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Dinli DL-901 - Service Manual

Dinli DL-901
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Table of Contents

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Summary

Foreword

How to Use This Manual

Guide on navigating the manual and understanding its structure and symbols.

General Information

Before Servicing

Crucial precautions and procedures before starting any inspection or maintenance.

Model Identification

Information on identifying the vehicle by engine and VIN numbers for accurate referencing.

General Specifications

Key technical data and specifications for the vehicle model DL901.

Chassis Specifications

Detailed dimensions and specifications related to the vehicle's frame and chassis components.

Periodic Maintenance Chart

Schedule for regular maintenance tasks based on time or mileage intervals.

Wheels and Tires

Wheel Specifications

Technical details for wheel alignment, tire sizes, and air pressures.

Wheel Alignment Procedures

Instructions for inspecting and adjusting steering centering and toe-in for proper alignment.

Wheel and Rim Maintenance

Steps for removing, installing, inspecting, and replacing wheels and rims.

Tire Maintenance

Procedures for tire removal, installation, and inspection for wear and damage.

Front Hub Service

Guidance on removing, installing, and disassembling the front wheel hub components.

Rear Hub Service

Instructions for installing and disassembling the rear wheel hub components.

Brake System

Brake Fluid Service

Recommendations, level inspection, and fluid change procedures for optimal brake performance.

Master Cylinder Maintenance

Steps for removing and installing the master cylinder, including torque specifications.

Caliper Service

Procedures for removing and installing brake calipers and bleeding the brake lines.

Brake Pad Service

Instructions for removing, installing, and inspecting brake pads for wear.

Brake Disc Service

Guidance on cleaning, removing, installing, and inspecting brake discs for wear and runout.

Brake Hose Maintenance

Procedures for inspecting and replacing brake hoses to ensure system integrity.

Brake Pedal Adjustments

Steps for inspecting and adjusting brake pedal position and free play.

Rear Brake Service

Procedures for rear caliper removal, installation, and brake pad maintenance.

Rear Brake Disc Service

Instructions for removing and installing rear brake discs and checking for wear.

Suspension and Steering

Shock Absorber Service

Procedures for removing, installing, inspecting, and adjusting front and rear shock absorbers.

Suspension Arm Maintenance

Steps for removing, installing, and disassembling/assembling suspension arms.

Swingarm Service

Instructions for removing, installing, and servicing swingarm bearings.

Steering Stem Maintenance

Procedures for removing, installing, and inspecting the steering stem and related components.

Steering Knuckle Service

Steps for removing and installing steering knuckles, including associated torque values.

Tie-Rod Maintenance

Procedures for removing, installing, and inspecting tie-rods and tie-rod ends.

Handlebar Service

Instructions for removing and installing the handlebar, including torque specifications.

Frame

Seat Service

Instructions for removing and installing the vehicle seat.

Fender and Cover Service

Procedures for removing and installing front covers and fenders.

Rear Fender Service

Steps for removing and installing the rear fender assembly.

Radiator Service

Instructions for removing and installing the vehicle's radiator system.

Foot Steps Service

Procedures for removing and installing the foot steps on the vehicle.

Engine Service

Engine Removal and Installation

Detailed steps for disassembling and reassembling the engine assembly.

MAG Cover Service

Procedures for removing and installing the MAG cover and related components.

Clutch Service

Steps for removing, disassembling, and inspecting clutch components.

Oil Pump Service

Procedures for removing and installing the engine oil pump assembly.

Head Cover Service

Instructions for removing and installing the engine head cover.

Chain Tensioner Service

Procedures for removing and installing the engine chain tensioner.

Camshaft Service

Steps for removing and installing camshafts and related components.

Magneto Assy Service

Procedures for removing and installing the magneto assembly.

Thermostat Service

Instructions for removing and installing the engine thermostat and cover.

Water Pump Service

Procedures for removing and installing the engine water pump.

Cylinder Head Service

Steps for removing and installing the cylinder head, including gasket.

Piston Service

Procedures for removing and installing the piston and piston pin.

Engine Inspection

Cylinder Head Inspection

Procedures for inspecting cylinder head warpage and valve guide inner diameter.

Valve Inspection

Procedures for inspecting valve stem runout, outer diameter, and clearance.

Camshaft Inspection

Procedures for inspecting cam profile height and oil clearance at cam journal.

Cylinder Inspection

Procedures for inspecting cylinder warpage and bore, and piston OD.

Piston and Piston Pin Inspection

Procedures for inspecting piston/cylinder clearance and piston pin dimensions.

Piston Ring Inspection

Procedures for measuring piston ring clearance and gap.

Crankshaft Inspection

Procedures for measuring crankshaft runout and connecting rod side clearance.

Timing Chain Inspection

Procedure for checking timing chain pitch for wear and damage.

Clutch Component Inspection

Visual checks for clutch pressure disk, plates, and friction material width.

Transmission Inspection

Procedures for inspecting shift fork grooves, shift fork craw, and clearances.

Engine Reassembly

Crankcase 1 Assembly

Steps for assembling the first crankcase, including crankshaft and shafts.

Crankcase 2 Assembly

Steps for assembling the second crankcase, including bearings and plugs.

Final Assembly Steps

Procedures for joining crankcases, installing position switch, and oil pump.

Engine Attachments

Special Tools

Visual catalog of special tools required for engine service procedures.

Timing Chain Arrangement

Diagram illustrating the correct arrangement of the engine timing chain.

Matrix Table for Valve Clearance

Table to determine the correct adjusting pad based on valve clearance measurements.

Fastener and Torque Table

A comprehensive list of fasteners and their specified tightening torques for engine components.

Crankcase Torque Chart

Diagram showing torque specifications for crankcase assembly bolts.

Cylinder Torque Chart

Diagram illustrating torque specifications for cylinder head and cam support bolts.

Crankshaft and Piston Torque

Diagram showing torque specifications for crankshaft, piston, and related parts.

Intake & Exhaust Torque

Diagram indicating torque values for intake/exhaust valves and tensioner assembly.

Clutch Torque

Diagram showing torque specifications for clutch components.

Transmission Torque

Diagram detailing torque specifications for transmission and clutch parts.

Cover (Chain) Torque

Diagram showing torque specification for the chain cover and shift pedal assembly.

Oil Pump Torque

Diagram illustrating torque specifications for the engine oil pump assembly.

Water Pump Torque

Diagram showing torque specifications for water pump components.

Engine Service Data

Cylinder Head and Valve Data

Specifications and service limits for cylinder head, valves, and camshafts.

Cylinder and Piston Data

Specifications and service limits for cylinder, piston, piston pin, and connecting rod.

Engine Lubrication and Sealants

Adhesive and Sealant Applications

List of adhesives/sealants and their application points for engine assembly.

Oil and Grease Applications

Guide on recommended oils and greases for various engine components.

Periodic Maintenance Schedule

Maintenance Schedule

Table outlining recommended maintenance intervals for various vehicle systems.

Engine Specifications

Engine Dimensions

Overall physical dimensions of the engine unit.

Engine Performance Specifications

Key performance metrics like horsepower, torque, speed, and cooling system details.

Drive Train Specifications

Primary Reduction System

Details of the primary reduction system, including gear type and ratio.

Clutch Type

Information on the clutch type, mechanism, and plate configuration.

Transmission Specifications

Gear ratios and type of transmission system used in the vehicle.

Final Drive System

Specifications for the final drive system, including chain and sprocket type.

Electrical System

Electrical System Specifications

Technical specifications for battery, alternator, ignition, and starter systems.

Parts Location

Diagrams showing the location of key electrical components on the vehicle.

Electrical Service Precautions

Essential safety warnings and guidelines for servicing electrical systems.

Electrical Wiring Inspection

Procedures for inspecting wiring harnesses and connectors for damage or corrosion.

Battery Service

Guidelines for battery charging, testing, and maintenance procedures.

Regulator;Rectifier Output Voltage Inspection

Method for checking the output voltage of the regulator/rectifier for system health.

Alternator Inspection

Procedures for checking alternator output voltage and CDI unit output.

Ignition System Service

Procedures for spark plug, ignition coil, and ignition timing checks and replacement.

Lighting System Service

Instructions for replacing headlight, taillight, and indicator bulbs.

Fuse Service

Procedures for removing, inspecting, and replacing fuses, including cautions.

Wiring Diagram

Comprehensive wiring diagrams for the vehicle's electrical system.

Appendix

Riding Conditions Considerations

Advice on adjusting carburetor and spark plug for various riding environments.

Carburetor Adjustment

Step-by-step guide for adjusting the carburetor's pilot screw for optimal performance.

Idle Speed Adjustment

Procedures for setting and adjusting the engine's idle speed.

Fuel System Service

Safety precautions and maintenance for the fuel tank, lines, and fuel delivery system.

Spark Plug Service

Guidance on spark plug inspection, cleaning, gap adjustment, and heat range selection.

Clutch Adjustment

Instructions for adjusting the clutch lever freeplay for proper engagement.

Troubleshooting Guide

A comprehensive list of common problems and their potential causes and solutions.

Summary

Foreword

How to Use This Manual

Guide on navigating the manual and understanding its structure and symbols.

General Information

Before Servicing

Crucial precautions and procedures before starting any inspection or maintenance.

Model Identification

Information on identifying the vehicle by engine and VIN numbers for accurate referencing.

General Specifications

Key technical data and specifications for the vehicle model DL901.

Chassis Specifications

Detailed dimensions and specifications related to the vehicle's frame and chassis components.

Periodic Maintenance Chart

Schedule for regular maintenance tasks based on time or mileage intervals.

Wheels and Tires

Wheel Specifications

Technical details for wheel alignment, tire sizes, and air pressures.

Wheel Alignment Procedures

Instructions for inspecting and adjusting steering centering and toe-in for proper alignment.

Wheel and Rim Maintenance

Steps for removing, installing, inspecting, and replacing wheels and rims.

Tire Maintenance

Procedures for tire removal, installation, and inspection for wear and damage.

Front Hub Service

Guidance on removing, installing, and disassembling the front wheel hub components.

Rear Hub Service

Instructions for installing and disassembling the rear wheel hub components.

Brake System

Brake Fluid Service

Recommendations, level inspection, and fluid change procedures for optimal brake performance.

Master Cylinder Maintenance

Steps for removing and installing the master cylinder, including torque specifications.

Caliper Service

Procedures for removing and installing brake calipers and bleeding the brake lines.

Brake Pad Service

Instructions for removing, installing, and inspecting brake pads for wear.

Brake Disc Service

Guidance on cleaning, removing, installing, and inspecting brake discs for wear and runout.

Brake Hose Maintenance

Procedures for inspecting and replacing brake hoses to ensure system integrity.

Brake Pedal Adjustments

Steps for inspecting and adjusting brake pedal position and free play.

Rear Brake Service

Procedures for rear caliper removal, installation, and brake pad maintenance.

Rear Brake Disc Service

Instructions for removing and installing rear brake discs and checking for wear.

Suspension and Steering

Shock Absorber Service

Procedures for removing, installing, inspecting, and adjusting front and rear shock absorbers.

Suspension Arm Maintenance

Steps for removing, installing, and disassembling/assembling suspension arms.

Swingarm Service

Instructions for removing, installing, and servicing swingarm bearings.

Steering Stem Maintenance

Procedures for removing, installing, and inspecting the steering stem and related components.

Steering Knuckle Service

Steps for removing and installing steering knuckles, including associated torque values.

Tie-Rod Maintenance

Procedures for removing, installing, and inspecting tie-rods and tie-rod ends.

Handlebar Service

Instructions for removing and installing the handlebar, including torque specifications.

Frame

Seat Service

Instructions for removing and installing the vehicle seat.

Fender and Cover Service

Procedures for removing and installing front covers and fenders.

Rear Fender Service

Steps for removing and installing the rear fender assembly.

Radiator Service

Instructions for removing and installing the vehicle's radiator system.

Foot Steps Service

Procedures for removing and installing the foot steps on the vehicle.

Engine Service

Engine Removal and Installation

Detailed steps for disassembling and reassembling the engine assembly.

MAG Cover Service

Procedures for removing and installing the MAG cover and related components.

Clutch Service

Steps for removing, disassembling, and inspecting clutch components.

Oil Pump Service

Procedures for removing and installing the engine oil pump assembly.

Head Cover Service

Instructions for removing and installing the engine head cover.

Chain Tensioner Service

Procedures for removing and installing the engine chain tensioner.

Camshaft Service

Steps for removing and installing camshafts and related components.

Magneto Assy Service

Procedures for removing and installing the magneto assembly.

Thermostat Service

Instructions for removing and installing the engine thermostat and cover.

Water Pump Service

Procedures for removing and installing the engine water pump.

Cylinder Head Service

Steps for removing and installing the cylinder head, including gasket.

Piston Service

Procedures for removing and installing the piston and piston pin.

Engine Inspection

Cylinder Head Inspection

Procedures for inspecting cylinder head warpage and valve guide inner diameter.

Valve Inspection

Procedures for inspecting valve stem runout, outer diameter, and clearance.

Camshaft Inspection

Procedures for inspecting cam profile height and oil clearance at cam journal.

Cylinder Inspection

Procedures for inspecting cylinder warpage and bore, and piston OD.

Piston and Piston Pin Inspection

Procedures for inspecting piston/cylinder clearance and piston pin dimensions.

Piston Ring Inspection

Procedures for measuring piston ring clearance and gap.

Crankshaft Inspection

Procedures for measuring crankshaft runout and connecting rod side clearance.

Timing Chain Inspection

Procedure for checking timing chain pitch for wear and damage.

Clutch Component Inspection

Visual checks for clutch pressure disk, plates, and friction material width.

Transmission Inspection

Procedures for inspecting shift fork grooves, shift fork craw, and clearances.

Engine Reassembly

Crankcase 1 Assembly

Steps for assembling the first crankcase, including crankshaft and shafts.

Crankcase 2 Assembly

Steps for assembling the second crankcase, including bearings and plugs.

Final Assembly Steps

Procedures for joining crankcases, installing position switch, and oil pump.

Engine Attachments

Special Tools

Visual catalog of special tools required for engine service procedures.

Timing Chain Arrangement

Diagram illustrating the correct arrangement of the engine timing chain.

Matrix Table for Valve Clearance

Table to determine the correct adjusting pad based on valve clearance measurements.

Fastener and Torque Table

A comprehensive list of fasteners and their specified tightening torques for engine components.

Crankcase Torque Chart

Diagram showing torque specifications for crankcase assembly bolts.

Cylinder Torque Chart

Diagram illustrating torque specifications for cylinder head and cam support bolts.

Crankshaft and Piston Torque

Diagram showing torque specifications for crankshaft, piston, and related parts.

Intake & Exhaust Torque

Diagram indicating torque values for intake/exhaust valves and tensioner assembly.

Clutch Torque

Diagram showing torque specifications for clutch components.

Transmission Torque

Diagram detailing torque specifications for transmission and clutch parts.

Cover (Chain) Torque

Diagram showing torque specification for the chain cover and shift pedal assembly.

Oil Pump Torque

Diagram illustrating torque specifications for the engine oil pump assembly.

Water Pump Torque

Diagram showing torque specifications for water pump components.

Engine Service Data

Cylinder Head and Valve Data

Specifications and service limits for cylinder head, valves, and camshafts.

Cylinder and Piston Data

Specifications and service limits for cylinder, piston, piston pin, and connecting rod.

Engine Lubrication and Sealants

Adhesive and Sealant Applications

List of adhesives/sealants and their application points for engine assembly.

Oil and Grease Applications

Guide on recommended oils and greases for various engine components.

Periodic Maintenance Schedule

Maintenance Schedule

Table outlining recommended maintenance intervals for various vehicle systems.

Engine Specifications

Engine Dimensions

Overall physical dimensions of the engine unit.

Engine Performance Specifications

Key performance metrics like horsepower, torque, speed, and cooling system details.

Drive Train Specifications

Primary Reduction System

Details of the primary reduction system, including gear type and ratio.

Clutch Type

Information on the clutch type, mechanism, and plate configuration.

Transmission Specifications

Gear ratios and type of transmission system used in the vehicle.

Final Drive System

Specifications for the final drive system, including chain and sprocket type.

Electrical System

Electrical System Specifications

Technical specifications for battery, alternator, ignition, and starter systems.

Parts Location

Diagrams showing the location of key electrical components on the vehicle.

Electrical Service Precautions

Essential safety warnings and guidelines for servicing electrical systems.

Electrical Wiring Inspection

Procedures for inspecting wiring harnesses and connectors for damage or corrosion.

Battery Service

Guidelines for battery charging, testing, and maintenance procedures.

Regulator;Rectifier Output Voltage Inspection

Method for checking the output voltage of the regulator/rectifier for system health.

Alternator Inspection

Procedures for checking alternator output voltage and CDI unit output.

Ignition System Service

Procedures for spark plug, ignition coil, and ignition timing checks and replacement.

Lighting System Service

Instructions for replacing headlight, taillight, and indicator bulbs.

Fuse Service

Procedures for removing, inspecting, and replacing fuses, including cautions.

Wiring Diagram

Comprehensive wiring diagrams for the vehicle's electrical system.

Appendix

Riding Conditions Considerations

Advice on adjusting carburetor and spark plug for various riding environments.

Carburetor Adjustment

Step-by-step guide for adjusting the carburetor's pilot screw for optimal performance.

Idle Speed Adjustment

Procedures for setting and adjusting the engine's idle speed.

Fuel System Service

Safety precautions and maintenance for the fuel tank, lines, and fuel delivery system.

Spark Plug Service

Guidance on spark plug inspection, cleaning, gap adjustment, and heat range selection.

Clutch Adjustment

Instructions for adjusting the clutch lever freeplay for proper engagement.

Troubleshooting Guide

A comprehensive list of common problems and their potential causes and solutions.

Dinli DL-901 Specifications

General IconGeneral
BrandDinli
ModelDL-901
CategoryOffroad Vehicle
LanguageEnglish

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