Dinli DL-801 User manual

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DINLI 270 cc QUAD 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.

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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 familiarize yourself with the
procedures before starting work, and then do the work carefully in a clean area. Whenever special
tools or equipment. 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.

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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.
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.

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CHAPTER INDEX
CHAPTER1 GENERAL
CHAPTER2 WHEELS/TIRES
CHAPTER3 BRAKE
CHAPTER4 SUSPENSION
CHAPTER5 FRAME
CHAPTER6 ENGINE
CHAPTER7 ELECTRICAL
CHAPTER8 APPENDIX

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

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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, 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
locking agent) in order to avoid damaging the screw heads.

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(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.

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(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.

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Model Identification
Engine serial 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.

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General Specification
NOTE:
Specifications subject to change without notice.
Model DL-801
Engine 4-stroke, DOHC
Bore and stroke ψ72.7 x 63.0 mm
Compression ratio 12.0
Displacement 261.5 cm3
Coolant system Liquid cooled
Coolant 1:1 water/anti-freeze[ethylene glycol(containing corrosion inhibitors
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)
Alternator Output 10.5 A / 5000 min-1
Thermostat Opening Temperature 60℃ ± 2℃
Note: Permissible operating temperature: -10℃~45℃。

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CHASSIS
Frame Steel
Overall length 1682 mm
Overall width 1060 mm
Overall height 1082 mm
Seat height 810 mm
Wheel base 1176 mm
Front tire 21 x 7 – 10
Rear tire 20 x 11 – 9
Recommended cold tire pressure (front/rear) 30kpa/ 30kpa
Turning radius (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
Brake disc thickness (MIN) 3.5 mm
Drive chain type 530 (O-ring type)

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Periodic Maintenance Chart
Perform a Pre-Ride inspection before every ride and at schedule maintenance periods.
Interval (whichever comes first)
C=Clean
R=Replace
L=Lubricate
I=Inspect, Verify, Clean, Adjust, Lubricate, Replace if
necessary.
Regular Maintenance Interal (houre)
Regular Maintenance
(Riding Km)
Items Break-in
(1 hour)
Inital
After 10 hr
Every 1
month
Every 3
month
Every 6
month
Note 200 Km 500Km 1000Km
WARNING LABELS (condition, readable) I I I I I I I I I
○FRAME (mainframe,subframe,swingarm) I I I
▲FUEL SYSTEM (hoses, tank, level) I I I
BATTERY (terminals) I,C I
▲THROTTLE OPERATION I I I I
AIR FILTER I C C R ★I I
AIRBOX DRAIN TUBE I,C I ★I I
SPARK PLUG I R R
○IDLE SPEED I I Adjust as required
▲EXHAUST (spark arrester) C C
SWITCH (engine, 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, condition, setting) I I I I
NUTS,BOLTS AND FASTENERS I I I I
○SEAT (condition, wear, damage) I
▲WHEELS/TIRES (pressure, condition, wear) I I I I I
SWINGARM (bearings) I I ★
▲STEERING ASSEMBLY (fasteners, operation) I ★I
A-ARM ( Bushing ball Joint) I ★I
TIE ROD ENDS I I I
★
▲Dinli dealer service suggested that servicing owners should have the proper tools, service data, and be mechanically qualified.
○Operational safety involved, The service should be performed by a Dinli dealer.
★Service more frequently if operation in dusty, sandy or snowy area or conditions.
＊Change every 2 years.

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WHEELS/TIRE
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Wheels/Tires
Table of Contents
Specifications---------------------------------------------------------------------------------------------------2-2
Wheel Alignment-----------------------------------------------------------------------------------------------2-3
Steering Centering Inspection----------------------------------------------------------------------------2-3
Steering Centering Adjustment--------------------------------------------------------------------------2-3
Toe-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

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WHEELS/TIRES
Specifications
Item Standard Service Limit
Wheel Alignment: Toe-in 2WD 25~40 mm - - -
Tires:
Standardtire: 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)
- - -
- - -
- - -
- - -
- - -

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Wheel Alignment
Toe-in is the amount that the front wheels are closer
together in front than at the rear at the axle height. When there
is toe-in, the distance A (Rear) is the greater than B (Front) as
shown.
The purpose of toe-in is to prevent the front wheels from
getting out of parallel at any time, and to prevent any slipping
or scuffing action between the tires and the ground, if ton-in is
incorrect, the front wheels will be dragged along the ground,
scuffing and wearing the tread knobs. Measure the distance
between vehicle center and each wheel. This will tell you
which tie rod needs adjusting.
Caster and camber are build-in and require no adjustment.
A (Rear)-B (Front) = Amount of Toe-in
(Distance A and B are measured at axle height)
CAUTION:
During the tie rod adjustment, it is very important that the
precautions be taken when tightening tie rod end jam nuts.
Steering Centering Inspection
●Test ride the vehicle.
★If the handlebar is straight when the vehicle is traveling in a
straight line, go on to the Toe-in Inspection procedure.
★Otherwise, go on to the Steering Centering Adjustment
procedure.
Steering Centering Adjustment
●Support the vehicle so that the front wheels are off the
ground and the front axles about the same height as the rear
axle.
○Hold a straightedge [A] against the rear wheel rim on one
side at axle height.
●With the handlebar straight ahead, loosen the locknuts [A]
[B] and Turn the tie-rod adjusting sleeve [C] until the front
wheel on that side is parallel to the straightedge.
NOTE
The locknut [A] on the tie-rod has left-hand threads. Turn the
wrench clockwise for loosening.
CAUTION
Adjust the tie-rod so that the visible thread length [A]is
even on both ends of the tie-rod, or the threads could be
damaged.

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WHEELS/TIRES
●Repeat the straightedge procedure on the other side of the
vehicle, now the front wheels are parallel to each other and
to the center line of the vehicle.
●Go on to the Toe-in Inspection procedure.
Toe-in Inspection
●Support the vehicle on a stand or the jack so that the front
wheels are off the ground.
●Apply a heavy coat of the chalk near the center of the front
tires.
●Using a needle nose scriber, mark a thin mark near the
center of the chalk coating while turning the wheel.
●Keeping the front wheels off the ground, set the handlebar
straight ahead.
●At the level of the axle height, 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 0~2mm
Toe-in Adjustment
●Loosen the locknuts [A] [B] and turn the adjusting sleeves
[C] the same number of turns on both sides to achieve the
specified toe-in.
NOTE
○The nut [A] on the tie-rod has left-hand threads. Turn the
nut clockwise for loosening.
○The toe-in will be near the specified value, if the tie-rod
length [D] is 385 mm on each tie-rod.
CAUTION
Adjust the tie-rod length so that the visible thread
length [E] is even on both ends of the tie-rod. Uneven
length could cause tie-rod damage.

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WHEELS/TIRE
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●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.
Wheels (Rims)
Wheel Removal
●Loosen the wheel nuts [A]
●Support the vehicle on a stand or the jack so that the wheels
are off the ground.
●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 Nuts: 52 N-m (5.3 kgf-m, 38 ft-lb )