DINLI DL-901 450cc QUAD Service & Repair Manual - !

【0-0】 FOREWORD/INDEX

【0-1】 FOREWORD/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.

【0-2】 FOREWORD/INDEX Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. 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, 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 is located in the General Information chapter. The chart gives a 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.

【0-3】 FOREWORD/INDEX △WARNING This warning symbol identifies special instructions or procedures, which if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures, which if not strictly observed, could result in damage to or destruction of equipment. This manual contains four more symbols (in addition to WARNING and CAUTION), which will help you distinguish different types of information. 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.

【0-4】 FOREWORD/INDEX CHAPTER INDEX CHAPTER1 GENERAL CHAPTER2 WHEELS/TIRES CHAPTER3 BRAKE CHAPTER4 SUSPENSION CHAPTER5 FRAME CHAPTER6 ENGINE CHAPTER7 ELECTRICAL CHAPTER8 APPENDIX

【0-5】 FOREWORD/INDEX

【1-1】 GENERAL INFORMATION GENERAL INFORMATION Table of Contents Before Servicing------------------------------------------------------------------------------------------------1-2 Model Identifications----------------------------------------------------------------------------------------- 1-5 General Specifications-----------------------------------------------------------------------------------------1-6 Periodic Maintenance Chart----------------------------------------------------------------------------------1-8

【1-2】 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 is being carried out, sparks from being generated while disconnecting the wires from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive wire to the positive (+) terminal of the battery. (3) Installation, Assembly Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is 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 is 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 especially 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

【1-3】 GENERAL INFORMATION 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 install 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) Oil 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 is driven, leading to a major problem.

DINLI DL-901 450cc QUAD Service & Repair Manual - !

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