Dinli DL-801 Service Manual Download

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Summary of Contents for DL-801

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Page 3: ...h 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...

Page 4: ...ls 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 chapt...

Page 5: ...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 NOT...

Page 6: ... 0 4 FOREWORD INDEX CHAPTER INDEX CHAPTER1 GENERAL CHAPTER2 WHEELS TIRES CHAPTER3 BRAKE CHAPTER4 SUSPENSION CHAPTER5 FRAME CHAPTER6 ENGINE CHAPTER7 ELECTRICAL CHAPTER8 APPENDIX ...

Page 7: ... 0 5 FOREWORD INDEX ...

Page 8: ... 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 ...

Page 9: ... 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 se...

Page 10: ...t 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 ...

Page 11: ...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 replacement parts 18 Electrical Wires All the electrical wires are either one color or two color A two color wire is identifie...

Page 12: ...rial number Vehicle identification number ENGINE SERIAL NUMBER Ex 13G6500xxx VEHICLE IDENTIFICATION ex RKWAJ74C45Txxxxxx Whenever corresponding with Dinli about a particular issues the engine number and serial number are important for vehicle identification ...

Page 13: ...ors for aluminum engines and radiators Starting system Electric Carburetor WVF 13 Transmission CVT Final drive 2WD chain Engine idle speed 1600 100 min 1 Spark plug standard DPR7EA NGK Spark plug gap 0 6 0 7 mm Lubrication system Wet sump Lubricant 4 cycle motorcycle engine oil 10W 40 Grade SF or higher Ignition system DC CDI Compression ratio Unleaded Automobile Premium Gasoline Ron 98 or higher ...

Page 14: ...us Inner Radius of Tire 1650 Fuse 15A Loading limit Incl rider cargo etc 150 kg Voltage 12V Battery GS GTX12 BS Ground clearance unloaded 220 mm Water crossing maximum depth 350 mm Front suspension travel 150 mm Rear suspension travel 180 mm Dry weight approx KGs 190 Fuel tank capacity 11 5 liters Throttle lever free play 5 6 mm Air filter Foam Brake fluid DOT 4 Brake pad thickness MIN 2 0 mm Brak...

Page 15: ...ngine stop start tether ignition I I LIGHTING headlight tail light turning lights I I ENGINE OIL I R R R R ENGINE OIL FILTER s C R R R R DRIVE CHAIN sag stretch buffer guide sprockets condition tightness guards I I I I BRAKE FLUID I I I BRAKE SYSTEM cables discs pads hoses etc I I I BRAKE REAR DISC CARRIER I I I R I COOLANT radiator cap hoses level strength I I R I SUSPENSION front rear shocks con...

Page 16: ...e in Inspection 2 4 Toe in Adjustment 2 4 Wheels Rims 2 5 Wheel Removal 2 5 Wheel Installation 2 5 Wheel Rim Inspection 2 6 Wheel Rim Replacement 2 6 Tires 2 6 Tires Removal 2 6 Tires Installation 2 7 Tires Inspection 2 8 Front Hub 2 9 Front Hub Removal 2 9 Front Hub Installation 2 9 Rear Hub 2 10 Real Hub Installation 2 10 Rear Hub Disassembly Assembly 2 10 ...

Page 17: ... 25 40 mm Tires Standard tire Front Rear Tire air pressure when cold Front Rear Maximum tire air pressure to seat beads when cold AT 21 7 10 25N MAXXIS M 971 1 Tubeless AT 20 11 9 38N MAXXIS M 972 2 Tubeless 35 kPa 0 35 kgf cm2 5 0psi 35 kPa 0 35 kgf cm2 5 0psi 250 kPa 2 5 kgf cm2 36 psi ...

Page 18: ...he 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 tha...

Page 19: ...ight measure the distance between the scribed lines for both 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 is 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 Loosen the locknuts A B and turn the adjusting sleeves C the same...

Page 20: ...that the wheels are off the ground Take off the wheel nuts and remove the wheel Wheel Installation Check the tire rotation mark A on the tire and install the wheel accordingly NOTE The direction of the tire rotation is shown by an arrow on the tire sidewall Position the wheel so that the air valve A is toward the outside of the vehicle Tighten the wheel nuts in a criss cross pattern Torque Wheel N...

Page 21: ...the air valve Install a new air valve in the new rim Remove the valve cap lubricate the stem with a soap and 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 Wh...

Page 22: ...e air valve Check the tire for wear and damage see Tire Inspection Lubricate the tire beads and rim flanges with a soap and water 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 The tires should be installed o...

Page 23: ...ter solution around the tire bead and check for bubbles Deflate 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 WARNING Do not operate the vehicle with the water and so...

Page 24: ... free Remove the axle nut and pull off the front hub brake disc Separate the brake disc from the front hub Front Hub Installation Grease Seal Front Spindle Tighten Torque Front Spindle Nut 145 N m 15 0 kgf m 110 ft lb Insert a new cotter pin A and bead it over the nut B 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...

Page 25: ... non permanent locking agent Rear Axle Nuts A Tighten Torque Rear Axle Nut 265 N m 27 0 kgf m 195ft lb Insert a new cotter pin B and bend it over the nut Rear Hub Disassembly Assembly Do not press the hub bolts A out If any hub bolt is damaged replace the hub B and bolts as a nut ...

Page 26: ...8 Disc Removal 3 8 Disc Installation 3 8 Disc Wear Inspection 3 8 Disc Runout 3 9 Brake Hoses 3 9 Brake Hose Inspection 3 9 Brake Hose Replacement 3 9 Rear Brake 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 Rem...

Page 27: ...her 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 inadv...

Page 28: ...t is already in the reservoir are unidentified Tighten Torque Reservoir Cap Screws 1 5 N m 0 15 kg m 13 in lb Brake Fluid Change Removal the reservoir cap and the rubber cap on the bleed valve Attach a clear plastic 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...

Page 29: ... Line Air Bleeding Bleed the air whenever brake parts are replaced or reassembled Remove the reservoir cap and fill the reservoir with new brake fluid Slowly pump the brake lever 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...

Page 30: ...ke Hose Banjo Bolt B Master Cylinder Clamp Bolts A Master Cylinder CAUTION 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 afte...

Page 31: ...r is to be disassembled after removal and if compressed air is not available disassemble the caliper before the brake hose is 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 lb Brake Hose Banjo Bolt 25N m 2 5kg m 18 0ft...

Page 32: ... Pad Mounting Bolts 18N m 1 8kg m 13 0ft lb 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 ...

Page 33: ...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 lb 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 Inspe...

Page 34: ...e is not properly maintained Bend and twist the brake hose while examining it Replace it if any cracks or bul ges 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 CAUTION Brake fluid quickly ruins paint...

Page 35: ...il pedal is 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 6 0 5 mm Brake Pedal Removal Remove Cir clip C Washer D Pin B Master Cylinder J...

Page 36: ...e the brake hose is 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 lb Brake Hose Banjo Bolt 25N m 2 5kg m 18 0ft lb Check the fluid level in the brake reservoir Bleed the brake line see Brake Line Air Bleeding Check the brake for good braking...

Page 37: ...ton in by hand as far as it will go Be sure that the anti rattle spring is in place Install the pads Be careful not mix it up inboard pads with the out board pad Tighten Torque Pad Mounting Bolts 18N m 1 8kg m 13 0ft lb 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...

Page 38: ...anjo Bolt 25N m 2 5kg m 18 0ft lb 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 WARNING Do not attempt to drive the vehicle until a full brake level is obtained by pumping the brake level until the pads are against each dis The brakes will...

Page 39: ...move 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 lb 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 ...

Page 40: ...nsion Arm Disassembly 4 3 Suspension Arm Assembly 4 4 Swingarm 4 4 Swingarm Removal 4 4 Swingarm Installation 4 4 Swingarm Bush Removal 4 4 Steering 4 5 Steering Stem Removal 4 5 Steering Stem Installation 4 6 Steering Knuckle Removal 4 6 Steering Knuckle Installation 4 7 Tie Rod Removal 4 7 Tie Rod Installation 4 7 Tie Rod End Removal 4 7 Tie Rod End Installation 4 8 Steering Maintenance 4 8 Stee...

Page 41: ...ce 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 photograph Turn the adjusting sleeve on front shock absorber to the...

Page 42: ...ont 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 Collar A Bearing Collar B Seal Cover C Holding the suspension arm with a vise remove the cir clip D and unscrew the knuckle joint E CAUTION Do not remo...

Page 43: ...aring 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 C Swingarm Installation Position the swingarm as shown The distance between the frame and left end of the s...

Page 44: ... Front Cover see Frame Chapter Remove Steering Clamp Bolts A Steering Clamp Support Plate B Steering Clamp C Tie Rod End Nuts D Steering Stem Cotter Pin E and Nut F Washer G CAUTION Do not loosen the locknut at the ends of the tie rod adjusting sleeve or the toe in of the front wheels will be changed Pull the steering stem out of the frame ...

Page 45: ...N m 3 0 kgf m 22 ft lb Bearing Housing Bolts 20 N m 2 0 kgf m 14 5 ft lb Clamp Allen Bolts 25 N m 2 5 kgf m 18 0 ft lb 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 A and Tie Rod End CAUTION Do not loosen the locknuts at the ends of the tie rod adjusting sleeve...

Page 46: ... 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 N m 4 8 kgf m 35 ft lb Inspect the toe in if necessary Tie Rod End Removal Remove...

Page 47: ...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 the tightness of the steering bolts and nuts Tighten loose bolts and nuts to the specified torque see Exploded View and check the st...

Page 48: ...lips and mating surface B of the clamp and pack the grooves C in the clamp with grease Steering Stem Clamp Inspection Inspect the steering stem clamps A If roughness excessive play or seizure is found replace both clamps Tie Rod End and Steering Knuckle Joint Inspection Inspect each spherical bearing A If roughness excessive play or seizure is found replace the tie rod end or steering knuckle join...

Page 49: ...er Bolts A Handlebar Holders B Handlebar C Handlebar Installation Install the handlebar so that the angle of the handlebar matches the angle of the steering stem as shown Tighten the holder rear bolts first A and then the front bolts B Torque Handlebar Holder Bolts 27 N m 2 8 kgf m 20 ft lb If the holder is correctly installed there will be no gap at the rear and an even gap at the front after tig...

Page 50: ...t and Rear Fenders 5 3 Front Cover Removal 5 3 Front Fender Removal 5 3 Front Fender Installation 5 3 Rear Carrier Removal 5 3 Rear Fender Removal 5 4 Rear Fender Installation 5 4 Radiator Removal 5 5 Foot Steps 5 5 Foot Steps Removal 5 5 Headlight Holder 5 6 Headlight Holder Removal 5 6 ...

Page 51: ...pulling the seat latch lever B up and then pulling the seat up to the rear Seat Installation Slip the seat hook A under the brace B on the frame and put the stoppers C into the holes on the frame Push down the rear parts of the seat until the lock clicks ...

Page 52: ...lebar Cover A see Handlebar Removal Handlebar B Fuel Tank Cap Remove Front Fender Screws A 2 Front Fender Bolts B 2 C 6 Front Fender Front Fender Installation Please reverse the Removal steps to install Rear Carrier Removal Remove Rear Carrier Bolts A B 4 Rear Carrier ...

Page 53: ... Removal Remove Air Cleaner Cover A Air Cleaner B Remove Battery A CDI Unit B Fuse C Starter Relay D Rear Fender Bolts E Rear Fender Bracket F Rear Fender Rear Fender Installation Please reverse the Removal steps to install ...

Page 54: ... D Fan Connector Radiator Bolts E 2 Radiator Remove Radiator Cover Bolts A 4 Radiator Protector B Radiator Installation Please reverse the Removal steps to install Foot Steps Removal Remove Step Bracket Bolts A B Bracket Screw C Bracket Bolts D Step Bracket E Step F ...

Page 55: ... 5 6 FRAME Headlight Holder Removal Remove Handlebar see Handlebar Removal Front Fender see Front Fender Removal Headlight Holder Screw A Headlight Bolts and Screw B Headlight Holder ...

Page 56: ... 6 14 SERVICE INFORMATION 6 14 CYLINDER PISTON 6 15 DRIVE AND DRIVEN PULLEYS 6 20 SERVICE INFORMATION 6 20 LEFT CRANKCASE COVER 6 21 DRIVE PULLEY 6 22 CLUTCH DRIVEN PULLEY 6 24 FINAL REDUCTION TRANSMISSION SYSTEM 6 25 SERVICE INFORMATION 6 25 TRANSMISSION CASE COVER 6 26 TRANSMISSION 6 28 CRANKCASE CRANKSHAFT BALANCE SHAFT 6 33 SERVICE INFORMATION 6 33 CRANKCASE CRANKSHAFT BALANCE SHAFT 6 34 ...

Page 57: ...Pipe Torque Value Engine Oil Drain Plug 1 5kgf m Exhaust Pipe Nut 1 8 2 2kgf m Disconnect the water hose from water pump cover Remove the bolt at the thermostat and disconnect the thermo sensor wire then disconnect the thermostat from the cylinder head Remove the bolt at the drive select arm and then disconnect the drive select arm from engine assembly ...

Page 58: ...rive sprocket cover and then remove the drive sprocket cover Remove the two bolts on the drive sprocket Remove the drive sprocket and washer Slide the rubber sleeve back to expose the starter motor wire nut Remove the starter motor wire nut for disconnect the starter motor wire ...

Page 59: ...the spark plug cap Unscrew the clamp and then disconnect the outlet hose from the left crankcase cover Unscrew the clamp and then disconnect the inlet hose from the left crankcase cover Remove the left foot step and the left foot holder refer to Frame chapter Remove the drive select lever ...

Page 60: ... 6 5 ENGINE Remove the three bolts and nuts for remove the left and right engine brackets Remove the engine assembly to the left side of the machine ...

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Page 62: ...nstall the cylinder head cover Install and tighten the cylinder head cover bolts Torque 0 8_ 1 2kgf m NOTE Be sure to install the O ring into the groove properly CAMSHAFT CAMSHAFT HOLDER REMOVAL Remove the cylinder head cover Refer to the cylinder head cover removal Remove the cam chain tensioner cap screw and the O ring Turn the cam chain tensioner screw clockwise to tighten it as show ...

Page 63: ...linder head nuts in 2 or 3 times Remove the camshaft holder and dowel pins Remove the camshaft gear from the cam chain and remove the camshaft CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts Remove the valve rocker arms and arm shafts Torque Valves Adjuster Nut 1 4 1 8kgf m ...

Page 64: ... D of each valve rocker arm Service limits ψ10 04 above Measure arm to shaft clearance Service limits 0 12 above Replace as a set if out of specification CAMSHAFT HOLDER ASSEMBLY Reverse the CAMSHAFT HOLDER DISASSEMBLY procedures NOTE Align the cross cutout on the exhaust valve rocker arm shaft with the bolt or the camshaft holder CAMSHAFT INSPECTION Check each camshaft bearing for play or damage ...

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Page 66: ...ostat Remember to drain the water in the hoses first Remove the bolt to disconnect the thermostat Remove the two cylinder head bolts Remove the cylinder head CYLINDER HEAD DISASSEMBLY Remove the valve keepers retainers springs spring seats spring seals valve guides o rings and valves by using a valve spring compressor NOTE Be sure to compress the valve springs with a valve spring compressor Mark a...

Page 67: ...Service limits IN 5 420mm replace if over EX 5 400mm replace if over NOTE If the stem to guide clearance exceeds the service limits replace the cylinder head as necessary CYLINDER HEAD INPECTION Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 05mm repair or replace if over Torque Value Spark Plug 2 2 2 8...

Page 68: ...alve cotters NOTE When assembling a valve spring compressor must be used Install the cotters with the pointed ends facing down from the upper side of the cylinder head Tap the valve stems gently with a plastic hammer for 2 3 times to firmly seat the cotters NOTE Be careful not to damage the valves INSTALLATION Install the dowel pins and a new cylinder head gasket Reverse the CYLINDER HEAD REMOVAL ...

Page 69: ...arpage 0 050 Cylindricity 0 012 Cylinder True roundness 0 012 Top 0 02 0 09 Ring to groove clearance Second 0 015 0 050 0 09 Top 0 10 0 25 0 50 Second 0 15 0 30 0 50 Ring end gap Oil ring 0 25 0 7 Piston O D ψ72 67 72 66 ψ72 60 Piston O D measuring position 10 0 Piston to cylinder clearance 0 030 0 055 0 10 Piston piston ring Piston pin hold I D ψ17 002 17 008 ψ17 04 Piston pin O D ψ16 995 16 990 ...

Page 70: ...connect the water hose Remove the cylinder Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface NOTE Be careful not to drop foreign matters into the crankcase Remove the piston pin clip NOTE Be careful to keep the piston pin clip from falling into the crankcase Press the piston pin out of the piston and remove the piston ...

Page 71: ... a new one Install the piston rings onto the piston and measure the piston ring to groove clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom NOTE Use the piston head to push each piston ring into the cylinder Measure the piston ring end gap Service Limit Top 0 50mm replace if over 2nd 0 50mm re...

Page 72: ...sure the cylinder I D at three levels of top middle and bottom at 90 to the piston pin in both X and Y directions Cylinder I D Service Limit ψ72 8mm replace if over Measure the cylinder to piston clearance Service Limit 0 10mm repair or replace if over The true roundness is the difference between the values measured in X and Y directions The cylindricity difference between the values measured at t...

Page 73: ... rings All rings should be installed with the markings facing up After installing the rings they should rotate freely without sticking Measure the connecting rod small end I D Service Limit ψ17 05mm replace if over Measure the connecting rod to piston pin clearance Service Limit 0 025mm replace if over Inspect the exhaust side and intake side chain guides Wear Damage Replace ...

Page 74: ...shop towel in the crankcase to keep the piston pin clip from falling into the crankcase CYLINDER INSTALLATION Install the dowel pins and a new cylinder gasket on the crankcase Coat the cylinder bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings NOTE Apply proper clean engine oil around cylinder wall Be careful not to dama...

Page 75: ...ase from them to minimize the slipping of drive belt and drive pulley SPECIFICATIONS TORQUE VALUES Drive face nut 5 0 6 0kgf m Clutch outer nut 5 0 6 0kgf m Item Standard mm Service Limit mm Movable drive face bushing I D ψ27 00 27 035 ψ27 06 Drive face collar O D ψ26 984 26 96 ψ26 94 Drive belt width 23 6 24 4 22 0 Clutch lining thickness 3 963 4 037 2 0 Clutch outer I D ψ153 153 2 ψ153 5 Driven ...

Page 76: ...ove the gasket and dowel pins INSPECTION Inspect the bearing for allow play in the left crankcase cover or the bearing turns roughly Replace INSTALLATION Install the dowel pins and new gasket Reverse the LEFT CRANKCASE COVER REMOVAL procedures Install the left crankcase cover and tighten the bolts Connect the drive belt air inlet and outlet hose and tighten band screws Install the starting cover a...

Page 77: ...using a universal holder and remove the drive face nut and washer Remove the drive pulley Remove the movable drive face assembly and drive pulley collar DISASSEMBLY Remove the ramp plate Remove the six weight rollers INSPECTION Check each weight roller for wear or damage Measure each weight roller O D Service Limit ψ22mm replace if below ...

Page 78: ...y collar sliding surface Service Limit ψ26 94mm replace if below INSTALLATION Install the drive pulley face assembly and collar Reverse the Removal procedure to install the drive pulley wash and nut NOTE When installing the drive pulley face compress it to let the drive belt move downward to the lowest position so that the drive pulley can be tightened Install the washer with the OUT SIDE mark fac...

Page 79: ...e whole clutch driven Assy to make sure the engine functioning well DRIVE BELT INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 22mm replace if below NOTE Use specified genuine parts for replacement CLUTCH OUTER INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit ψ153 5mm rep...

Page 80: ...d with the engine installed in the frame When replacing the drive shaft use a special tool to hold the bearing inner race for this operation SPECIFICATIONS Specified Oil GEAR OIL SAE Oil Capacity At change 0 8 liter At disassembly 0 78 liter TORQUE VALUES Transmission case cover bolt M8 x 1 25 2 6 3 2kgf m M6 x 1 25 1 0 1 4kgf m ...

Page 81: ... sprocket Refer to Engine Removal section Remove the drive select lever Refer to Engine Removal section Remove the transmission case cover attaching bolts Remove the transmission case cover dowel pins and gasket Inspect the bearings for allow play in the transmission case cover or the bearings turn roughly If any defects are found replace the bearing with a new one ...

Page 82: ...ng Inspect the bearing for allow play in the transmission case cover or the bearing turns roughly If any defects are found replace the bearing with a new one Inspect the drive axle gear teeth for wear or damage Remove the bearing to expose the oil seal Inspect the oil seal for wear or damage If any defects are found replace the oil seal with a new one ...

Page 83: ...e the bearing with a new one ASSEMBLY Install the needle bearing Install the oil seal and bearing Install the bearing cir clip Install the drive axle and drive axle cir clip TRANSMISSION REMOVAL Remove the transmission cover Refer to TRANSMISSION CASE COVER REMOVAL Check the transmission operation Unsmooth operation Repair Remove the shift shaft ...

Page 84: ...transmission guide bar Measure the guide bar runout Out of specification Replace NOTE Do not attempt to straighten a bent guide bar Remove shift cam Check the shift cam groove and shift cam gear Wear or damage Replace Remove the shift fork Inspect the shift fork cam Scoring beads wear Replace ...

Page 85: ... 6 30 ENGINE Inspect shift shaft gear Damage Replace Inspect shift shaft Damage bends wear Replace Remove the main axle MAIN AXLE DISASSEMBLY Remove the washers collar primary driven gear and clutch dog ...

Page 86: ...rs reverse wheel gear and needle bearing Inspect the gear teeth Blue discoloration pitting wear Replace Inspect the mated dogs Rounded edges cracks missing portions Replace Remove the counter axle Inspect the gear teeth Blue discoloration pitting wear Replace ...

Page 87: ...If any defects are found replace the bearing with a new one INSTALLATION Reverse the TRANSMISSION REMOVAL procedure to install the primary drive axle the counter axle the main axle the shift cam the shift fork guide bar and shift shaft NOTE Make sure that the lever on the gear change switch correctly engages with the locating slot on the shift shaft Align the mark on the shift shaft gear with the ...

Page 88: ...ed before separating the crankcase Cylinder head Cylinder piston Drive and driven pulleys A C generator Starter clutch Oil pump SPECIFICATIONS TORQUE VALUES Crankcase bolt 1 0 1 4kgf m Cam chain tensioner slipper bolt 1 0 1 4kgf m Cam chain cover bolt 1 0 1 4kgf m Item Standard mm Service Limit mm Connecting rod big end side clearance 0 15 0 35 0 60 Connecting rod big end radial clearance 0 004 0 ...

Page 89: ...VAL Remove the timing chain from right crankcase Remove the left and right crankcase attaching bolts Remove the right crankcase NOTE Do not damage the crankcase gasket surface Remove the gasket and dowel pins Remove the crankshaft from the left crankcase ...

Page 90: ...ating surfaces NOTE Avoid damaging the crankcase mating surfaces Inspect the balance shaft gear teeth Burrs chips roughness wear Replace CRANKSHAFT INSPECTION Inspect the crankshaft gear teeth Burrs chips roughness wear _ Replace Measure the connecting rod small end I D Service Limit ψ17 05 mm replace if over ...

Page 91: ...05 mm Replace the crankshaft Turn the crankshaft bearings and check for excessive play Measure the crankshaft bearing play Pitting wear damage Replace CRANKCASE BALANCER INSTALLATION Install the balance shaft and crankshaft into the left crankcase NOTE Align the mark on the balance shaft with the mark on the crankshaft Install the dowel pins and new gasket Install the right crankcase and tighten t...

Page 92: ... Ignition System 7 11 Spark Plug Removal Installation 7 11 Spark Plug Cleaning Inspection 7 11 Spark Plug Gap 7 11 Ignition Coil Removal 7 11 Ignition Coil Installation 7 12 Ignition Coil Inspection 7 12 Ignition Timing Test 7 13 CDI Unit Inspection 7 13 Lighting System 7 14 Headlight Bulb Replacement 7 14 Turn Signal Bulb Replacement 7 14 Taillight Bulb Replacement 7 15 Rear View Mirror Replaceme...

Page 93: ...ternator type CDI Charging voltage Regulator rectifier output 14 5V 0 5V Alternator output voltage 244V Charge Coil 0 3 1 0Ω Stator Resistance Pulser Coil 110Ω 15 Primary 1 5 3 5Ω Ignition Coil Resistance Secondary 12 21Ω Spark plug Gap 0 6 0 7 mm Starter motor Nominal Output 12V 0 6KW ...

Page 94: ...rts Location Light Dimmer Switch A Switch B Indicator Switch C Starter Button D Ignition Switch E Horn Switch F Battery A CDI Unit B Fuse C Starter Circuit Relay D Indicator Relay A Flasher Relay B Ignition Coil C Spark Plug D ...

Page 95: ... 7 4 ELECTRICAL SYSTEM Regulator Rectifier E Magneto CP A Starter Motor B Horn B Temperature Sensor C ...

Page 96: ...y 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 Caution Take care not to short the leads that are directly connected to the battery positive terminal to the chassis ground Troubles may involve one or in some cases all items Ne...

Page 97: ... 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 Set the tester to the x 1 Ω range and read the tester If the tester does not read 0 Ω the lead is defective Replace the lead or the wiring harness B if necessary Battery Removal Disconnect the battery negative cable Black first a...

Page 98: ... 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 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 temp...

Page 99: ...cates 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 To test charge a battery perform the ordinary charging procedure and monitor the battery voltage and other signs as mentioned below If the battery voltage suddenly jumps to over 13 V just after the start of ...

Page 100: ...e specified voltage Regulator Rectifier Output Voltage Connections Tester Range Tester to Tester to Reading 25 VDC Battery Battery 14 15 V 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 is considered to be working normally If the output voltage is much higher ...

Page 101: ...ng 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 7 5 Amps at 2000RPM 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 e...

Page 102: ...tion Remove or install the spark plug A using the spark plug wrench from the vehicle right side Torque Spark Plug 2 2 2 8kgf m 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...

Page 103: ...Connect the tester between the coil terminals Set the tester to the 1Ω range and read the tester Measure the secondary winding resistance as follows Remove the plug cap by turning it counterclockwise Connect the tester between the spark plug lead and terminal Set the tester to the 1 kΩ range and read the tester If the hand tester does not read as specified replace the coil To install the plug cap ...

Page 104: ...llowing 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 B Set the hand tester to the 1kΩ range and make the measurements shown in the table If the te...

Page 105: ... 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 Turn Signal Bulb Replacement Remove Turn Signal Connector A Turn Signal Screw B Turn Signal C Remove Turn Signal Lens Mounting Screws A and Nuts Turn Signal Lens B Remove the bulb A by turning it counterclockwise Insert the new bulb by turnin...

Page 106: ...SYSTEM Taillight Bulb Replacement Remove Taillight Holder Nut A Taillight Remove Taillight Lens Screws B Taillight Lens C Turn the Taillight Bulb A counterclockwise to Remove it Insert a new bulb by turning it clockwise ...

Page 107: ...ight wire B to remove the mirror Reverse above procedure to assemble the new mirror Be sure to connect wiring with correct color as following chart Color Mirror Wiring Wiring Harness Green Green L Mirror Black Black Green Brown R Mirror Black Black Neutral Light Bulb Replacement Please refer the Headlight Bulb Replacement ...

Page 108: ...lace the fuse Before replacing a blow fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit CAUTION 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...

Page 109: ... 7 18 ELECTRICAL SYSTEM Wiring Diagram ...

Page 110: ... 7 19 ELECTRICAL SYSTEM Wiring Diagram ...

Page 111: ... 7 20 ELECTRICAL SYSTEM NOTE ...

Page 112: ... 8 1 APPENDIX Appendix Table of Contents Considerations for Various Riding Conditions 8 2 Carburetor 8 2 Spark Plug 8 4 Fuel System 8 6 Troubleshooting Guide 8 7 ...

Page 113: ... replaced with a smaller or larger one A smaller numbered jet gives a leaner mixture and a larger numbered jet a richer mixture Carburetor Pilot Screw Adjustment Note Pilot screw is covered by a welsh plug Plug removal will be required to perform these procedures Start engine and warm it up to operating temperature about 10 minutes With engine off turn pilot screw in clockwise until lightly seated...

Page 114: ...engine and warm it up thoroughly Adjust idle speed by turning the idle adjustment screw in clockwise to increase or out counterclockwise to decrease RPM Note Adjusting the idle speed affects throttle cable freeplay and electronic throttle control ETC adjustment Always check throttle cable freeplay after adjusting idle speed and adjust if necessary Idle Speed 1600 100 RPM ...

Page 115: ...he 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 o C 750 1 450 o F and can be judged by noting the condition and color of the ceramic insulator around the center electrode If the ceramic is clean and of a light of a light brown color the plug is operating at the right temperat...

Page 116: ...white the plug is operating at too high a temperature and it should be replaced with the next colder type CAUTION If the spark plug is replaced with a type other than the 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 ...

Page 117: ...ely 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 Never drain the float bowl when the engine is hot Severe burns may result Fuel Lines Check fuel lines for signs of wear deterioration damage or leakage Replace if necessary Be sure fuel line...

Page 118: ...park 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 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 clearan...

Page 119: ...h 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 Air 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 ...

Page 120: ...se 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...

Page 121: ... 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 ...

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