All Terrain Vehicle DL-601 pales} SERVICE MANUAL oan pe al Ces 1, Tichang, Tina, is desgned piney or i tts a tables containing the mance and easy reference for mechanics when noi do the work its recommended tht» sealed ne = cany out all adjustments i ey a beeen maki improvement onthe desig ofits mode. Where thee ar changes in Product specification, they will be incinded in a tepinced sors eee served to Dili Metal Indastial Co, No ptf meats, without he price penis Publication msy be reproduced o tansmited, form orby any Dinli Metal Industrial Co,, TaiwanLMode! Identification... i 2.Front Brake Inspection And Adjustment. 3-Rear Drake Inspection And Adjustment... 4-Front & Rear Shock Absorbers... S.Steering Mechanism Inspection And Adjustmen 6-Transmission Inspection And Adjustme 7-Engine Disassembly... 8.Engine Separation. 9.Carburetor Removal. 11-Transmission Removal And Assembly. 12.Installation Of 3-Speed Transmission. 13.Installation Of 4-Speed ‘Transmission, 14.Clean Carburetor. 1S. Wiring Diagrams. Engine Number2, FRONT BRAKE INSPE( ION AND ADJUSTMENT ) Adjustment + Proper bake lever ie play can woid brake dvegiog. * Properly tam he ating ats wl he ie py 8 spied | Front eae inspection ‘Appl the foot brake lever. + To adjust the fron brake, adja he lef and ight Oreck ‘heeds athe same time. crac tate annie web orcas witht lange 5 Ateradhatng ph ec ever to check ‘on the brake hub cover. replace the from brake shoe ‘he left and right whecs for braking simuttonone Otherwise adja aga + Toreplce the brake shoe ropace the left and igh bake Stoel he same time 2. Front bake ajusiment * Before adjusting the font brake, chek the brake shoe frst Check lever fee py Nota pecifod > adjust Front rake eve free ply 10 ~ 20am> replace Not as specified replace Min. Thickness timit? 3.0m ‘& REAR SHOCK ABSORBERS the font ahockabscbers bs and drop the handebs vp snl down sevcal ies the movement hes trouble or leaks, check. 2 Bar stock absorber inspection 1 Movement Tre the handlebar ond sc, ad shake up and down several times, ithe ear shock absorber has tcuble or leaks, chBs with 9 work stn raise theft wheel the ground is herd t move emove the ‘heck the sleeve a Itricate the jst pans of 6. TRANSMISSION INSPECTION AND ADJUSTMENT. 1. Check (Dave chain + Check the dive chain or slack or dryness, Slacklsmaged -> replace Worndamaged > replace (2) Sprocket * Chock the sprocket Wornidtormed-p replace + dy, apply grease or lubsicent tothe sprocket or dive chain, 0) Adie + Loosen the oek mut of ear axe bearing seat assembly asst he isting ne to make the dive cha tight as specified + Then igen he lock ma ofthe beasng sat othe peo one Tongue Ale bearing eat oe mut: 25 — 40 -m7. ENGINE DISASSEMBLY CARBURETOR Remne; HOSES, CABLES AND WIRES Remove: ‘il pump cable Remave Remove stall lock yew ateryENGINE SEPARATION Lever, gear shit Remove: Bo Bor 9 COVER, GEAR NUT a Bot Gearassenbly Gasket 38, ENGINE SEPARATION CYLINDER HEAD, CYLINDER AND PISTON Do not clan fhe gin T repay clnter al piston ony the folks pats nus crear “fends foirest carburetor Remove naeused Remove: “lindo bf shu Pall out ofthe cylinder bate shrosd fom the Prcformed hole ‘ofthe Ket chinkemse, spacer spask pag * Loosen ats by crossing them. ‘omen every nut 14 arn Only rernove raster a ut ar ooscod Remove evsinder gasket "Block te open end of the crankcase wil lean cloth [Prevent the irelip(D cropping ino the cankeaseRemove O-ring Nut atc hab) i Ss hh bois ce ng Renae rear ak ple ssenty vic sn he Hem Sa itn “Riera he Hate, resi mab pally as mb sia IRS AHE tld ales ase A esac tine a Remove Oring @ STARTER CLUTCH To inypect and repair the cluich, only the fling pats ae tbe ‘moved. 1s ot necessary to dsenle theeasine “eft eres cover Remine fixed pte strter catch 2 Remove bush starr whet 2 nasherMAGNETO. Remove stator assembly wood key 2 Special pullers needed to remove fy whee lL PUMP: To inspect and epithe ol pomp, only the follwing eave tinal necessary to dismal the engin. fenders: irckancr Date sroud +l pun cable Remove «il pump 1Remove: dowel pin STARTER MOTOR ‘Te eck 4nd epaicie sarc mote: oal the following pts far be ear I snot necessary irante the cine amie sembly Remove: CRANKCASE (RIGHT) Remone crankcase (igh) © Aer removal of crows splitcases ‘Do no yo sealing sffe: Damage will occu,Remove crank assembly from cases. When inspecting rod assy i = (On cranks check for any movement up and down, iw replace | Cera care e | Before assembly, clean cases thorugh No zashetis used her, sealant nly Aer gluing, put certain dowel pins in pace ‘Alay elec crank say ce you remone ca ay SEMBLY INSPECTING PARTS BEFORE AS Crankease separating procedures: check replace pulley) © ‘TOOTHED BELT Oreck toothed belt Crackedatvathread Ssparationtreach > replace saluted by oll > replaceREAR BELT PULLEY Check ear bal palleyfsed) ‘ar bel palleyslide) 2 “il seat Sompodieva.heurtamaged-> replace the whole set STARTER CLUTCH AND GEAR Check stare luch Insal the dow pin into the so, and turn itn the lot. in the owhead direction Not smooth -b replace starter latch assembly Che: eth of tater gear ‘ecth of idle gear @ DefomeiAbleted/Abradedtreach> replace Om. PUMP aside abrasion of pump or breakdown of inside meckanism front ouput of lubricant than hat designed bythe factory, However Situation ae I the output ofthe pun is amoral check the fllcing cilinlet and dro pipes Swfedptired-> blow th Check rive worm of ol pamp 3 ‘riven worm of ol pump replace BEARING AND OIL SEAL Check -Dcatings ll at of engine) After cleaning and Isang, se inside race ofthe bearings Bul movemen-> replaceCheek Beating (al parts of engine) Damazedfbraded-> replace + Apply humped heat, Ins Breather Hose 2 Flange STARTER CLUTCH Insall: + Apply emyedenam distide engi ft the pot bab Insal: svat idle gear svasher smhInsal: starter clutch fixed pa © ‘TOOTHED BELT, FRONT AND REAR BELT PULLEYS, AND KICK-START MECHANISM Cea: side surface (rom bel pulley) Testa role 0 roller path Do ot apply any arosse to rollers o pulleys, For smoothe sion, py tqud graph eles and alot de lnsal collar whole Set of side disk © Ina: Ong @ Ins sector gear asembly 4) rewum spring tush plate washer sieclip 9Hook: — eum spring | Ina spring clip 4 Stet pinion <2 Jes ster and snap ing to asi of caves, on sector gear assembly Ina: dust cover Inst: ei dome pia | -tasket tinder bead) le erankeate cover -€ylinder ead sparkplug 2 Insta: * Always ws now gasket, shock absorber pd + The harp sie of paket should be inaeg Ins s ‘ova the cinerea! ick lever J + Fasten the outs aeewie, + Make the kik lever goal 1 the wl fhe crane (CYLINDER HEAD, CYLINDER AND PISTON Ins gasket (cylinder sylinder > + Alays ues gasket,Isa east red valve ENGINE ASSEMBLY Insta ive sprocket exhaust mutter 2 9. CARBURETOR REMOVAL Remove: lig able hat is attaches to automatic choke Remove airbox screws Remove: nore + Go to pages 59 and 60 fr carburetor maintainance proseeduve ‘acum pipe © screw (cabarr body) lite Gale fie dn pp oa rca om eaten es | eSASSEMBLY Aa from assembling the caturetor according to the reverse onler of removal, ote the following sal replace Min. Thickness Limit 0 mmBRAKE DISC HOLDER INSPECTION Remove the NUT Measure the key slot for darsge end the Remove the drive chin ngegement with eral IF auly, replace Remove the driven procter, nie and sproche DRIVE MECHANISM ‘ Inspect the civen sprocket for wear. o damage Replace if necessary. Uooest the suckler spline at for wear o damage Replace if nara | 6 | | SPROCKET HOLDER“Turn he fener ac of ach bearing with your finger The bearings ‘ould tn smoothly and quietly. Alo chek thatthe Beating | ‘terrace its tightly im al dee oe i“ INSTALLATION Apply grease tothe dase sal ip and inal dts, me ost the rar ane, dive sprocket and ane volar REAR WHEEL INSTALLATION Inst the oar whee Install he waste. Install the rear axe out and tighten ito the specied trp, TORQUE: 80-05 @ 11 TRANSMISSION REMOVAL AND ASSEMBLY 3 Remove exhaust pipe by ‘wo bots, Remove bok Remove counters no.(Remove tensioner sping 32.When removal s complete, scrape _sket material fim both cave or cove. 12. INSTALLATION OF 3-SPEI NOTEA yw are going to conti 4 sped transmission kip this ection and proceed 1B, Remove camshaf assembly and a notice he parts iicated 3 Arow having LEFT and RIGHT cieetion 2A. Coamtershaf assembly 2B, Install coumtersut assembly as shown,28 Install andtghten drain bolt.i. 46 Install ear exhaust bok 38.nsallR footboard ead bls, 37 sal L footboard and bot, Completion 13. INSTALLATION OF 4-SPEED TRANSMISSION 1A. Camshatt assembly BOGE =o @ 2A. Counter shat assembly 2B. Install eoumershotasembly as shown,B.lstall mainshart as shown, SSA.Shif forks ad shaft 5B. Lostall shi forks an shaft as shown, @ ‘Proceed to page 49 to Fins procedure 14, CLEAN CARBURETOR foarserems that hd the 2 Remove he hol Bowe! tothe Cutureor tJ v s 6. Wash or soak msn, pie, serw sn hoe sew the hee 4. Remove Air Serw and Thre Screw 5. Rewove Thrtle Compartrene1S. WIRING DIAGRAM. DL 603 (No REVERSE MODEL) aba2. DL 603 (REVERSE MODEL)4-DLOO1 REVERSE MODEL)