission case cover bolt M8 x 1.25 2.6 – 3.2kgf-m M6 x 1.25 1.0 – 1.
ENGINE TRANSMISSION CASE COVER REMOVAL ● Drain transmission gear oil into a clean container.(Refer to “Engine Removal” section) ● Remove drive sprocket cover and drive sprocket. (Refer to “Engine Removal” section) ● Remove the drive select lever. (Refer to “Engine Removal” section) ● Remove the transmission case cover attaching bolts. ● Remove the transmission case cover, dowel pins and gasket. ● Inspect the bearings for allow play in the transmission case cover or the bearings turn roughly.
ENGINE TRANSMISSION CASE COVER DISASSEMBLY ● Remove the drive axle cir-clip. ● Remove the drive axle from the transmission case cover. ● Remove the bearing. ● Inspect the bearing for allow play in the transmission case cover or the bearing turns roughly. If any defects are found, replace the bearing with a new one. ● Inspect the drive axle gear teeth for wear or damage. ● Remove the bearing to expose the oil seal. ● Inspect the oil seal for wear or damage.
ENGINE ● Inspect the needle bearing for allow play in the transmission case cover or the bearing turns roughly. If any defects are found, replace the bearing with a new one. ASSEMBLY ● Install the needle bearing. ● Install the oil seal and bearing. ● Install the bearing cir-clip. ● Install the drive axle and drive axle cir-clip. TRANSMISSION REMOVAL ● Remove the transmission cover. (Refer to “TRANSMISSION CASE COVER REMOVAL”) ● Check the transmission operation. Unsmooth operation – Repair.
ENGINE ● Remove the stopper plug. ● Remove spring, washer and shift cam stopper. ● Remove the transmission guide bar. ● Measure the guide bar runout. Out of specification – Replace. NOTE: Do not attempt to straighten a bent guide bar. ● Remove shift cam. ● Check the shift cam groove and shift cam gear. Wear or damage – Replace. ● Remove the shift fork. ● Inspect the shift fork cam. Scoring/beads/wear – Replace.
ENGINE ● Inspect shift shaft gear. Damage – Replace. ● Inspect shift shaft. Damage/bends/wear – Replace. ● Remove the main axle. MAIN AXLE DISASSEMBLY ● Remove the washers, collar, primary driven gear and clutch dog.
ENGINE ● Remove the cir-clip and then remove the washers, reverse wheel gear and needle bearing. ● Inspect the gear teeth. Blue discoloration/pitting/wear – Replace. ● Inspect the mated dogs. Rounded edges/cracks/missing portions – Replace. ● Remove the counter axle. ● Inspect the gear teeth. Blue discoloration/pitting/wear – Replace.
ENGINE PRIMARY DRIVE AXLE REMOVAL ● Remove the clutch/driven pulley. (Refer to “DRIVE AND DRIVEN PULLEYS”) ● Remove the oil seal and cir-clip. ● Remove the primary drive axle. ● Inspect the bearings for allow play in the transmission case cover or the bearing turns roughly. If any defects are found, replace the bearing with a new one.
ENGINE CRANKCASE/CRANKSHAFT/BALANCE SHAFT SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. The following parts must be removed before separating the crankcase. Cylinder head/Cylinder/piston/Drive and driven pulleys /A.C.
ENGINE CRANKCASE/CRANKSHAFT/BALANCE SHAFT REMOVAL ● Remove the timing chain from right crankcase. ● Remove the left and right crankcase attaching bolts. ● Remove the right crankcase.. NOTE: Do not damage the crankcase gasket surface. ● Remove the gasket and dowel pins. ● Remove the crankshaft from the left crankcase.
ENGINE ● Remove balance shaft from the left crankcase. ● Clean off all gasket material from the crankcase mating surfaces. NOTE: Avoid damaging the crankcase mating surfaces. ● Inspect the balance shaft gear teeth. Burrs/chips/roughness/wear – Replace. CRANKSHAFT INSPECTION ● Inspect the crankshaft gear teeth. Burrs/chips/roughness/wear _ Replace. ● Measure the connecting rod small end I.D. Service Limit: ψ17.
ENGINE ● Measure the crankshaft run out (A). Service Limit: 0.10mm replace if over ● Measure the connecting rod big end side clearance (B). Service Limit: 0.6mm replace if over ● Measure the connecting rod big end radial clearance (C). Out of specification (0.05 mm) – Replace the crankshaft. ● Turn the crankshaft bearings and check for excessive play. ● Measure the crankshaft bearing play.
ELECTRICAL SYSTEM Electrical System Table of Contents Specifications---------------------------------------------------------------------------------------------------7-2 Parts Location---------------------------------------------------------------------------------------------------7-3 Precautions------------------------------------------------------------------------------------------------------7-5 Electrical Wiring-----------------------------------------------------------------------------------------
ELECTRICAL SYSTEM Specifications Item Standard Battery Capacity 12V ; 12Ah (10hr) Alternator type CDI Charging voltage (Regulator/rectifier output) 14.5V ± 0.5V Alternator output voltage 244V Stator Resistance 0.3 – 1.0Ω 110Ω ± 15% 1.5 – 3.5Ω 12 – 21Ω 0.6 – 0.7 mm 12V ; 0.
ELECTRICAL SYSTEM Parts Location Light/Dimmer Switch [A] Switch [B] Indicator Switch [C] Starter Button [D] Ignition Switch [E] Horn Switch [F] Battery [A] CDI Unit [B] Fuse [C] Starter Circuit Relay [D] Indicator Relay [A] Flasher Relay [B] Ignition Coil [C] Spark Plug [D] 【7-3】
ELECTRICAL SYSTEM Regulator/Rectifier [E] Magneto CP [A] Starter Motor [B] Horn [B] Temperature Sensor[C] 【7-4】
ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. ○ Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. ○ Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests.
ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection ● Visually inspect the wiring for signs of burning, fraying, etc. ★ If any wiring is poor, replace the damaged wiring. ● Pull each connector [A] apart and inspect it for corrosion, dirt, and damage. ★ If the connector is corroded or dirty, clean it carefully. If it is damaged, replace it. ● Check the wiring for continuity. ○ Use the wiring diagram to find the ends of the lead which is suspected of being a problem.
ELECTRICAL SYSTEM Battery Battery Charging △WARNING Keep the battery away from sparks and open flames during charging, since the battery gives off an explosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger. This procedure prevents sparks at the battery terminals, which could ignite any battery gases. The battery is a maintenance-free design and construction. Use of conventional lead-acid batteries is not recommended.
ELECTRICAL SYSTEM Charging Procedure ● Remove the battery (see Battery Removal). ● Connect a charger to the battery BEFORE plugging it in or turning it on. ● Set the charging rate and time according to the battery condition previously determined CAUTION Always remove the battery from the vehicle for charging. Do not use a high rate battery charger, as is typically employed at automotive service stations, unless the charger rate can be reduced to the level required.
ELECTRICAL SYSTEM Regulator / Rectifier Output Voltage Inspection ● Check the battery condition (see Battery section) ● Warm up the engine to obtain actual alternator operating conditions. ● Check that the ignition switch is turned off, and connect the hand tester to the battery terminal. ● Start the engine, and note the voltage readings at various engines speeds with the headlight turned on and then turned off.
ELECTRICAL SYSTEM Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic field, or just by again, will result in low output. ● To check the alternator output voltage, do the following procedures.
ELECTRICAL SYSTEM Ignition System △WARNING The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil, or spark plug lead while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent CDI unit damage. Do not install the battery backwards. The negative side is grounded.
ELECTRICAL SYSTEM Ignition Coil Installation ● Connect the primary winding leads to the ignition coil terminals Ignition Coil Inspection ● Remove the ignition coil. ● Measure the primary winding resistance as follows: ○ Connect the tester between the coil terminals. ○ Set the tester to the × 1Ω range, and read the tester. ● Measure the secondary winding resistance as follows: ○ Remove the plug cap by turning it counterclockwise. ○ Connect the tester between the spark plug lead and terminal.
ELECTRICAL SYSTEM Ignition Timing Test ● Remove the plug to expose the timing hole [A]. ● Attach the timing light and a tachometer in the manner prescribed by the manufacturer. ● Start the engine and aim the timing light at the timing mark on the Alternator rotor. ● Run the engine at the speeds specified and note the alignment of the timing marks. NOTE Do not mix up the timing marks with the top mark “T” ★ If the ignition timing is incorrect, replace the CDI unit and the pickup coil.
ELECTRICAL SYSTEM Lighting System Headlight Bulb Replacement ● Remove: Bulb Holder Screws [A]*2 Bulb Holder Bolts [B]*2 Bulb Holder Bulb ○ Turn the holder counterclockwise and pull it out. ● Be sure the socket is clean. ● Insert the new bulb by aligning the tang with the notch in the headlight unit. ● Push the holder in, turn it clockwise, and release it, it should lock in position.
ELECTRICAL SYSTEM Taillight Bulb Replacement ● Remove: Taillight Holder Nut [A] Taillight ● Remove: Taillight Lens Screws [B] Taillight Lens [C] ● Turn the Taillight Bulb [A] counterclockwise to Remove it. ● Insert a new bulb by turning it clockwise.
ELECTRICAL SYSTEM Rear-View Mirror Replacement ● Loosen the nut [A] anti-clockwise and disconnect the front indicator light wire [B] to remove the mirror. ● Reverse above procedure to assemble the new mirror. ○ Be sure to connect wiring with correct color as following chart.
ELECTRICAL SYSTEM Fuses Main Fuse Removal ● Remove the seat (see Frame chapter) ● Remove the fuse case cap [A] and take out the fuse [B]. Fuse Inspection ● Inspect the fuse element [A] ★ If it is blown out, replace the fuse. Before replacing a blow fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short circuit.
ELECTRICAL SYSTEM Wiring Diagram 【7-18】
ELECTRICAL SYSTEM Wiring Diagram 【7-19】
ELECTRICAL SYSTEM NOTE: 【7-20】
APPENDIX Appendix Table of Contents Considerations for Various Riding Conditions-------------------------------------------------------------8-2 Carburetor----------------------------------------------------------------------------------------------------8-2 Spark Plug----------------------------------------------------------------------------------------------------8-4 Fuel System--------------------------------------------------------------------------------------------------8-6 Troubleshooting Guide----
APPENDIX Considerations for Various Riding Conditions This vehicle has been designed and manufactured to operate under a wide range of riding conditions. However, it is not feasible to anticipate all of the conditions under which this vehicle might be used. Extremes of temperature, altitude, and riding usage may make changing some carburetor parts pr the spark plug desirable to maintain the vehicle in peak operating condition.
APPENDIX ● Readjust idle speed to specification. Note: Always check throttle cable freeplay after adjusting idle speed and adjust if necessary. Idle Speed Adjustment ● Start engine and warm it up thoroughly. ● Adjust idle speed by turning the idle adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM. Note: Adjusting the idle speed affects throttle cable freeplay and electronic throttle control (ETC) adjustment.
APPENDIX Spark Plug: The spark plug ignites the fuel and air mixture in the combustion chamber. To do this effectively and at the proper time, the correct spark plug must be kept clean and the gap adjusted. Tests have shown the plug listed in the General Information chapter to be the best plug for general use.
APPENDIX The carbon on the electrodes conducts electricity, and can short the center electrode to ground by either coating the ceramic insulator or bring across the gap. Such a short will prevent an effective spark. Carbon build-up on the plug can also cause other troubles. It can heat up red-hot and cause pre-ignition and knocking, which may eventually burn a hole in the top of the piston. Spark Plug Inspection ● Remove the spark plug and inspect the ceramic insulator.
APPENDIX Fuel System WARNING Gasoline is extremely flammable and explosive under certain conditions. ● Always stop the engine and refuel outdoors or in a well ventilated area. ● Do not smoke or allow open lames or sparks in/near the area where refueling is performed or where gasoline is stored. ● Do not overfill the tank. Do not fill the tank neck. ● If you get gasoline in your eyes of if you swallow gasoline, seek medical attention immediately.
APPENDIX Troubleshooting Guide NOTE ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
APPENDIX Other: Carburetor vacuum piston doesn’t slide smoothly Engine oil viscosity too high Brake dragging CDI unit trouble Front or rear final gear case oil viscosity too high Poor Running or No Power at High Speed: Firing incorrect: Spark plug dirty, broken, or maladjusted Spark plug cap or Spark plugs lead trouble.
APPENDIX Over shifts: Shift arm positioning bole spring weak or broken Shift tie-rod maladjusted Abnormal Engine Noise: Knocking: CDI unit trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston Slap: Cylinder/piston clearance excessive Cylinder, piston holes worn Connecting rod bent Piston pin, piston holes worn Valve noise: Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm worn Other noise: Connecting rod sma
APPENDIX Break Doesn’t Hold Front brake: Air in the brake line Brake fluid leakage Brake fluid deteriorated Primary or secondary cup trouble Master cylinder scratched inside Pad over worn or worn unevenly Oil, grease on pads and disc Disc worn or warped Brake overheated Rear Brake: Brake not properly adjusted Linings over worn or worn unevenly Drum worn unevenly or scored Oil, grease on lining and drum Dirt, water between lining and drum Overheated Battery Discharged: Battery faulty (e.g.
