Dinli DL-702 2008 User manual

FOREWORD/INDEX
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FOREWORD/INDEX
DINLI700ccServiceManual
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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..
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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.
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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.
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Allinformationcontainedinthispublicationisbasedonthelatestproductinformationavailableatthe
timeofpublication.
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Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmaynotdepict
actualmodelcomponentparts.
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○,CCOPYRIGHTDINLIMETALINDUSTRIALCO.,LTD.2008

FOREWORD/INDEX
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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to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.
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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oftheirchapters.
EachchapterinturnhasitsowncomprehensiveTableofContents.
ThePeriodicMaintenanceChartislocatedinthePeriodicMaintenance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.
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FOREWORD/INDEX
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WheneveryouseetheseWARNI NGandCAUTIONsymbols,heedtheirinstructions!Alwaysfollowsafe
operatingandmaintenancepractices.
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WARNING
Thiswarningsymbolidentifiesspecialinstructionsorprocedures,whichifnotcorrectly
followed,couldresultinpersonalinjury,orlossoflife.
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CAUTION
Thiscautionsymbolidentifiesspecialinstructionsorprocedures,whichifnotstrictly
observed,couldresultindamagetoordestructionofequipment.
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Thismanualcontainsfourmoresymbols(inadditiontoWARNINGandCAUTION),whichwillhelpyou
distinguishdifferenttypesofinformation.
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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.
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FOREWORD/INDEX
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CHAPTERINDEX
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CHAPTER1GENERALINFORMATION
CHAPTER2WHEELS/TIRES
CHAPTER3BRAKE
CHAPTER4SUSPENSION/STEERING
/DRIVESHAFT
CHAPTER5BODY
CHAPTER6ENGINE
CHAPTER7COOLINGAND
LUBRICATIONSYSTEM
CHAPTER8ELECTRICALSYSTEM
CHAPTER9PERIODIC
MAINTENANCE
CHAPTER10APPENDIX
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GENERAL I
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GENERALINFORMATION
TableofContents
BeforeServicing‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐-‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐--‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐2
GeneralPrecautions‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐-‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐5
DINLIDL‐702‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐6
ModelIdentifications‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐7
Fuel,OilandEngine CoolantRecommendation‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐8
Fuel(ForUSAandCanada)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐8
Fuel(ForOtherCountries)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐8
EngineOil(ForUSA)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐8
EngineOil(ForOtherCountries)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐-‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐8
FrontDifferentialGearOil‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐8
RearGear(Final)BoxOil‐‐‐‐‐‐‐‐‐‐‐‐‐-‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐-‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐8
BrakeFluid‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐9
EngineCoolant‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐9
WaterForMixing‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐9
Anti‐Freeze/EngineCoolant‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐9
LiquidAmountofWater/EngineCoolant‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐9
Break‐InProcedures‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐10
InformationLabels‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐11
GeneralSpecifications‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐1‐12
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GENERAL I
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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,
make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.

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GENERAL I
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(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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

【1-4】
GENERAL I
NF
ORMATIO
N
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.
(15)Lubrication
Enginewearisgenerallyatitsmaximumwhiletheengineiswarmingupandbeforeallthesliding
surfaceshaveanadequatelubricationfilm.Duringassembly,makesuretoapplyoiltoanysliding
surfaceorbearingthathasbeencleaned.Oldgreaseordirtyoilcouldhavelostitslubricationquality
andmaycontainforgingparticlesthatactasabrasives;therefore,makesuretowipeitoffandapply
freshgreaseoroil.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is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is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replacementparts.
(18)ElectricalWires
Alltheelectricalwiresareeitherone‐colorortwo‐color.Atwo‐colorwireisidentifiedfirstbythe
primarycolorandthenthestripecolor.Forexample,ayellowwirewiththinredstripesis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isanydoubtastotheconditionofthem,replacethemwithnewones.
AbrasionCrackHardeningWarp
BentDentScratchWear
ColorchangeDeteriorationSeizure
(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.

【1-5】
GENERAL I
NF
ORMATIO
N
GeneralPrecautions
WARNING

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

○Properserviceandrepairproceduresareimportantforthesafetyoftheservicemechanicandthesafety
andreliabilityofthevehicle.
○When2ormorepersonsworktogether,payattentiontothesafetyofeachother.
○Whenitisnecessarytoruntheengineindoors,makesurethatexhaustgasisforcedoutdoors.
○Whenworkingwithtoxicorflammablematerials,makesurethattheareayouworkiniswell‐ventilated
andthatyoufollowallofthematerialmanufacturer’sinstructions.
○Neverusegasolineasacleaningsolvent.
○Toavoidgettingburned,donottouchtheengine,engineoil,radiatorandexhaustsystemuntilthey
havecooled.
○Afterservicingthefuel,oil,water,exhaustorbrakesystems,checkalllinesandfittingsrelatedtothe
systemforleaks.

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CAUTION
○Ifpartsreplacementisnecessary,replacethepartswithgenuinepartsortheirequivalents.
○Whenremovingpartsthataretobereused,keepthemarrangedinanorderlymannersothattheymay
bereinstalledintheproperorderandorientation.
○Besuretousespecialtoolswheninstructed.





○Makesurethatallpartsusedinreassemblyareclean.Lubricatethemwhenspecified.
○Usethespecifiedlubricant,bond,orsealant.
○Whenremovingthebattery,disconnectthenegativecablefirstandthenthepositivecable.
○Whenreconnectingthebattery,connectthepositivecablefirstandthenthenegativecable,andreplace
theterminalcoveronthepositiveterminal.
○Whenperformingservicetoelectricalparts,iftheserviceproceduresdonotrequireuseofbattery
power,disconnectthenegativecablefromthebattery.
○Whentighteningthecylinderheadorcaseboltsandnuts,tightenthelargersizesfirst.Alwaystighten
theboltsandnutstothespecifiedtorque.
○Wheneveryouremoveoilseals,gaskets,packing,O‐rings,lockingwashers,self‐lockingnuts,cotter
pins,circlipsandcertainotherpartsasspecified,besuretoreplacethemwithnewones.Also,before
installingthesenewparts,besuretoremoveanyleftovermaterialfromthematingsurfaces.
○Neverreuseasnapring.Wheninstallinganewsnapring,takecarenottoexpandtheendgaplarger
thanrequiredtoslipthesnapringovertheshaft.Afterinstallingasnapring,alwaysensurethatitis
completelyseatedinitsgrooveandsecurelyfitted.
○Useatorquewrenchtotightenfastenerstothespecifiedtorque.Wipeoffgreaseandoilifathreadis
smearedwiththem.
○Afterreassembling,checkpartsfortightnessandproperoperation.
CAUTION
○Toprotecttheenvironment,donotunlawfullydisposeofusedmotoroil,enginecoolantandother
fluids:batteries,andtires.
○ToprotectEarth’snaturalresources,properlydisposeofusedvehicleandparts.






【1-6】
GENERAL I
NF
ORMATIO
N
DINLIDL‐702

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
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

















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Right Side
Left Side

●Differencebetweenphotographandactualvehiclemayexistdependingonthemarkets.




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

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

【1-7】
GENERAL I
NF
ORMATIO
N
ModelIdentification

Engineserialnumber
Vehicleidentificationnumber

ENGINESERIALNUMBER(Ex.15M18XXXXX)

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

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
VEHICLEIDENTIFICATION(ex.RFWAK85CX6Txxxxxx)


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WhenevercorrespondingwithDINLIaboutaparticularissue,theenginenumberandserialnumberare
importantforvehicleidentification.


【1-8】
GENERAL I
NF
ORMATIO
N
Fuel,OilandEngineCoolantRecommendation
Fuel(ForUSAandCanada)
●Useonlyunleadedgasolineofatleast87pumpoctane(R/2+M/2)or95octaneorhigherratedbythe
ResearchMethod.
●GasolinecontainingMTBE(MethylTertiaryButylEther),lessthan10%ethanol,orlessthan5%methanol
withappropriatecosolventsandcorrosioninhibitorispermissible.


Fuel(ForOtherCountries)
●Gasolineusedshouldbegraded95octane(ResearchMethod)orhigher.Anunleadedgasolineis
recommended.


EngineOil(ForUSA)
●DinlirecommendstheoilwhichisratedSForSGundertheAPI(AmericanPetroleumInstitute)service
classification.TherecommendedviscosityisSAE10W‐40.IfSAE10W‐40oilisnotavailable,selectan
alternativeaccordingtothefollowingchart.


EngineOil(ForOtherCountries)
●Useapremiumquality4‐strokemotoroiltoensurelonger
servicelifeofyourvehicle.Useonlyoilwhicharerated
SForSGundertheAPIserviceclassification.The
recommendedviscosityisSAE10W‐40.IfSAE10W‐40
motoroilisnotavailable,selectanalternativeaccording
totherightchart.


FrontDifferentialGearOil
●UsehypoidgearoilthatmeetstheAPIserviceclassificationGL‐5andisratedSAE#80W‐90.


RearGear(Final)BoxOil
●UsehypoidgearoilthatmeetstheAPIserviceclassificationGL‐5andisratedSAE#80W‐90.






【1-9】
GENERAL I
NF
ORMATIO
N

BrakeFluid
●Specificationandclassification:DOT4
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
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WARNING
○Sincethebrakesystemofthisvehicleisfilledwithaglycol‐basedbrakefluidbythemanufacturer,do
notuseormixdifferenttypesoffluidsuchassilicone‐basedandpetroleum‐basedfluidforrefillingthe
system,otherwiseseriousdamagewillresult.
○Donotuseanybrakefluidtakenfromoldorusedorunsealedcontainers.
○Neverre‐usebrakefluidleftoverfromapreviousservicing,whichhasbeenstoredforalongperiod.

EngineCoolant
●Useananti‐freeze/enginecoolantcompatiblewithanaluminumradiator,mixedwithdistilledwateronly.
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WaterForMixing
●Usedistilledwateronly.Waterotherthandistilledwatercancorrodeandclogthealuminumradiator.
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Anti‐Freeze/EngineCoolant
●Theenginecoolantperformsasacorrosionandrustinhibitoraswellasanti‐freeze.Therefore,theengine
coolantshouldbeusedatalltimeseventhoughtheatmospherictemperatureinyourareadoesnotgo
downtofreezingpoint.
●Dinlirecommendstheuseofenginecoolantiscompatiblewithanaluminumradiator.
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LiquidAmountofWater/EngineCoolant
Solutioncapacity(total):Approx.1950ml
●Forenginecoolantmixtureinformation,refertocoolingsystemsectioninpage7‐2.
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CAUTION
Mixingofanti‐freeze/enginecoolantshouldbelimitedto70%.Mixingbeyonditwouldreduceits
efficiency.Iftheanti‐freeze/enginecoolantmixingratioisbelow50%,rustinhabitingperformanceis
greatlyreduced.Besuretomixitabove50%eventhoughtheatmospherictemperaturedoesnotgodown
tothefreezingpoint.
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【1-10】
GENERAL I
NF
ORMATIO
N
Break‐InProcedures
●Duringmanufactureonlythebestpossiblematerialsareusedandallmachinedpartsarefinishedtoavery
highstandardbutitisstillnecessarytoallowthemovingpartsto“Break‐In”beforesubjectingtheengine
tomaximumstresses.Thefutureperformanceandreliabilityoftheenginedependsonthecareand
restraintexercisedduringitsearlylife.Thegeneralrulesareasfollows.
○Keeptothesebreak‐inenginespeedlimits:
Break‐inenginespeeds
Initial500km:Lessthan1/2throttle
○Uponreachingasodometerreadingof500kmyoucansubjectthevehicletofullthrottleoperation,for
shortperiodsoftime.
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

【1-11】
GENERAL I
NF
ORMATIO
N
InformationLabels
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Always stop the vehicle
completely before changing
from forward to reverse or
vice versa.
Failure to do so can be
hazardous.
Do not consume alcohol,
drugs or cigarettes before or
during operating theATV
Maximum Vehicle Load:
250kg, (551 lbs)
Includes weight of operator,
cargo and accessories.
Never load over 250kg or
may cause loss of control.
Always wear protective
clothing when driving your
ATV.
Never operate this ATV if
you are under age 16.
Operating this ATV if you are
under the age of 16
increases your chance or
severe injury or death.
Read the Owner’s Manual
before riding the vehicle.


【1-12】
GENERAL I
NF
ORMATIO
N
GeneralSpecification
NOTE:
Specificationssubjecttochangewithoutnotice.

ENGINE


ModelDL‐702

Engine4–stroke,DOHC
Numberofcylinders1
Boreandstroke102mm×85mm
10.0：1
Compressionratio
Displacement694.6cc
AircleanerFoam
CoolantsystemLiquidcooled
85℃
Coolingdeviceoperatingtemperature
1:2water/anti‐freeze[ethyleneglycol(containingcorrosion
inhibitorsforaluminumenginesandradiators)].
Coolant
StartersystemElectricalandrecoilstarter
CarburetorMikuniBSR42
Idlespeed1300±100rpm
LubricationsystemForcepressureandwetsump
4–cyclemotorcycleengineoilSAE10W‐40,gradeAPISFor
higher
Lubricant
GasolineUnleaded,Octane95orhigher
Note:Permissibleoperatingtemperature:‐10‐45

【1-13】
GENERAL I
NF
ORMATIO
N

CHASSIS


FrameSteel

Overalllength2200mm

Overallwidth1230mm

Overallheight1230mm

Seatheight916mm

Wheelbase1305mm

Groundclearance,unloaded295mm

Watercrossingmaximumdepth520mm

DryweightApprox.298kg

Loadinglimit(Incl.rider,cargo,etc…)250kg

Fronttrack952mm
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Reartrack982mm

ClutchtypeAutomaticCVT,wetdrum

TransmissionAutomaticvariableratio(V‐belt)
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Transfer2‐speedforwardwithreverse
TransmissionAutomatic
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GearshiftpatternTransferL‐H‐N‐R‐P
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AutomatictransmissionratioVariablechange(2.670–0.787)
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Secondaryreductionratio2.158(40/21×17/15)
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Finalreductionratio(Front&Rear)3.600(36/10)
Low2.294(39/17)
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TransmissiongearratioHigh1.133(30/26)
Reverse1.882(32/17)
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DrivesystemShaftdrive
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Differentialdrive2WD/4WD/4WD‐lock,shaft
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FrontsuspensionIndependent,doubleA‐arm,coilspring,oildamped
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RearsuspensionIndependent,doubleA‐arm,coilspring,oildamped
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Frontsuspensiontravel170mm
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Rearsuspensiontravel170mm
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Steeringangle30°(Right&Left)
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Turningradius3.25m
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FrontbrakeDualhydraulicdisc
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RearbrakeSinglehydraulicdisc
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BrakefluidDOT4
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Brakediscthickness(MIN)Front3mm/Rear3.5mm
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【1-14】
GENERAL I
N
F
ORMATIO
N
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FronttireAT25×8–12,tubeless
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ReartireAT25×10–12,tubeless
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Recommendedcoiltirepressure(Front/Rear) 35kPa/35kPa(5.0psi/5.0psi)
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ELECTRICAL
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IgnitiontypeCDI
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Ignitiontiming7°B.T.D.Cat1300rpm
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SparkplugNGKCR6E
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Sparkpluggap0.7–0.8mm
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AlternatortypeThree‐phaseAC
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AlternatoroutputDC14V‐23A@3000rpm
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BatteryGS,GTX20L‐BS,12V/20Ah
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Mainfuse30A
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Fuse5A,7.5A,10A,15A,30A
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Headlight12V35/35W(Main);3W(Position)
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TaillightP215W;RY10W(Indicator)
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SpeedometerLCD
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HighbeamindicatorlightLED
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TransferindicatorlightLCD
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EnginecoolanttemperatureindicatorlightLED

DifferentiallockindicatorlightLCD
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Capacities
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Fueltank20L
Oilchange3300ml(Maybeslightlydifferentafterchangedoilfilter)
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EngineoilOverhaul

3500ml

Differentialgearoil150ml
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Reardrivergearoil310ml
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Coolant1.95L
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WHEELS/TIRES
【2-1】
WHEELS/TIRES
TableofContents
Specifications‐‐‐‐‐‐‐‐‐‐‐-‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐2
Construction‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐3
Wheel(Rim)‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐4
Removal‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐4
Installation‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐4
Inspection‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐5
Replacement‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐5
Tire‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐6
Removal‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐6
Installation‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐6
Inspection‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐8
Hub‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐9
FrontHubRemoval‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐9
FrontHubInspection‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐9
FrontHubInstallation‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐10
RearHubRemoval‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐10
RearHubInspection‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐10
RearHubInstallation‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2‐11
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