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CHAPTER INDEX

1. BATTERY 12 TRANS GU STARTER a STARTER WNKER SWTCH TT MOTOR 9 S RELAY Lj b FUSE 20A e LEFT REAR DIRECTIONAL B SIGNAL RIGHT REAR LBu DIRECTIONAL B 4 SIGNAL BuW K HOT LAMP SWTCH G GB s FAN MOTOR Kj iid K FAN SWITCH P GY 4 TAIL LIGHT B K TETHER e GY FOOT BRAKE RW SWITCH lt lt lt 2 2 REAR GROUND lt lt lt Vu _ R r VOLTAGE iW 5 E RECTIFIER WR B REGULATOR Wo Bu G 57 SPARK PLUG 7 170 DINEI ELECTRICAL SYSTEM NOTE 7 180 APPENDIX L Appendix Table of Contents Considerations for Various Riding Conditions 8 2 Carburetor 8 2 Fuel System 8 3 Spark
2. N o e o o OFF ON LE EL SPEEDOMETER MAIN SWITCH SW INDICATOR LIGHTS SWT STARTER WINKER RW WR LBu ON O 0 Left CU ED ZU U ZU ZU lt Uo S OFF Rit o O cJ v HAZARD H L BEAM VN G YB l P W Y Ll High UD 20 0 720 20 lt lt e Low c E 9 e 4 WR WR RAV e gt x LG LG x l m B B e RE 0 uj Or Or W W LBu LBu o Y LEFT FRONT DIRECTIONAL B SIGNAL e RIGHT FRONT LBu DIRECTIONAL SIGNAL 2 d N N LG n RIB i ETE 7 P P W HEADLIGHT Y Y B B e CLUTCH GW B GW SWTCH B rz e HAND GY gt GY B mE SWITCH RW CRW Pn FAT B B Black Pu Purple Brown R Red 90 Wu Bu Blue W White 5 R G Green Y Yellow B Gy Gray Ha LBu Light Blue i B LG Light Green M Or Orange P Pink 1 7 16 ELECTRICAL SYSTEM _ QINLI cqd Wiring Diagram
3. Clearance between Piston and Cylinder e Clearance is Cylinder ID minus Piston OD Clearance between Piston and Cylinder Service Limit 0 100 mm ID of Piston hole for Pin Clean Piston hole for Pin Measure ID in the up and down direction and the right angle direction with dial caliper gauge ID of Piston hole for Pin Standard 23 001 to 23 007 mm Piston Pin OD e Check for ware and damage on the sliding surface Measure OD at total 3 positions both ends and middle position the X and Y direction Piston Pin OD Standard 22 996 to 23 000 mm CONNECTING ROD Small end ID Check for ware and damage on the sliding surface Measure ID in the X and Y direction with caliper dial gauge Small end ID Standard 23 007 to 23 020 mm Clearance between small end ID and Piston Pin OD Clearance 15 small end ID minus Piston Pin OD Service Limit of Clearance Service Limit 0 05 mm 6 11 INL I ENGINE PISTON RINGS Clearance between
4. Headlight Assy Removal Remove Handlebar see Handlebar Removal Front Cover see Front Cover Removal Headlight Holder Bolts A Headlight Screws B Headlight Base 0 5 61 ENGINE ad L Engine Table of Contents Removal and Installation 6 2 Inspection 6 7 Reassembly 6 15 Attachment 1 Special Tool 6 32 2 Timing Chain 6 33 3 Matrix Table 6 34 4 Tightening Torque table 6 35 5 Tightening Torque chart 6 40 6 Se
5. Wheel Installation Check the tire rotation mark A on the tire and install the wheel accordingly NOTE O The direction of the tire rotation B is shown by an arrow on the tire sidewall Position the wheel so that the air valve A 1s toward the outside of the vehicle Tighten the wheel nuts in a criss cross pattern Torque Wheel Nuts 52 N m 5 3 kgf m 38 ft Ib 2 50 DINEI w EELS TIRES Wheel Rim Inspection Q Examine both sides of the rim for dents A If the rim 1s 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 1f 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 Do not reuse the air valve Install a new air valve in the new rim
6. Front Hub Removal Remove the cotter pin A and loosen the axle nut Remove the wheel see Wheel Removal Remove the caliper by taking off the mounting bolts and let the caliper hang free Remove the axle nut A and pull off the front hub brake disc Separate the brake disc from the front hub Front Hub Installation Grease Seal Front Spindle A Tighten Torque Front Spindle Nut 145 N m 15 0 kgf m 110 ft Ib Insert a new cotter pin A and bead it over the nut Front Hub Disassembly Assembly Don not press the hub bolts out If any hub bolt A is damaged replace the hub B and bolts as a unit 1 2 90 DINEI w EELS TIRES Rear Hub Rear Hub Installation Grease the axle spindle non permanent locking agent Rear Axle Nuts Tighten Torque Rear Axle Nut 265 N m 27 0 kgf m 195ft Ib Insert a new cotter pin B and bend it over the nut Rear Hub Disassembly
7. 7 7 Battery 7 7 Charging Procedures 7 8 Battery Test Charging 7 8 Regulator Rectifier Output Voltage Inspection 7 9 Alternator Inspection 7 10 Ignition System 7 11 Spark Plug Removal Installation 7 11 Spark Plug Cleaning Inspection 7 11 Spark Plug 7 11 Ignition Coil Removal 7 11 Ignition Coil Installation 7 12 Ignition Coil Inspection 7 12 Ignition Timing Test
8. Lighting System Headlight Bulb Replacement Remove Headlight Unit See Frame Removal Chapter Bulb Holder Slide back the dust protection and remove the bulb from the headlight unit 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 Fit the dust cover completely Bul Hulk 0 Taillight Bulb Replacement Remove Taillight Bracket Bolt 2 A Taillight Bracket Screw 2 B Taillight Unit Remove Taillight Screw 4 C Insert the new bulb Indicator Bulb Replacement Remove Indicator Screw A Indicator Lens B Insert the new bulb 1 7 14 ELECTRICAL SYSTEM INLEI Rear View Mirror Replacement Q Loosen the
9. 8 4 Clutch 8 6 Troubleshooting 8 7 0 8 10 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 Carburetor Some an alteration may be desirable for good performance under different riding conditions when proper mixture 15 not obtained after the carburetor has been adjusted and all parts cleaned and found to be functioning properly If the engine still exhibits symptoms of overly rich or lean carburetion after all maintenance and adjustments are correctly performed the main Jet can be replaced with a smaller or larger one A smaller numbered jet gives a leaner mixture and a larger numbered jet a richer mixture Carburetor
10. A WARNING Do not attempt to drive the vehicle until a full brake level 1s 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 1s not done Caliper Removal Removal the front wheel see Wheels Tires chapter Loose the banjo bolt A at the brake hose lower end tighten it loosely Unscrew the caliper mounting bolts B and detach the caliper C from the disc Unscrew the banjo bolt and remove the brake hose D from the caliper NOTE O If the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose 1s removed see Caliper Disassembly Caliper Installation Install the caliper and brake hose lower end Replace the washers that are on each side of hose fitting with new ones Tighten Torque Caliper Mounting Bolts 25N m 2 5kg m 18 0ft Ib Brake Hose Banjo Bolt 25N m 2 5kg m 18 0ft Ib Check the fluid level the brake reservoir Bleed the brake line see Brake Line Air Bleeding Check the brake for good braking power no brake drag and no fluid leakage A 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 disc The brakes will
11. 4 4 Swingarm 4 4 Swingarm Installation 4 4 Swingarm Bearing Removal 4 4 Swingarm Bearing Installation 4 5 Swingarm Bearing Removal 4 5 Swingarm Bearing Lubrication 4 5 4 6 Steering Stem Removal 4 6 Steering Stem Installation 4 7 Steering Knuckle Removal 4 7 Steering Knuckle Installation 4 8 Tie Rod Removal 4 8 Tie Rod Installation
12. WHEELS TIRES QQ OINLI 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 Measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting Caster and camber are build in and require no adjustment A Rear B Front Amount of Toe in Distance A and B are measured at axle height CAUTION During the tie rod adjustment it is very important that the precautions be taken when tightening tie rod end jam nuts Steering Centering Inspection Test ride the vehicle If the handlebar is straight when the vehicle is traveling in a straight line go on to the Toe in Inspection procedure Otherwise go on to the Steering Centering Adjustment procedure Steering Centering Adjustment Support the vehicle so that the front wheels are off the ground and the front axles about the same height as the rear axle
13. 11111 aessa 1 T L JI IL I TS 220252232301230 2523020 m ma s Valve Clearance Before Adjusting mm 20 23 30 s i SAM 1 30 um iu 187 192 16 16 16 17 17 18 18 19 19 2 2 21 22 22 230 6 34 ENGINE ad L ATTACHMENT 4 Fasteners and Tightening Torque table N m Adapter CP Hex bolt 8 2 16 20 Camshaft Support Bolt 6 8 9 11 Chain Guide Special bolt 8 1 13 5 16 5 Chain Tensioner Bolt M6 2 9 11 Chain Tensioner itself Bolt M6 1 4 5 6 Clutch Nut M18 1 90 110 Clutch Cover Bolt M6 12 9 11 Crankcase Bolt M6 16 9 11 Hex bolt PT 1 8 1 9 15 At counter shaft 1 1070 Magmtosde Cylinder Head BotM 2 2 9 Filter Cover BotM 2 92 20 1 1 55 Guide Plate BotM 2 2 20 HexheadbotM 3 55 65 Sealant pre applied onto threads _ Cover HexbotM322 1 1 0 Plastics 0 1 1 235 X Plastics Main Shaft HexbotM 1 1214 Bearingretaining Neutral Swit
14. 2 6 Tires Installation 2 7 Tires 2 8 Front 2 9 Front Hub Removal 2 0 Front Hub Installation 2 9 Rear 2 10 Real Hub Installation 555 55 2 10 Rear Hub Disassembly Assembly 2 10 0 2 10 DINEI w EELS TIRES Specifications Wheel Alignment Toe in 2WD 25 40 mm Tires Standard tire Front AT 21 X 10 KENDA K300F 002 Tubeless Rear AT 20 11 9 KENDA K300 004 Tubeless Tire air pressure when cold Front 35 kPa 0 35 5 0 psi Rear 35 kPa 0 35 kgf cm 5 0 psi Maximum tire air pressure 250 kPa 205 kgf cm 36 psi to seat beads when cold 2 21
15. 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 B under seat and put the stoppers into the holes on the rear fender Push down the rear parts of the seat until the lock clicks 0 5 20 Front and Rear Fenders Front Cover Removal Remove Headlight Assy A Handlebar B Fuel Tank Cap Front Cover Screws C 2 D 2 E 6 Bolts A 2 B 2 Front Fender Removal Remove Front Left Fender Bracket Screws A 4 Front Left Fender Bracket Front Left Fender Screw 4 Front Left Fender Remove Front Right Fender Bracket Screw C 4 Front Right Fender Bracket Front Right Fender Screw D 4 Front Right Fender
16. ELECTRICAL SYSTEM OINLI 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 The electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them To prevent damage to electrical parts do not disconnect the battery leads or any other electrical connections when the ignition switch is on or while the engine is running Because of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor windings Do not use a illumination bulb rated for other than the voltage or wattage specified in the wiring diagram as the handle cover could be warped by excessive heat radiated from the bulb Take care not to short the leads that are directly connected to the battery positive terminal to the chassis ground O Troubles may involve one o
17. 3 14 0 3 10 DINLI pp KE 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 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any parts will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake 7 When handing the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Replace the pads with n
18. Cover Note Adopt tray or clothes waste to prevent oil pollution e Remove Reduction Gear 1 Shaft 1 Reduction Gear 2 Shaft 2 e sure their original positions for reassembling e Remove Oil Filter Cover and take out Oil Filter CP O ring and Spring Filter Note Adopt tray or clothes waste to prevent oil pollution e Remove Clutch Cover CP Note Adopt tray or clothes waste to prevent oil pollution Clutch e Remove bolts and take out Spring and Washer e Take out Disk Clutch Pressure e Take out Pusher e Remove Push Rod by depressing Release Lever e Remove Lock Nut Note Lock Nut was caulked and so unlock the caulk by using drill e Take out Lock Washer e Take out Clutch Distance Collar and Thrust Washer 6 30 INL I ENGINE Oil Pump e Take out Snap Ring and Oil Pump Gear e Remove bolts and take out Oil Pump Case am E z y m F
19. ELECTRICAL SYSTEM OINLI 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 15 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 The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage Regulator Rectifier Output Voltage Connections 25 V DC Battery Battery 14 15V Q Turn off the ignition switch to stop the engine and disconnect the hand tester If the regulator rectifier output voltage is kept between the values given in the table the charging system 15 considered to be working normally If the output voltage is much higher than the values specified in the table the regulator rectifier 15 defective or the regulator rectifier leads are loose or open If the battery voltage does not rise as the engine speed increases then the regulator rectified 1s defective or the alternator output is insufficient for the loads check the alternator and regulator rectifier to determine which part 15 defective 0 7 90 DINEI ELECTRICA
20. Ignition Coil Removal Remove Front Side Covers see Frame Removal Spark Plug Cap A Primary Lead connectors Bolt 2 Ignition Coil 7 110 DINEI 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 A as follows Connect the tester between the coil terminals Set the tester to the x 1Q range and read the tester Measure the secondary winding resistance B as follows Remove the plug cap by turning it counterclockwise Connect the tester between the spark plug lead and terminal Setthe tester to the x 1 kQ range and read the tester O00000 If the hand tester does not read as specified replace the coil O To install the plug cap turn it clockwise 0 7 120 ELECTRICAL SYSTEM INLEI Ignition Timing Test Remove the ignition inspection plug 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
21. FOREWORD INDE Xo OINLI 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 Precision measurements can only be made if the proper instruments are used and the use of substitute tools may adversely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle Follow the Periodic Maintenance Chart in the Service Manual Be alert for problems and non scheduled maintenance Use proper tools and genuine DINLI vehicle parts Genuine parts provided as spare parts are listed in the Parts Catalog Follow the procedures in this manual carefully Don t take shortcuts Remember to keep complete records of maintenance and repair with dates and any replaced parts How to Use This Manual In preparing this manual
22. 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 A WARNING These cleaning fluids are usually highly flammable and harmful if breathed for prolonged periods Be sure to heed the fluid manufacturer s warnings Disc Removal Remove Front Hub see Wheels Tires chapter Brake Disc Mounting Bolts A Brake Disc B 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 8kg m 27ft Ib After installing the discs check the disc runout Completely clean off any grease that has gotten on either side of the disc with a high flash point solvent Disc Wear Inspection Measure the thickness of each disc at the point A where it has worn the most Replace the disc if has worn past the service limit B Measuring Area Disc Thickness Standard 3 5mm Service Limit 3mm 3 80 Disc Runout Jack up the vehicle so that the wheels are off the g
23. Suspension Arm Assembly When installing the rubber bushing into the arm lubricate the outer surface of the bushings with a soap and water solution 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 Swingarm Removal Support the vehicle on a stand or the jack so that the rear wheels are off the ground Remove Rear Wheels Rear Brake Disc see Caliper Removal Rear shock Absorber Mounting Bolt and nut Chain Speedometer Cable Rear Axle Swingarm Shaft Nut A and Shaft B Swingarm Installation Position the swingarm as shown The distance between the frame and left end of the swingarm is 0 5 mm also right side distance 15 0 5 mm Tighten Torque Swingarm Shaft Nuts 110 N m 11 0 kegf m 80 ft lb Swingarm Bearing Removal Remove Grease Seals A 4 Bearing 4 Spacer C 2 4 40 SUSPENSION STEERING _ nM Swingarm Bearing Installation Lubricate the swingarm bearing before installation see swingarm bearing Lubrication P Use the bearing dri
24. 3 6 Brake 6 3 7 Brake Pads Removal 3 7 Brake Pads Installation 3 7 Brake Pads Wear Inspection 3 7 Brake 18 85 3 8 Disc 3 8 Disc 3 8 Disc Installation 3 8 Disc Wear Inspection 3 8 Disc 3 0 Brake 5 5 3 0 Brake Hose Inspection 3 0 Brake Hose Replacement
25. 4 8 Tie Rod End Removal 4 8 Tie Rod End Installation 4 9 Steering Maintenance 4 9 Steering 4 9 Steering Stem 4 9 Steering Lubrication 4 10 Steering Stem Clamp Inspection 4 10 Tie Rod End and Steering Knuckle Joint Inspection 4 10 4 11 Handlebar 4 11 Handlebar Installation 4 11 4 10 INES s S PENSION STEERING Front Shock Absorber Removal While supporting the vehicle
26. a Disk Clutch Pressure e Euer CP 1 6 40 ENGINE q DINI 6 CLUTCH No 2 Reverse Idele Gear Reverse Shaft CP 4 5th Driven Sacr Ge A a 1st m 69 Arm Lever a Y t UC Reverse Gear Shift Fork Right Shift Fork Left Gd Sth Drive Fork Shaft ee Main Shaft Assy d a ie 3 5 La rd IM 52 Switch Assy el in 2 Pom r T UEM umm Shift Drum CP Beau i Shift Shaft CP 10 cap V k A Guide Plate Y s 7 at 6 410 INL I ENGINE 7 COVER CHAIN 6 420 ENGINE L 8 OIL PUMP Oil Pump Case2 Oil Pump Shaft Oil Pump Gear 1 6 43 Oil Strainer Unit Outer Rotor 5cav Inner Rotor 5cav Oil Pump Case1 INL I ENGINE 27 8 WATER PUMP te Install the Thermostat CP so that
27. Disassembly e Remove One way Clutch from Flywheel Assy Fastener 6 X 16L Bolt socket head 8pcs CLUTCH Visual checking Pressure disk e Check for ware and damage e Check for movement of bearing e f any fault would be found replace with new one Visual checking Plate and Disk Check for ware and deformation on Plate e Check for ware and damage on Disk e f any damage or excessive ware would be found replace with new one as a set Visual checking Release shaft and Push rod e Check for ware and damage Width of friction material Measure the width of friction material with caliper gauge Width of friction material Note Clutch Disk A and B are available Clutch Disk B should be facing front side 6 13 INL I ENGINE TRANSMISSION Visual checking Shift Fork and Drum e Check for ware and damage e f any ware on the Fork craw portion replace with new one Visual checking Main Shaft and Counter Shaft Assy e After disassembling check for ware and damage on dug clutch portion gears and spline portions e f any ware and damage replace with new one Width of Shift Fork groove Check for ware and scratch
28. 3 9 Rear 3 10 Brake Pedal Position Inspection 3 10 Brake Pedal Position Adjustment 3 10 Brake Pedal Free Play Inspection 3 10 Brake Pedal Removal 3 10 Brake Pedal Installation 3 11 Caliper Removal 3 11 Caliper Installation 3 11 Rear Brake Pads Removal 3 12 Rear Brake Pads Installation 3 12 Master Cylinder Removal 3 13 Master Cylinder Installation 3 13 Brake Disc Removal 3 4 Brake Disc Installation
29. e Align the markings between Crank Sprocket and marking pale of Chain Apply oil to Camshafts attaching portion and install Camshaft IN and EX with Cam Sprocket marking and marking plate of Timing Chain aligned Note Decompression 1 furnished on Camshaft EX Do not mixed up e Fit Bearing Stopper onto Ball Bearing Apply oil to Cam Support and install in position Tightening Torque 9 11 N m Fastener 6 X 401 8 pcs e Depress Chain Tensioner plunger into the bottom position by Special Tool Chain Tensioner Tool and then Install Tensioner Tightening Torque 9 11 N m Fastener 6 X 25L 2 pcs 1 6 25 INL I ENGINE e Take out Special Tool and install bolt with Gasket Aluminum Tightening Torque 4 5 6 N m Fastener M6 X SL 1 pc Make sure of smooth operation by turning Crankshaft Adjust valve clearance with thickness gauge adopted a
30. Outer diameter of Piston Pin 22 996 23 000 mm Clearance between Piston and Piston Pin 0 001 0 011 mm Clearance between Piston Pin and Connecting Rod 0 007 0 024 mm 0 050 mm small end hole Top ring 0 20 0 35 mm Second ring 0 030 0 070 mm orae oowoo At 11 mm point from piston skirt bottom end Gap Opening end of Piston Ring Clearance Between Ring and Ring Groove 6 460 ENGINE e ad L ATTACHMENT 7 Adhesive Sealant and Oil application Adhesive or Sealant Application Adhesive or Sealant Application TB 1215 Spotting application for keeping gasket in MAG Cover position TB 1306 Flywheel Oil removing from taper portion M8 Bolt Threads Shift Shaft M6 Bolt Threads TB Three Bond Oil or Grease Application Application Engine Oil 10W 30 Oil Pump Rotor Gears and Crank Shaft IN and EX Valve Water Pump Shaft Position Switch O ring Cylinder Head N and EX Cam Shaft 4 portions Shift Shaft Clutch Caller hole rotate after application Push Rod Shaft 1 amp 2 outersurface andends Clutch Cover Oil seal lip portion 1 6 47 JINL ENGINE bs ATT
31. Remove the valve cap lubricate the stem with a soap water solution and pull the stem A through the rim from the inside out until it snaps into place CAUTION Do not use engine oil or petroleum distillates to lubricate the stem because they will deteriorate the rubber Mount the tire on the new rim see Tire Installation Install the wheel see Wheel Installation TIRES Tire Removal Remove the wheel Unscrew the valve core to deflate the tire O Use a paper valve core tool Lubricate the tire beads and rim flanges on both sides of the wheel with a soap and water solution or water A This helps the tire beads slip off the rim flanges 2 61 WHEELS TIRES QQ OINLI 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 O 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 Check the tire for wear and
32. 7 13 CDI Unit 7 13 Lighting 7 14 Headlight Bulb Replacement 7 14 Taillight Bulb Replacement 7 14 Indicator Bulb Replacement 7 14 Rear View Mirror Replacement 7 15 Neutral Light Bulb Replacement 7 15 Fuses 7 15 Main Fuse 7 15 Fuse 7 15 Wiring 7 16 0 7 10 DINEI ELECTRICAL SYSTEM Specifications Battery Capacity 12 V 14Ah Alternator type Three phase AC Charging voltage Regulator rectifier output 14 15 V Alternator output voltag
33. Suspension amp 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 Preload Adjustment 4 2 Rear Shock Absorber Removal 4 2 Rear Shock Absorber Installation 4 2 Rear Shock Absorber Scrapping 4 3 Suspension ArmS 4 3 Suspension Arm Removal 4 3 Suspension Arm Installation 4 3 Suspension Arm Disassembly 4 3 Suspension Arm Assembly 4 4
34. DRIVE TRAIN SPECIFICATIONS PRIMARY REDUCTION SYSTEM TYPE GEAR REDUCTION RATIO 2880 72 25 CLUTCH TYPE MANUAL RELEASE MULTI PLATE 8 PLATES WET TRANSMISSION TYPE SSPEED DOG CLUTCH CONSTANT MESH GEAR RATIO CRANKSHAFT VS OUTPUTSHAFT GEAR RATIO 1 2 429 34 14 6 994 2 1 611 29 18 4 640 280 1 286 27 21 3 703 ge 1 087 25 23 3 130 8 0 920 23 25 2 650 REV 2 071 29 14 5 966 FINAL DRIVE SYSTEM TYPE ROLLER CHAIN amp SPROCKET OUTPUTSHAFT HAS SPLINE FOR DRIVE SPROCKET REDUCTION RATIO 2 714 38 14 NOTE 1 UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS ARE MONINAL 2 UNLESS OTHERWISE SPECIFIED ALL DIMENSIONS IN MILLIMETERS 3 PERMISSIBLE OPERATING TEMPERATURE 10 C 45 C 4 THIS ENGINE IS ADAPTED TO ASBESTOS FREE 6 500 ELECTRICAL SYSTEM OINLI Electrical System Table of Contents Specifications 7 2 Parts 7 3 PrecautIons 7 5 Electrical 7 6 Wiring 7 6
35. 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 Ifthe ignition timing 1s incorrect replace the CDI unit and the pickup coil Ignition Timing for EW45 Max 30 23500 RPM CDI Unit Inspection When inspecting the CDI unit observe the following to avoid damage to the CDI unit Do not disconnect the CDI unit with the ignition switch on This may damage the CDI unit Do not disconnect the battery leads while the engine is running This may damage the CDI unit Remove the seat see Frame chapter Remove the CDI unit A and disconnect the connectors Set the hand tester to the x 1kQ range and make the measurements shown in the table If the tester readings are not as specified replace the CDI unit Starter Relay Inspection Remove Seat see Frame chapter Starter Relay A Connect the hand tester and 12V battery to the starter relay as shown If the relay does not work as specified the relay is defective replace the relay Testing Relay Hand Tester Range x 10 range Criteria When battery is connected 00 When battery is disconnected Q 7 130 DINEI ELECTRICAL SYSTEM
36. WHEELS TIRES QQ OINLI Wheels Tires Table of Contents 0 5 2 2 Wheel Alignment 2 3 Steering Centering 2 3 Steering Centering Adjustment 2 3 2 4 Adjustment 2 4 Wheels 5 2 5 Wheel Removal 2 5 Wheel Installation 2 5 Wheel Rim Inspection 2 6 Wheel Rim Replacement 2 6 5 2 0 Tires
37. ATTACHMENT 3 Matrix Table lt Intake Adjusting Pad Selection Matrix Existing Adjusting Pad Marking numeral mark w 3 digits on Adjusting Pad Suitable Adjusting Pad Marking numeral mark w 3 digits Adjusting Pad wwe espsopsopsspis reopreopisz pes 16770 72 75 77 sois ss we ro rea rss ror oo or ri o esses usfso ss iss eo ie ve res ner rro rra rs rr ro rs s s a res ror oo mz 20s eo 1 2o 225 Existing Adjusting Pad Suitable Adjusting Pad 155 or 70 79175 78 v e reo ree ror oo en ees or ro ps pao oo esp 026030 ieo i62 i6 rs rr wo ro rss er 190 is s er oo 202 pus o ra ns mo opas as rrr iso s ws rs reo sz ss o poa pas or o i2 is zo opas zs oso rss e o rea ros sr aoo 202 ps sao ons esposo e eo rez iss n oo ooa 046030 rre rez iss o pos or io usns oo ops pas soe oo nz pos oo ro ma ns oo eoo pes pos oz pos aw ne ma ns zo oo eespes osos pon ow me na TT I TL owon propera pns poop pas LL TL ITL L oros oops pus pas epo omw
38. Insert another shorter pin 3 X 15L into the hole of Oil Pump Shaft Assemble Outer Rotor Feed and Inner Rotor Feed with Pump Case 2 and apply oil into rotor chamber e Set Oil Pump Shaft into Pump Case 2 fix Case 1 and 2 with two longer pins 3 X 19 8L e Fit Outer Rotor Scavenge nstall Oil Pump Assy Tightening Torque 9 11 N m Fastener 6 30L 3 pcs Note Make sure the smooth rotation of Oil Pump shaft 6 200 Assemble Drum Shifter and related parts Make sure the spring force and smooth operation by moving the ratchet pole with finger Install Drum Shifter along with Shifter Collar and Guide Plate onto Shift Cam Tightening Torque 9 11 N m Fastener 6 X 20L 2 pcs e Fit Oil Pump Gear and adopt snap ring into the groove on Oil Pump Shaft end nsert Shift Shaft CP with Special Tool Oil Seal Guide adopted Apply oil to Special Tool Oil Seal Guide in advanc
39. 1 5 General Specifications 1 6 Periodic Maintenance 1 8 l 1 10 7 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 Especially note the following 1 Dirt Before removal and disassembly clean the quad Any dirt entering the engine will shorten the life of the quad For the same reason before installing a new part clean off any dust or metal fillings 2 Battery Ground Disconnect the ground wire from the battery before performing any disassembly operations on the quad This prevents the engine from accidentally turning over while work 1s being carried out sparks from being generated while disconnecting the wires from electrical parts as well as damage to the electrical parts themselves For r
40. O Hold a straightedge A against the rear wheel rim on one side at axle height With the handlebar straight ahead loosen the locknuts A B and Turn the tie rod adjusting sleeve C until the front wheel on that side is parallel to the straightedge NOTE The locknut A on the tie rod has left hand threads Turn the wrench clockwise for loosening CAUTION Adjust the tie rod so that the visible thread length A 16 even on both ends of the tie rod or the threads could be damaged 2 30 DINEI 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 needle nose scriber mark a thin mark near the center of the chalk coating while turning the wheel Keeping the front wheels the ground set the handlebar straight ahead At the level of the axle height measure the distance between the scribed lines for both
41. 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 Since spark plug requirements change with the ignition and carburetion adjustments and with riding conditions whether or not a spark plug of the correct heat range 15 used should be determined by removing and inspecting the plug Terminal A Insulator B Gasket C Center Electrode D Gap E 0 8 0 9 mm Reach Side Electrode G When a plug of the correct heat range 1s being used the electrodes will stay hot enough to keep all the carbon burned off but cool enough to keep from damaging the engine and the plug itself This temperature is about 400 800 C 750 1 450 F and be judged by noting the condition and color of the ceramic insulator around the center electrode If the ceramic 15 clean and of a light of a light brown color the plug 15 operating at the right temperature A spark plug for higher operating temperatures sometimes may be needed for severe conditions such as continuous high speed riding or towing heavy loads Such a plug 15 designed for better cooling efficiency so that i
42. Front Fender Installation Please reverse the Removal steps to Install 5 30 DINLI Rear Fender Removal Remove Air Intake Duct C Rear Fender Bracket Bolts A 6 Rear Fender Bracket Screw B 4 Rear Fender Installation Q Please reverse the Removal steps to install 5 4 Radiator Removal Remove Side Cover Screw A Side Cover B Water Tube C D E Connector F G Cooler Bolts 2 H Cooler I Remove Radiator Cover Bolts Radiator Protector B Radiator Installation Please reverse the Removal steps to install 15 5 DINLI VE Foot Steps Removal Remove Step Bracket Bolts A B Step Screw 4 C and Bolts 2 D Step Bracket E Step F
43. MAG side Apply TB 1306 and remove oil from the taper portion of Crankshaft e Fit Needle Bearing and apply grease Not to apply grease onto the taper portion Install One way Clutch onto Flywheel Tightening Torque 13 15 N m Fastener M6 X 16L Adhesive applied bolt 8 pcs Fit Starter Gear and make sure of smooth counterclockwise rotation e Apply 1306 and remove oil from taper hole of Flywheel e Fit Flywheel apply oil to threads and retaining surface of M14 nut e Tighten the nut to the specified tightening torque with Special Tool Wrench Crank Sprocket adopted to Crankshaft for preventing rotation Tightening Torque 150 170 N m Fastener MIA Nut Install Primary Gear with the inside marking aligned to spline Tightening Torque 110 130 N m Fastener M18 Nut Fit Release Shaft along with Spring Release and Plate Release in position Tightening Torque 9 11 N m Fastener 6 X 20L 1 pc 6 271 INL I ENGINE Install Clutch Assy Assemble Clutch Assy properly after checking disassembled parts e Fit
44. again from the beginning since air will have entered the line O 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 55 kg m 48 Apply the brake level forcefully for a few seconds and check for fluid leakage around the fittings Master Cylinder Removal Removal Brake Hose Banjo Bolt B Master Cylinder Clamp Bolts A Master Cylinder Brake fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately Master Cylinder Installation The master cylinder clamp must be installed with the UP mark C upwards Tighten the upper clamp bolt first and then the lower clamp bolt There will be a gap at the lower part of the clamp after tightening Torque Master Cylinder Clamp Bolts 8 8N m 0 90kg m 78in Ib Use a new flat washer on each side of the brake hose fitting and tighten the banjo bolt Torque Brake Hose Banjo Bolt 25N m 2 5kg m 18 0ft Ib Bleed the brake line after master cylinder installation see Brake Line Air Bleeding Check the brake for good braking power no braking brag and no fluid leakage 3 50 DINLI pp x7
45. and detach the caliper from the disc Unscrew the banjo bolt and remove the brake hose from the caliper NOTE the caliper is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose 1s removed Caliper Installation Install the caliper and brake hose lower end Replace the washers that are on each side of hose fitting with new ones Tighten Torque Caliper Mounting Bolts 25N m 2 5kg m 18 0ft Ib Brake Hose Banjo Bolt 25N m 2 5kg m 18 0ft Ib Check the fluid level 1n the brake reservoir Bleed the brake line see Brake Line Air Bleeding Check the brake for good braking power no brake drag and no fluid leakage A 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 disc The brakes will not function on the first application of the level if this is not done 3 110 DINLI zikr Rear Brake Pads Removal Remove the caliper see Caliper Removal Remove Anti rattle Spring C Brake Pads B 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 1s in place Install the pads O Be ca
46. A e Take out Oil Pump feed Pump Scavenging Pump and Oil Pump Shaft etc e Take out Shift Shaft CP along with washer Note Fit the washer onto the Shaft not to lose it GUIDE PLATE DRUM SHJIFTER and SHIFT CAM e Remove Guide Plate Drum Shifter and Shift Cam e Remove Guide Plate and Drum Shifter Note Pay attention Drum Shifter is not disassembled e Take out Shifter Pin and then pull out Shifter Cam e Remove Stopper Arm and Spring Stopper e Take out Point Neutral along with Spring Point and then remove Switch Position e Remove nut and take out washer and Primary Gear HEAD COVER e Remove bolts and take out Rubber Mounts O ring and Head Cover CHAIN TENSIONER e Align the TDC and remove adjusting bolt e Remove bolts and tale out Tensioner CAM SUPPORT CAMSHAFTS e Remove bolts and take out Cam Support e Tank out intake Camshaft exhaust Camshaft and Bearing Stoppers Note Pay attention not to lose Bearing Stoppers e Take out Crank Sprocket by holding the chain at the upper portion cylinder head side e Take out Timing Chain 1 6 40 ENGINE q MAGNETO ASSY e Remove flange nut e
47. Assembly Do not press the hub bolts A out If any hub bolt is damaged replace the hub B and bolts as a nut 2 100 srake _ DINLI 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 3 4 Master Cylinder 3 5 Master Cylinder Removal 3 5 Master Cylinder Installation 3 5 Calipers 3 6 Calipers Removal 3 6 Calipers Installation
48. Battery voltage low Fuel air mixture incorrect Pilot screw and or idle adjusting screw maladjusted Pilot jet or air passage clogged Starter plunger stuck open cleaner clogged poorly sealed or missing Fuel level too high or too low Fuel tank air vent obstructed Carburetor holder loose cleaner duct loose Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface bs 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 Spark plug cap shorted or not in good contact Spark plug incorrect Pickup coil trouble CDI unit trouble Ignition coil trouble Fuel air mixture incorrect Main jet clogged or wrong size Jet needle or needle jet worn Main air jet clogged Bleed holes of air bleed pipe or needl
49. OD Oil clearance at cam journal portion 0 10 mm 6 90 DINED ENGINE Visual Checking e Check for ware and damage on Cam Sprocket gear teeth e Check for ware and damage on decompression related parts Check if decompression would be operated smoothly e f any parts would be damaged or worn replace with new Camshaft Assy CYLINDER Cylinder warpage e Clean and remove carbon deposits from the surface Never damage the surface when cleaning Place the measuring block diagonally on the surface and check with thickness gauge Cylinder warpage Cylinder bore Check for damage or ware on bore surface Measure the cylinder bore at total 6 positions top middle and bottom positions and axial Camshaft and right angle directions Cylinder bore 94 000 to 94 020mm PISTON and PISTON PIN Piston OD Check for ware and damage on the sliding surface e Measure OD of Piston at 11 mm distance from the bottom end in the right angle against Piston Pin with micrometer 93 955 to 93 970 mm 6 100
50. Pilot Screw Adjustment 2 FRONT Pilot screw is covered by a welsh plug Plug removal will be Engine required to perform these procedures rat a Q Start engine and warm it up to operating temperature about 10 minutes With engine off turn pilot screw in clockwise until lightly seated Note Do not tighten the pilot screw forcefully against the seat or the screw and or seat will be permanently damaged Connect an accurate tachometer that will read In increments of or 50 RPM Start engine Set idle speed to 1600 RPM Note Always heck throttle cable freeplay after adjusting 1dle speed and adjust if necessary Slowly turn mixture screw clockwise using the pilot screw wrench until engine begins to miss Slowly turn mixture screw counterclockwise until idle speed increases to maximum RPM Continue turning counterclockwise until idle RPM begins to drop Center the pilot screw between the points in Step 5 and 6 8 20 APPENDIX L Readjust idle speed to specification Note Always check throttle cable freeplay after adjusting idle speed and adjust 1f 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 d
51. Piston Ring and groove e Remove carbon deposits from Rings and grooves Measure the clearance between Piston Ring and groove by holding the Ring upwards in the groove with thickness gauge Service Limit of clearance Top 0 15 mm Piston Ring gap Opening Insert Piston Ring into the lower portion of Cylinder horizontally by using Piston Measure the Piston Ring gap opening with thickness gauge Service Limit of Piston Ring gap Opening Oil ring side rail CRANKSHAFT Runout e Set on the V block and measure runout with dial gauge Crankshaft Runout Side clearance at large end of Connecting Rod Measure the side clearance at large end of Connecting Rod with thickness gauge Side clearance at large end 6 120 ENGINE E ad L TIMING CHAIN Chain Pitch Check for ware damage and roller fallout Place Chain on the flat table and pull with the 4 53 kg force and then measure the length of 20 pitches Timing Chain Pitch 20 pitches STARTER GEAR ONE WAY CLUTCH
52. Setthe tester to the x 1 range and read the tester If the tester does not read 0 Q the lead is defective Replace the lead or the wiring harness B if necessary Battery Removal Disconnect the battery negative cable Black first and then the positive cable red Take out the battery Battery Installation Connect the positive cable first and then the negative cable 7 60 ELECTRICAL SYSTEM OINLI Battery Battery Charging 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 15 a maintenance free design and construction Use of conventional lead acid batteries is not recommended No electrolyte or refilling water is required Because this battery is a completely sealed type abuse of the battery can cause an explosion Please adhere to the following points 1 Follow the instructions shown on battery package for preparation and filling with battery electrolyte 2 Never interfere
53. Take out Magneto Assy along with Starter Gear Needle Bearing and Spacer by means of Special Tool MAG Remover THERMOSTAT e Remove bolts and take out Thermostat Cover and Thermostat WATER PUMP e Remove bolts and take out Water Pump Case Note Adopt tray to prevent coolant pollution Make sure the original one position of a cupper washer e Take out Impeller e Take out Sealing Washer Note When reassembling replace with new Sealing Washer CYLINDER HEAD e Remove two 2 M6 bolts e Remove four 4 M11 bolts evenly and diagonally LEVER CP e Remove pivot bolt and take out Lever CP e Take out Cylinder and Gasket Note Hold Piston not to damage it PISTON e Take out Clip and pull out Piston Pin and then take out Piston e Remove Starter Motor 6 50 INL I ENGINE CRANKCASE e Remove bolt on the clutch side e Remove bolts on the MAG side e Take out the crankcase from Special Tool Engine Base Plate AY and set it with the clutch side facing up on the plastic containers e Attach the Special Tool Case Separator Kit onto the clutch cover mating surface of the crankcase e Tighten two 2
54. damage see Tire Inspection Lubricate the tire beads and rim flanges with a soap and water A WARNING Do not use the lubricant other than a water and soap solution or water to lubricate the tire beads and rim because it may cause tire separation Check the tire rotation mark A on the tire and install the tire on the rim accordingly O The tires should be installed on the rims so that each air valve 1s toward outside of the vehicle NOTE O The direction of the tire rotation B 1 shown by an arrow on the tire sidewall Install the tire on the rim using a suitable commercially available tire changer Lubricate the tire beads again and center the tire on the rim 2 70 DINEI 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 cm 36 psi A 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 Chec
55. disassembled parts with marking as necessary Place them in order on the clean table e Remove Valve lifter and adjusting pad While depressing Valve Spring with exclusive tool Valve spring compressor take out Colette Take out Spring Retainer Spring inner and outer Seat spring e Take out IN and EX Valve e Take out Valve Seal Cylinder Head warpage e Clean and remove carbon deposits from the surface Never damage the surface when cleaning Place the measuring block diagonally on the surface and check with thickness gauge e f the result 1s out of specifications replace with new Cylinder Head Cylinder Head warpage Inner diameter ID of Valve Guide e Clean up the Valve Guide hole e Measure ID of Valve Guide at total 6 points upper middle and bottom positions and X and Y directions by means of dial caliper Service Limit of Valve Guide ID 6 000 to 6 012 mm 6 000 to 6 012 mm 6 70 INL I ENGINE INTAKE amp EXHAUST VALVE Valve Stem runout e Remove carbon deposits Place on the V block Measure the runout by means of dial gauge e f the result is out of specifications replace with new Valve Outer diameter OD of Valve Stem e Measure OD of Valve Stem s
56. front and rear of the front tires Subtract the measurement of the front from the measurement of the rear to get the toe in If the toe in 15 not in the specified range go on to the Toe in adjustment procedure Toe in of Front Wheels Standard Standard 0 2 mm Toe in Adjustment Q Loosen the locknuts A B and turn the adjusting sleeves C the same number of turns on both sides to achieve the specified toe in NOTE The nut A on the tie rod has left hand threads Turn the nut clockwise for loosening O The toe in will be near the specified value if the tie rod length D is 385 mm on each tie rod CAUTION Adjust the tie rod length so that the visible thread length E is even on both ends of the tie rod Uneven length could cause tie rod damage 12 4 WHEELS TIRES QQ Check the toe in Tighten Torque Tie Rod Adjusting Sleeve Locknuts 33 N m 3 4 kgf m 45 ft lb lest 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 lake off the wheel nuts and remove the wheel
57. sure of the smooth operation by turning Crankshaft with Cylinder pressed down by hand 6 220 Install Chain Guide 1 onto Cylinder Assemble Cylinder Head as shown in the illustration 1 Seal valve 4 pcs 2 Intake Valve 2 pcs 3 Exhaust Valve 2 pcs 4 Valve Spring Inner 4 pcs 5 Valve Spring Outer 4 pcs 6 Spring Retainer 4 pcs 7 Colette Valve 8 pcs 8 Seat Valve Spring 4 pcs Press fit Seal Valve by means of exclusive tool Note Pay attention on the Seal Valve appearance Intake IN side Black Exhaust EX side Green e Fit Seat Valve Spring not to over ride the step e Set Valve Spring Inner facing the green paint marking upwards e Set Valve Spring Outer facing the yellow paint marking upwards Apply oil onto the shaft ends of IN and EX Valve Valve Guide and Seal Valve and fit the valves Into Cylinder Head Note Keep the IN and EX valve fitting in the original position Do not mix IN and EX valves e While depressing Valve Springs with exclusive tool fit Spring Retainer and Colette onto valve shaft end Note Make su
58. the Fork groove Measure the width of Shift Fork groove with caliper gauge Width of Shift Fork groove 5 10 to 5 17 mm Width of Shift Fork craw Measure the width of Shift Fork craw with micrometer Width of Shift Fork craw 4 93 to 5 00 mm Clearance between Shift Fork and groove Measure the clearance between Shift Fork and transmission gear groove at craw portion with thickness gauge 6 14 ENGINE p Reassembly CRANKCASE 1 Press fit crankshaft into crankcase 1 by means of Special Tool CRANK ASSY TOOL KIT Note Hold Connecting Rod not to strike the Crankcase mating surface while press fitting Install 1 8 plug in position Tightening Torque 9 15 N m Attach Reverse Arm CP onto Crankcase 1 e Retain the Reverse Arm CP with washer and snap ring from the outside of Crankcase 1 Note Be sure not to damage oil seal Make sure the snap ring 1 the eroove without fail plastic containe
59. we divided the product into its major systems These systems became the manual s chapters All information for a particular system from adjustment through disassembly and inspection is located in a single chapter The Quick Reference Guide shows you all of the product s system and assists in location their chapters Each chapter in turn has its own comprehensive Table of Contents The Periodic Maintenance Chart 1 located 1n the General Information chapter The chart gives time schedule for required maintenance operations If you want spark plug information for example go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices 0 21 2INL hn 4 OREWORD INDEX A 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 destructi
60. 0 MEN S 4 SUSPENSION STEERING _ nM 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 3 kgf m 31 ft lb Suspension Arm Disassembly Tighten Bushings A Rubber Bushings B O Ring C Holding the suspension arm with a vise remove the cir clip D and unscrew the knuckle joint E CAUTION Do not remove the knuckle joint grease seal It is packed with grease 0 4 30 INES s S PENSION STEERING
61. 1 8 80 APPENDIX DINLI Xn 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 small end clearance excessive Connecting rod big end clearance excessive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head connection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Camshaft chain pensioner trouble Camshaft chain sprocket guides worn Balancer bearing worn Balancer gear worn or shipped Loose alternator rotor Abnormal Drive Train Noise Converter noise Belt worn Drive or driven pulley sheave worn Drive or driven pulley movable sheave bush worn Drive or driven pulley mount loose Drive pulley shoe worn Drive pulley weight or roller side washer worn Drive pulley weight or roller worn Wear guides worn Transmission noise Bearing worn Transmission gears worn or chipped Metal chips jamme
62. 2 pcs 6 31 INL I ENGINE Attachment 1 Special Tool 6 32 ENGINE EXHAUST HERD COVER FITTING SURFACE P CS 9 M HEAD TIMING MARK foe dn TIMING MARK m L 3 6 33 INL I ENGINE
63. ACHMENT 8 Periodic Maintenance Schedule Note The maintenance schedule indicated in the following table 1s based on the normal operation condition If operated in the extremely dusty condition or in heavier loading condition the maintenance intervals must be Shortened depending on the conditions of oil clogging of oil filter and air cleaner elements ware of parts and so on Every 6 Every two Check COOLANT level X Clean AIR CLEANER Replace ENGINE OIL Replace ENGINE OIL FILTER X Clean SPARK PLUG and adjust ELECTRODE Check and replace FUEL SYSTEM Check and replace CARBURETOR FLOAT BOWL EN X Check and replace ENGINE BREATHER HOSES Check and adjust IDLE SPEED Check and adjust VALVE CLEARANCE Check and adjust IGNITION TIMING Replace COOLANT Replace FUEL LINES one month or 1 000 km operation whichever comes first after that every 100 hours or 2 000 km operation whichever comes first 6 48 ENGINE E ad L ATTACHMENT 9 SPECIFICATIONS DIMENSIONS DRY WEIGHT ENGINE SPECIFICATIONS DISPLACEMENT 0 448 L MAXIMUM TORQUE SAE 41 2 N m 7500 rpm 4 2 Kg m 7500 rpm LUBRICATION SYSTEM FORCED LUBRICATION DRY SUMP ep eps 1 6 49 INL I ENGINE bs
64. ALL TERRAIN VEHICLE DINL gt Metal Industrial Co Ltd 1 Service Manual FOREWORD INDE Xo OINLI DINL I 0 00 2INL hn 4 OREWORD INDEX DINLI 450 cc 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 The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 0 10
65. Cover Set the harness grommet into the groove e Fit Gasket MAG Cover onto Crankcase after spot applying TB 1215 onto the Crankcase surface e Fit MAG Cover and tighten bolts Tightening Torque 9 11 N m Fastener 6 X 35L 11 pcs Fit Oil Delivery Pipe Tightening Torque 15 21 N m Note Fit gasket on both sides of banjo fitting Set the rubber pipe in horizontal direction 1 6 30 Make sure O ring Head Cover and Chain Guide 2 are furnished and fit Head Cover Fit rubber mount and tighten bolts Tightening Torque 9 11 N m Install Adapter with convex portion upwards Tightening Torque 16 20 N m Fastener M8 X 20L 2 pcs Install carburetor onto Adapter Set Adapter band screw with the screw head upwards on side Fastener 4 X 30L 1 pc Fit Shift Pedal with the markings aligned Tightening Torque 9 11 N m Fastener 6 X 25L pc Apply grease onto front and rear surfaces of Sprocket 14T and install it in position Apply grease to Counter Shaft sprocket and install Fixing Plate over the sprocket Tightening Torque 9 11 N m Fastener 6 X 12L
66. DINLI Table of Contents 5 2 Seat 5 2 Seat Installation 5 2 Front and Rear Fenders 5 3 Front Cover 5 3 Front Fender Removal 5 3 Front Fender Installation 5 3 Rear Fender Removal 5 4 Rear Fender Installation 5 4 Radiator Removal 5 5 Foot StepS 5 6 Foot Steps Removal 5 6 0O 5 10 DINLI
67. Distance Collar into Main Shaft apply oil into hole and turn Collar by one turn e Hit Cultch Outer CP lock washer with the hollow surface inwards and lock nut Tightening Torque 90 110 N m Fastener Special nut Caulk the lock nut with Special Tool Caulking Tool Apply oil onto Push Rod and insert into Main Shaft and then fit Pusher Fit Disk Clutch and Plate Clutch Note Make sure the widest friction plate is in the bottom position Set the top plate into the shallow depth groove of Clutch Outer e Fit Disk Clutch Pressure e Fit Spring Clutch and tighten bolts evenly Tightening Torque 9 11 N m Fastener 6 X 36L 6 pcs Make sure again the tightening torque of Primary Gear fixing nut Tightening Torque 110 130 N m 1 6 28 Install Clutch Cover e Hit Spring Filter e Hit Filter Cover along with Oil Filter CP and O ring Tightening Torque 9 11 N m Fastener 6 X 25L 2 pcs e Fit Gasket Clutch Cover onto Crankcase after spot applying TB 1215 onto the Crankcase surface e Fit Clut
68. ERAL INFORMATION bs 15 Lubrication Engine wear is generally at its maximum while the engine 1s 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 Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended 16 Direction of Engine Rotation To rotate the crankshaft manually make sure to do so in the direction of positive rotation Positive rotation 1s counterclockwise as viewed from the left side of the engine To carry out proper adjustment it is furthermore necessary to rotate the engine in the direction of positive rotation as well 17 Replacement Parts When there 15 a replacement instruction replace these parts with new ones every time they are removed Always replace these parts with new ones every time they are removed Although the previously mentioned gasket O ring ball bearing needle bearing grease seal oil seal cir clip and cotter pin have not been so designated in their respective text they are replaceme
69. L 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 Disconnect the alternator connector Connect the hand tester to red white to white start the engine Run it at the rpm Note the voltage readings total 3 measurements Alternator Output Voltage Minimum of 5 AC Amps at Idle OOOOO e CDI Output Test Using Peak Reading Adaptor Connect all CDI wires to stator wires Disconnect CDI module wire from ignition coil primary terminal Connect one lead to engine ground and the other to the ignition coil primary wire leading from the CDI module Set meter to read DC Volts Crank engine and check output of CDI wire to coil Reconnect CDI wire to coil Average Output w Digital Voltmeter with or without Peak Reader 200 400 DCV 1 7 10 ELECTRICAL SYSTEM OINLI Ignition System The ignition sys
70. Shift Fork Main Apply oil into the grooves of Fork Shaft and Shift Drum e Turn Main Shaft and make sure that Counter Shaft Shift Drum and Shift Fork can be smoothly operated 6 160 ENGINE DINLI CRANKCASE 2 e When replacing Bearing with new one Install Bearing Retainer Plates Stopper Plate for Main Shaft Bearing Tightening Torque 12 14 N m Fastener M6 Hex bolt 1 pcs Stopper Plate B for Shift Drum Bearing Tightening Torque 7 9 N m Fastener M6 Hex bolt 1 pcs Apply TB 1316 to threads e Install Drain Plug Tightening Torque 7 9 N m Fastener M16 Bolt 1 pcs e Fit Oil Strainer UN On plastic containers place Crankcase 2 with the mating surface to crankcase 1 upwards Apply TB 1215 evenly onto the mating surface e Adjust the convex position on the end surface of Water Pump Shaft to meet with the groove on the end surface of Balancer Shaft on Crankcase 1 side 6 171 INL I ENGINE Cover Crankcase 2 over Cran
71. Steering Clamp Support Plate Steering Clamp C Tie Rod End Nuts D Steering Stem Cotter Pin E and Nut F 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 remove the steering stem bearing G remove the cotter pin and nut from the bottom end of the steering stem 0 4 60 SUSPENSION STEERING _ 80 07 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 Ib 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 0 ft Ib Tie Rod End Nuts 47 N m 4 8 kgf m 35 ft lb Inspect the toe in if necessary Steering Knuckle Removal Remove Front wheel and Hub see Wheels Tires chapter Brake Hose Clamp Tie Rod End Nut and Ti
72. ainframe subframe swingarm frm siren omnes LL L TL TL D LL amor t t tls mmm x umo Cewe bem A EXHAUST spark arrester Regular Maintenance SWITCH engine stop start tether ignition LT T DRIVE CHAIN sag stretch buffer guide sprockets Pr far fo far fw 1 condition tightness guards Gene L pp pe Fi BRAKE SYSTEM cables discs pads hoses etc or lt rr fe P CLUTCH lever cable and arm position a COOLANT radiator cap hoses level strength fr fo SUSPENSION front rear shocks condition setting Pp fp eL T SEAT condition wear damage la WHEELS TIRES pressure condition wear NL LAE E STEERING ASSEMBLY fasteners operation choking a TIE ROD ENDS DINLI dealer service suggested that servicing owners should have the proper tools service data and be mechanically qualified O Operational safety involved The service should be performed by a DINLI dealer Service more frequently if operation in dusty sandy or snowy area or conditions Change every 2 years 1 80
73. bolts evenly keeping the opening between mating surfaces of crankcase in the parallel condition TRANSMISSION e Take out Fork Shafts e Pull out Spring located under the Fork Shaft on the counter shaft side e Take out Shift Fork Main Shift Fork Right and Shift Fork Left Note Make sure their original positions for reassembling e Take out Shift Drum CP with the Reverse Lock released e With the case put in the upright position take out Main Shaft and Counter Shaft e With the case put in the original position again take out Reverse Shaft CP Reverse Idle Gear collar Washer etc Note Pay attention not to lose the Counter Shaft washer BALANCER GEAR e Align the mating markings e Take out Balancer Shaft and Gear by lightly tapping with plastic hammer CRANKSHAFT e Depress the MAG side end of the Crankshaft by means of hand press machine and take out Crankshaft 6 61 E L i i v un i x INSPECTION CYLINDER HEAD Disassembling Note Identify the original position of
74. c hose to the bleed valve on the caliper and run the other end of the hose into a container Fill the reservoir with new brake fluid Change the brake fluid as follows Open the bleed valve O Apply the brake level and hold it B Close the bleed valve O Release the brake level D Check the fluid level in the reservoir often replenishing it as necessary NOTE O If the fluid in the reservoir runs completely out any time during fluid change air will enter the line and the system must be bled Repeat this operation until fresh brake fluid comes out into the plastic hose or the color of the fluid change 1 3 30 DINLI pp x7 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 Ib Apply the brake level forcefully for a few second and check for fluid leakage around the fittings A WARNING If the brake level has a soft or spongy feeling when it is applied
75. ch Serew M5 _ 2 SP Oil Delivery Pipe BanjbotMI2 3 Oil Drain Plug BotMIG J 1 20 Oil Drain Case BotM 3 9 20 One way Clutch Plate release shaft __ C C BA Pulsar Coil 2535 Reverse Lock Shift Drum Shift Drum Bearing 9 NOD IN Shift Shaft New plug Lo 94 7 9 p 9298 1 Spark Plug MI2 Starter Motor Stopper Arm CP Thermo Cover Thermo Switch Water Pump Case Water Pump Impeller 6 35 DINLI ENGINE TTACHMENT 5 Tightening Torque chart 1 CRANKCASE IRI Drain Plug 20 29 H mi Apply 1215 auto mating surface 6 36 ENGINE q INE 2 CYLINDER Head Cover o5 Cam Support a h Ex amp 0 Oi d Cover mt 1 nea Band is Ring H ver TE k 1 ues kn i mp F mes r A Ti 4 mi a 4 z 1 i in L us i 1 e lI r 1 the eT Fi Head Cylinder 2 7 2 ee e C y Exhaust lt gt F Culinder CP r Fix four 4 bolts as follows 1 Tighter ta 30 Nm 2 Ti
76. ch Cover and tighten bolts Tightening Torque 9 11 N m Fastener 6 X 25L 11 pcs M6 X 65L pc Commonly tighten Filter Cover e Tighten Filter Cover plug to the specified tightening torque Install Thermostat with the hole upward and Thermostat Cover Tightening Torque 7 9 N m Fastener 6 20L 2 pcs Install Thermo Switch with the TB 1344 applied to threads Tightening Torque 32 38 N m Install Spark Plug Tightening Torque 15 20 N m 1 6 29 INL I ENGINE Install MAG Cover e Apply grease around Shaft 1 and 2 and fit Reduction Gear 1 and 2 in position correspondingly Apply grease to gears e Fit Stator Coil into MAG Cover Tightening Torque 5 5 6 5 N m Fastener M5 X 30L 3 pcs e Route the coil wiring along the groove and fix Pulsar Coil over the wiring Tightening Torque 2 5 3 5 N m Fastener M5 X 12L 2 pcs e Fit Plug 1 and 2 MAG Cover Tightening Torque Plug 1 10 12 N m Plug 2 3 5 N m Note Make sure O ring 15 attached onto Plug MAG
77. d in gear teeth Engine oil insufficient or too thin Front or rear final gear case noise Insufficient lubricant Incorrect oil Front final gear case Bevel gear bearings worn Bevel gears worn or chipped Bevel gears maladjusted Front axle or propeller shaft noise Constant velocity universal joint damaged Abnormal Frame Noise Shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Other noise Bracket nut bolt etc not properly mounted or tightened Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Cylinder head gasket damaged Engine oil level to high Black Smoke cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level too high Brown smoke Main jet too small Fuel level too low cleaner duct loose cleaner poorly sealed or missing Handing and or stability Unsatisfactory Handlebar hard to turn Tire air pressure too low Steering stem bearing damaged Steering stem bearing lubrication inadequate Steering stem bent Damaged steering knuckle joint Damage tie rod end Handlebar shakes or excessively vibrates Tire worn Wheel rim warped Rear axle runout excessive Wheel bearing worn Handlebar clamp loose Handlebar pulls to one side Frame bent Wheel maladjustment Suspension arm bent or twisted Steering stem bent Front or rear tire air p
78. e Engage Stopper Pin and Shifter Collar into the groove of Shifter Lever Note Be sure to fit washer onto Shift Shaft e Take out Special Tool Oil Seal Guide temporally fit Shift Pedal CP and make sure gear 1s shifted properly Also make sure reverse locking operation 6 21 INL I ENGINE e Apply oil to O ring and install Starter Motor in position Tightening Torque 9 11 N m Fastener M X 25L 2 pcs e Fit two Pipe Knocks set Cylinder Gasket Assemble and install Piston e Set Piston Rings into Piston grooves Expander Ring into Oil Ring groove Second Ring facing the marking upwards Top Ring facing the marking upwards e Make sure rings are smoothly moved and adjust the openings gaps at 120 degrees intervals Fit new clip into the groove on one side and make sure of the clip fitting properly in the groove Place Special Tool Piston Support Plate Insert Piston with the marking on the top surface faced to magneto side into cylinder Apply oil to small end hole of Connection Rod Piston Pin and hole Then fit Piston Pin into Piston e Fit new clip into the groove on another side and make sure the clip fitting properly in the groove Apply oil around Piston and Rings and cylinder bore Install Cylinder by holding Rings by Special Tool Ring Band Make
79. e DC14V 13 7A 3000 rpm 1 2 0 52 Q Q Charge Coil Y2 Y R YGrund fe W R W 1900 Pascol Cir Y R Y1 0 49 Q Ignition Coil Cap resistance 5 Starter motor Nominal Output 0 7 kW Reduction Ratio 28 235 ap 0 7 20 ELECTRICAL SYSTEM INL Parts Location High Low Beam Switch A Hazard Lights Switch B Horn Switch F Indicator Switch D Ignition Switch E starter Button Battery starter Circuit Relay B CDI Unit C Ignition Coil D Spark Plug E Indicator Relay 0O 7 30 DINEI ELECTRICAL SYSTEM Regulator Rectifier G Magneto CP A Starter Motor B Horn B Temperature Sensor C 0 7 40
80. e Rod End Do not loosen the locknuts at the ends of the tie rod adjusting sleeve or the toe in of the front wheels will be changed Remove Front Shock Absorber Clamp Bolt B and Nut Knuckle Joint Bolt C and Nut Suspension Arm D 1 4 70 amp JINIL f s S PENSION STEERING Steering Knuckle Installation Clean the sealing surface A and the hole 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 Ib Front Shock Absorber Clamp Nut 52 N m 5 3 kgf m 38 ft Ib 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 When removing the tie rod be careful not to bend it Do not loosen the locknut C at the end of the tie rod adjusting sleeve or the toe in of the front wheel will be changed Tie Rod Installation The right and left tie rods are identical Install the tie rod with the flattened area A located inboard Tighten Torque Tie Rod End Nuts 47 4 8 kgf m 35 ft lb Inspect the toe in if necessary Tie Rod End Removal Remove the tie rod see Tie Rod Removal Holding the tie rod flattened area loosen the locknut and unscrews the ti
81. e jet clogged Fuel level too high or too low cleaner clogged poorly sealed or missing Starter plunger stuck open Water or foreign matter in fuel Carburetor holder loose cleaner duct loose Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston rings bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect CDI unit trouble Miscellaneous Throttle valve won t fully open Carburetor vacuum piston doesn t slide smoothly Brake dragging Overheating Engine oil level too high Engine oil viscosity too high Balancer mechanism malfunctioning Front or rear final gear case oil viscosity too high Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect CDI unit trouble Fuel air mixture incorrect Main jet clogged Fuel level too low Carburetor holder loose cleaner poorly sealed or missing Air cleaner duct loose Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Engine oil level too high Engine oil viscosity too high Dr
82. e rod end B NOTE O The while locknut on the tie rod has left hand threads Turn the wrench clockwise for loosening 0 4 80 SUSPENSION STEERING _ CO 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 Ib Steering Inspection Turn the handlebar left and right and check the steering action If the steering is not smooth or if the steering binds or catches before the stop lubricate the steering NOTE O The cables and wires will have some effect on the steering action which must be taken into account Check the steering action again If the steering lubrication does not remedy the problem inspect the steering stem warp steering stem clamps and tie rod bearings If you feel looseness or if the steering rattles as it turns check
83. e standard plug make certain the replacement plug has the same thread pitch and reach length of threaded portion and the same insulator type regular type or projected type as the standard plug If the plug reach is too short carbon will build up on the plug hole threads in the cylinder head causing overheating and marking it very difficult to insert the correct spark plug later If the reach is too long carbon will build up on the exposed spark plug threads causing overheating pre ignition and possibly burning a hole in the piston top In addition it may be impossible to remove the plug without damaging the cylinder head The heat range of the spark plug functions like a thermostat for the engine Using the wrong type of spark plug can make the engine run too hot resulting in engine damage or too cold with poor performance misfiring and stalling 8 50 APPENDIX Clutch Adjustment Clutch Lever Freeplay Measure clutch lever freeplay between the perch and the lever A This distance should be 3 4 5mm If adjustment is required slide the clutch perch pivot boot down the clutch cable to access the clutch adjustment screw B and lock ring C Loosen the lock ring and turn the screw in clockwise to increase lever travel Turn the screw out counterclockwise to decrease lever trave
84. ecrease RPM Note Adjusting the idle speed affects throttle cable freeplay and electronic throttle control ETC adjustment Always check throttle cable freeplay after adjusting idle speed and adjust if necessary Idle Speed 1600 100 RPM 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 15 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 If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time Q Never drain the float bowl when the engine 1 hot Severe burns may result Fuel Lines Check fuel lines for signs of wear deterioration damage or leakage Replace 1f necessary Q Be sure fuel lines are routed properly and secured with cable ties CAUTION Make sure lines are not kinked or pinched Replace all fuel lines every two years 1 amfi u 1 8 30
85. einstallation first connect the positive wire to the positive terminal of the battery 3 Installation Assembly Generally installation or assembly 1s the reverse of removal or disassembly However if installation or assembly sequence 1 given in this Service Manual follow it Note parts locations and cable wire and hose routing during removal or disassembly so they can be installed or assembled in the same way It is preferable to mark and record the locations and routing whenever possible 4 Tightening Sequence When installing bolts nuts or screws for which a tightening sequence 15 given in this Service Manual mark sure to follow the sequence When installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit thus ensuring that the part has been installed in its proper location Then tighten them to the specified torque in the tightening sequence and method indicated If tightening sequence instructions are not given tighten them evenly in a cross pattern Conversely to remove a pat first loosen all the bolts nuts or screws that are retaining the part a 1 4 turn before removing them 5 Torque When torque values are given in this Service Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench 6 Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems e
86. ew ones if they cannot be cleaned satisfactorily 8 fluid quickly ruins painted surface any spilled fluid should be completely washed away immediately 9 If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Brake Fluid Recommendation Recommended fluid 1 given in the table below If none of the recommended fluid 1 available use extra heavy duty brake fluid only from a container marked DOT 3 or 4 3 20 Brake Fluid Level Inspection Position the reservoir horizontal and check that the fluid level the reservoir 1s 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 1s already the reservoir And then install the reservoir cap A WARNING Change the fluid in the brake line completely if the fluid must be refilled but the type and brand of the fluid that is already in the reservoir are unidentified Tighten Torque Reservoir Cap Screws 1 5 N m 0 15 kg m 13 in Ib Brake Fluid Change Removal the reservoir cap and the rubber on the bleed valve Attach a clear plasti
87. fuel flow Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level too high Float valve worn or stuck open starting technique faulty when flooded crank the engine with the throttle fully opened to allow more air to reach the engine Fuel air mixture incorrect Pilot screw and or idle adjusting screw maladjusted Pilot jet or air passage clogged cleaner clogged poorly sealed or missing Starter Jet clogged No spark spark weak Spark plug dirty broken or maladjusted Spark plug cap or spark plug lead trouble Spark plug cap not in good contact Spark plug incorrect Pickup coil trouble 0 8 70 CDI unit trouble Ignition coil trouble Battery voltage low Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or Spark plug lead trouble Spark plug cap shorted or not in good contact Spark plug incorrect CDI unit trouble Pickup coil trouble Ignition coil trouble
88. g Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting Q Turn the charger off or unplug it then disconnect it from the battery Q Check battery condition If the battery condition indicates that is not fully charged additional charging time is necessary Battery Test Charging If the battery is suspected of being defective sulfated or unable to take a charge consult the table test charge a battery perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below Ifthe battery voltage suddenly jumps to over 13 V just after the start of charging the plates are probably sulfated A good battery will rise to 12 V immediately and then gradually go up to 12 5 or13 V in about 30 min to an hour after the start of charging If there does not appear be enough sediment in a cell to short the plates but that cell has a very low specific gravity after the battery is fully charged the trouble may be that there is not enough acid in that one cell In this case only sulfuric acid solution may be added to correct the specific gravity Ifa fully charged battery not in loses its charge after 2 to 7 days or if the specific gravity drops markedly the battery is defective The self discharge rate of a good battery is only about 1 per day 7 80
89. ghter to 20 Nim 3 Looseri by 180 degrees 4 Loosen by 180 degrees 5 Tighter to 35 Nm t 6 Turn by 80 to 90 degrees clockwise WP apt 7 Turn by additional 80 to SO degrees clockwise Gasket Cylinder 6 370 OINLI lt ENGINE 3 CRANKSHAFT amp PISTON tr Offset the Piston Ring gaps by approxi mately 120 te each other es cma 55 ke n Piston Ring Set Ness S incen Et pt 7 gt Needle Bearing is Mag Side Clutch Side p E i ER 522 T a 1 doma wm 4 Crank Sprocket ih d Primary Gear e f Drive Balancer Shaft CP 110 130 N m 6 38 ENGINE 4 INTAKE amp EXHAUST F zu i i ws wt Camshaft A 3 EX CP Tay LE E i E Chain Guide F 1 Fi LN L VETTER J m i FI 1111111 z i i i j i Exhaust Valve Tensioner Assy Tensioner 0 bl UR us 1 6 39 ENGINE 3 CLUTCH No 1 B Clutch Friction
90. htening Torque 9 11 N m Fastener M8 X I2L 1 pc Note Make sure the Reverse Arm Spring orientation Apply TB 1316 to Stopper Pin threads and tighten to the specified tightening torque Tightening Torque 20 26 N m e Align the locator pin of Shift Drum at the groove of Shift Cam and assemble Fix with Shifter Pin Tightening Torque 20 26 N m Note When re using Shifter Pin apply TB 1316 to threads Adhesive 15 applied onto new Shifter Pin threads 6 19 INL I ENGINE Apply TB 1316 to M6 Stepped bolt threads and fix Stopper Arm CP and Spring Stopper with M6 Stepped bolt Tightening Torque 9 11 N m Fastener M6 Stepped bolt 1 pc Note Make sure the Spring Stopper orientation Assembly Oil Pump Assy as shown in the illustration in advance 1 Oil Pump Case 1 2 Oil Pump Case 2 3 Inner Rotor Feed 4 Outer Rotor Feed 5 Inner Rotor Scavenge 6 Outer Rotor Scavenge 7 Oil Pump Shaft 8 Dowel Pin 2 pcs Insert shorter pin 3 X 15L into the hole of Oil Pump Shaft and then assemble with Inner Rotor Scavenge e Set Pump Case 1 into Oil Pump Shaft
91. its small hole lacates on top N is i r Fi I a A a i i 4 bI NN u E R AO i E i 1 m a ka tr ds 7 i LH LI md 1 d rer kh k td Impeller 1 Gasket Water Pump WT HB Water Pump Case x 7 B n m Ed pon The copper gasket is used in this position only 6 440 ENGINE E ad LI ATTACHMENT 6 Service Data Cylinder Head and Valve Compression Pressure Engine cranking speed at 400 rpm 588 618 KPa 6 0 6 3 Kgf cm 0 150 x 0 05 mm Valve Clearance Cold engine 42 35 42 45 mm 42 05 mm 42 35 42 45 mm Inner diameter of Camshaft bearing Camshaft Outer diameter of Camshaft bearing Oil clearance of camshaft bearing 5 950 5 965 mm Outer diameter of Valve Stem ae Marginal width of Valve face portion Valve and Valve Guide 6 000 6 012 mm Inner diameter of Valve Guide 6 45 JINL ENGINE bs Cylinder and Piston LI NEN sama _ Cylindricality Piston Ring Clearance between cylinder and piston 0 030 0 065 mm Piston Pin Inner diameter of Piston Pin hole 23 001 23 007 mm
92. ive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Front or rear final gear case overheating Insufficient oil Bevel gears maladjusted Converter Operation Faulty Belt slipping Belt dirty worn or wetted Drive or driven pulley sheave dirty or worn Drive pulley spring broken or weak Converter engagement speed too low Drive pulley spring broken or weak Converter engagement speed too high Belt drive or worn Drive or driven pulley sheave dirty worn Drive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Drive or driven pulley movable sheave bush worn Drive pulley weight or roller worn Shifting too quickly Drive pulley spring weak Driven pulley spring weak or incorrectly installed too loose Shifting too slowly Belt dirty or worn Drive or driven pulley sheave dirty or worn D rive pulley weight doesn t move smoothly Drive pulley movable sheave doesn t move smoothly Driven pulley spring incorrectly installed too tight Drive pulley movable sheave doesn t move smoothly Gear Shifting Faulty Doesn t go into gear Shift arm bent or seized Gear stuck on the shaft Shift tie rod maladjusted Shift tie rod damaged Jumps out of gear Shifter groove worn Gear dogs worn Shift block worn Shift arm positioning bolt spring weak or broken Shift tie rod maladjusted Drive shaft output shaft and or gear worn
93. k to see that rim lines A on both sides of the tire are parallel with the rim flanges If the rim lines and the rim flanges are not paralleled deflate the tire lubricate the sealing surfaces again and re inflate the tire After the beads are properly seated check for air leaks Apply a soap and water solution around the tire bead and check for bubbles Detlate the tire to the specified pressure Check the tire pressure using an air pressure gauge Tire Air Pressure when cold Front 50 kPa 7 0 psi Rear 50 kPa 7 0 psi Install the wheel see Wheel Installation Wipe off the soap and water solution on the tire and dry the tire before operation A WARNING Do not operate the vehicle with the water and soap still around the tire beads They will cause tire separation and a hazardous condition may result Tire Inspection Examine the tire for damage and wear Vertical Sides Worn Away O If the tire 1s cut or cracked replace it OLumps or high spots on the tread or sidewalls indicate internal damage requiring tire replacement Remove any foreign objects from the tread After removal check for leaks with a soap and water solution Check the shape of the tread knobs If no vertical side 15 left on the drive side of the knobs replace the tire 1 2 80 WHEELS TIRES
94. kcase 1 assemble cases by lightly and carefully tapping with hummer to fit mating surfaces properly without decline Note Hold Connecting Rod to keep the position of the groove on the end surface of Balancer Shaft e Tighten bolts to the specified tightening torque Tightening Torque 9 11 N m Fastener Case 1 side MOXAOL 7 pcs M6X75L_ 7 pcs M6X50L 1pc Case 2 M6X75L pc Note After tightening all bolts securely make sure Crankshaft 1 smoothly rotated Install Position Switch Caution Install Position Switch after assembling Crankcase 1 and 2 without fail If the switch is installed onto Crankcase advance it will be depressed by Shift Drum and damaged when assembling nsert Spring Point into the hole on the end surface of Shift Drum Then insert Point Neutral Apply oil onto O ring of Position Switch and set the switch Tightening Torque 3 5 N m Fastener 5 X20L 2pcs 1 6 18 e Set the case assembly onto Special Tool Engine Base Plate AY Apply TB 1344 to Reverse Arm Lever threads M6 install along with Reverse Arm Spring Tig
95. l Tighten the lock ring Squeeze the lever fully and release Slightly squeeze the lever again until a slight resistance is felt Measure the freeplay again If necessary repeat the adjustment procedure until proper freeplay 15 attained Replace the clutch perch pivot boot over the screw and lock ring 8 61 APPENDIX DINLI Xn 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 Engine Doesn t Start Starting Difficulty Starter motor not rotating Neutral switch trouble Starter motor trouble Battery voltage low Relays not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn Starter motor clutch trouble Recoil starter not operating Recoil starter spring broken Recoil starter pawl not engaging Engine won t turn over Valve seizure Rocker arm seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Balancer bearing seizure No
96. liding portion at total 6 points upper middle and lower positions and and Y directions by means of micrometer Service Limit of Valve Guide OD 5 950 to 5 965 mm 5 945 to 5 960 mm Clearance between Valve stem and Guide Service Limit of Clearance Width of Valve face Measure the marginal width of valve face portion e f the result 1 out of specifications replace with new valve service Limit of marginal width 0 5 mm 6 80 Valve Spring free length Measure the free length of inner and outer Valve Spring e f the result 1 out of specifications replace with Spring as a set Service Limit of free length CAMSHAFT Cam profile height e Check for damage and ware on cam profile portion Measure the height of cam profile Service Limit of cam profile height Oil clearance at cam journal portion Measure the ID of cam journal portion with Cam Support fixed to the specified tightening torque 9 11 N m ID of cam journal portion 25 000 to 25 021 mm e Measure the OD of Camshaft journal portion with micrometer OD of Camshaft journal portion 24 946 to 24 963 mm clearance is ID minus
97. not function on the first application of the level if this is not done 3 60 srake DINLI 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 Brake Pad Installation Push the caliper piston in by hand as far as it will go Be sure that the anti rattle spring 1s in place Install the pads Tighten Torque Pad Mounting Bolts 18N m 1 8kg m 13 0ft Ib A 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 disc The brakes will not function on the first application of the level if this is not done Brake Pad Wear Inspection Check the lining thickness A of the pads in each caliper If the lining thickness of either pad is less than the service limit B replace both pads in the caliper as a set Pad Lining Thickness Standard 4 5mm Service Limit 2mm 1 3 70 DINLI zikr
98. nt parts 18 Electrical Wires the electrical wires are either one color or two color two color wire 15 identified first by the primary color and then the stripe color For example a yellow wire with thin red stripes 15 referred to as a yellow red wire it would be a red yellow wire if the colors were reversed Unless instructed otherwise electrical wires must be connected to wires of the same color 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there 1 any doubt as to the condition of them replace them with new ones Warp 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or deteriorated performance replace the damaged parts 1 40 GENERAL INFORMATION QQ wi NLI Model Identification Engine serial number Vehicle identification number ENGINE SERIAL NUMBER Ex EW450SR00100000xxx 9 nd AX VEHICLE IDENTIFICATION RFWAK85CX6TXxxxxx Whenever corresponding with DINLI about a particular i
99. nut A anti clockwise and disconnect the front indicator light wire B to remove the mirror Reverse above procedure to assemble the new mirror O Besure to connect wiring with correct color as following chart Green Orange Neutral Light Bulb Replacement Please refer the Headlight Bulb Replacement Fuses Main Fuse Removal Remove the seat see Frame chapter Remove the fuse case A and take out the fuse 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 15 equal to or greater than the fuse rating check the wiring and related components for a short circuit When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components 7 15 DINEI ELECTRICAL SYSTEM lt Wiring Diagram
100. on of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE This note symbol indicates points of particular interest for more efficient and convenient operation Indicates a procedural step or work to be done Indicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub step it follows 0 30 FOREWORD INDE Xo OINLI CHAPTER INDEX CHAPTERI GENERAL CHAPTER2 WHEELS IIRES CHAPTER3 BRAKE CHAPTER4 SUSPENSION CHAPTERS FRAME CHAPTER6 ENGINE CHAPTER7 ELECTRICAL CHAPTERS APPENDIX 0 40 2INL hA 4 OREWORD INDEX 0 50 GENERAL INFORMATION NLI GENERAL INFORMATION Table of Contents Before Servicing 1 2 Model Identifications
101. orrect 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 1 correctly positioned Tighten the nut A Check the brake pedal free play see Brake Pedal Free Play Inspection Brake Pedal Free Play Inspection Check the brake pedal free play A Depress the brake pedal lightly by hand until the brake is applied If the free play is incorrect adjust it Pedal Free Play Standard 2 2 0 5 mm Brake Pedal Removal Remove Cir clip B Pin C Master Cylinder Joint A Pulling down the springs where circled remove the brake pedal 3 10 srake DINLI Brake Pedal Installation Please reverse the Removal steps to install the brake pedal 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
102. osos LT LIT T ewe TT T T T T P T Tl TT Pee eee Valve Clearance Before Adjusting mm Exhaust Adjusting Pad Selection Matrix aS SOP SS SOAS OTTO 2 2 50092195 97 5 50 Existing Adjusting Pad Suitable Adjusting Pad wwe 8415154154155155164164 621661611417315 7711860 821185182 90092157 won pie ro iraprs rr sofas ss 197 22 jo7 212 O12016 95150055 5 1606 rez ies err isa sfr oz ros rer poo ao o a pao ron jespsessisspeo ieoneapispier rropajrs rrjisoisaprss is ienprea ies ier aon poa oos oor 12 2025 isspeopesprerpropapos permisos onpozpasporfiopiopispanpaopaspao 162161172115171 285 ez reopisa estre goopozposprropisprspaopaopespesgso 116717277 eo reafrs iz aon oa por opiaprspaopoopospzspsopo Trapa iss ienfeorea ies ror poo osporirepizprspaopaopaspespsopio 77 rs2 187 190 i92 5jr97 poo po2 os por io 212J 15p2o220225225 30 3o zJis s7iro2 195 i97 o0 202 20220252250 202
103. r in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again O Make sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc poor wires and bad connections will affect electrical system operation Measure coil and winding resistance when the parts 15 cold at room temperature Color codes Green P Pink B G Light green Electrical Connectors Female Connectors A Male Connectors B 7 50 DINEI 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 Connect the hand tester between the ends of the leads O
104. re of Colette fitting securely to Valve Retainer Do not depress Valve Spring extremely e Fit Adjusting Pad and Valve Lifter Note Keep Adjusting Pad and Valve Lifter fitting the original positions e Fit two pipe knocks and Head Gasket 6 230 DINED ENGINE Install Cylinder Head Apply oil to M11 bolts threads and washer and then tighten them in the following procedure As shown in Attachment 5 Fastener M11 X 198L 4 pcs e Tighten MO bolts Tightening Torque 9 11 N m Fastener 6 X 401 2 pcs Install Chain Lever with pivot bolt Tightening Torque 13 5 16 5 N m Fastener M8 X 22 5L Pivot bolt pc e Put Timing Chain from the Cylinder Head side and set in position as shown in Attachment 2 e Hit Crank Sprocket with the chamfer portion inside and with each spline aligned 6 240
105. reful not mix it up inboard pads with the out board pad Tighten Torque Pad Mounting Bolts 15N m 1 S5kg m 13 0ft Ib A 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 disc The brakes will not function on the first application of the level if this is not done 3 120 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 Loose the master cylinder mounting bolts D 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 Torque Brake Hose Banjo Bolt 25N m 2 5kg m 18 0ft Ib Check the fluid level A In the brake reservoir Bleed the brake line after master cylinder installation see Brake Line Air Bleeding Check the brake for good braking power no braking brag and no fluid leakage A WARNING Do not attempt to drive the vehicle until a full brake le
106. ressure unbalanced Front shock absorber unbalanced Shock absorption unsatisfactory Too hard Tire air pressure too high Shock absorber maladjusted Too soft Shock absorber oil leaking Shock absorber spring weak Tire air pressure too low Shock absorber maladjusted 0 8 90 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 plates sulfated shorted through Sedimentation electrolyte level too low Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Regulator rectifier trouble Alternator trouble Wring faulty Battery Over charged Regulator rectifier trouble Battery trouble 8 100 DINLI METAL INDUSTRIAL CO LTD wew dinliglobal com D N D4022 0001 EDITION O1 PRINTED 2006
107. round 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 1s not properly maintained Bend and twist the brake hose while examining it Replace it if any cracks or bulges are noticed Brake Hose Replacement Pump the brake fluid out of the line as explained in the Brake Fluid Change Remove the banjo bolts at both ends of the brake hose and pull the hose off the vehicle Immediately wipe up any brake fluid that spills Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately Use a new flat washer for each side of the hose fittings Install the new brake hose in its place and tighten the banjo bolts Torque Brake Hose Banjo Bolts 25N m 2 5kg m 18 0ft Ib 1 3 90 DINLI pp x7 Brake Pedal Position Inspection Check that the brake pedal A 1s in the correct position as shown Pedal Position C Standard 41 46 mm above footrest If it is c
108. rs place Crankcase 1 with the mating surface upwards e nstall Balancer Shaft with the markings between Drive Gear of Crankshaft and Driven Gear of Balancer Shaft aligned Install Reverse Shaft CP 6 15 INL I ENGINE e Install Main Shaft Assy and Counter Shaft Assy with gears engaged into Crankcase 1 Note Pay attention not to miss washer fitting to Counter Shaft Be sure not to damage the lip portion of oil seal by the Counter Shaft end spline e nstall Shifter Fork Main facing the ID marking M upwards into the groove of Main Shaft Install Shifter Fork Right facing the ID marking upwards into the upper groove of Counter Shaft Install Shifter Fork left facing the ID marking L upwards into the lower groove of Counter Shaft Install Shift Drum CP the pin side upright condition Set each pin of Shift Forks into applicable groove of Shift Drum nsert Spring Fork Shaft into the hole Inner diameter 11 mm each of Shift Fork Right and Left Insert Fork Shaft into Shift Fork Right and Left Insert Fork Shaft into
109. rvice Data 6 45 7 Adhesive Sealant and Oil application 6 47 8 Periodic Maintenance Schedule 6 48 9 Specifications 6 49 0 6 10 INL I ENGINE Removal and Installation Thoroughly clean the engine and chassis Clean work area Drain coolant and engine oil Disassembly Set the engine assembly onto Special Tool Engine Base Plate AY e Take out Cover CP Drive Chain and Plate Drive Chain Operate Shift Pedal to engage the transmission gears Remove bolts and take out Fixing Plate and then remove Sprocket 14T Remove Shift Pedal e Remove Reverse Arm Lever Reverse Lock e Remove Carburetor e Remove upper side banjo bolt oil fitting first after that other bolts and then take out Oil Delivery Pipe Assy Note Pay attention not to lose total 6 copper washer 6 21
110. specially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removing screws held by non permanent 1 20 GENERAL INFORMATION NLI locking agent in order to avoid damaging the screw heads 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 9 Gasket O Ring Replace a gasket or an O ring with a new part when disassembling Remove any foreign matter from the mating surface of the gasket or O ring to ensure a perfectly smooth surface to prevent oil or compression leaks 10 Liquid Gasket Locking Agent Clean and prepare surfaces where liquid gasket or non permanent locking agent will be used Apply them sparingly Excessive amount may block engine oil passages and cause serious damage 11 Press When using a press or driver to ins
111. ssues the engine number and serial number are important for vehicle identification LU 1 50 7 GENERAL INFORMATION bs General Specification NOTE Specifications subject to change without notice Engine 4 4 stroke DOHC r r r rkr DOHC 94mm x 64 6 mm Displacement Coolant system Liquid cooled 1 1 water anti freeze ethylene glycol containing corrosion inhibitors for aluminum engines and radiators Alternator Output DC14V 13 7A 3000rpm Note Permissible operating temperature 10 C 45 Q Coolant 1 60 GENERAL INFORMATION NLI CHASSIS Overall height 115 cm Wheel base 1830 mm Front tire 22 8 0 Recommended cold tire pressure front rear 35kpa 35kpa Ground clearance unloaded l 1 70 amp JINIL 7 GENERAL INFORMATION Periodic Maintenance Chart Perform a Pre Ride inspection before every ride and at schedule maintenance periods C Clean Interval whichever comes first R Replace L Lubricate I Inspect Verify Clean Adjust Lubricate Replace if Regular Maintenance Interal houre necessary Riding Gw O FRAME m
112. t TDC position in the following procedures Valve Clearance IN 0 15 0 05 mm Cold condition EX 0 27 0 05 mm e Temporally fit original Adjusting Pad and check the valve clearance n accordance with the matrix table Attachment 3 make sure the relationship between checking results and listed figures 3 digits e Select applicable Adjusting Pad and fit it In place with original one e Check again valve clearance and make sure it is within the specifications e If out of the specifications repeat the procedures e Fit One way Valve Tightening Torque 15 21 N m Note Make sure One way Valve Assy is placed in position and then fix plug Install Water Pump e Fix Impeller along with Seal Washer by means of Special Tool Wrench Counter Shaft adopted to Counter Shaft Tightening Torque 9 11 N m e Fit Case along with Gasket Tightening Torque 9 11 N m Fastener M6 X 25L 7 pcs Note At the bottom one position fit the cupper gasket without fail 1 6 26 Install Flywheel e Fit Spacer with the chafer side inside onto Crankshaft on the
113. t will not overheat and thus is often called a colder plug If a spark plug with a heat range is used that is a cold plug that cools itself too well the plug will stay too cool to burn off the carbon and the carbon will collect on the electrodes and the ceramic insulator 8 40 APPENDIX L 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 e Remove the spark plug and inspect the ceramic insulator Whether or not the right temperature plug 1s being used can be ascertained by noting the condition of the ceramic insulator around the electrode A light brown color indicates the correct plug is being used If the ceramic is black it indicates that the plug 1 firing at too low a temperature so the next hotter type should be used instead If the ceramic 1s white the plug 1s operating at too high a temperature and it should be replaced with the next colder type If the spark plug is replaced with a type other than th
114. tall a part such as a wheel bearing apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit 12 Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless it is absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver Apply force only to the end of the race that contacts the press fit portion and press it evenly over the base component 13 Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally damages seals Oil or grease seals should be pressed into place using a suitable driver applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole unless instructed otherwise When pressing in an oil or grease seal which has manufacturer s marks press it in with the marks facing out 14 Cir clip Retaining Ring and Cotter Pin When installing cir clips and retaining rings take care to compress or expand them only enough to install them and no more Install the cir clip with its chamfered side facing load side as well Replace any cir clips retaining rings and cotter pins with new ones as removal weakens and deforms them they could become detached while the quad 15 driven leading to a major problem 1 30 7 GEN
115. tem 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 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 This is to prevent damage to the diodes and CDI unit Use the standard regulator rectifier or the CDI unit will be damaged Spark Plug Removal Installation Remove or install the spark plug using the spark plug wrench A from the vehicle right side Torque Spark Plug 14 N m 1 4 kgf m 10 0 ft lb Spark Plug Cleaning Inspection Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool If the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug or its equivalent Spark Plug Gap Measure the gap A with a wire type thickness gauge Ifthe gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap 0 8 0 9 mm
116. the tie rod end 4 100 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 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 and then the front bolts Torque Handlebar Holder Bolts 27 N m 2 8 kgf m 20 ft Ib O If the holder is correctly installed there will be no gap at the rear and an even gap at the front after tightening Fires T Fo hexond 4 11 DINLE su spENSION STEERING NOT E 4 120
117. the tightness of the steering bolts and nuts Tighten loose bolts and nuts to the specified torque see Exploded View and check the steering action again If the steering action does not change by tightening the bolts and nuts inspect the steering stem clamps steering stem bearing tie rod bearings and steering knuckle joints Steering Stem Warp Remove the steering stem see Steering Stem Removal Check the steering stem for straightness O Use a straightness along the stem If the steering stem is bent replace the steering stem 1 4 90 INES s S PENSION 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 O 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 If roughness excessive play or seizure is found replace both clamps Tie Rod End and Steering Knuckle Joint Inspection Inspect each spherical bearing If roughness excessive play or seizure is found replace the tie rod end or steering knuckle joint If damage wear or deterioration is found replace
118. there might be air in the brake line or the brake may be defective Since it is dangerous to operate the vehicle under such condition bleed the air from the brake line immediately Brake Line Air Bleeding Bleed the air whenever brake parts are replaced or reassembled Removal the reservoir cap and fill the reservoir with new brake fluid Slowly pump the brake level several times until no air bubbles can be seen rising up through the fluid from the hose at the bottom of the reservoir This bleeds the air from the master cylinder and the brake line NOTE Tap the brake hose lightly going from the caliper to the reservoir side and bleed the air off at the reservoir Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a container Bleed the brake line and the caliper as follows Hold the brake level applied O Quickly open and close the valve O Release the brake level C The fluid level must be checked several times during the bleeding operation and replenished as necessary 1 3 40 srake NOTE O If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be done over
119. 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 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 Front Shock Absorber Inspection Since the front shock absorbers are sealed units which cannot be disassembled only external checks are necessary If one unit is damaged replace both shock absorbers as a set If only one unit is replaced and the two are not balance vehicle at high speed may endanger driver s safety Front Shock Absorber Preload Adjustment The spring adjusting sleeve on rear shock absorber has 5 positions so that the spring can be adjusted for different terrain and loading conditions If the spring action feels too soft or too stiff adjust it in accordance with the following table Turn the adjusting sleeve on front shock absorber to the desired position with the wrench Rear Shock Absorber Removal Support the vehicle on a stand or the jack so that the rear wheels are off the ground While holding the rear wheels remove the lower and upper shock absorber mounting bolts and nuts Remove the rear shock absorber Rear Shock Absorber Installation Tighten Torque Rear Shock Absorber Mounting Nuts 6 2 N m 6 3 kgf m 46ft Ib See the Front Shock Absorber Preload Adjustment 4 2
120. vel 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 3 13 DINLI zikr 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 8kg m 27ft Ib After installing the discs check the disc runout see Disc Runout Completely clean off any grease that has gotten on either side of the disc with a high flash point solvent Check the disc wear see Disc Wear 3 140 SUSPENSION STEERING _ lw
121. ver set to press in the tapered roller bearing outer races and grease seals Swingarm Bearing Inspection Move the swingarm up and down to check for abnormal friction and push and pull it back and forth to check for bearing play If abnormal friction 15 felt the bearings are damaged Replace the grease seals and both left and right bearing The play developed during use may indicated bearing damage In this case remove the swingarm and inspect the bearings Replace both left and right bearings 1f one of the bearing is damaged Swingarm Bearing Lubrication Remove the swingarm Using a high flash point solvent wash the bearings clean of grease and dry them Inspect the bearings and grease seals for abrasion color change or other damage Apply grease to the outer races and pack the tapered roller bearing with the same grease Apply grease to the inside of the grease seals 1 4 50 INES s S PENSION STEERING Steering Stem Removal Remove Speedometer Cover Bolts Speedometer Cover B Handlebar Holder Bolts 4 C Handlebar D Front Cover see Frame Chapter Remove Steering Clamp Bolts A
122. with the sealed state of the battery 3 Check the charging conditions with a voltmeter Normal charging voltage should be 12 8V 4 This battery may be installed on if replaces a similar sealed type battery 5 Keep away from high temperature of fire 6 In the case of an accident sulfuric acid may escape Avoid contact with skin eyes or clothing Charging Method Normal Charge 1 4 5 10 hrs Fast Charge 14A 0 5 hrs New Battery Use of conventional lead acid batteries 1s not recommended Batteries must be NEVER attempt to add electrolyte or water to the maintenance free design and construction Doing so will damage the case and shorten the life of the battery 0O 7 70 DINEI 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 Always remove the battery from the vehicle for charging 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 Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shortin

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