2003 Denli 90cc Diamond Back

I was given this thing for free after a neighbor decided to clean out his garage and I decided it might be a cheap starter quad for my 7 year old son.

History: It's been sitting for 3 years not started or ran.

Missing Parts: Battery
headlight bulb holders missing and 5-6 wires under the headlight cover area not connected

Motor does not seem to turn over when using the kick starter...
kick starter moves but just barely and is very hard to kick down



I ordered & installed the correct size battery and all I get is a clicking sound and the engine does not turn over like it should with the left side handbrake held while pushing the starter button. I tapped on the starter with a screwdriver and now it no longer clicks nor will the engine turn over.

Also....Oil light does not glow when the switch is turned on,

Any ideas what I might be dealing with here ?????

Seized engine maybe ???

 

spray some lubricant in on top of the piston, let it set for a little while, keep the spark plug OUT and try to slowly turn the engine over with the kick start. as far as the starter goes, you may need to pull it to test it. BUT, let's start with turning it over slowly first so we can rule out a seized engine. does it have oil in the crankcase?

 

Thanks for that great advice @ Jaster94

Pulled the spark plug
sprayed (soaked) the cylinder down with WD-40
let it soak for an hour

Wa---laaaaaaaa......

I guess the rings were seized because now the kick starter turns over the engine. Still no luck with the starter even after tapping on it with a screw driver.

What kind of compression should it have and what's the easiest method to test it ?
Figured I better test that just to be sure the rings didn't break.

As for the starter, if I used a screwdriver to short out the starter relay/solenoid and it turned over the engine would that mean the starter is bad ?

Also, I've seen a few Jap starters starting @ $22.00 on Ebay (Fee-bay) and Amazon that appear to look the same as the top mount starter on the Dinli. Are they compatable aftermarket starters or should I try to score a more expensive factory original replacement ?

 

i use a compression gauge that has a conical rubber boot that fits inside of the spark plug threads that doesn't hurt the threads. put it on there then crank the engine to gauge the pressure.
solenoid.......now, was the battery fully charged or were you jumping it with cables? touching the solenoid's post together is a way to test the starter by bypassing the safety interlocks that are installed on your little quad. did the starter turn over normally? i hope so. part of the safety interlock system is the brake switch located at the left handlebar lever there at the brake reservoir. see the piston actuated by the lever in/out of the reservoir? see those 2 little wires? make sure that switch works. easy test is: brake light illluminating? hear a small "tink" when squeezing the lever? is there a rear tether kill switch located under the seat near the rear? if so, make sure it is intact. these interlocks are there to prevent a kid from starting the quad while standing beside it and taking a chance the quad takes off and runs them over. savvy? yeah, do some checking and report back the details.

 

I'll have to buy a compression tester today.
The battery is brand new and I did charge it for 2 hrs prior to installing it.
The rear brake light does illuminate when the left brake lever is pulled.
The rear tether kill switch under the tail light is in tact & connected.

Today I'll be pulling the plastics off the quad to get a better look at what's under them because theres several wires on the front end that are disconnected and to locate the starter relays. I'll post a few pics of the disconnected wires and anything else in question a little later today.

Oh.....I did find and print a copy of the Manual online and it's should help identifying a few things even though it's a bit not to detailed.

 

good deal. i'll be on the forum off/on all day. after all, it IS labor day. bwahaha.

 

I removed the plastic to get a better look at what I'm dealing with and now I have a better view....man things are a bit tight under there. I did find some wires not connected and also found out that the actual headlight holders (sockets) are not there so my guess is that some of those wires are for the headlights. They also might be the cause for the light not coming on when I turn the switch on.

Here's a shot of the wires found that are not connected. If you know what they go to feel free to in-lighten me with the info

Also, where can I found the starter solenoid on this thing ?

 

trace the hot wire off of the battery. it'll go to it. it'll be somewhere near the battery mounted to the frame. or backtrack from the starter back up to the solenoid. either way, you're gonna find it. i've not worked on a Dinli before, i'd have to find a wiring diagram. this first link is a manual for your quad. the 2nd link is the main manual page to choose from.

http://www.dinlisales.com/docs/2003B...DBACK%20NP.pdf

Dinli Parts Manuals

i'll PM you other stuff i don't want to publish.

 

Compression should be 90 min.
Justin at MaximumRPM.com may be able to help with parts and such. He was the original importer for your finely made Tiawanese machine.

 

LOL @ finely made Tiwanese machine.
Seriously ?????

This thing was given to me for free and my son is stoked digging it but if it's going to cost me a grip of cash to get it running right I'll be parting it out. Cheapest starter I've found for it is $79.00 and they appear to be hard to come by.

90 huhhh....
I'll do a compression test on it later today when I get home from work.