KYMCO G-DINK 300i Service Manual

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G-DINK 300i

By KWANG YANG Motor Co., Ltd.

1st Edition, ,Mar. 2012

unauthorized use without the written

permission of KWANG YANG Motor Co., Ltd.

is expressly prohibited.

T300-LHG7-A1

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for KYMCO G-DINK 300i

Page 1 G-DINK 300i By KWANG YANG Motor Co., Ltd. 1st Edition, ,Mar. 2012 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T300-LHG7-A1...
Page 2: Table Of Contents
G-DINK 300i PREFACE TABLE OF CONTENTS This Service Manual describes the technical features servicing GENERAL INFORMATION procedures for the KYMCO G-DINK 300i EXHAUST MUFFLER/FRAME COVERS Section 1 contains the precautions for all operations stated in this manual. INSPECTION/ADJUSTMENT Read them...
Page 3: General Information
1. GENERAL INFORMATION G-DINK 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION ________________________________________________________________________________ SERIAL NUMBER ------------------------------------------------------------------------------------ 1-1 SPECIFICATION ------------------------------------------------------------------------------------- 1-2 SERVICE PRECAUTIONS ------------------------------------------------------------------------- 1-5 TORQUE VALUES ----------------------------------------------------------------------------------- 1-9 SPECIAL TOOLS ----------------------------------------------------------------------------------- 1-11 LUBRICATION POINTS -------------------------------------------------------------------------- 1-12 CABLE & HARNESS ROUTING------------------------------------------------------------------- 1-14...
Page 4 1. GENERAL INFORMATION G-DINK 300i Identification Numbers Record...
Page 5: Specification
1. GENERAL INFORMATION G-DINK 300i SPECIFICATIONS Oil filter type Full-flow filtration Name G-DINK 300i Oil capacity 1.1 liter Model No. SH60AA Exchanging capacity 0.9 liter Overall length 2090 mm Fi injection system Overall width 770 mm Air cleaner type & No...
Page 6: Service Precautions
1. GENERAL INFORMATION G-DINK 300i Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication points. Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with When two persons work together, pay larger-diameter to smaller ones at several attention to the mutual working safety.
Page 7 1. GENERAL INFORMATION G-DINK 300i Before connecting a terminal, check for After operation, terminal caps shall be damaged terminal cover or loose negative installed securely. terminal. Confirm Capacity When taking out the connector, the lock on Check the double connector cover for the connector shall be released before proper coverage and installation.
Page 8 1. GENERAL INFORMATION G-DINK 300i Protect wires and harnesses with electrical Do not squeeze wires against the weld or tape or tube if they contact a sharp edge or its clamp. corner. Do not pull too tight！ After clamping, check each harness to...
Page 9 1. GENERAL INFORMATION G-DINK 300i Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent surrounding parts steering positions. When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions.
Page 10 1. GENERAL INFORMATION G-DINK 300i Symbols: following symbols represent servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) Grease : Apply grease for lubrication.
Page 11: Torque Values
1. GENERAL INFORMATION G-DINK 300i TORQUE VALUES...
Page 12 1. GENERAL INFORMATION G-DINK 300i TORQUE VALUES...
Page 13 1. GENERAL INFORMATION G-DINK 300i TORQUE VALUES FRAME 1-10...
Page 14: Special Tools
1. GENERAL INFORMATION G-DINK 300i SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page Flywheel puller E003 A.C. generator flywheel removal 4.10 One way clutch puller E006 One way clutch removal Tappet adjuster E012 Tapper adjustment Oil seal & bearing installer E014 Oil seal &...
Page 15: Lubrication Points
1. GENERAL INFORMATION G-DINK 300i LUBRICATION POINTS FRAME The following is the lubrication points for the frame. Use grease for parts not listed. Apply engine oil or grease to cables and movable parts not specified. It will avoid abnormal noise and damage the durability of the motorcycle.
Page 16: Cable & Harness Routing
1. GENERAL INFORMATION G-DINK 300i CABLE & HARNESS ROUTING Tilt Switch Speedometer Radiator Filler Cap Coolant Reserve Tank Ignition Switch Horn 1-13...
Page 17 1. GENERAL INFORMATION G-DINK 300i CABLE & HARNESS ROUTING Winker Relay Start Relay ECU Relay Hi Beam Relay Fuel Pump Relay Lo Beam Relay Fan Relay 1-14...
Page 18 1. GENERAL INFORMATION G-DINK 300i Throttle Body MAP Sensor Injector O2 Sensor 1-15...
Page 19 1. GENERAL INFORMATION G-DINK 300i Ignition Coil Regulator/Rectifier Hazard Control Unit Starter Relay Crank Position Sensor 1-16...
Page 20: Troubleshooting
1. GENERAL INFORMATION G-DINK 300i TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Possible cause ! Faulty fuel pump 1. Check for operation of the fuel pump Abnormal Normal ! Faulty pressure regulator 2. Inspect the fuel flow...
Page 21 1. GENERAL INFORMATION G-DINK 300i ENGINE LACKS POWER Possible cause ! Brake dragging 1. Raise wheel off the ground Wheels do not ! Worn or damaged wheel bearing and spin by hand spin freely Wheel spins freely ! Faulty tire valve 2.
Page 22 1. GENERAL INFORMATION G-DINK 300i Possible cause ! Oil level too high 9. Check oil level and condition Incorrect ! Oil level too low ! Contaminated oil Correct ! Clogged oil 10. Remove cylinder head cover Valve train not ! Clogged oil control orifice...
Page 23 1. GENERAL INFORMATION G-DINK 300i POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause ! Improper ignition timing 1. Check ignition timing Incorrect Correct ! Faulty pressure regulator 2. Inspect the fuel flow Abnormal Normal ! Faulty injector 3. Inspect the fuel injector...
Page 24 1. GENERAL INFORMATION G-DINK 300i POOR PERFORMANCE AT HIGH SPEED Possible cause ! Faulty ECU 1. Check ignition timing Incorrect Correct ! Faulty pressure regulator 2. Inspect the fuel flow Abnormal Normal ! Faulty injector 3. Inspect the fuel injector...
Page 25: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS G-DINK 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 2- 1 TROUBLESHOOTING----------------------------------------------------- 2- 1 FASTENER REMOVAL AND REINSTALLATION------------------ 2- 2 FRAME COVERS REMOVAL/INSTALLATION --------------------- 2- 3 EXHAUST MUFFLER ----------------------------------------------------- 2-14...
Page 26: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS G-DINK 300i 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 27: Fastener Removal And Reinstallation
. EXHAUST MUFFLER/FRAME COVERS G-DINK 300i FASTENER REMOVAL AND REINSTALLATION REMOVAL Depress the head of fastener center piece ←. Pull out the fastener. INSTALLATION Let the center piece stick out toward the head so that the pawls ↑ close. Insert the fastener into the installation hole.
Page 28: Frame Covers Removal/Installation
. EXHAUST MUFFLER/FRAME COVERS G-DINK 300i FRAME COVERS REMOVAL/ INSTALLATION LUGGAGE BOX Unlock the seat with the ignition key. Open the seat. Remove 2 bolts, 2 screws and 4 nuts on the luggage box. Nuts SEAT Unlock the seat with the ignition key.
Page 29 . EXHAUST MUFFLER/FRAME COVERS G-DINK 300i Center Cover CENTER COVER Remove the luggage box and seat. Remove the center cover. ＊ During removal, do not pull the joint claws forcedly to avoid damage. Installation is in the reverse order of removal.
Page 30 . EXHAUST MUFFLER/FRAME COVERS G-DINK 300i BODY COVER SET Remove the screws, bolts, nuts and connecter to remove the body cover set. Bolt Screws Body cover set Nuts Screw Screw Dismantle Direction Connector...
Page 31 . EXHAUST MUFFLER/FRAME COVERS G-DINK 300i FRONT SIDE MOLD Remove the fasteners to remove the right and left of front side molds. Fastener Front side mold Remove the mat leg shield. Mat leg shield Fasteners UNDER COWL Remove the fasteners and under cowl.
Page 32 . EXHAUST MUFFLER/FRAME COVERS G-DINK 300i SKIRT SET Remove the screws and fasteners to remove the right and left skirt sets. Fasteners Screws Screws Fasteners Skirt set Screws Screw Screws...
Page 33 . EXHAUST MUFFLER/FRAME COVERS G-DINK 300i PANEL FLOOR Remove the bolts and panel floor. Panel floor Bolts...
Page 34 . EXHAUST MUFFLER/FRAME COVERS G-DINK 300i HANDLE UP COVER Handle up cover Remove screws and bolts to remove the handle up cover. Screw Screw Bolt Bolt Handle low cover HANDLE LOW COVER Remove throttle cables to remove the handle low cover.
Page 35 . EXHAUST MUFFLER/FRAME COVERS G-DINK 300i Handle up cover WINDSHIELD Remove five bolts and windshield. FRONT METER COVER SET Remove the front meter cover. Front meter cover set. 2-10...
Page 36 . EXHAUST MUFFLER/FRAME COVERS G-DINK 300i FRONT COVER SET Remove the screws, nuts, fasteners and connector to remove the front cover set. Screws Nuts Front cover set Connector Fastener Dismantle Direction 2-11...
Page 37 . EXHAUST MUFFLER/FRAME COVERS G-DINK 300i REAR METER COVER SET Remove the fasteners, main switch lid, bolts and connectors to remove the rear meter cover set. Fasteners Rear meter cover set Main switch lid Bolts Connectors 2-12...
Page 38 . EXHAUST MUFFLER/FRAME COVERS G-DINK 300i LEG SHIELD SET Remove the screws, bolt, center clip, connector and fuel filler cap to remove the leg shield. Bolt Connector Screws Center clip Bolt Leg shield set Fuel filler cap Bolts 2-13...
Page 39 . EXHAUST MUFFLER/FRAME COVERS G-DINK 300i FRONT INNER FENDER Remove the bolts, fasteners to remove the front inner fender. Bolts Fasteners Leg shield set FRONT FENDER Front fender Remove the bolts to remove the front fender. Bolt bolt Bolts Bolt...
Page 40: Exhaust Muffler
. EXHAUST MUFFLER/FRAME COVERS G-DINK 300i EXHAUST MUFFLER Muffler Bolts REMOVAL Disconnect the connector with O2 heater/O2 sensor. Remove the bolts and nuts to remove the muffler. O2 sensor Nuts Installation is in the reverse order of removal. 2-15...
Page 41: Inspection/Adjustment
3. INSPECTION/ADJUSTMENT G-DINK 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ INSPECTION / ADJUSTMENT ________________________________________________________________________________ SERVICE INFORMATION----------------------------------------------------------------------- 3- 1 MAINTENANCE SCHEDULE------------------------------------------------------------------- 3- 2 THROTTLE OPERATION ----------------------------------------------------------------------- 3- 3 ENGINE OIL ---------------------------------------------------------------------------------------- 3- 4 RESERVE TANK ---------------------------------------------------------------------------------- 3- 5 AIR CLEANER ------------------------------------------------------------------------------------- 3- 6...
Page 42: Inspection/Adjustment
3. INSPECTION/ADJUSTMENT G-DINK 300i 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 43: Maintenance Schedule
3. INSPECTION/ADJUSTMENT G-DINK 300i MAINTENANCE SCHEDULE...
Page 44: Throttle Operation
3. INSPECTION/ADJUSTMENT G-DINK 300i THROTTLE OPERATION Check the throttle grip for smooth movement. Measure the throttle grip free play. Free Play: 2～6 mm Major adjustment of the throttle grip free play is made with the adjusting nut at the throttle body side.
Page 45: Engine Oil
3. INSPECTION/ADJUSTMENT G-DINK 300i ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the scooter upright on the level ground. Wait for 2～3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when checking the oil level.
Page 46 3. INSPECTION/ADJUSTMENT G-DINK 300i The spring will come out when the filter cap is removed. Let the engine oil drain out. Check that the O-ring is in good condition. Spring Install a new oil filter. ＊ Make sure the rubber seal on the oil...
Page 47: Air Cleaner
3. INSPECTION/ADJUSTMENT G-DINK 300i AIR CLEANER AIR FILTER REPLACEMENT Remove screws attaching to remove air cleaner cover. Remove screws attaching to remove filter. Check the filter and replace it if it is excessively dirty or damaged. CHANGE INTERVAL Air Cleaner Filter More frequent replacement is required when riding in unusually dusty or rainy areas.
Page 48: Valve Clearance
3. INSPECTION/ADJUSTMENT G-DINK 300i VALVE CLEARANCE ＊ • Inspect and adjust valve clearance while the engine is cold (below 35℃). Remove the seat assy and luggage box. Remove the four bolts and then cylinder head cover. Turn the A.C. generator flywheel to the top dead center (TDC) on the compression stroke so that the “T”...
Page 49: Final Reduction Gear Oil
3. INSPECTION/ADJUSTMENT G-DINK 300i FINAL REDUCTION GEAR OIL ＊ • Place the scooter on its main stand on level ground. Remove the transmission fluid drain bolt. Remove the transmission fluid filler bolt, then slowly rotate the rear wheel to drain the fluid.
Page 50 3. INSPECTION/ADJUSTMENT G-DINK 300i BRAKE DISK/BRAKE PAD Check the brake disk surface for scratches, unevenness or abnormal wear. Check if the brake disk runout is within the specified service limit. Check if the brake pad wear exceeds the wear indicator line.
Page 51: Clutch Shoe Wear
3. INSPECTION/ADJUSTMENT G-DINK 300i CLUTCH SHOE WEAR Start engine and check the clutch operation by increasing the engine speed gradually. If the motorcycle tends to creep or the engine stop, check the clutch shoes for wear and replace if necessary.
Page 52: Nuts/Bolts/Fasteners
3. INSPECTION/ADJUSTMENT G-DINK 300i 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 53: Side Stand
2. Put the side stand up and start the engine. 3. Lower the side stand. The engine should stop as you put the side stand down. ＊ If the side stand system does not operate as described, see your KYMCO dealer for service. 3-12...
Page 54: Lubrication System
4. LUBRICATION SYSTEM G-DINK 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ LUBRICATION SYSTEM ________________________________________________________________________________ LUBRICATION SYSTEM ------------------------------------------------------------------------ 4-1 SERVICE INFORMATION----------------------------------------------------------------------- 4-2 TROUBLESHOOTING --------------------------------------------------------------------------- 4-2 ENGINE OIL/OIL FILTER ----------------------------------------------------------------------- 4-3 OIL PUMP ------------------------------------------------------------------------------------------- 4-5...
Page 55: Lubrication System
4. LUBRICATION SYSTEM G-DINK 300i LUBRICATION...
Page 56: Service Information
4. LUBRICATION SYSTEM G-DINK 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed on the frame. • Drain the coolant before starting any operations. • Carefully when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 57: Engine Oil/Oil Filter
4. LUBRICATION SYSTEM G-DINK 300i ENGINE OIL/OIL FILTER ＊ • Place the scooter upright on level ground for engine oil level check. • Run the engine for 2～3 minutes and check the oil level after the engine is stopped for 2～3 minutes.
Page 58 4. LUBRICATION SYSTEM G-DINK 300i OIL FILTER REPLACEMENT Remove the oil filler cap attaching the right-under crankcase cover. The spring will come out when the filter cap is removed. Let the engine oil drain out. Check that the O-ring is in good condition.
Page 59: Oil Pump
4. LUBRICATION SYSTEM G-DINK 300i Bolts OIL PUMP REMOVAL Remove the flywheel. Remove the attaching bolt and oil separator cover. ＊ When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
Page 60 4. LUBRICATION SYSTEM G-DINK 300i Oil Pump Remove the two oil pump bolts to remove the oil pump. Bolts Oil Pump Cover DISASSEMBLY Remove the screw and oil pump cover. Screw Oil Pump Body Dowel Pin Inner Rotor Remove the dowel pin, oil pump shaft, oil pump outer rotor and inner rotor.
Page 61 4. LUBRICATION SYSTEM G-DINK 300i INSPECTION Temporarily install the oil pump shaft. Install the outer and inner rotors into the oil pump body. Measure the tip clearance. Service limit: 0.2 mm (0.008 in) ＊ Measure at several points and use the largest reading to compare the service limit.
Page 62 4. LUBRICATION SYSTEM G-DINK 300i Dowel Pin Oil Pump Cover ASSEMBLY Dip all parts in clean engine oil. Install the outer rotor into the oil pump body. Install the inner rotor into the outer rotor. Install the oil pump shaft.
Page 63 4. LUBRICATION SYSTEM G-DINK 300i Drive Chain Driven Gear Install the oil pump driven sprocket and drive chain. Install the snap ring. Snap Ring Bolts Install the oil separator cover properly and tighten two bolts securely as shown. Oil Separator Cover...
Page 64: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION G-DINK 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 5-1 ENGINE REMOVAL/INSTALLATION--------------------------------- 5-2 ENGINE HANGER --------------------------------------------------------- 5-6...
Page 65 5. ENGINE REMOVAL/INSTALLATION G-DINK 300i 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 scooter body, cables and wires during engine removal. • Use shop towels to protect the scooter body during engine removal.
Page 66 . ENGINE REMOVAL/INSTALLATION G-DINK 300i ENGINE REMOVAL/INSTALLATION REMOVAL Remove the air cleaner Disconnect the connector including of ISC, Throttle body, TPS, WTS, MAP sensor and injector. Disconnect the O2 sensor connector. Disconnect the throttle cables. Disconnect Regulator/Rectifier connector. Disconnect the starter relay wire from starter motor.
Page 67 5. ENGINE REMOVAL/INSTALLATION G-DINK 300i Bolt Remove the muffler. Remove the rear fork mounting bolts attaching to the crankcase. Torque: 3.5 kgf-m (35 N-m) Remove the rear axle nut . Torque: 12.0 kgf-m (120 N-m) Remove bolts attaching to the rear brake caliper.
Page 68 . ENGINE REMOVAL/INSTALLATION G-DINK 300i Remove the spark plug cap. Spark Plug Cap Radiator Hose Disconnect the radiator hose. Bolt Remove the right and left rear cushion lower mount bolts. Torque: 4.0 kgf-m (40N-m)
Page 69 5. ENGINE REMOVAL/INSTALLATION G-DINK 300i Remove the engine mount nut and pull it out. Remove the engine from the frame. ＊ At removing the engine, be careful not to catch your hand or finger between the engine hanger and crankcase.
Page 70 . ENGINE REMOVAL/INSTALLATION G-DINK 300i ENGINE HANGER Mount Nut REMOVAL Remove the engine mount nut and pull it out. ＊ Be careful to put the engine down. Remove the left/right engine hanger mount bolt. Remove the engine from frame. INSTALLATION Installation is in the reverse order of removal.
Page 71: Cylinder Head/Valves
6. CYLINDER HEAD/VALVES G-Dink 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 6- 1 SERVICE INFORMATION------------------------------------------------ 6- 2 TROUBLESHOOTING----------------------------------------------------- 6- 3 CYLINDER COMPRESSION TEST ------------------------------------- 6- 4 CYLINDER HEAD COVER----------------------------------------------- 6- 5 CAMSHAFT ----------------------------------------------------------------- 6- 6...
Page 72: Cylinder Head/Valves
6. CYLINDER HEAD/VALVES G-Dink 300i...
Page 73: Service Information
6. CYLINDER HEAD/VALVES G-Dink 300i 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 74: Troubleshooting
6. CYLINDER HEAD/VALVES G-Dink 300i 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 • Worn valve stem or valve guide •...
Page 75: Cylinder Compression Test
6. CYLINDER HEAD/VALVES G-Dink 300i CYLINDER COMPRESSION TEST Warm up the engine to normal operating temperature. Stop the engine and remove the spark plug cap and remove the spark plug. Park Plug Cap Install a compression gauge into the spark plug hole.
Page 76: Cylinder Head Cover
6. CYLINDER HEAD/VALVES G-Dink 300i CYLINDER HEAD COVER DISASSEMBLY Remove the floorboard Disconnect the crankcase breather hose from the cylinder head cover. Remove the four bolts and two nuts, then remove cylinder head cover. Remove the cylinder head cover O-ring.
Page 77: Camshaft
6. CYLINDER HEAD/VALVES G-Dink 300i CAMSHAFT REMOVAL Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the right crankcase cover Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke.
Page 78 6. CYLINDER HEAD/VALVES G-Dink 300i Camshaft Holder/Dowel Pins Remove the camshaft holder and dowel pins. Cam Chain Remove the camshaft gear from the cam chain to remove the camshaft. Camshaft Gear...
Page 79 6. CYLINDER HEAD/VALVES G-Dink 300i INSPECTION Camshaft Check each cam lobe for wear or damage. Measure the cam lobe height. Service Limits: IN : 34.14 mm (1.3656 in) EX: 34.02 mm (1.3608 in) Check each camshaft bearing for play or Camshaft Bearings damage.
Page 80: Rocker Arms
6. CYLINDER HEAD/VALVES G-Dink 300i Valve Rocker Arms ROCKER ARMS REMOVAL Remove the camshaft. Remove the rocker arm shafts and then remove the rocker arms. Rocker Arm Shafts INSPECTION Camshaft holder Camshaft Holder Inspect the bearing surface of camshaft holder for scoring, scratches, or evidence of insufficient lubrication.
Page 81: Cylinder Head
6. CYLINDER HEAD/VALVES G-Dink 300i CYLINDER HEAD First drain the coolant from the radiator and water jacket, then remove the thermostat water hose. Remove the camshaft. Remove the carburetor and intake pipe. Remove the two cylinder bolts. Cylinder Bolts Remove the bolt attaching the thermostat housing and the thermostat housing.
Page 82 6. CYLINDER HEAD/VALVES G-Dink 300i Valve Spring Compressor CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor. ＊ • Be sure to compress the valve springs with a valve spring compressor.
Page 83 6. CYLINDER HEAD/VALVES G-Dink 300i VALVE /VALVE GUIDE INSPECTION Inspect each valve for bending, burning, scratches or abnormal stem wear. If any defects are found, replace the valve with a new one. Check valve movement in the guide. Measure each valve stem O.D.
Page 84 6. CYLINDER HEAD/VALVES G-Dink 300i Measure compressed force (valve spring) and installed length. Replace if out of specification. Standard: Inner: 2.95 kg (at 26.6 mm, 1.064 in) Outer: 10.45 kg (at 29.6 mm, 1.184 in) Measure the spring tilt. Replace if out of specification.
Page 85 6. CYLINDER HEAD/VALVES G-Dink 300i Gasket INSTALLATION Install the cam chain guide. Install the dowel pins and a new cylinder head gasket. Cam Chain Guide Dowel Pins Cam Chain Install the cylinder head and take out the cam chain Valve Rocker Arms Assemble the camshaft holder.
Page 86 6. CYLINDER HEAD/VALVES G-Dink 300i Punch Marks Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the right crankcase cover. Keep the round hole on the camshaft gear facing up and align the punch marks on the...
Page 87 6. CYLINDER HEAD/VALVES G-Dink 300i Tensioner Screw Turn the cam chain tension screw counterclockwise to release it. O-ring Apply engine oil to a new O-ring and install Tighten the cam chain tension cap screw. ＊ Be sure to install the gasket into the groove properly.
Page 88: Cylinder/Piston
7. CYLINDER/PISTON G-Dink 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 7- 1 SERVICE INFORMATION------------------------------------------------ 7- 2 TROUBLESHOOTING----------------------------------------------------- 7- 2 CYLINDER/PISTON ------------------------------------------------------- 7- 3 10-0...
Page 89 7. CYLINDER/PISTON G-Dink 300i SCHEMATIC DRAWING 10-1...
Page 90 7. CYLINDER/PISTON G-Dink 300i 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 91 7. CYLINDER/PISTON G-Dink 300i Dowel Pins CYLINDER/PISTON REMOVAL Remove the cylinder head. Remove the water hose from the cylinder. Remove the cylinder head gasket and dowel pine. Water Hose Gasket Cylinder Remove the cam chain guide. Remove the cylinder. Cam Chain Guide Gasket Remove the cylinder gasket and dowel pins.
Page 92 7. CYLINDER/PISTON G-Dink 300i PISTON RING REMOVAL Spread each piston ring and remove it by lifting up at a point opposite the gap ＊ Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston ring grooves.
Page 93 7. CYLINDER/PISTON G-Dink 300i Piston/Piston pin Measure the piston O.D. at the point (A) from 10 mm the bottom and 90° to the piston pin hole. Service Limit: 72.6 mm (2.904 in) at (A): 9 mm Calculate the cylinder-to-piston clearance Measure the piston pin hole.
Page 94 7. CYLINDER/PISTON G-Dink 300i Cylinder Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown. Service Limit: 0.05 mm (0.002 in) Check the cylinder wall for wear or damage. Measure and record the cylinder I.D. at three levels in an X and Y axis.
Page 95 7. CYLINDER/PISTON G-Dink 300i Measure the connecting rod small end I.D.. Service Limit: 17.06 mm (0.6824 in) Calculate the connecting rod-to-piston pin clearance. Service Limit: 0.06 mm (0.002 in) PISTON RING INSTALLATION Carefully install the piston rings into the piston ring grooves with the markings facing ＊...
Page 96 7. CYLINDER/PISTON G-Dink 300i CYLINDER/PISTON INSTALLATION Remove any gasket material from the crankcase surface. ＊ • Be careful not to drop foreign matters into the crankcase. “IN” Mark Piston Install the piston, piston pin and a new piston pin clip.
Page 97 7. CYLINDER/PISTON G-Dink 300i Install the cam chain guide. ＊ • Insert the tab on the cam chain guide into the cylinder groove. Cam Chain Guide Dowel Pins Install the cylinder gasket and dowel pins. Connect the water hose to the cylinder.
Page 98 8. DRIVE AND DRIVEN PULLEY G-Dink 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEY __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 8- 1 TROUBLESHOOTING----------------------------------------------------- 8- 2 LEFT CRANKCASE COVER --------------------------------------------- 8- 3 DRIVE PULLEY ------------------------------------------------------------ 8- 4 CLUTCH/DRIVEN PULLEY---------------------------------------------- 8-10 11-0...
Page 99 8. DRIVE AND DRIVEN PULLEY G-Dink 300i 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 100 8. DRIVE AND DRIVEN PULLEY G-Dink 300i TROUBLESHOOTING Engine starts but motorcycle won‘t move Lack of power • Worn drive belt • Worn drive belt • Broken ramp plate • Weak driven face spring • Worn or damaged clutch lining •...
Page 101 11. DRIVE AND DRIVEN PULLEY G-Dink 300i Bolts LEFT CRANKCASE COVER REMOVAL Remove the left crankcase cover bolts and left crankcase covers. Left Crankcase Cover Remove the seal gasket and dowel pins. Gasket 11-3...
Page 102 11. DRIVE AND DRIVEN PULLEY G-Dink 300i DRIVE PULLEY REMOVAL Universal Holder Remove the left crankcase cover Hold the drive pulley face with the special tool and loosen the drive pulley face nut. Special tool: Universal holder A120E00017 Remove the nut, washer and drive pulley Drive Pulley Face face.
Page 103 11. DRIVE AND DRIVEN PULLEY G-Dink 300i Drive Pulley Collar Remove the movable drive face assembly while holding the back of the face (ramp plate). Movable Drive Face Assembly 11-5...
Page 104 11. DRIVE AND DRIVEN PULLEY G-Dink 300i DISASSEMBLY Ramp Plate Drive pulley Remove the ramp plate and slide pieces. Remove the weight rollers. Weight Roller 11-6...
Page 105 11. DRIVE AND DRIVEN PULLEY G-Dink 300i INSPECTION Movable Drive Face Check the drive face boss for wear or damage. Measure the boss O.D.. Service limit: 26.9 mm (1.076 in) Measure the face bushing I.D.. Service limit: 27.13 mm (1.058 in) Weight Roller Check each roller for wear or damage.
Page 106 11. DRIVE AND DRIVEN PULLEY G-Dink 300i ASSEMBLY Clean any oil and grease from the pulley faces and weight rollers. Install the drive face boss into the movable drive face. Install the weight rollers to the movable drive face. ＊...
Page 107 11. DRIVE AND DRIVEN PULLEY G-Dink 300i Hold the clutch outer with the special tool as Driven Pulley shown. Drive Pulley Collar Special tool: Universal holder A120E00017 Install the nut. Tighten the nut to the specified torque. Torque: Drive Belt 54 N•m (5.4 kgf•m, 36 lbf•ft)
Page 108 11. DRIVE AND DRIVEN PULLEY G-Dink 300i CLUTCH/DRIVEN PULLEY REMOVAL Universal Holder Remove the left crankcase cover. Hold the drive pulley face with the special tool and loosen the drive pulley face nut. Special tool: Universal holder A120E00017 Remove the nut, washer and drive pulley face.
Page 109 11. DRIVE AND DRIVEN PULLEY G-Dink 300i Lock Nut Wrench DISASSEMBLY Clutch/Driven Pulley Hold the clutch/driven pulley assembly with the clutch spring compressor. ＊ Be sure to use a clutch spring compressor to avoid spring damage. Special tool: Clutch Spring Compressor...
Page 110 11. DRIVE AND DRIVEN PULLEY G-Dink 300i Remove the guide roller pins, guide rollers and the movable driven face. Guide Roller Guide Roller Pin O-ring Movable Driven Face Remove the O-rings and oil seals from the movable driven face. Oil Seal...
Page 111 11. DRIVE AND DRIVEN PULLEY G-Dink 300i Needle Bearing Filling 25 g of grease to the driven face inner surface. Apply grease to new needle bearing. Press the needle bearing into the driven. Grease INSPECTION Clutch Outer Check the clutch outer for wear or damage.
Page 112 11. DRIVE AND DRIVEN PULLEY G-Dink 300i Driven Face Spring Measure the driven face spring free length. Service limit: 130.5 mm (5.22 in) Driven Face Check the driven face for scratches, scoring or damage. Measure the driven face boss O.D..
Page 113 . FINAL REDUCTION G-Dink 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 114 . FINAL REDUCTION G-DINK 300i SCHEMATIC DRAWING...
Page 115: Final Reduction
. FINAL REDUCTION G-Dink 300i 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 116: Final Reduction
. FINAL REDUCTION G-DINK 300i Bolts FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. Remove the rear brake caliper. Remove the right rear shock absorber. Remove the rear fork. Remove the rear wheel. Remove the left crankcase cover. Remove the clutch/driven pulleys.
Page 117 . FINAL REDUCTION G-Dink 300i 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 Final Shaft Bearing...
Page 118 . FINAL REDUCTION G-DINK 300i Bearing Remover, 15mm 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, 15mm Drive new bearings into the transmission case cover.
Page 119: Final Reduction Assembly
. FINAL REDUCTION G-Dink 300i Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Pilot FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Drive Shaft Install the final gear and final shaft into the...
Page 120 . FINAL REDUCTION G-DINK 300i 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 Install the transmission case cover. Transmission Case Cover Bolts Install and tighten the transmission case cover bolts.
Page 121 . FINAL REDUCTION G-Dink 300i 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 122: Generator/Starter Clutch
. A.C. GENERATOR/STARTER CLUTCH G-DINK 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 123: Schematic Drawing
. A.C. GENERATOR/STARTER CLUTCH G-Dink300i SCHEMATIC DRAWING 10-1...
Page 124: Service Information
. A.C. GENERATOR/STARTER CLUTCH G-DINK 300i 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 125: Right Crankcase Cover Removal
. A.C. GENERATOR/STARTER CLUTCH G-Dink300i Bolts Water Inlet Hose RIGHT CRANKCASE COVER REMOVAL Disconnect the water hoses from the right crankcase cover. Remove the nine bolts attaching the right crankcase cover and the cover. Water Outlet Hose A.C. Generator Stator Screws STATOR REMOVAL Remove the two pulser coil attaching screws...
Page 126: Starter Clutch
. A.C. GENERATOR/STARTER CLUTCH G-DINK 300i Starter Idle Gear Shaft STARTER CLUTCH REMOVAL Remove the starter driven gear. Starter Driven Gear Remove the starter idle gear and shaft. Starter Idle Gear INSPECTION Inspect the starter driven gear for wear or damage.
Page 127: Flywheel Installation
. A.C. GENERATOR/STARTER CLUTCH G-Dink300i Remove the starter one-way clutch rollers, plungers and springs. Starter Idle Gear Shaft INSTALLATION Install the starter driven gear onto the crankshaft. Install the starter idle gear and shaft. Starter Driven Gear Flywheel FLYWHEEL INSTALLATION Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel.
Page 128: Stator Installation
. A.C. GENERATOR/STARTER CLUTCH G-DINK 300i 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 129: Crankcase/Crankshaft
. CRANKCASE/CRANKSHAFT G-DINK 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 130: Schematic Drawing
. CRANKCASE/CRANKSHAFT G-DINK 300i SCHEMATIC DRAWING 11-1...
Page 131: Service Information
. CRANKCASE/CRANKSHAFT G-DINK 300i 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 132: Crankcase Separation
. CRANKCASE/CRANKSHAFT G-DINK 300i Cam Chain Tensioner Slipper CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt. Remove the cam chain tensioner slipper and cam chain. Remove the three right crankcase attaching bolts. Bolt Cam Chain Remove the left crankcase.
Page 133: Crankshaft Inspection
. CRANKCASE/CRANKSHAFT G-DINK 300i 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. Service Limit: 17.06mm replace if over...
Page 134: Crankcase Assembly
. CRANKCASE/CRANKSHAFT G-DINK 300i 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 135 . CRANKCASE/CRANKSHAFT G-DINK 300i 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. Gasket Install the two dowel pins and a new gasket.
Page 136 . CRANKCASE/CRANKSHAFT G-DINK 300i 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 137: Cooling System
12. COOLING SYSTEM G-DINK 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ COOLING SYSTEM ________________________________________________________________________________ SCHEMATIC DRAWING------------------------------------------------------------------------- 12- 1 SERVICE INFORMATION----------------------------------------------------------------------- 12- 2 TROUBLESHOOTING --------------------------------------------------------------------------- 12- 2 COOLING SYSTEM TESTING----------------------------------------------------------------- 12- 3 RADIATOR ------------------------------------------------------------------------------------------ 12- 3 WATER PUMP ------------------------------------------------------------------------------------- 12- 7 THERMOSENSOR -------------------------------------------------------------------------------- 12- 10...
Page 138: Schematic Drawing
12. COOLING SYSTEM G-DINK 300i SCHEMATIC DRAWING 12-1...
Page 139: Service Information
12. COOLING SYSTEM G-DINK 300i 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 140: Cooling System Testing
12. COOLING SYSTEM G-DINK 300i COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Radiator Tester 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 sealing cap surface before testing.
Page 141 12. COOLING SYSTEM G-DINK 300i Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects are clogging the radiator, wash them off. Carefully straighten any bent fins. RADIATOR REMOVAL Drain the coolant.
Page 142 12. COOLING SYSTEM G-DINK 300i Remove three bolts/nuts on the radiator. Remove the radiator. RADIATOR DISASSEMBLY Remove bolts and then remove the fan rubber from the radiator. Check fan motor by battery. 12-5...
Page 143 12. COOLING SYSTEM G-DINK 300i THERMOSTATIC SWITCH When the coolant temperature is lower than 85 ℃, the thermostatic switch OFF. When coolant temperature is over 90 ℃, the thermostatic switch ON. Thermostatic Switch RADIATOR INSTALLATION Install the fan rubber on the radiator with three bolts.
Page 144: Water Pump
12. COOLING SYSTEM G-DINK 300i 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. WATER PUMP/IMPELLER REMOVAL Remove the coolant inlet hose and outlet hose.
Page 145 12. COOLING SYSTEM G-DINK 300i WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove bolts attaching the right crankcase cover. Remove the water pump bearing snap ring from the water pump assembly. Remove the water pump shaft and inner bearing.
Page 146 12. COOLING SYSTEM G-DINK 300i Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover. Tighten 12 bolts to secure the right crankcase cover. ＊ When installing water pump assembly, aligning the groove on the water pump shaft with the tab on the oil pump shaft.
Page 147: Thermosensor
12. COOLING SYSTEM G-DINK 300i Thermosensor THERMOSENSOR THERMOSENSOR REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor Wire Thermosensor THERMOSENSOR INSPECTION...
Page 148: Thermostat
12. COOLING SYSTEM G-DINK 300i Thermosensor THERMOSTAT THERMOSTAT REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the thermosensor wire from the thermosensor. Disconnect the water hose from the thermostat housing.
Page 149: Fuel Injection System
13. FUEL INJECTION SYSTEM G-DINK 300i __________________________________________________________________________________ __________________________________________________________________________________ FUEL INJECTION SYSTEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 13- 1 SPECIFICATIONS ---------------------------------------------------------- 13- 2 INJECTION SYSTEM DIAGRAM --------------------------------------- 13- 3 PARTS LOCATION -------------------------------------------------------- 13- 4 TROUBLESHOOTING----------------------------------------------------- 13- 8 SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL------------------------------------------------------- 13- 9...
Page 150: Fuel Injection System
13. FUEL INJECTION SYSTEM G-DINK 300i SERVICE INFORMATION GENERAL INSTRUCTIONS ● Scooter services can be done with the engine installed in the frame. ● Be sure to relieve the fuel pressure before fuel pump or fuel hose removal. ● Bending or twisting the control cables will affect operation and could cause the cables to stick or bind, resulting in loss of vehicle control.
Page 151: Specifications
13. FUEL INJECTION SYSTEM G-DINK 300i SPECIFICATIONS ITEM SPECIFICATIONS Throttle body identification number LHG7 Idle speed 1600±100 rpm Throttle grip free play 2～6 mm (1/16～1/4 in) Fuel injector resistance (at 20°C/68°F) 11.7±0.6Ω Fuel pump resistance Float at full position 1100±33 Ω...
Page 152: Injection System Diagram
13. FUEL INJECTION SYSTEM G-DINK 300i INJECTION SYSTEM DIAGRAM FULL NAME ABBREVIATIONS (01) Electronic control unit (02) Tilt switch (Angle detect sensor) ROLL (03) Fuel pump/Fuel level unit (04) Water temperature sensor WTS sensor (05) Crank position sensor (Pulser) (06)
Page 153: Parts Location
13. FUEL INJECTION SYSTEM G-DINK 300i PARTS LOCATION Tilt Switch Speedometer Radiator Filler Cap Coolant Reserve Tank Ignition Switch Horn 13-4...
Page 154 13. FUEL INJECTION SYSTEM G-DINK 300i CABLE & HARNESS ROUTING Winker Relay Start Relay ECU Relay Hi Beam Relay Fuel Pump Relay Lo Beam Relay Fan Relay 13-5...
Page 155 13. FUEL INJECTION SYSTEM G-DINK 300i Throttle Body MAP Sensor Injector O2 Sensor 13-6...
Page 156 13. FUEL INJECTION SYSTEM G-DINK 300i Ignition Coil Regulator/Rectifier Hazard Control Unit Starter Relay Crank Position Sensor 13-7...
Page 157: Troubleshooting
13. FUEL INJECTION SYSTEM G-DINK 300i TROUBLESHOOTING Engine fail to start Backfiring or misfiring during acceleration • Intake manifold air leak • Ignition system malfunction • Fuel contaminated/deteriorated • Pinched or clogged fuel hose • Faulty fuel pump • Clogged fuel filter, throttle body •...
Page 158: Self-Diagnostic Procedures Without
13. FUEL INJECTION SYSTEM G-DINK 300i SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL SELF-DIAGNOSTIC PROCEDURES ＊ It can be performed without diagnostics program. Place the scooter on its main stand. Put the side stand up and the engine stop switch is at “RUN”.
Page 159: Efi Self-Diagnosis Check Engine Lamp (Celp) Failure
13. FUEL INJECTION SYSTEM G-DINK 300i EFI SELF-DIAGNOSIS CHECK ENGINE LAMP (CELP) FAILURE If more than a damaged part has occurred, the CODES “CELP” begins blinking in order. The “CELP” denotes the failure codes. When the indicator lights for one second that For example: If the indicator blinks six times, is equal to ten.
Page 160: Self-Diagnosis Reset Procedure
13. FUEL INJECTION SYSTEM G-DINK 300i SELF-DIAGNOSIS RESET PROCEDURE 1. Put the side stand up and engine stop switch is at “RUN”. 2. Turn the key to the ON position and wait for ten seconds. 3. Fully open the throttle and wait for ten seconds.
Page 161 13. FUEL INJECTION SYSTEM G-DINK 300i CELP FAILURE CODES LIST Failure Codes Blinks Contents Causes Symptoms (diagnostic tool) ● Faulty TPS voltage range (0.3~4.5 V) ● Loose or poor connection on TPS Engine operates Sensor P0120 Faulty TPS normally ● Open or short circuit on the TPS wire ●...
Page 162 13. FUEL INJECTION SYSTEM G-DINK 300i Failure Codes Blinks Contents Causes Symptoms (diagnostic tool) ● Faulty Inductive ignition coil Ω range (4.2 Ω ± 15%) Faulty ● Loose or poor connection on Engine fail to be inductive P0351 inductive ignition coil...
Page 163 13. FUEL INJECTION SYSTEM G-DINK 300i SPARK PLUG ANTI-FLOOD When have not failure code occurs and pressing starter switch repeatedly, can still not start the engine, maybe the spark plug is wet by fuel, perform the spark plug anti-flood to purge the fuel in the engine.
Page 164: Tps/Isc Reset
13. FUEL INJECTION SYSTEM G-DINK 300i TPS/ISC RESET ● If close or open the throttle grip randomly, the ECU may record the incorrect TPS when the ECU or the throttle body has been reinstalled. It can cause hard to start engine or idling speed is not smooth when engine installation.
Page 165: Fuel Pump
13. FUEL INJECTION SYSTEM G-DINK 300i FUEL PUMP INSPECTIION Full Position Put the side stand up and the engine stop switch is at “RUN” Disconnect fuel pump/fuel unit connector. Connect the multimeter (+) probe to the Red/Black terminal and the multi-meter (-) probe to the Green terminal.
Page 166 13. FUEL INJECTION SYSTEM G-DINK 300i REMOVAL Disconnect the connector and fuel band from the fuel pump. Hose band Remove the six screws onto the fuel pump. Remove the fuel pump and O-ring. INSTALLATION Replace a new O-ring on the fuel tank.
Page 167 13. FUEL INJECTION SYSTEM G-DINK 300i Battery FUEL PUMP RELAY INSPECTION Remove the fuel pump relay. Connect the ohmmeter to the fuel pump relay connector terminals. Connection: Black – Red/Black Connect 12 V battery with the fuel pump pump Fuel Relay relay connector.
Page 168: Tilt Switch
13. FUEL INJECTION SYSTEM G-DINK 300i TILT SWITCH INSPECTION Support the scooter level surface. Put the side stand up and engine stop switch Tilt Switch “UP” Mark is at “RUN”. Turn the ignition switch to “OFF” Remove the screws, washers and tilt switch.
Page 169: Electronic Control Unit (Ecu)
13. FUEL INJECTION SYSTEM G-DINK 300i ELECTRIC CONTROL UNIT (ECU) REMOVAL/INSTALLATION ＊ ● Do not disconnect or connect the ECU connector during the ignition switch “ON”; it may cause the ECU damaged. ● The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when throttle body, MAP, TPS, ISC or ECU has been reinstalled.
Page 170 13. FUEL INJECTION SYSTEM G-DINK 300i INSPECTION Disconnect and remove the ECU from the frame. Check for continuity between pin 9 and 10 of the ECU side connector. There should be continuity at all times. Check for continuity between each pins 2, 4 and 23 of the ECU side connector.
Page 171: Fuel Injector
13. FUEL INJECTION SYSTEM G-DINK 300i FUEL INJECTOR INSPECTION Disconnect the fuel injector connector. Measure the resistance between 2 pins of the fuel injector connector. Standard: 11.7±0.6 Ω (at 20°C/68°F) REMOVAL Disconnect the connector from the fuel injector. Remove the bolt of the fuel injector.
Page 172 13. FUEL INJECTION SYSTEM G-DINK 300i Groove INSTALLATION Apply the engine oil to a new O-ring. Install the fuel injector into the fuel pipe. Ensure the tab of the fuel injector inserted into the groove of the fuel pipe. Install the fuel pipe into the intake manifold by aligning the dowel pin.
Page 173: Wts Sensor
13. FUEL INJECTION SYSTEM G-DINK 300i WTS SENSOR (Water Temperature Sensor) REMOVAL / INSTALLATION Drain the coolant from the cooling system. Disconnect the WTS sensor connector from the sensor. Remove the WTS sensor and O-ring. Install a new O-ring and WTS sensor.
Page 174: O 2 Sensor
13. FUEL INJECTION SYSTEM G-DINK 300i SENSOR The O sensor issues signal to ECU when the temperature is over 350°C during the engine is working. The temperature is up to 350°C earlier than the muffler for O heater sensor. So the O sensor begins performance.
Page 175: Throttle Body/Map/Isc/Tps
● Do not damage the throttle body, it may cause the throttle and idle valve isn’t synchronization. ● The throttle body is preset in KYMCO factory, do not disassemble it by a wrong way. ● Do not loosen or tighten the painted bolts and screws for the throttle body.
Page 176 13. FUEL INJECTION SYSTEM G-DINK 300i TPS INSPECTION Support the scooter on a level surface. Put the side stand up and engine stop switch is at “RUN”. Turn the ignition switch to “ON”. Measure if the ECU voltage outputs to TPS between the following terminals of the TPS connector.
Page 177 13. FUEL INJECTION SYSTEM G-DINK 300i DISASSEMBLY Screw/Set Plate ＊ The throttle position sensor (TPS) and idle air bypass valve (ISC) have to be reset when the throttle body MAP, TPS, ISC or ECU has been reinstalled. Remove the screw and then remove the ISC and set plate.
Page 178: Diagnostic Tool Connector
13. FUEL INJECTION SYSTEM G-DINK 300i Apply oil onto a new O-ring. When install the MAP onto the throttle body, being careful not to damage the O-ring. ＊ Always replace an O-ring with a new one. Install the set plate and tighten the screw securely.
Page 179 13. FUEL INJECTION SYSTEM G-DINK 300i FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A-LEB2-E00 13-30 13-28...
Page 180 13. FUEL INJECTION SYSTEM G-DINK 300i 1. FI DIAGNOSTIC TOOL This tool is developed by KYMCO and for KYMCO vehicle only. Please refer to the specification when serving this vehicle. This tool is without battery inside. The power is provided from vehicle.
Page 181 13. FUEL INJECTION SYSTEM G-DINK 300i 2. DTC INSPECTION PROCEDURE Showing four functions on the screen when switching on power. LHG7 is for LHG7 G-Dink 300i A). ECU version: Including of model name, ECU number, identifications number and software version.
Page 182 13. FUEL INJECTION SYSTEM G-DINK 300i B). Press the " Down " button and then turn to the first page. LHG7 LHG7 is for G-Dink 300i C). Press the " Enter " button to check the DTC failure code LHG7 is for...
Page 183 13. FUEL INJECTION SYSTEM G-DINK 300i D). Press the " Enter " button E). Press the " Enter " button F). Display what's DTC number on this DTC-List. Press the " Enter " button and then turn to the previous page...
Page 184 5. FUEL INJECTION SYSTEM G-DINK 300i G). Press the " UP " button H). Press the " Enter " button and then turn to the previous page with red color. I). Press the " UP " button 5-33 13-35...
Page 185 5. FUEL INJECTION SYSTEM G-DINK 300i J). Press the " Enter " button and then turn to the first page. LHG7 is for G-Dink 300i LHG7 is for G-Dink 300i 5-34 13-36...
Page 186 5. FUEL INJECTION SYSTEM G-DINK 300i 3. DTC CLEAR PROCEDURE ). Check the DTC LHG7 is for G-Dink 300i ). Press the " Enter " button LHG7 is for G-Dink 300i ). Choose " Load DTC " Press the " Down " button...
Page 187 5. FUEL INJECTION SYSTEM G-DINK 300i ). Press the " Enter " button and the indicator is lighting. ). Clearing DTC completed if the indicator is off. 5-36 13-38...
Page 188 5. FUEL INJECTION SYSTEM G-DINK 300i 4. DATA ANALYSIS PROCEDURE ). Press the " Down " twice LHG7 is for G-Dink 300i ). Choose “ Data Analyze” Press the " Enter " button to enter page 01 LHG7 is for G-Dink 300i ).
Page 189 5. FUEL INJECTION SYSTEM G-DINK 300i ). Down-page 02 The measure figures including of TPS position, Intake pressure and Intake air temperature. Press the “ Down” button to enter page 03. ). Down-page 03 The measure figures including of Atmosphere pressure, Fuel Injector interval and Ignition advance timing.
Page 190 5. FUEL INJECTION SYSTEM G-DINK 300i ). Down-page 05 The measure figures including of ISC target, ISC step and ISC learn step. Press the “ Down” button to enter page 06. ). Down-page 06 The measure figures including of ISC motor state.
Page 191: Vehicle Can Not Be Started
5. FUEL INJECTION SYSTEM G-DINK 300i 5. Vehicle can not be started – Handling method (Steps) Preliminary Checking: 6 basic inspection 1. Is the battery with voltage (12 V or higher) 2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay (It will turn off automatically in 5-10 seconds) 3.
Page 192: Manual Trouble Shooting Procedure
5. FUEL INJECTION SYSTEM G-DINK 300i 6. Manual Trouble Shooting Procedure How to read DTC from speedometer? New Phase 5 Fuel Injection Engine Vehicle DTC Reading: Automatic indication – ECU upgrade version (with Oxygen sensor): Reading DTC from speedometer directly.
Page 193 14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 14- 1 TROUBLESHOOTING----------------------------------------------------- 14- 2 HANDLEBAR --------------------------------------------------------------- 14- 3 FRONT WHEEL------------------------------------------------------------- 14- 6 FRONT BRAKE FLUID---------------------------------------------------- 14- 9...
Page 194: Service Information
14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM 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 195: Troubleshooting
14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim • Loose front axle cone race • Broken steering balls • Bent spoke plate • Insufficient tire pressure •...
Page 196: Handlebar
14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM HANDLEBAR REMOVAL Remove the lower handlebar cover and front cover. Remove two bolts and disconnect the brake light switch wire, then remove the rear brake master cylinder. Remove the two bolts and disconnect the brake light switch wire, then remove the front brake master cylinder.
Page 197 14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM Install the front and rear master cylinders and connect the brake light switch wires. DISASSEMBLY Remove two screws attaching to the right handlebar switch. Throttle cable Disconnect the throttle cable from the throttle grip.
Page 198 14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM Remove two screws and then remove the left handlebar switch. ASSEMBLY Install the left handlebar switch. ＊ Align the pin on the left handlebar switch with the hole on the handlebar.
Page 199: Steering Handlebar/Front Wheel/Front Brake/Front
14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM FRONT WHEEL REMOVAL Jack the scooter front wheel off the ground. Remove the bolt and then pull out the axle. Remove the front wheel and collar. AXLE RUNOUT INSPECTION Set the axle in V blocks and measure the runout using a dial gauge.
Page 200 14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM INSTALLATION Apply grease to the collar, then install the collar onto the wheel. Dust Seal DISASSEMBLY 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 201: Front Brake Fluid
14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM FRONT BRAKE FLUID FLUID REPLACEMENT/AIR BLEEDING ＊ ● A contaminated brake disc or pad reduces stopping power. Discard contaminated pads clean contaminated disc with a high quality brake degreasing agent. ● Do not allow foreign material to enter the system when filling the reservoir.
Page 202 14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM Loosen the bleed valve and apply the brake lever. Stop operating the brake when no more fluid flows out of the bleed valve. BRAKE FLUID FILLING/AIR BLEEDING ＊ Do not mix different types of fluid since they are not compatible.
Page 203 14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM If the brake bleeder is not available, perform the following procedure. Pump up the system pressure with the brake lever until these are not air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt.
Page 204: Front Brake Pad
14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM FRONT BRAKE PAD BRAKE PAD REPLACEMENT Remove the caliper mounting bolts, then remove the caliper. Brake Pads Remove the brake pads. ＊ Always replace the brake pads in pairs to ensure even disc pressure.
Page 205: Brake Disc Inspection
14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM Install new pads so that their ends rest on the pad retainer on the brake properly. Install the front caliper onto the fork leg and then install and tighten the new two caliper mounting bolts to the specified torque.
Page 206: Front Shock Absorber
14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM FRONT SHOCK ABSORBER REMOVAL Remove the front cover and front fender. Remove the front brake caliper Remove the front wheel Remove the speed wheel sensor bolt and then remove the brake hose guide from right front shock absorber.
Page 207: Steering Stem
14. HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM STEERING STEM REMOVAL Remove the steering handlebar. Remove the front brake hose and speed wheel sensor connector from the guide. Right Hold the steering stem top cone race and remove the steering stem lock nut by using the special tool.
Page 208 14. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ G-DINK 300i FRONT SHOCK ABSORBER/STEERING STEM Ball Inspect the ball races, cone races and steel balls for wear or damage. Replace if necessary. Remove the top balls. Remove the upper ball race by using a chisel if necessary.
Page 209: Rear Brake/Rear Fork/Rear
15. REAR BRAKE/REAR FORK/REAR G-DINK 300i WHEEL/REAR SHOCK ABSORBER ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ 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----------------------------------------------------------------------------------------- 15-6 REAR WHEEL -------------------------------------------------------------------------------------- 15-7...
Page 210: Schematic Drawing
15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER G-DINK 300i SCHEMATIC DRAWING 15-1...
Page 211: Service Information
15. REAR BRAKE/REAR FORK/REAR G-DINK 300i WHEEL/REAR SHOCK ABSORBER 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 212: Rear Brake
15. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER G-DINK 300i REAR BRAKE Bolt REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler. Remove the rear brake fluid tube bolt and disconnect the brake fluid tube. Remove two bolts attaching the rear brake caliper.
Page 213 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION G-DINK 300i Compressed Air Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a towel under the caliper to avoid contamination caused by the removed piston.
Page 214 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION G-DINK 300i ＊ Make sure the spring plate next to the brake pad dowel pin orientation. Install two brake pads. Brake Pads INSTALLATION Install the brake caliper to the rear fork and Bolt tighten the two bolts.
Page 215: Rear Fork
. REAR WHEEL/REAR BRAKE/ REAR SUSPENSION G-DINK 300i REAR FORK REMOVAL Remove the exhaust muffler. Remove the rear brake caliper. Bear Axle Nut Bolt Remove the right rear shock absorber lower mount bolt. Remove the rear axle nut and remove the collar.
Page 216: Rear Wheel
. REAR WHEEL/REAR BRAKE/ REAR SUSPENSION G-DINK 300i REAR WHEEL REMOVAL Remove the exhaust muffler. Remove the rear brake caliper. Remove the rear fork. Remove the rear axle collar. Remove the rear wheel. Bear Axle Collar INSTALLATION The installation sequence is the reverse of removal.
Page 217 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION G-DINK 300i 15-8...
Page 218: Battery/Charging System
. BATTERY/CHARGING SYSTEM G-DINK 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT ---------------------------------------- 16-1 CHARGING CIRCUIT ----------------------------------------------------- 16-1 SERVICE INFORMATION------------------------------------------------ 16-2 TROUBLESHOOTING----------------------------------------------------- 16-3 BATTERY CHARGING --------------------------------------------------- 16-4 CHARGING SYSTEM ---------------------------------------------------- 16-6 REGULATOR/RECTIFIER ---------------------------------------------- 16-6 16-0...
Page 219: Battery/Charging System
. BATTERY/CHARGING SYSTEM G-DINK 300i CHARGING SYSTEM LAYOUT BATTERY REGULATOR/RECTIFIER 16-1...
Page 220: Service Information
. BATTERY/CHARGING SYSTEM G-DINK 300i 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 221: Troubleshooting
. BATTERY/CHARGING SYSTEM G-DINK 300i 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 • Faulty ignition switch...
Page 222 . BATTERY/CHARGING SYSTEM G-DINK 300i BATTERY REMOVAL The battery is in the battery box below seat. 1. Remove the seat. 2. Remove the met-in box 3. Remove four screws then the battery retainer. (+) Terminal (-) Terminal 4. Pull battery out to expose the terminal leads 5.
Page 223: Battery Charging
. BATTERY/CHARGING SYSTEM G-DINK 300i BATTERY CHARGING Remove the battery Connect the charger positive (+) cable to the battery positive (+) terminal. Connect the charger negative (-) cable to the battery negative (-) terminal. ＊ Turn the power ON/OFF at the charger, not at the battery terminals.
Page 224: Regulator/Rectifier
. BATTERY/CHARGING SYSTEM G-DINK 300i REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the luggage box Disconnect the regulator/rectifier connectors. Check the connectors for loose contacts of corroded terminals. Regulator/Rectifier BATTERY WIRE Measure the voltage between the Red/White wire terminal and ground. There should be battery voltage at all times.
Page 225 . BATTERY/CHARGING SYSTEM G-DINK 300i CHARGING COIL WIRE Measure the resistance between each Yellow wire terminals. Standard: 0.4 ~ 0.6 Ω (20ºC/68ºF) Disconnect the regulator/rectifier connector. Check for continuity between each Yellow wire terminal regulator/rectifier side and ground. There should be no continuity.
Page 226: Ignition System
17. IGNITION SYSTEM G-DINK 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ 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 TILT SWITCH INSPECTION ------------------------------------------------------------------- 17-4...
Page 227: Ignition System Layout
17. IGNITION SYSTEM G-DINK 300i IGNITION SYSTEM LAYOUT Tilt switch Ignition Coil Ignition Switch Crank Position Sensor A.C. Generator IGNITION CIRCUIT 17-1...
Page 228: Service Information
17. IGNITION SYSTEM G-DINK 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. • When servicing the ignition system, always follow the steps in the troubleshooting on page 17-2.
Page 229: Spark Plug
17. IGNITION SYSTEM G-DINK 300i Ignition Coil SPARK PLUG For spark plug inspection and adjustment, refer to page 3-5. IGNITION COIL INSPECTION Remove the seat and met-in box. ( 2-6) Remove the ignition coil. Primary Coil IGNITION COIL CONTINUITY TEST Inspect the continuity of the ignition coil, primary coil and secondary coil.
Page 230: Generator Inspection
17. IGNITION SYSTEM G-DINK 300i A .C. GENERATOR INSPECTION CRANK POSITION SENSOR INSPECTION ＊ This test is performed with the stator installed in the engine. Remove the seat and met-in box. Disconnect the Crank Position Sensor Wire Coupler. Measure resistance between blue/white and green/white wire terminals.
Page 231 17. IGNITION SYSTEM G-DINK 300i REMOVAL/INSTALLATION Tilt Switch “UP” Mark Disconnect the connector and remove two screws, then remove tilt switch. Installation is in the reverse order of removal. ＊ Install the tilt switch with its “up” mark facing up.
Page 232: Starting System
18. STARTING SYSTEM G-DINK 300i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ STARTING SYSTEM ________________________________________________________________________________ STARTING SYSTEM LAYOUT ---------------------------------------------------------------- 18-1 SERVICE INFORMATION----------------------------------------------------------------------- 18-2 TROUBLESHOOTING --------------------------------------------------------------------------- 18-2 STARTER MOTOR-------------------------------------------------------------------------------- 18-3 STARTER RELAY INSPECTION-------------------------------------------------------------- 18-4 18-0...
Page 233: Starting System Layout
18. STARTING SYSTEM G-DINK 300i STARTING SYSTEM LAYOUT Starter Relay Ignition Switch STARTING CIRCUIT Relay 18-1...
Page 234: Service Information
18. STARTING SYSTEM G-DINK 300i SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
Page 235 18. STARTING SYSTEM G-DINK 300i 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 make sure the starter motor can’t operate securely.
Page 236: Starter Motor
18. STARTING SYSTEM G-DINK 300i Starter Motor Cable INSTALLATION Connect the starter motor cable. Check the O-ring for wear or damage and replace if necessary. Apply grease to the O-ring and install it to the starter motor. Tighten the two mounting bolts.
Page 237: Lights Switches/ Fuel Pump
19. LIGHTS SWITCHES/ FUEL PUMP G-DINK 300i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/METERS/SWITCHES __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 19- 1 BULB REPLACEMENT --------------------------------------------------- 19- 2 BRAKE LIGHT SWITCH-------------------------------------------------- 19- 6 IGNITION SWITCH -------------------------------------------------------- 19- 6 HANDLEBAR SWITCH --------------------------------------------------- 19- 7 LUGGAGE BOX LIGHT SWITCH -------------------------------------- 19- 8...
Page 238 19. LIGHTS SWITCHES/ FUEL PUMP G-DINK 300i SERVICE INFORMATION GENERAL ＊ A halogen head light bulb becomes very hot while the head light is on, and remains for a while after it is turned off. Be sure to let it cool down before servicing.
Page 239 19. LIGHTS SWITCHES/ FUEL PUMP G-DINK 300i BULB REPLACEMENT LICENECE LIGHT Remove the seat assembly and luggage box. Remove the body covers. Disconnect the license bulb socket. Remove the bulb and replace with a new one. 19-2...
Page 240 19. LIGHTS/METERS/SWITCHES G-DINK 300i HEADLIGHT Connector Headlight Bulb ＊ A halogen headlight bulb becomes hot while the headlight is ON and remains for a while after it is turned OFF. Be sure to let it cool down before servicing. Remove the front cover...
Page 241 19. LIGHTS/METERS/SWITCHES G-DINK 300i FRONT TURN SIGNAL LIGHT Remove the front cover. Turn the bulb socket, then remove the front turn signal light. Push and turn the bulb counterclockwise to remove it, then replace with a new one. Installation is in the reverse order of removal.
Page 242 19. LIGHTS/METERS/SWITCHES G-DINK 300i REAR TURN SIGNAL LIGHT Push and turn the bulb counterclockwise to remove it, then replace with a new one. Installation is in the reverse order of removal. Rear Turn Signal Light Taillight/Brake Light 19-5...
Page 243: Brake Light Switch
19. LIGHTS/METERS/SWITCHES G-DINK 300i BRAKE LIGHT SWITCH Remove the upper handlebar cover. Disconnect front or rear brake light switch connectors and check for continuity between the switch terminals. There should be continuity with the front or rear brake lever squeezed, and there should be no continuity with the front or rear brake lever is released.
Page 244: Handlebar Switch
19. LIGHTS/METERS/SWITCHES G-DINK 300i RIGHT HANDLEBAR SWITCH Engine Stop Switch INSPECTION Remove the front cover Disconnect right handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows: Starter Switc...
Page 245: Luggage Box Light Switch
19. LIGHTS/METERS/SWITCHES G-DINK 300i Dimmer Switch LEFT HANDLEBAR SWITCH INSPECTION Disconnect left handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows: Horn Switch Turn Signal light Switch...
Page 246: Side Stand Switch
19. LIGHTS/METERS/SWITCHES G-DINK 300i Connector SIDE STAND SWITCH INSPECTION Remove the luggage box. Side stand switch is located on side stand. Disconnect the side stand switch connector. There should be continuity between the Yellow/Green and Green with the side stand is up.
Page 247: Horn
19. LIGHTS/METERS/SWITCHES G-DINK 300i HORN INSPECTION Remove the front cover. Disconnect the horn connectors from the horn. Connect a 12 V battery to the horn terminals. The horn is normal if it sounds when the 12 V battery connected across horn terminals.

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Sh60aa

KYMCO G-DINK 300i Service Manual

Preface

2. Exhaust Muffler/Frame Covers

3. Inspection/Adjustment

4. Lubrication System

Cylinder Head/Valves

9. Final Reduction

10. A.C. Generator/Starter Clutch

11. Crankcase/Crankshaft

12. Cooling System

13. Fuel Injection System 13

Handlebar/Front Wheel/Front Brake/ Front Shock Absorber/Steering Stem

Wheel/Rear Shock Absorber 15

16. Battery/Charging System

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Troubleshooting

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