Dinli DL-801 Wartungshandbuch

【1-3】GENERAL INFORMATION (7) Edges Watch for sharp edges, as they could cause injury through careless handing, especially during major engine disass

【7-9】ELECTRICAL SYSTEMRegulator / Rectifier Output Voltage Inspection ● Check the battery condition (see Battery section) ● Warm up the engine t

【7-10】ELECTRICAL SYSTEMAlternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor m

【7-11】ELECTRICAL SYSTEMIgnition System WARNING△ The ignition system produces extremely high voltage. Do not touch the spark plug, ignition coil, o

【7-12】ELECTRICAL SYSTEMIgnition Coil Installation ● Connect the primary winding leads to the ignition coil terminals Ignition Coil Inspection ●

【7-13】ELECTRICAL SYSTEMIgnition Timing Test ● Remove the plug to expose the timing hole [A]. ● Attach the timing light and a tachometer in the ma

【7-14】ELECTRICAL SYSTEMLighting System Headlight Bulb Replacement ● Remove: Bulb Holder Screws [A]*2 Bulb Holder Bolts [B]*2 Bulb Holder

【7-15】ELECTRICAL SYSTEMTaillight Bulb Replacement ● Remove: Taillight Holder Nut [A] Taillight ● Remove: Taillight Lens Screws [B] Tai

【7-16】ELECTRICAL SYSTEMRear-View Mirror Replacement ● Loosen the nut [A] anti-clockwise and disconnect the front indicator light wire [B] to remove

【7-17】ELECTRICAL SYSTEMFuses Main Fuse Removal ● Remove the seat (see Frame chapter) ● Remove the fuse case cap [A] and take out the fuse [B].

【7-18】ELECTRICAL SYSTEMWiring Diagram

【1-4】GENERAL INFORMATION(15) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces

【7-19】ELECTRICAL SYSTEMWiring Diagram

【7-20】ELECTRICAL SYSTEMNOTE:

【8-1】APPENDIX Appendix Table of Contents Considerations for Various Riding Conditions-----------------------------

【8-2】APPENDIX Considerations for Various Riding Conditions This vehicle has been designed and manufactured to operate under a wide range of ridi

【8-3】APPENDIX● Readjust idle speed to specification. Note: Always check throttle cable freeplay after adjusting idle speed and adjust if necessary.

【8-4】APPENDIX Spark Plug: The spark plug ignites the fuel and air mixture in the combustion chamber. To do this effectively and at the proper ti

【8-5】APPENDIXThe carbon on the electrodes conducts electricity, and can short the center electrode to ground by either coating the ceramic insulator

【8-6】APPENDIX Fuel System ● Always stop the engine and refuel outdoors or in a well ventilated area. ● Do not smoke or allow open lames or sparks

【8-7】APPENDIXTroubleshooting Guide NOTE ○This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as

【8-8】APPENDIX Other: Carburetor vacuum piston doesn’t slide smoothly Engine oil viscosity too high Brake dragging CDI unit trouble Front or r

【1-5】GENERAL INFORMATION Model Identification Engine serial number Vehicle identification number ENGINE SERIAL NUMBER (Ex. 13G6500xxx)

【8-9】APPENDIX Over shifts: Shift arm positioning bole spring weak or broken Shift tie-rod maladjusted Abnormal Engine Noise: Knocking

【8-10】APPENDIX Break Doesn’t Hold Front brake: Air in the brake line Brake fluid leakage Brake fluid deteriorated Primary or secon

【1-6】GENERAL INFORMATION General Specification NOTE: Specifications subject to change without notice. Model DL-801 Engine 4-stroke, DOHC Bore and s

【1-7】GENERAL INFORMATION CHASSIS Frame Steel Overall length 1682 mm Overall width 1060 mm Overall height 1082 mm Seat height 810 mm Wheel ba

【1-8】GENERAL INFORMATION Periodic Maintenance Chart Perform a Pre-Ride inspection before every ride and at schedule maintenance periods. Interval (

【2-1】WHEELS/TIRESWheels/Tires Table of Contents Specifications-------------------------------------------------------------------------------------

【2-2】WHEELS/TIRES Specifications Item Standard Service Limit Wheel Alignment: Toe-in 2WD 25~40 mm - - - T

【2-3】WHEELS/TIRESWheel Alignment Toe-in is the amount that the front wheels are closer together in front than at the rear at the axle height. When t

【2-4】WHEELS/TIRES ●Repeat the straightedge procedure on the other side of the vehicle, now the front wheels are parallel to each other and to th

【0-0】FOREWORD/INDEX

【2-5】WHEELS/TIRES●Check the toe-in. ●Tighten: Torque - Tie-Rod Adjusting Sleeve Locknuts: 33 N-m (3.4 kgf-m, 45 ft-lb) ●Test ride the vehicle. Whee

【2-6】WHEELS/TIRES Wheel (Rim) Inspection ●Examine both sides of the rim for dents [A]. If the rim is dented, replace it. ●If the tire is remov

【2-7】WHEELS/TIRES CAUTION Do not lubricate the tire beads and rim flanges with engine oil or petroleum distillates because they will deteriorate the

【2-8】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 s

【2-9】WHEELS/TIRESFront Hub Removal ●Remove the cotter pin [A] and loosen the axle nut [B]. ●Remove the wheel (see Wheel Removal). ●Remove the

【2-10】WHEELS/TIRES Rear Hub Rear Hub Installation ●Grease the axle spindle. ●Apply non-permanent locking agent: Rear Axle Nuts [A] ●Tighten: Torque

【3-1】BRAKEBrake Table of Contents Brake Fluid-----------------------------------------------------------------------------------------------------3

【3-2】BRAKE Brake Fluid WARNING△ When working with the disc brake, observe the precautions listed below. 1.Never reuse old brake fluid. 2.Do not use

【3-3】BRAKEBrake Fluid Level Inspection ●Position the reservoir horizontal, and check that the fluid level in the reservoir is higher than the lowe

【3-4】BRAKE WARNING△ Do not mix two brand of fluid. Change the brake fluid in the brake line completely if the fluid must be refilled but the type

【0-1】FOREWORD/INDEX DINLI 270 cc QUAD Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval

【3-5】BRAKENOTE ○If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the

【3-6】BRAKE WARNING△ Do not attempt to drive the vehicle until a full brake level is obtained by pumping the brake level until the pads are against

【3-7】BRAKEBrake Pad Removal ●Remove the front wheel (see Wheels/Tires chapter). ●Remove the caliper (see Caliper Removal) ●Push the anti-rattle spri

【3-8】BRAKE Disc Cleaning Poor braking can be caused by oil on a disc. Oil on a disc must be cleaned off with an oil cleaning fluid such as t

【3-9】BRAKEDisc Runout ●Jack up the vehicle so that the wheels are off the ground. ●Remove the front wheels and turn the handlebar fully to one side.

【3-10】BRAKE Brake Pedal Position Inspection ●Check that the brake pedal [A] is in the correct position as shown. [B] step Pedal Position [C] S

【3-11】BRAKECaliper Removal ●Removal the Rear wheel (see Wheels/Tires chapter). ●Loose the banjo bolt [A] at the brake hose lower end, and tighten it

【3-12】BRAKE Rear Brake Pads Removal ●Remove the caliper (see Caliper Removal) ●Remove the Cir-clip [A] and bolt [B] ●Remove: Anti-rattle Spring

【3-13】BRAKEMaster Cylinder Removal ●Remove the master cylinder joint [A] and the banjo bolt [B] at the brake hose lower end, and tighten it loosely.

【3-14】BRAKE Brake Disc Removal ●Remove the rear caliper, unscrew the banjo bolt and remove the brake hose from the caliper. ●Loose the brake disc mo

【0-2】FOREWORD/INDEX Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. A basic knowledge of mecha

【4-1】SUSPENSION/STEERINGSuspension & Steering Table of Contents Shock Absorbers----------------------------------------------------------------

【4-2】SUSPENSION/STEERINGFront Shock Absorber Removal ●While supporting the vehicle to up with the jack. ●Remove: Front Shock Absorber Mounting

【4-3】SUSPENSION/STEERING Rear Shock Absorber Preload Adjustment ●See the Front Shock Absorber Preload Adjustment Suspension Arm Removal ●Remove:

【4-4】SUSPENSION/STEERINGSuspension Arm Assembly ●When installing the rubber bushing into the arm, lubricate the outer surface of the bushings with a

【4-5】SUSPENSION/STEERINGSteering Stem Removal ●Remove: Speedometer Bracket Bolts [A] Speedometer Bracket [B] Handlebar Holder Bolt

【4-6】SUSPENSION/STEERING Steering Stem Installation ●Lubricate the steering stem clamp, grease seals, (see Steering Lubrication). ●Install the gre

【4-7】SUSPENSION/STEERINGSteering Knuckle Installation ●Clean the sealing surface [A] and the hole [B]. ●Grease the sealing surface. ●Tighten: Torqu

【4-8】SUSPENSION/STEERING CAUTION Do not remove the grease seal. It is packed with grease. Tie-Rod End Installation ●Install the tie-rod ends so tha

【4-9】SUSPENSION/STEERINGSteering Lubrication ●Lubricate the steering stem clamps. ○Remove the steering stem (see Steering Stem Removal). ○Wipe all t

【4-10】SUSPENSION/STEERINGHandlebar Removal ●Remove: Throttle Switch (see Steering Stem Removal) Front Brake Master Cylinder Left-h

【0-3】FOREWORD/INDEX△WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in pers

【5-1】FRAMEFrame Table of Contents Seat-------------------------------------------------------------------------------------------------------------

【5-2】FRAME Seat Seat Removal ● To remove the seat [A] by pulling the seat latch lever [B] up and then pulling the seat up to the rear.

【5-3】FRAMEFront and Rear Fenders Front Fender Removal ● Remove: Handlebar Cover [A] (see Handlebar Removal) Handlebar [B] Fuel Tank Cap

【5-4】FRAME Rear Fender Removal ● Remove: Air Cleaner Cover [A] Air Cleaner [B] ● Remove: Battery [A] CDI Unit [B] Fuse [C] St

【5-5】FRAMERadiator Removal ● Remove: Water Tube [A], [B] and [C] Connector [D] Fan Connector Radiator Bolts [E] *2 Radiator

【5-6】FRAME Headlight Holder Removal ● Remove: Handlebar (see Handlebar Removal) Front Fender (see Front Fender Removal) Headlight Holder Screw [A]

【6-1】ENGINEEngine Table of Contents ENGINE REMOVAL-----------------------------------------------------------------------------------------6-2 CYLI

【6-2】ENGINE ENGINE REMOVAL ● Drain engine oil and transmission oil. ● Remove frame covers (Refer to the “Frame” chapter). ● Remove the carbure

【6-3】ENGINE● Disconnect the speedometer cable. ● Remove the three bolts at the drive sprocket cover and then remove the drive sprocket c

【6-4】ENGINE Remove the A.C.Generator, pulser and gear change switch couplers. ● Disconnect the spark plug cap. ● Unscrew the clamp and

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

【6-5】ENGINE● Remove the three bolts and nuts for remove the left and right engine brackets. ● Remove the engine assembly to t

【6-7】ENGINECYLINDER HEAD COVER REMOVAL ● Remove the four bolts at the cylinder head cover and then remove the cylinder head cover. INSTALL

【6-8】ENGINE ● Remove the four camshaft holder nuts and washers. NOTE: Diagonally loosen the cylinder head nuts in 2 or 3 times. ● Remove the ca

【6-9】ENGINECAMSHAFT HOLDER INSPECTION ● Inspect the camshaft holder for wear or damage. ● Inspect the rocker arm shaft for blue discoloration or g

【6-11】ENGINECYLINDER HEAD REMOVE ● Remove the camshaft. (Refer to the “Camshaft Remove” section ) ● Remove the carburetor and exhaust muffler.. ●

【6-12】ENGINE VALVE /VALVE GUIDE INSPECTION ● Inspect each valve for bending, burning, scratches or abnormal stem wear. If any defects are found, r

【6-13】ENGINEASSEMBLY ● Install the valve spring seats and oil seal. NOTE: Be sure to install new oil seal. ● Lubricate each valve with engine oi

【6-14】ENGINE CYLINDER/PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder and piston can be serviced with the engine installed in the

【0-5】FOREWORD/INDEX

【6-15】ENGINECYLINDER/PISTON REMOVAL ● Remove the cylinder head. (Refer to “Cylinder Head/Valves”) ● Remove the two dowel pins, cylinder head gask

【6-16】ENGINE INSPECTION ● Inspect the piston, piston pin and piston rings. ● Remove the piston rings. NOTE: Take care not to damage or break the

【6-17】ENGINE● Measure the piston pin O.D. Service Limit: ψ17.06mm replace if below ● Measure the piston O.D. NOTE: Take measurement at

【6-18】ENGINE PISTON RING INSTALLATION ● Install the piston rings onto the piston. ● Apply engine oil to each piston ring. NOTE: Be careful not

【6-19】ENGINEPISTON INSTALLATION ● Remove any gasket material from the crankcase surface. NOTE: Be careful not to drop foreign matters into the cra

【6-20】ENGINE DRIVE AND DRIVEN PULLEYS SERVICE INFORMATION GENERAL INSTRUCTIONS The drive pulley, clutch and driven pulley can be serviced with

【6-21】ENGINELEFT CRANKCASE COVER REMOVAL ● Loosen the drive belt air inlet and outlet hose band screws and disconnect them from the left crankcase

【6-22】ENGINE DRIVE PULLEY REMOVAL ● Remove the left crankcase cover. (Refer to the “LEFT CRANKCASE COVER REMOVAL” section) ● Hold the drive pulle

【6-23】ENGINE● Measure the movable drive face bushing I.D. Service Limit: ψ27.06mm replace if over ASSEMBLY ● Install the weight rollers into th

【6-24】ENGINE CLUTCH/DRIVEN PULLEY REMOVAL ● Remove the left crankcase cover. (Refer to “LEFT CRANKCASE COVER REMOVAL”) ● Remove the drive pulley.

【1-1】GENERAL INFORMATION GENERAL INFORMATION Table of Contents Before Servicing---------------------------------------------------------------------

【6-25】ENGINEFINAL REDUCTION/TRANSMISSION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS The transmission system can be serviced with the engine

【6-26】ENGINE TRANSMISSION CASE COVER REMOVAL ● Drain transmission gear oil into a clean container.(Refer to “Engine Removal” section) ● Remove

【6-27】ENGINETRANSMISSION CASE COVER DISASSEMBLY ● Remove the drive axle cir-clip. ● Remove the drive axle from the transmission case cover. ● Re

【6-28】ENGINE ● Inspect the needle bearing for allow play in the transmission case cover or the bearing turns roughly. If any defects are found, r

【6-29】ENGINE● Remove the stopper plug. ● Remove spring, washer and shift cam stopper. ● Remove the transmission guide bar. ● Me

【6-30】ENGINE ● Inspect shift shaft gear. Damage – Replace. ● Inspect shift shaft. Damage/bends/wear – Replace. ● Remove the main axle.

【6-31】ENGINE● Remove the cir-clip and then remove the washers, reverse wheel gear and needle bearing. ● Inspect the gear teeth. Blue d

【6-32】ENGINE PRIMARY DRIVE AXLE REMOVAL ● Remove the clutch/driven pulley. (Refer to “DRIVE AND DRIVEN PULLEYS”) ● Remove the oil seal and cir-cl

【6-33】ENGINECRANKCASE/CRANKSHAFT/BALANCE SHAFT SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers crankcase separation to service the

【6-34】ENGINE CRANKCASE/CRANKSHAFT/BALANCE SHAFT REMOVAL ● Remove the timing chain from right crankcase. ● Remove the left and right cra

【1-2】GENERAL INFORMATIONBefore Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a

【6-35】ENGINE● Remove balance shaft from the left crankcase. ● Clean off all gasket material from the crankcase mating surfaces. NOTE: A

【6-36】ENGINE ● Measure the crankshaft run out (A). Service Limit: 0.10mm replace if over ● Measure the connecting rod big end side clearance (B

【7-1】ELECTRICAL SYSTEMElectrical System Table of Contents Specifications---------------------------------------------------------------------------

【7-2】ELECTRICAL SYSTEM Specifications Item Standard Battery Capacity 12V ; 12Ah (10hr) Alternat

【7-3】ELECTRICAL SYSTEMParts Location Light/Dimmer Switch [A] Switch [B] Indicator Switch [C] Starter Button [D] Ignition Switch [E] Horn Switch [F

【7-4】ELECTRICAL SYSTEMRegulator/Rectifier [E] Magneto CP [A] Starter Motor [B] Horn [B] Temperature Sensor[C]

【7-5】ELECTRICAL SYSTEMPrecautions There are a number of important precautions that are musts when servicing electrical systems. Learn and observ

【7-6】ELECTRICAL SYSTEMElectrical Wiring Wiring Inspection ● Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor

【7-7】ELECTRICAL SYSTEMBattery Battery Charging WARNING△ Keep the battery away from sparks and open flames during charging, since the battery giv

【7-8】ELECTRICAL SYSTEMCharging Procedure ● Remove the battery (see Battery Removal). ● Connect a charger to the battery BEFORE plugging it in or t