Dinli DL702 User manual

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FOREWORD/INDEX

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FOREWORD/INDEX
DINLI 700 cc Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Dinli Metal Industrial Co., Ltd..
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an
obligation to make such changes to products manufactured previously. See your dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the
time of publication.
Illustrations and photographs in this publication are intended for reference use only and may not depict
actual model component parts.
○,CCOPYRIGHT DINLI METAL INDUSTRIAL CO., LTD. 2008

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FOREWORD/INDEX
Foreword
This manual is designed primarily for use by trained mechanics in a properly equipped shop. A basic
knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to
carry out maintenance and repair satisfactorily. In order to perform the work efficiently and to avoid costly
mistakes, read the text thoroughly 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.
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 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.

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FOREWORD/INDEX
Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe
operating and maintenance practices.
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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FOREWORD/INDEX
CHAPTER INDEX
CHAPTER 1 GENERAL
CHAPTER 2 WHEELS/TIRES
CHAPTER 3 BRAKE
CHAPTER 4 SUSPENSION
CHAPTER 5 FRAME
CHAPTER 6 ENGINE
CHAPTER 7 ELECTRICAL
CHAPTER 8 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,
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.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a part

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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
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

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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.

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GENERAL I
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Model Identification
Engine serial number
Vehicle identification number
ENGINE SERIAL NUMBER (Ex. 15M18XXXXX)
VEHICLE IDENTIFICATION (ex. RFWAK85CX6Txxxxxx)
Whenever corresponding with DINLI about a particular issue, 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 DL702
Engine 4-stroke, DOHC
Bore and stroke 102mm x 85 mm
Compression ratio 10.0:1
Displacement 694.6 cc
Coolant system Liquid cooled
Coolant
1:2 water/anti-freeze [ethylene glycol(containing corrosion
inhibitors for aluminum engines and radiators)], Quantity = 3
liter
Starting system Electric
Carburetor Mikuni BSR42
Transmission L-H-N-R-P
Final drive 2WD/4WD/4WD LOCK ; Shaft
Clutch type Automatic CVT; wet drum
Engine idle speed 1300 ± 100 rpm
Spark plug, standard CR6E (NGK)
Spark plug gap 0.8~0.9 mm
Lubrication system Forced pressure and wet sump
Lubricant 4-cycle motorcycle engine oil 10W-40, Grade SF or higher
Ignition system CDI
Gasoline Unleaded, Octane 95 or higher
Alternator Output DC 12V-18A @ 3000rpm
Cooling Device Operating Temperature 85℃
Note: Permissible operating temperature: -10~45。

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GENERAL I
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CHASSIS
Frame Steel
Overall length 2208 mm
Overall width 1129 mm
Overall height 1120 mm
Seat height 916 mm
Wheel base 1305 mm
Front tire 25 x 8 – 12
Rear tire 25 x 10 – 12
Recommended cold tire pressure (front/rear) 35kpa/ 30kpa (5.0psi/ 4.4psi)
Turning radius 6.5m
Fuse 5A, 10A, 15A, 30A
Loading limit (Incl. rider, cargo, etc….) 250kg
Voltage 12V
Battery GS, GTX20L-BS
Ground clearance, unloaded 295 mm
Water crossing maximum depth 520 mm
Front suspension travel 170mm
Rear suspension travel 170mm
Dry weight (approx KGs) 298
Fuel tank capacity 20L
Throttle lever free play 3~8 mm
Air filter Foam
Brake fluid DOT 4
Brake pad thickness (MIN) 3.5 mm
Brake disc thickness (MIN) 4 mm
Drive system Shaft

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Periodic Maintenance Chart
Perform a Pre-Ride inspection before every ride and at schedule maintenance periods.
C=Clean
R=Replace
L=Lubricate
I=Inspect, Verify, Clean, Adjust, Lubricate, Replace if necessary
Regular Maintenance Internal
Interval
Items
Break in Initial week Every 1
month Every 3 month Every 6 month
Note
First hour After 10
hours Every 10 Every 50 Every 100
0 Initial 200 Every 200 Every 1000 Every 2000
WARNING LABELS (condition, readable) I I I I I I
AIR FILTER I C C ★
FRAME (mainframe, subframe) I I I
FUEL LINE I I I Replace every four years
▲THROTTLE OPERATION I I I I I
SPARK PLUG I Replace every 6000 km
○IDLE SPEED I I
ENGINE OIL I R R
▲ENGINE OIL FILTER (s) C R R
DIFFERENTIAL GEAR OIL I Replace every two years
FINAL GEAR OIL I Replace every year
COOLANT I I I Replace every two years
SWITCHES (engine, stop, start, tether, ignition) I I ★
BRAKE FLUID I I I Replace every two years
▲BRAKE SYSTEM (cables, discs, pads, hosed, etc.) I I I I I ★
BRAKE DISCS I I I I Replace every 10000 km
▲LIGHTING (headlight, tail light, turning lights) I I
BATTERY (terminals) I,C
▲EXHAUST (spark arrester) C
SUSPENSION I I I
NUTS, BOLTS AND FASTENERS I I I I
▲WHEELS/TIRES (pressure, condition, wear) I I I
▲Steering assembly (fasteners, operation) I I I I ★
General Lubrication L L L
▲DINLI dealer service suggested 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.
Day/Months
Hours
km

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WHEELS/TIRES
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-----------------------------------------------------------------------------2-5
Wheel (Rim) Replacement--------------------------------------------------------------------------2-6
Tires-----------------------------------------------------------------------------------------------------------2-6
Tires Removal----------------------------------------------------------------------------------------2-6
Tires Installation-------------------------------------------------------------------------------------2-7
Tires Inspection--------------------------------------------------------------------------------------2-8
Front Hub---------------------------------------------------------------------------------------------------2-8
Front Hub Removal---------------------------------------------------------------------------------2-8
Front Hub Installation------------------------------------------------------------------------------2-9
Front Hub Disassembly/Assembly-------------------------------------------------------------2-9
Rear Hub---------------------------------------------------------------------------------------------------2-9
Real Hub Installation-----------------------------------------------------------------------------2-9
Rear Hub Disassembly/Assembly-------------------------------------------------------------2-9

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WHEELS/TIRES
Specifications
Item Standard
Wheel Alignment: Toe-in 11~40 mm
Tires:
Standardtire: Front
Rear
Tire air pressure (when cold):
Front
Rear
Vehicle Maximum load-capacity
AT 25×8-12
MAXXIS M915, Tubeless
AT 25×10-12
MAXXIS M916, Tubeless
35 kPa (0.35 kgf/cm
2
, 5.0 psi)
30 kPa (0.31 kgf/cm
2
, 4.4 psi)
250 KG

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WHEELS/TIRES
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 toe-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 secured and required no adjustment.
A (Rear)-B (Front) = Amount of Toe-in
(Distance A and B are measured at axle height)
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 straight edge [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.
A
CAUTION
During the tie rod adjustment, it is very important that the
precautions be taken when tightening tie rod end jam nuts.
A
B
C
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.
NOTE
The locknut [A] on the tie-rod has left-hand threads. Turn the
wrench clockwise for loosening.

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WHEELS/TIRES
●Repeat the straight edge 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.
●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.
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.
A
B
C

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WHEELS/TIRES
Wheels (Rims)
Wheel Removal
●Support the vehicle on a stand or the jack so that the wheels are
off the ground.
●Loosen the wheel nuts [A]
●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.
●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 )
Wheel (Rim) Inspection
●Examine both sides of the rim for dents [A]. If the rim is dented,
replace it.
●If the tire is removed, inspect the air sealing surfaces [A] of the
rim for scratches or nicks. Smooth the sealing surfaces with fine
emery cloth if necessary
AA
NOTE
○The direction of the tire rotation is shown by an arrow on the
tire sidewall.
A

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WHEELS/TIRES
Wheel (Rim) Replacement
●Remove the wheel (see Wheel Removal)
●Disassemble the tire from the rim (see Tire Removal).
○Remove the air valve and discard it.
●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.
●Mount the tire on the new rim (see Tire Installation).
●Install the wheel (see Wheel Installation).
TIRES
Tire Removal
●Remove the wheel.
●Unscrew the valve core to deflate the tire.
○Use a paper valve core tool.
●Lubricate the tire beads and rim flanges on both sides of the
wheel with a soap and water solution, or water. This helps the
tire beads slip off the rim flanges.
●Remove the tire from the rim using a suitable commercially
available tire changer.
CAUTION:
Replace the air valve whenever the tire is replaced. Do not
reuse the air valve.
CAUTION:
Do not use engine oil or petroleum distillates to lubricate the
stem because they will deteriorate the rubber.
CAUTION:
Do not lubricate the tire beads and rim flanges with engine
oil or petroleum distillates because they will deteriorate the
tire.
NOTE
○The tires cannot be removed with hand tools because they fit
the rims tightly.
A
A

【2-7】
WHEELS/TIRES
Tire Installation
●Inspect the rim (see Wheel (Rim) Inspection).
●Replace the air valve with a new one.
●Check the tire for wear and damage (see Tire Inspection)
●Lubricate the tire beads and rim flanges with a soap and water.
●Check the tire rotation mark [A] on the tire, and install the tire
on the rim accordingly.
○The tires should be installed on the rims so that each air valve is
toward outside of the vehicle.
●Install the tire on the rim using a suitable commercially available
tire changer.
●Lubricate the tire beads again and center the tire on the rim.
●Support the wheel rim [A] on a suitable stand [B] to prevent the
tire from slipping off.
●Inflate the tire until the tire beads seat on the rim.
●Check to see that rim lines [A] on both sides of the tire are
parallel with the rim flanges [B].
If the rim lines and the rim flanges are not paralleled, deflate the
tire, lubricate the sealing surfaces again, and re-inflate the tire.
●After the beads are properly seated, check for air leaks.
○Apply a soap and water solution around the tire bead and check
for bubbles.
●Deflate the tire to the specified pressure.
CAUTION:
Replace the air valve whenever the tire is replaced. Do not
reuse the air valve.
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.
NOTE
○The direction of the tire rotation is shown by an arrow on the
tire sidewall.
WARNING
Do not inflate the tire to more than the maximum tire air
pressure. Over inflation can explode the tire with possibility
of injury and loss of line.
B
A