KYMCO GRAND DINK 125 Service Manual
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KYMCO GRAND DINK 125 Service Manual

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See also: Service Manual , Owner's Manual
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO GRAND
DINK 125/150.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 5 through 13 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 14 is the
removal/ installation of chassis. Section
16 states the testing and measuring
methods of electrical equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
GRAND DINK 125/150

TABLE OF CONTENTS

EXHAUST MUFFLER/FRAME COVERS
SHOCK ABSORBER/FRONT FORK
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

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  • Page 1: Table Of Contents

    PREFACE TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION technical features and servicing EXHAUST MUFFLER/FRAME COVERS procedures for the KYMCO GRAND DINK 125/150. INSPECTION/ADJUSTMENT Section 1 contains the precautions for LUBRICATION SYSTEM all operations stated in this manual.

  • Page 2: General Information

    . GENERAL INFORMATION GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ ENGINE SERIAL NUMBER--------------------------------------------- 1-1 SPECIFICATION---------------------------------------------------------- 1-2 SERVICE PRECAUTIONS----------------------------------------------- 1-4 TORQUE VALUES ------------------------------------------------------- 1-8 SPECIAL TOOLS --------------------------------------------------------- 1-9 LUBRICATION POINTS------------------------------------------------1-10 CABLE & HARNESS ROUTING-----------------------------------------1-12 WIRING DIAGRAM-------------------------------------------------------------------1-17 TROUBLESHOOTING --------------------------------------------------1-18...

  • Page 3: General Information

    . GENERAL INFORMATION GRAND DINK 125/150 SERIAL NUMBER Vehicle Identification Serial Number Location of Frame Serial Number Location of Engine Serial Number...

  • Page 4: Specification

    . GENERAL INFORMATION GRAND DINK 125/150 SPECIFICATIONS Cooling Type Water cooling Name & Model No. SH25DA Motorcycle Name & Type Overall length 2060mm Overall width 770mm Air cleaner type & No Paper element, wet Overall height 1360mm Fuel capacity 9.0 liters...
  • Page 5 . GENERAL INFORMATION GRAND DINK 125/150 SPECIFICATIONS Cooling Type Water cooling Name & Model No. SH30DA Motorcycle Name & Type Overall length 2060mm Air cleaner type & No Paper element, wet Overall width 770mm Fuel capacity 9.0 liters Overall height...

  • Page 6: Service Precautions

    . GENERAL INFORMATION GRAND DINK 125/150 n Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication points. n Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. n After reassembly, check all parts for proper tightening and operation.
  • Page 7 . GENERAL INFORMATION GRAND DINK 125/150 n If the fuse is burned out, find the cause and n The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. n If the double connector has a lock, lock it at the correct position.
  • Page 8 . GENERAL INFORMATION GRAND DINK 125/150 n After clamping, check each wire to make n Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not pull too tight n Do not squeeze wires against the weld or its clamp.
  • Page 9 . GENERAL INFORMATION GRAND DINK 125/150 n After routing, check that the wire harnesses n Symbols: are not twisted or kinked. The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points.

  • Page 10: Torque Values

    . GENERAL INFORMATION GRAND DINK 125/150 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (N-m) Item Torque (N-m) 5mm bolt, nut 5mm screw 6mm bolt, nut 6mm screw, SH bolt 8mm bolt, nut 21.6 6mm flange bolt, nut 11.8 10mm bolt, nut 34.3...

  • Page 11: Special Tools

    . GENERAL INFORMATION GRAND DINK 125/150 SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page Valve guide driver Valve guide removal/installation Valve guide reamer Valve guide grinding Valve spring compressor Valve removal Lock nut wrench, 39mm E027 Clutch disassembly Bearing driver...

  • Page 12: Lubrication Points

    . GENERAL INFORMATION GRAND DINK 125/150 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part •Genuine KYM CO Engine Oil (SAE15W-40) Camshaft protruding surface •API SE, SJ Egnine Oil Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut...
  • Page 13 . GENERAL INFORMATION GRAND DINK 125/150 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.

  • Page 14: Cable & Harness Routing

    . GENERAL INFORMATION GRAND DINK 125/150 CABLE & HARNESS ROUTING Front Brake Rear Brake Speedometer Cable Pressure Type Radiator Air Radiator Cap Vent Tube Horn Radiator 1-12...

  • Page 15: Rear View

    . GENERAL INFORMATION GRAND DINK 125/150 Reserve Tank Cap Ignition Switch Fuel Filler Fuel Tank Thermostatic Breather Tube Switch Fuel Tank Inlet Tube Water Hose Fuel Strainer Front Brake Fluid Tube Water Hoses 1-13...
  • Page 16 . GENERAL INFORMATION GRAND DINK 125/150 Front Stop Switch Rear Stop Switch Radiator Air Throttle Cable Vent Tube Fuel Filler Fuel Tank Breather Tube Fuel Tank Inlet Tube Rear Brake Fluid Tube Water Hose Wire Harness Fuel Tank Throttle Cable...
  • Page 17 . GENERAL INFORMATION GRAND DINK 125/150 Fuel Unit Fuel Tube Auto Bystarter Wire Thermostat Ignition Coil Air Cut-off Valve (A.C.V.) Carburetor Starter Motor Starter Relay C.D.I. Regulator/ Rectifier Hazard Control Unit Battery (-) Cable Fuse Box Battery (+) Cable 1-15...
  • Page 18 . GENERAL INFORMATION GRAND DINK 125/150 Ignition Coil Air Cut-off Valve (A.C.V.) Throttle Cable Thermostat Auto Bystarter Vacuum Fuel Tube Spark Plug Fuel Pump Vacuum Tube Regulator/ Ignition Coil Rectifier Fuel Tube Fuel Pump Vacuum Tube Wire Harness Fuel Pump...

  • Page 19: Wiring Diagram

    . GENERAL INFORMATION GRAND DINK 125/150 WIRING DIAGRAM 1-17...

  • Page 20: Troubleshooting

    . GENERAL INFORMATION GRAND DINK 125/150 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by ÅEmpty fuel tank loosening drain screw ÇClogged carburetor fuel inlet tube, vacuum tube or fuel tube ÉClogged auto fuel valve...
  • Page 21 . GENERAL INFORMATION GRAND DINK 125/150 ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate ÅClogged air cleaner lightly for observation ÇRestricted fuel flow ÉClogged fuel line between fuel tank and carburetor Engine speed Engine speed does ÑClogged exhaust muffler...
  • Page 22 . GENERAL INFORMATION GRAND DINK 125/150 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing ÅFaulty CDI unit Correct timing Incorrect timing ÇFaulty A.C. generator Check carburetor pilot screw adjustment ÅMixture too rich (turn screw...
  • Page 23 . GENERAL INFORMATION GRAND DINK 125/150 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing ÅFaulty CDI unit Correct timing Incorrect timing ÇFaulty A.C. generator Check valve clearance ÅImproperly adjusted valve Correctly adjusted Incorrectly adjusted clearance ÇWorn valve seat...
  • Page 24 . GENERAL INFORMATION GRAND DINK 125/150 ENGINE NOISE Symptom Probable Cause ÅValve clearance too large Valve noise ÇWorn camshaft lobe ÅWorn piston rings ÇWorn piston pin and connecting rod Piston noise small end ÉExcessive carbon build-up in combustion chamber ÅDamaged cam chain tensioner ÇWorn cam gear teeth...
  • Page 25 . GENERAL INFORMATION GRAND DINK 125/150 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause ÅWorn or slipping drive belt ÇBroken ramp plate ÉBroken drive face spring Engine starts but ÑSeparated clutch lining motor-cycle does not move ÖDamaged driven pulley shaft splines ÜDamaged final gear...

  • Page 26: Inspection/Adjustment

    . GENERAL INFORMATION GRAND DINK 125/150 STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of stop switch by ÅBurned out fuse applying brake ÇWeak or dead battery Stoplight does not ÉFaulty stop switch Stoplight comes come on ÑLoose or disconnected...
  • Page 27 . GENERAL INFORMATION GRAND DINK 125/150 closed NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark ÅFaulty spark plug Check spark plug cap and high-tension wire...
  • Page 28 . GENERAL INFORMATION GRAND DINK 125/150 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals ÅFaulty AC generator Voltage does not Normal voltage ÇFaulty regulator/rectifier increase ÉFaulty battery...
  • Page 29 . GENERAL INFORMATION GRAND DINK 125/150 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn ÅBurned out fuse signals ÇWeak or dead battery Signals operate Signals dim, remain ÉFaulty ignition switch...
  • Page 30 . GENERAL INFORMATION GRAND DINK 125/150 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) ÅSteering stem nut too tight Steering is heavy ÇBroken steering steel balls ÅExcessive wheel bearing play Front or rear wheel is ÇBent rim...
  • Page 31 . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 2-1 SERVICE INFORMATION -------------------------------------------- 2-2 TROUBLESHOOTING ------------------------------------------------- 2-2 FRAME COVERS REMOVAL----------------------------------------- 2-3 EXHAUST MUFFLER REMOVAL ----------------------------------- 2-6...

  • Page 32: Schematic Drawing

    . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 125/150 SCHEMATIC DRAWING...

  • Page 33: Service Information

    . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. • Make sure to route cables and harnesses according to the Cable & Harness Routing.

  • Page 34: Frame Covers Removal

    . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 125/150 Bolt FRAME COVERS REMOVAL REAR CARRIER & HAND RAIL REMOVAL Remove the met-in box: First remove the three bolts and two nuts attaching the met-in box. Remove the met-in box. Nuts Bolts Remove the hand rail right and left lock hex bolts.
  • Page 35 . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 125/150 Remove the two screws on the molding covers. Remove the molding covers. Molding Cover Screws Remove the two nuts and one bolt on the back taillight. Nuts Blot Screws Remove the left and right sides screws on the frame body cover.
  • Page 36 . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 125/150 Screws Bolt Remove the left and right side screws on the side cover. Remove the side cover. Bolts Remove the four bolts on the floor board. Remove the floor board. Screws FRONT UPPER COVER REMOVAL Remove the two screws on the front upper cover.

  • Page 37: Front Cover Removal

    . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 125/150 FRONT COVER REMOVAL First remove the front upper cover. Remove the two bolts attaching the front cover. Bolts Remove the six screws on the back of the front cover. Disconnect the right/left turn signal light wire connectors.

  • Page 38: Bottom Cover Removal

    . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 125/150 Screws Remove the three screws attaching fuel tank inlet tube join. Remove the back cover. Fuel Tank Inlet Tube Bolts BOTTOM COVER REMOVAL Remove the side stand. Remove the four bolts attaching the bottom cover.
  • Page 39 . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 125/150 HANDLEBAR COVER REMOVAL First remove the three screws attaching the handlebar under cover. Remove the handlebar under cover. Screws Screw Remove the screw from the handlebar upper cover. Screw Remove the screw from the bottom of handlebar upper cover.
  • Page 40 . INSPECTION/ADJUSTMENT GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 3- 1 MAINTENANCE SCHEDULE ---------------------------------------- 3- 2 FUEL LINE/FUEL FILTER ------------------------------------------- 3- 3 THROTTLE OPERATION --------------------------------------------- 3- 3 ENGINE OIL ------------------------------------------------------------ 3- 4 AIR CLEANER ---------------------------------------------------------- 3- 5...

  • Page 41: Service Information

    . INSPECTION/ADJUSTMENT GRAND DINK 125/150 SERVICE INFORMATION GENERAL WARNING •Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people.

  • Page 42: Maintenance Schedule

    . INSPECTION/ADJUSTMENT GRAND DINK 125/150 MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period. I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary. A: Adjust C: Clean R: Replace T : Tighten Regular Service Mileage (km) Whichever...

  • Page 43: Fuel Line/Fuel Filter

    . INSPECTION/ADJUSTMENT GRAND DINK 125/150 FUEL LINE/FUEL FILTER Remove the center cover. Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. Check for dirty or clogged fuel filter and replace with a new one if it is clogged.

  • Page 44: Engine Oil

    . INSPECTION/ADJUSTMENT GRAND DINK 125/150 Oil Dipstick ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the motorcycle upright on level ground. Wait for 2 3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when making this check.

  • Page 45: Air Cleaner

    . INSPECTION/ADJUSTMENT GRAND DINK 125/150 Screws AIR CLEANER Remove the seven air cleaner case cover screws and the cover. Air Cleaner Case Cover Air Cleaner Element Remove the air cleaner element. Check the element and replace it if it is excessively dirty or damaged.

  • Page 46: Valve Clearance

    . INSPECTION/ADJUSTMENT GRAND DINK 125/150 Bolts VALVE CLEARANCE • Inspect and adjust valve clearance while the engine is cold (below 35 Remove the cylinder head cover. Cylinder Head Cover “T” Mark Turn the A.C. generator flywheel to the top dead center (TDC) on the compression stroke so that the “T”...

  • Page 47: Ignition Timing

    . INSPECTION/ADJUSTMENT GRAND DINK 125/150 Timing Hole Cap IGNITION TIMING • The CDI unit is not adjustable. • If the ignition timing is incorrect, check the ignition system, Remove the timing hole cap. “F” Mark Check the ignition timing with a timing light.

  • Page 48: Final Reduction Gear Oil

    . INSPECTION/ADJUSTMENT GRAND DINK 125/150 Oil Check Bolt Hole/Oil Filler FINAL REDUCTION GEAR OIL • Place the motorcycle on its main stand on level ground. Stop the engine and remove the oil check bolt. The oil level shall be at the oil check bolt hole.

  • Page 49: Headlight Aim

    . INSPECTION/ADJUSTMENT GRAND DINK 125/150 HEADLIGHT AIM Turn the ignition switch ON. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting bolt. Headlight Aim Adjusting Bolt CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually.

  • Page 50: Brake System

    . INSPECTION/ADJUSTMENT GRAND DINK 125/150 Coolant capacity : 1400±20cc Radiator capacity : 1000±20cc Reserve tank capacity : 400±20cc Start the engine and check if there is no bubbles in the coolant and the coolant level is stable. Reinstall the radiator cap.

  • Page 51: Nuts/Bolts/Fasteners

    . INSPECTION/ADJUSTMENT GRAND DINK 125/150 NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages. Check the tire pressure.

  • Page 52: Lubrication System

    . LUBRICATION SYSTEM GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM-------------------------------- 4-1 SERVICE INFORMATION -------------------------------------------- 4-2 TROUBLESHOOTING ------------------------------------------------- 4-2 ENGINE OIL/OIL FILTER -------------------------------------------- 4-3 OIL PUMP REMOVAL------------------------------------------------- 4-4 OIL PUMP DISASSEMBLY ------------------------------------------- 4-4 OIL PUMP INSPECTION ---------------------------------------------- 4-5...

  • Page 53: Lubrication System Diagram

    . LUBRICATION SYSTEM GRAND DINK 125/150 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump Oil Filter Screen...

  • Page 54: Service Information

    . LUBRICATION SYSTEM GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed in the frame. • Drain the coolant before starting any operations. • Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.

  • Page 55: Engine Oil/Oil Filter

    . LUBRICATION SYSTEM GRAND DINK 125/150 ENGINE OIL/OIL FILTER Place the motorcycle upright on • level ground for engine oil level check. Run the engine for 2 • minutes and check the oil level after the engine is stopped for 2 3 minutes.

  • Page 56: Oil Pump Removal

    . LUBRICATION SYSTEM GRAND DINK 125/150 Bolts OIL PUMP REMOVAL First drain the coolant. Remove the right crankcase cover. ( 10-3) Remove the A.C. generator starter driven gear. ( 10-4) Remove the attaching bolt and oil separator cover. Oil Separator Cover...

  • Page 57: Oil Pump Inspection

    . LUBRICATION SYSTEM GRAND DINK 125/150 Pump Body Outer Rotor OIL PUMP INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.25mm replace if over Outer Rotor Inner Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.20mm replace if over Measure the rotor end-to-pump body clearance.

  • Page 58: Oil Pump Installation

    . LUBRICATION SYSTEM GRAND DINK 125/150 Pump Cover Hole Screw Install the pump cover by aligning the hole in the cover with the dowel pin. Tighten the screw to secure the pump cover. Make sure that the pump shaft rotates freely without binding.

  • Page 59: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 5-1 SERVICE INFORMATION -------------------------------------------- 5-2 ENGINE REMOVAL --------------------------------------------------- 5-3 ENGINE INSTALLATION -------------------------------------------- 5-5...

  • Page 60: Engine Removal/Installation

    5. ENGINE REMOVAL/INSTALLATION GRAND DINK 125/150 SCHEMATIC DRAWING...

  • Page 61: Service Information

    . ENGINE REMOVAL/INSTALLATION GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal.

  • Page 62: Engine Removal

    5. ENGINE REMOVAL/INSTALLATION GRAND DINK 125/150 Wire Connectors ENGINE REMOVAL Disconnect the battery negative cable. Remove the frame body cover. ( 2-3) Disconnect the engine negative cable. Disconnect all of the A.C. generator, auto bystarter, spark plug, thermosensor wire couplers and connectors.
  • Page 63 . ENGINE REMOVAL/INSTALLATION GRAND DINK 125/150 Rear Shock Absorber Upper Mount Bolts Remove the right/left rear shock absorber upper mount bolts. Remove the two engine mounting bolts and pull out the engine with the engine hanger backward. Engine Hanger Bolt...

  • Page 64: Engine Installation

    5. ENGINE REMOVAL/INSTALLATION GRAND DINK 125/150 ENGINE INSTALLATION Install the engine in the reverse order of removal. Tighten the engine mounting bolts. Torque: 49N-m Engine Hanger Bolt Tighten the rear shock absorber upper mount Rear Shock Absorber Upper Mount Bolts bolts.

  • Page 65: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 6- 1 SERVICE INFORMATION -------------------------------------------- 6- 2 TROUBLESHOOTING ------------------------------------------------- 6- 3 CYLINDER HEAD COVER REMOVAL ----------------------------- 6- 4 CAMSHAFT REMOVAL----------------------------------------------- 6- 4 CYLINDER HEAD REMOVAL --------------------------------------- 6- 6...

  • Page 66: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES GRAND DINK 125/150 SCHEMATIC DRAWING...

  • Page 67: Service Information

    . CYLINDER HEAD/VALVES GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.

  • Page 68: Troubleshooting

    . CYLINDER HEAD/VALVES GRAND DINK 125/150 TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler • Compression too low •...

  • Page 69: Cylinder Head Cover Removal

    . CYLINDER HEAD/VALVES GRAND DINK 125/150 Cylinder Head Cover CYLINDER HEAD COVER REMOVAL Remove the center cover. ( 2-3) Remove the met-in box. ( 2-3) Remove the cylinder head cover four bolts and then remove the cylinder head cover. Bolt CAMSHAFT REMOVAL Turn the A.C.
  • Page 70 . CYLINDER HEAD/VALVES GRAND DINK 125/150 Cam Chain Remove the camshaft gear from the cam chain to remove the camshaft. Camshaft Gear CAMSHAFT INSPECTION Check each cam lobe for wear or damage. Measure the cam lobe height. Service Limits: SH30DA IN: 30.75mm replace if below SH25DA EX:30.26mm replace if below...

  • Page 71: Cylinder Head Removal

    . CYLINDER HEAD/VALVES GRAND DINK 125/150 Camshaft Holder CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage. If the valve rocker arm contact surface is worn, check each cam lobe for wear or damage.

  • Page 72: Cylinder Head Disassembly

    . CYLINDER HEAD/VALVES GRAND DINK 125/150 Cylinder Head CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor. Be sure to compress the valve • springs with a valve spring compressor.

  • Page 73: Cylinder Head Assembly

    . CYLINDER HEAD/VALVES GRAND DINK 125/150 Straight Edge INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. Service Limit: 0.05mm repair or replace if...

  • Page 74: Cylinder Head Installation

    . CYLINDER HEAD/VALVES GRAND DINK 125/150 Plastic Hammer Tap the valve stems gently with a plastic hammer to firmly seat the cotters. Be careful not to damage the valves. Cylinder Head Gasket CYLINDER HEAD INSTALLATION Install the cam chain guide.

  • Page 75: Camshaft Installation

    . CYLINDER HEAD/VALVES GRAND DINK 125/150 Punch Marks CAMSHAFT INSTALLATION Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear facing up and align the punch marks on the...

  • Page 76: Cylinder Head Cover Installation

    . CYLINDER HEAD/VALVES GRAND DINK 125/150 Lock Pawl Gasket Install a new cam chain tensioner gasket. Release the lock pawl and push the push rod all the way in. Cam Chain Tensioner Push Rod Sealing Bolt Cam Chain Tensioner Install the cam chain tensioner and tighten the two bolts.

  • Page 77: Cylinder/Piston

    . CYLINDER/PISTON GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 7-1 SERVICE INFORMATION -------------------------------------------- 7-2 TROUBLESHOOTING ------------------------------------------------- 7-2 CYLINDER REMOVAL------------------------------------------------ 7-3 PISTON REMOVAL ---------------------------------------------------- 7-3 PISTON INSTALLATION --------------------------------------------- 7-7 CYLINDER INSTALLATION----------------------------------------- 7-7...

  • Page 78: Cylinder/Piston

    . CYLINDER/PISTON GRAND DINK 125/150 SCHEMATIC DRAWING...

  • Page 79: Service Information

    . CYLINDER/PISTON GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.

  • Page 80: Cylinder Removal

    . CYLINDER/PISTON GRAND DINK 125/150 Cylinder CYLINDER REMOVAL Remove the cylinder head. ( 6-7) Remove the water hose from the cylinder. Remove the cylinder base bolt. Cam Chain Guide Water Hose Remove the cam chain guide. Remove the cylinder. Gasket Remove the cylinder gasket and dowel pins.
  • Page 81 . CYLINDER/PISTON GRAND DINK 125/150 Inspect the piston, piston pin and piston rings. Remove the piston rings. • Take care not to damage or break the piston rings during removal. Clean carbon deposits from the piston ring grooves. Install the piston rings onto the piston and measure the piston ring-to-groove clearance.

  • Page 82: Cylinder Inspection

    . CYLINDER/PISTON GRAND DINK 125/150 Measure the piston pin O.D. Service Limit: 14.96mm replace if below Measure the piston O.D. • Take measurement at 9mm from the bottom and 90° to the piston pin hole. Service Limit: 57.90mm replace if below SH30DA 57.30mm replace if below...

  • Page 83: Piston Ring Installation

    . CYLINDER/PISTON GRAND DINK 125/150 Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the connecting rod small end I.D. Service Limit: 15.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston.

  • Page 84: Piston Installation

    . CYLINDER/PISTON GRAND DINK 125/150 PISTON INSTALLATION Remove any gasket material from the crankcase surface. • Be careful not to drop foreign matters into the crankcase. Piston Install the piston, piston pin and a new piston pin clip. Position the piston “IN” mark •...
  • Page 85 . CYLINDER/PISTON GRAND DINK 125/150 Cylinder Base Bolt Tighten the cylinder base bolt. Install the cam chain guide. • Insert the tab on the cam chain guide into the cylinder groove. Connect the water hose to the cylinder. Install the cylinder head. ( 6-9) Tighten the cylinder base bolt.

  • Page 86: Drive And Driven Pulleys/Kick Starter

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS/ KICK STARTER __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 8- 1 SERVICE INFORMATION -------------------------------------------- 8- 2 TROUBLESHOOTING ------------------------------------------------- 8- 2 LEFT CRANKCASE COVER------------------------------------------ 8- 3...

  • Page 87: Drive And Driven Pulleys/ Kick Starter

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER SCHEMATIC DRAWING...

  • Page 88: Service Information

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.

  • Page 89: Left Crankcase Cover

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Air Tube Band LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw. Bolts Remove the left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins.

  • Page 90: Drive Pulley

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Install the drive belt air tube and tighten the tube band screw. Tube Band Screw Universal Holder DRIVE PULLEY REMOVAL Remove the left crankcase cover. Hold the drive pulley using an universal holder and remove the drive face nut and washer.
  • Page 91 . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Drive Pulley Collar Remove the movable drive face assembly. Remove the drive pulley collar. Movable Drive Face Assembly Ramp Plate DISASSEMBLY Remove the ramp plate. Remove the weight rollers. Weight Roller INSPECTION Check each weight roller for wear or damage.
  • Page 92 . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Measure the movable drive face bushing assemblyy I.D. Service Limit: 27.20mm replace if over Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface.
  • Page 93 . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Ramp Plate Install the ramp plate. Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly...

  • Page 94: Clutch/Driven Pulley

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Drive Pulley Face Install the drive pulley face, washer and drive face nut. Drive Face Nut Washer Universal Holder Hold the drive pulley with the universal holder and tighten the drive face nut.

  • Page 95: Kick Starter

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY DISASSEMBLY Clutch Spring Compressor Hold the clutch/driven pulley assembly with the clutch spring compressor.
  • Page 96 . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Guide Roller Guide Roller Pin Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. O-ring Movable Driven Face Remove the oil seal from the movable driven Oil Seal face.
  • Page 97 . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play.
  • Page 98 . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Press a new needle bearing into the driven face. Special Bearing Driver Circlips CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. Keep grease off the clutch •...
  • Page 99 . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER CLUTCH ASS EMBLY Circlips Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips.
  • Page 100 . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Guide Roller Pin Guide Roller Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face.
  • Page 101 . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Clutch Outer Install the clutch outer. Hold the clutch outer with the universal holder. Install and tighten the clutch outer nut. Torque: 49.0 58.8kg-m Special Universal Holder Install the drive belt. ( 8-7) Install the left crankcase cover.
  • Page 102 . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Plastic Bushing Spindle INSPECTION Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushings for wear or damage.
  • Page 103 . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Install the kick lever. Install the left crankcase cover and tighten the cover bolts diagonally. Connect the drive belt air tube and tighten the band screw. Left Crankcase Cover LEFT CRANKCASE COVER BEARING...

  • Page 104: Final Reduction

    . FINAL REDUCTION GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 9-1 SERVICE INFORMATION -------------------------------------------- 9-2 TROUBLESHOOTING ------------------------------------------------- 9-2 FINAL REDUCTION DISASSEMBLY------------------------------- 9-3 FINAL REDUCTION INSPECTION---------------------------------- 9-3 FINAL REDUCTION ASSEMBLY ----------------------------------- 9-6...

  • Page 105: Final Reduction

    . FINAL REDUCTION GRAND DINK 125/150 SCHEMATIC DRAWING...

  • Page 106: Service Information

    . FINAL REDUCTION GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The servicing operations of this section can be made with the engine installed. • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation.

  • Page 107: Final Reduction Disassembly

    . FINAL REDUCTION GRAND DINK 125/150 Bolts FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. ( 2-6) Remove the rear brake caliper. ( 15-3) Remove the right rear shock absorber. ( 15-5) Remove the rear fork. ( 15-4) Remove the rear wheel. ( 15-4) Remove the left crankcase cover.
  • Page 108 . FINAL REDUCTION GRAND DINK 125/150 Inspect the final gear and final shaft for wear, damage or seizure. Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Countershaft Bearing...
  • Page 109 . FINAL REDUCTION GRAND DINK 125/150 Bearing Remover, 12mm BEARING REPLACEMENT (TRANSMISSION CASE COVER) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Drive Shaft Bearing Pilot, 12mm Drive new bearings into the transmission case cover.

  • Page 110: Final Reduction Assembly

    . FINAL REDUCTION GRAND DINK 125/150 Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Pilot, 15mm FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Drive Shaft Install the final gear and final shaft into the...
  • Page 111 . FINAL REDUCTION GRAND DINK 125/150 Install the countershaft and gear into the left crankcase. Install the resin washer onto the counter- shaft. Install the dowel pins and a new gasket. Countershaft Washer Install the transmission case cover. Transmission Case Cover...
  • Page 112 . FINAL REDUCTION GRAND DINK 125/150 Oil Check Bolt Hole/Oil Filler After installation, fill the transmission case with the specified oil. • Place the motorcycle on its main stand on level ground. • Check the oil sealing washer for wear or damage.

  • Page 113: Generator/Starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 10-1 SERVICE INFORMATION -------------------------------------------- 10-2 TROUBLESHOOTING ------------------------------------------------- 10-2 RIGHT CRANKCASE COVER REMOVAL-------------------------- 10-3 STATOR REMOVAL --------------------------------------------------- 10-3 FLYWHEEL REMOVAL----------------------------------------------- 10-3 STARTER CLUTCH ---------------------------------------------------- 10-4...

  • Page 114: Generator/Starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 125/150 SCHEMATIC DRAWING 10-1...

  • Page 115: Service Information

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • All servicing operations and inspections in this section can be made with the engine installed. • Drain the coolant before removing the right crankcase cover. • Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.)

  • Page 116: Right Crankcase Cover Removal

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 125/150 RIGHT CRANKCASE COVER Bolts Water Outlet Hose REMOVAL Disconnect the water hoses from the right crankcase cover. Remove the nine bolts attaching the right crankcase cover and the cover. Bolts Water Inlet Hose STATOR REMOVAL A.C.

  • Page 117: Starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 125/150 Starter Idle Gear Shaft STARTER CLUTCH REMOVAL Remove the starter idle gear and shaft. Starter Driven Gear Starter Driven Gear Remove the starter driven gear. INSPECTION Inspect the starter driven gear for wear or damage.

  • Page 118: Flywheel Installation

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 125/150 Spring Roller Remove the starter one-way clutch rollers, plungers and springs. Inspect each roller and plunger for wear or damage and check for broken or weak spring. Plunger Shaft Starter Idle Gear INSTALLATION Install the starter driven gear onto the crankshaft.

  • Page 119: Stator Installation

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 125/150 A.C. Generator Stator Screws STATOR INSTALLATION Install the A.C. generator stator on the right crankcase cover and secure it with the three bolts. Install the pulser coil on the right crankcase cover and secure it with the two screws.

  • Page 120: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 11-1 SERVICE INFORMATION -------------------------------------------- 11-2 TROUBLESHOOTING ------------------------------------------------- 11-2 CRANKCASE SEPARATION ----------------------------------------- 11-3 CRANKSHAFT INSPECTION----------------------------------------- 11-4 CRANKCASE ASSEMBLY -------------------------------------------- 11-5 11-0...

  • Page 121: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT GRAND DINK 125/150 SCHEMATIC DRAWING 11-1...

  • Page 122: Service Information

    . CRANKCASE/CRANKSHAFT GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces.

  • Page 123: Crankcase Separation

    . CRANKCASE/CRANKSHAFT GRAND DINK 125/150 Cam Chain Tensioner Slipper CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt. Remove the cam chain tensioner slipper and cam chain. Remove the two right crankcase attaching bolts. Bolt Cam Chain Bolts Remove the five left crankcase bolts.

  • Page 124: Crankshaft Inspection

    . CRANKCASE/CRANKSHAFT GRAND DINK 125/150 Oil Seal Remove the oil seal from the left crankcase. Left Crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.6mm replace if over Measure the connecting rod small end I.D.

  • Page 125: Crankcase Assembly

    . CRANKCASE/CRANKSHAFT GRAND DINK 125/150 Measure the crankshaft runout. Service Limit: 0.10mm replace if over Measure the crankshaft bearing play. Play Service Limits: Play Axial : 0.20mm replace if over Radial : 0.05mm replace if over Axial Radial CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces.
  • Page 126 . CRANKCASE/CRANKSHAFT GRAND DINK 125/150 Place the left crankcase down and install the crankshaft into the left crankcase. Avoid damaging the oil seal. • Apply grease to the lip of the oil • seal. Dowel Pins Install the two dowel pins and a new gasket.
  • Page 127 . CRANKCASE/CRANKSHAFT GRAND DINK 125/150 Cam Chain Tensioner Slipper Install the cam chain. Install the cam chain tensioner slipper. Install and tighten the cam chain tensioner slipper bolt. Torque: 7.8 11.8N-m Bolt 11-7...

  • Page 128: Cooling System

    . COOLING SYSTEM GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 12- 1 SERVICE INFORMATION -------------------------------------------- 12- 2 TROUBLESHOOTING ------------------------------------------------- 12- 2 COOLING SYSTEM TESTING --------------------------------------- 12- 4 RADIATOR -------------------------------------------------------------- 12- 4 WATER PUMP ---------------------------------------------------------- 12- 9...

  • Page 129: Cooling System

    . COOLING SYSTEM GRAND DINK 125/150 SCHEMATIC DRAWING Left Hand Threads Torque: 9.8 13.7N-m 12-1...

  • Page 130: Service Information

    . COOLING SYSTEM GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. • The engine must be cool before servicing the cooling system.
  • Page 131 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071 COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water 425cc 975cc -44.5 Cautions for Using Coolant: •...

  • Page 132: Cooling System Testing

    . COOLING SYSTEM GRAND DINK 125/150 COOLING SYSTEM TESTING Radiator Tester RADIATOR CAP INSPECTION Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. Apply water to the cap sealing surface before testing.
  • Page 133 . COOLING SYSTEM GRAND DINK 125/150 Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator, wash them off. Carefully straighten any bent fins.
  • Page 134 . COOLING SYSTEM GRAND DINK 125/150 Thermostatic Switch Wire Thermostatic Switch Disconnect the thermostatic switch wire coupler. Disconnect the fan motor wire coupler. Fan Motor Wire Coupler Bolts Radiator Remove the two bolts and one nut on the radiator. Fan/Shroud...
  • Page 135 . COOLING SYSTEM GRAND DINK 125/150 Battery Check fan motor by battery. Fan Motor Thermostatic Switch CHECK THERMOSTATIC SWITCH When coolant temperature lower then 83~87 the thermostatic switch OFF. When coolant temperature over 88~92 the thermostatic switch ON. Bolts Install the fan shroud on the radiator with the four bolts.
  • Page 136 . COOLING SYSTEM GRAND DINK 125/150 Radiator Bolts RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts and one nut. Upper Hose Connect the upper and lower hoses and secure them with hose bands. Connect the thermostatic switch wire and fan motor wire couplers.

  • Page 137: Water Pump

    . COOLING SYSTEM GRAND DINK 125/150 Install the front upper cover. Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.
  • Page 138 . COOLING SYSTEM GRAND DINK 125/150 Bolts Water Pump Cover Remove the four bolts and the water pump cover, gasket and 2 dowel pins. Impeller (Left Hand Threads) Remove the water pump impeller. The impeller has left hand threads. Mechanical Seal...
  • Page 139 . COOLING SYSTEM GRAND DINK 125/150 Bolts WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove the 3 bolts attaching the water pump assembly. Remove the water pump assembly, gasket and dowel pins. Water Pump Assembly...
  • Page 140 . COOLING SYSTEM GRAND DINK 125/150 Water Pump Assembly MECHANICAL S EAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside. Mechanical Seal (Water Seal) Mechanical Seal Driver Drive in a new mechanical seal using a mechanical seal driver.
  • Page 141 . COOLING SYSTEM GRAND DINK 125/150 Snap Ring Water Pump Shaft Install the water pump shaft and shaft inner bearing into the waster pump assembly. Install the snap ring to secure the inner bearing properly. Inner Bearing Water Pump Assembly...
  • Page 142 . COOLING SYSTEM GRAND DINK 125/150 Impeller (Left Hand Threads) Install the impeller onto the water pump shaft. Torque: 9.8 13.7N-m The impeller has left hand threads. Dowel Pins Install the two dowel pins and a new gasket. Gasket Water Pump Cover Install the water pump cover and tighten the 4 bolts.

  • Page 143: Thermosensor

    . COOLING SYSTEM GRAND DINK 125/150 THERMOSENSOR Thermosensor THERMOSENSOR REMOVAL Remove the seat, met-in box and center cover. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor Wire THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water...

  • Page 144: Thermostat

    . COOLING SYSTEM GRAND DINK 125/150 Thermostat Housing Bolt THERMOSTAT THERMOSTAT REMOVAL Remove the seat, met-in box and center cover. Drain the coolant. Disconnect the thermosensor wire from the thermosensor. Disconnect the water hose from the thermostat housing. Disconnect the air vent tube from the thermostat housing.
  • Page 145 . COOLING SYSTEM GRAND DINK 125/150 THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water Thermostat temperature to check its operation. Technical Data Thermometer Begins to open 80±2 Full-open Valve lift 4.5mm...
  • Page 146 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM/CARBURETOR/FUEL PUMP __________________________________________________________________________________ FUEL SYSTEM --------------------------------------------------------- 13- 1 SCHEMATIC DRAWING ---------------------------------------------- 13- 2 OPERATION OF CARBURETOR JETS------------------------------ 13- 3 SERVICE INFORMATION -------------------------------------------- 13- 5...

  • Page 147: Fuel System/Carburetor/Fuel Pump Fuel Tank

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 FUEL SYSTEM 13-1...

  • Page 148: Schematic Drawing

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 SCHEMATIC DRAWING 13-2...

  • Page 149: Operation Of Carburetor Jets

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 OPERATION OF CARBURETOR JETS LOW SPEED Venturi (slightly opened throttle valve) Air Bleed Holes‡ Mixture……. Low Speed Air Inlet Fuel in Float Chamber‡ Slow Jet -------------------- Low Speed Small Jet Holes 2.MIDDLE SPEED...
  • Page 150 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 FUEL PUMP CONSTRUCTION: The fuel pump adopted for this model is a vacuum-type fuel pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve.

  • Page 151: Service Information

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • When working with gasoline, keep away from sparks and flames. • Note the locations of O-rings when disassembling and replace them with new ones during assembly.
  • Page 152 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 TROUBLESHOOTING Engine does not start Engine idles roughly, stalls or runs poorly • No fuel in tank • Incorrect idle speed • Restricted fuel line • Rich mixture • Too much fuel getting to cylinder •...

  • Page 153: Carburetor Removal

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 Auto Bystarter Wire Auto Bystarter CARBURETOR REMOVAL Remove the seat, met-in box and center cover. Disconnect the fuel tube and vacuum tube at the carburetor. Disconnect the auto bystarter wire.
  • Page 154 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 Screws Remove the two vacuum chamber cover screws and the cover. Vacuum Chamber Cover Spring Remove the compression spring and vacuum piston. Vacuum Piston Vacuum Piston Diaphragm Remove the needle holder, spring and jet needle from the piston.

  • Page 155: Float Chamber Disassembly

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 Float Chamber FLOAT CHAMBER DISASSEMBLY Remove the four float chamber screws and the float chamber. Screws Float Remove the float pin, float and float valve. Float Pin Float Valve Float Valve...
  • Page 156 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 JETS/SCREWS REMOVAL • Before removing the pilot screw, turn the pilot screw clockwise until it seats lightly and record the rotating turns. Do not force the pilot screw against its seat to avoid seat damage.

  • Page 157: Auto Bystarter Inspection/Removal

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 AUTO BYSTARTER INSPECTION /REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 10W (10 minutes minimum after stopping the engine) If the reading is not within the limit, replace the auto bystarter with a new one.

  • Page 158: Air Cut-Off Valve (A.c.v.)

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks, wear or damage. If any faulty part is found, replace the auto bystarter with a new one. Bystarter Needle...
  • Page 159 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 Air Cut-off Valve Body Hose Disconnect the hose at the valve seat. Remove the two screws and the air cut-off valve body. Screws CARBURETOR BODY CLEANING Blow compressed air through all passages of the carburetor body.

  • Page 160: Auto Bystarter Installation

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 Diaphragm O-ring Install the O-ring onto the air-cut-off valve body securely. • Install the O-ring with the flat face toward the valve body side. Install the diaphragm, spring, and cover.

  • Page 161: Float Chamber Assembly

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 Main Jet Slow Jet FLOAT CHAMBER ASSEMBLY Install the main jet. Install the slow jet. Install the pilot screw. • Be sure to record the rotating turns when it is removed.

  • Page 162: Float Level Inspection

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 FLOAT LEVEL INSPECTION Measure the float level at the location of the main jet (just contacting the float valve). Float Level: 18.5±1.0mm Replace the float if the level is incorrect.

  • Page 163: Carburetor Installation

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 Check the heater with battery. If the heater is getting hot, means the heater without problem, otherwise the heater has to be changed. Heater Throttle Cable CARBURETOR INSTALLATION Tighten the drain screw.

  • Page 164: Fuel Pump Removal/Disassembly

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 Outlet Tube FUEL PUMP REMOVAL Remove the frame center cover. Disconnect the fuel pump inlet, outlet and vacuum tubes. Remove the two fuel pump attaching bolts and the fuel pump.

  • Page 165: Fuel Pump Inspection

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 Diaphragm FUEL PUMP INSPECTION Inspect the fuel pump diaphragms A and B for damage. Inspect each gasket for damage. Gaskets Relief Valve Outlet Suction Valve Inspect the suction valve, outlet valve and relief valve in the fuel pump body for damage, cracks or foreign matters.

  • Page 166: Fuel Pump Installation

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 Outlet Tube Vacuum Tube Inlet Tube FUEL PUMP INSTALLATION Install the fuel pump and secure it with the two bolts. Connect the fuel pump inlet, outlet and vacuum tubes. Install the seat, met-in box and frame center cover.
  • Page 167 . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 125/150 FUEL STRAINER REMOVAL Remove the fuel strainer from the fuel tank. INSPECTION Inspect if the fuel strainer is clogged and clean it with compressed air. Replace the fuel strainer at every 6000 km.

  • Page 168: Steering Handlebar/Front Wheel/Front Brake/Front

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 14- 1 SERVICE INFORMATION -------------------------------------------- 14- 2 TROUBLESHOOTING ------------------------------------------------- 14- 3 STEERING HANDLEBAR--------------------------------------------- 14- 4...

  • Page 169: Schematic Drawing

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SCHEMATIC DRAWING 14-1...

  • Page 170: Service Information

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.

  • Page 171: Troubleshooting

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim cone race • Loose front axle • Broken steering balls • Bent spoke plate •...

  • Page 172: Steering Handlebar

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. ( 2-6) Remove the front and rear brake master cylinder attaching bolts. Remove the front upper cover. ( 2-5) Remove the front lower cover.

  • Page 173: Front Wheel

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Throttle Grip Throttle Cable Lubricate the throttle grip front end with grease and then install the throttle grip. Connect the throttle cable to the throttle grip. Install the right and left handlebar switches and tighten the screws.
  • Page 174 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over FRONT WHEEL BEARING Remove the side collar and dust seal. Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly.
  • Page 175 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Driver Handle Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. Do not allow the bearings to tilt •...

  • Page 176: Front Brake

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Holder Bolts FRONT BRAKE BRAKE MASTER CYLINDER REM OVAL Remove the handlebar covers. ( 2-6) First drain the brake fluid from the hydraulic brake system. Disconnect the front stop switch wire connector.
  • Page 177 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75mm Measure the brake master cylinder piston O.D. Service Limit: 12.645mm Before assembly, inspect the lst and 2nd rubber cups for wear.
  • Page 178 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Connect the front stop switch wire connector. Install the handlebar covers. ( 2-6) Stop Switch Wire Connector BRAKE FLUID REFILLING Keep the handlebar upright and remove the brake reservoir cover and diaphragm.
  • Page 179 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bleed Valve BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper.
  • Page 180 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge. Service Limit: 25.30mm Check the caliper cylinder for scratches or wear and measure the cylinder bore.
  • Page 181 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Fluid Tube Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt. Torque: 24.5 34.3N-m Fill the brake reservoir with the specified brake fluid and bleed air from the brake system.

  • Page 182: Front Shock Absorber

    14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Front Fork FRONT SHOCK ABSORBER REMOVAL Remove the front upper cover. ( 2-5) Remove the front lower cover. ( 2-5) Remove the front wheel. ( 14-5) Remove the front brake caliper. ( 14-11) Remove the front shock absorber upper mount bolts.
  • Page 183 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Shock Absorber Tube INSPECTION Inspect the following items and replace if necessary. •Front shock absorber tube bending, damage or wear •Weak front shock absorber spring •Damper and damper rod bending •Oil seal damage or wear...
  • Page 184 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ASSEMBLY Install the damper spring onto the damper rod and then install them into the front shock absorber tube. Install the shock absorber spring onto the front shock absorber tube.
  • Page 185 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Lock Nut Socket FRONT FORK REMOVAL Remove the handlebar covers. ( 2-6) Remove the steering handlebar. ( 14-4) Remove the front upper cover. ( 2-5) Remove the front lower cover. ( 2-5) Remove the front inner fender.
  • Page 186 14.STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 125/150 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race. Then, install the front fork.

  • Page 187: Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 15-1 SERVICE INFORMATION -------------------------------------------- 15-2 TROUBLESHOOTING ------------------------------------------------- 15-2 REAR BRAKE ----------------------------------------------------------- 15-3 REAR FORK ------------------------------------------------------------- 15-4...

  • Page 188: Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER GRAND DINK 125/150 SCHEMATIC DRAWING 15-1...
  • Page 189 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding. • During servicing, keep oil or grease off the brake pads and brake disk.
  • Page 190 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER GRAND DINK 125/150 Fluid Tube Bolt REAR BRAKE REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler. ( 2-6) Remove the rear brake fluid tube bolt and disconnect the brake fluid tube. Remove the two bolts attaching the rear brake caliper.

  • Page 191: Rear Fork

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER GRAND DINK 125/150 REAR FORK Shock Absorber Lower Mount Bolt REMOVAL Remove the exhaust muffler. ( 2-6) Remove the rear brake caliper. ( 15-3) Remove the right rear shock absorber lower mount bolt.

  • Page 192: Rear Shock Absorber

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER GRAND DINK 125/150 Shock Absorber Lower Mount Bolt INSTALLATION The installation sequence is the reverse of removal. Torque: Rear shock absorber lower mount bolt: 19.6 29.4N-m Rear axle nut: 78.4 98N-m Brake Caliper Bolts...

  • Page 193: Battery/Charging System

    . BATTERY/CHARGING SYSTEM GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT-------------------------------------- 16-1 SERVICE INFORMATION -------------------------------------------- 16-2 TROUBLESHOOTING ------------------------------------------------- 16-3 BATTERY---------------------------------------------------------------- 16-4 CHARGING SYSTEM -------------------------------------------------- 16-5 A.C. GENERATOR INSPECTION ------------------------------------ 16-5 REGULATOR/RECTIFIER INSPECTION --------------------------- 16-6...

  • Page 194: Battery/Charging System

    . BATTERY/CHARGING SYSTEM GRAND DINK 125/150 CHARGING SYSTEM LAYOUT Fuse Battery A.C. Generator Regulator/Rectifier CHARGING CIRCUIT 16-1...

  • Page 195: Service Information

    . BATTERY/CHARGING SYSTEM GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention •...

  • Page 196: Troubleshooting

    . BATTERY/CHARGING SYSTEM GRAND DINK 125/150 SPECIAL TOOLS Universal holder Flywheel puller TROUBLESHOOTING No power Intermittent power • Dead battery • Loose battery cable connection • Disconnected battery cable • Loose charging system connection • Fuse burned out • Loose connection or short circuit in ignition system •...

  • Page 197: Battery

    . BATTERY/CHARGING SYSTEM GRAND DINK 125/150 Battery Cover Screw BATTERY Remove the seat and met-in box. ( 2-3) Remove the battery cover screw and the battery cover. Remove the battery. First disconnect the battery negative (-) cable and then the positive (+) cable.

  • Page 198: Charging System

    . BATTERY/CHARGING SYSTEM GRAND DINK 125/150 CHARGING SYSTEM CURRENT TEST Use a fully charged battery (12.8V min.) to check the charging system. Warm up the engine after connecting a fully charged battery. Connect an electric tester across the battery terminals.

  • Page 199: Regulator/Rectifier Inspection

    . BATTERY/CHARGING SYSTEM GRAND DINK 125/150 A.C. Generator Stator Pulser Coil A.C. GENERATOR REMOVAL A.C. generator removal ( 10-3) A.C. generator installation ( 10-6) Right Crankcase Cover Bolts REGULATOR/RECTIFIER INSPECTION Remove the frame front cover. ( 2-5) Remove the regulator/rectifier wire coupler.

  • Page 200: Ignition System

    . IGNITION SYSTEM GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT --------------------------------------- 17-1 SERVICE INFORMATION -------------------------------------------- 17-2 TROUBLESHOOTING ------------------------------------------------- 17-2 SPARK PLUG ----------------------------------------------------------- 17-3 IGNITION COIL INSPECTION --------------------------------------- 17-3 A.C. GENERATOR INSPECTION ------------------------------------ 17-4...

  • Page 201: Ignition System Layout

    . IGNITION SYSTEM GRAND DINK 125/150 IGNITION SYSTEM LAYOUT CDI Unit Ignition Coil Ignition Switch Pulser Coil A.C. Generator IGNITION CIRCUIT 17-1...

  • Page 202: Service Information

    . IGNITION SYSTEM GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. ( 1-28) • The ignition system adopts CDI unit and the ignition timing cannot be adjusted. • If the timing is incorrect, inspect the CDI unit and A.C. generator and replace any faulty parts.

  • Page 203: Spark Plug

    . IGNITION SYSTEM GRAND DINK 125/150 SPARK PLUG Ignition Coil For spark plug inspection and adjustment, refer to page 3-5. IGNITION COIL INSPECTION Remove the seat and met-in box. ( 2-3) Remove the ignition coil IGNITION COIL CONTINUITY TEST Ignition Coil...

  • Page 204: A .C. Generator Inspection

    . IGNITION SYSTEM GRAND DINK 125/150 A .C. GENERATOR INSPECTION EXCITER COIL/PULSER COIL INSPECTION This test is performed with the stator installed in the engine. Remove the frame right cover. ( 2-4) Disconnect the A.C. generator connector. Measure the exciter coil resistance between the black/red wire terminal and ground.

  • Page 205: Cdi Unit Resistance Inspection

    . IGNITION SYSTEM GRAND DINK 125/150 Å (Black/Yellow) (Green) (Blue/Yellow) CDI UNIT RESISTANCE INSPECTION Measure the resistance between the terminals. Replace the CDI unit if the readings are not within the specifications in the table below. • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing.

  • Page 206: Starting System

    . STARTING SYSTEM GRAND DINK 125/150 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT -------------------------------------- 18-1 SERVICE INFORMATION -------------------------------------------- 18-2 TROUBLESHOOTING ------------------------------------------------- 18-2 STARTER MOTOR ----------------------------------------------------- 18-3 STARTER CLUTCH INSPECTION----------------------------------- 18-5 STARTER RELAY INSPECTION ------------------------------------ 18-6 18-0...

  • Page 207: Starting System

    . STARTING SYSTEM GRAND DINK 125/150 STARTING SYSTEM LAYOUT Stop Switches Starter Relay Starter Button Starter Motor STARTING CIRCUIT Start SW 18-1...

  • Page 208: Service Information

    . STARTING SYSTEM GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • For the starter clutch removal, refer to page 10-3. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.

  • Page 209: Starter Motor

    . STARTING SYSTEM GRAND DINK 125/150 STARTER MOTOR REMOVAL • Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly.
  • Page 210 . STARTING SYSTEM GRAND DINK 125/150 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush.

  • Page 211: Starter Clutch Inspection

    . STARTING SYSTEM GRAND DINK 125/150 ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover.

  • Page 212: Starter Relay Inspection

    . STARTING SYSTEM GRAND DINK 125/150 STARTER RELAY INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.

  • Page 213: Switches/Horn/Fuel Unit/Thermostatic

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH/TEMPERATURE GAUGE/ INSTRUMENTS/LIGHTS __________________________________________________________________________________ ELECTRICAL EQUIPMENT LAYOUT------------------------------ 19-1 SERVICE INFORMATION -------------------------------------------- 19-2 TROUBLESHOOTING ------------------------------------------------- 19-2 SWITCHES -------------------------------------------------------------- 19-3 HORN INSPECTION --------------------------------------------------- 19-5 FUEL UNIT-------------------------------------------------------------- 19-5...

  • Page 214: Electrical Equipment Layout

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS ELECTRICAL EQUIPMENT LAYOUT Stop Switches Headlight Instruments Dimmer Switch Turn Signal Switch Horn Button Auto Bystarter Headlight Ignition Switch Switch Horn Starter Button Fuel Unit Thermostatic Switch Thermosensor 19-1...

  • Page 215: Service Information

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS • After installation of each switch, a continuity check must be performed. A continuity check can usually be made without removing the part from the motorcycle. TESTING INSTRUMENT...

  • Page 216: Switches

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS SWITCHES IGNITION SWITCH INSPECTION Remove the frame front covers. ( 2-5) Disconnect the ignition switch wire couplers. Check for continuity between the wire terminals. Color Black/Wh Green Black Position PARK LOCK HEADLIGHT SWITCH INSPECTION Remove the frame front covers.
  • Page 217 . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HORN BUTTON INSPECTION Remove the frame front covers. ( 2-5) Disconnect the horn wire couplers. Depress the horn button and check for continuity between the wire terminals. Color Light Green Brown/Blue...

  • Page 218: Horn Inspection

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HORN INSPECTION Remove the front upper cover. ( 2-5) Disconnect the horn wire couplers. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals.

  • Page 219: Thermostatic Switch

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS Thermostatic Switch THERMOSTATIC SWITCH INSPECTION Remove the front covers. ( 2-5) Start and run the engine to make the water temperature reaches 85 and check if the cooling fan motor operates.

  • Page 220: Instruments

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS INSTRUMENTS Speedometer Cable REMOVAL Remove the front upper cover. ( 2-5) Disconnect the instrument wire couplers and connectors. Disconnect the speedometer cable. Remove the four instrument cover and leg shield screws.

  • Page 221: Lights

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS Wire LIGHTS HEADLIGHT BULB REPLACEMENT Remove the front upper cover. ( 2-5) Disconnect the headlight and turn signal light wire couplers. Remove the rubber boot from the bulb socket. Remove the bulb socket and replace the bulb.

  • Page 222: Heater Wiring Diagram

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 125/150 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HEATER WIRING DIAGRAM 19-9...
  • Page 223 KYMCO Clean Air System (For EURO 2) The KYMCO Clean Air System is a secondary air suction system that helps the exhaust gases to burn more completely. When the spent fuel charge is released into the exhaust system, it is still hot enough to burn.
  • Page 224 YM CO EC HNIC AL NF ORMATI ON Model_ ALL MODEL (For EURO 2) Date: 8.JAN.04 Subject_ KYMCO Clean Air System (For EURO 2) NO.: KTI-04002 Secondary Air Suction System Diagram (2-stroke)

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Grand dink 150

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