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PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO Grand Dink
250.
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 250
TABLE OF CONTENTS
PUMP FUEL TANK
SHOCK ABSORBER/FRONT FORK
SWITCHES/HORN/FUEL UNIT/
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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   Also See for KYMCO GRAND DINK 250

   Summary of Contents for KYMCO GRAND DINK 250

  • 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 250. INSPECTION/ADJUSTMENT Section 1 contains the precautions for LUBRICATION SYSTEM all operations stated in this manual.

  • Page 2

    GRAND DINK 250...

  • Page 3: General Information

    . GENERAL INFORMATION GRAND DINK 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ ENGINE SERIAL NUMBER ------------------------------------------------ 1-1 SPECIFICATION-------------------------------------------------------------- 1-2 SERVICE PRECAUTIONS -------------------------------------------------- 1-3 TORQUE VALUES ----------------------------------------------------------- 1-7 TOOLS -------------------------------------------------------------------------- 1-8 LUBRICATION POINTS ---------------------------------------------------- 1-9 CABLE & HARNESS ROUTING-------------------------------------------- 1-11...

  • Page 4

    . GENERAL INFORMATION GRAND DINK 250 SERIAL NUMBER Vehicle Identification Serial Number Location of Frame Serial Number Location of Engine Serial Number...

  • Page 5: General Information

    . GENERAL INFORMATION GRAND DINK 250 SPECIFICATIONS Name & Model No. SH50DA Air cleaner type & No Paper element, wet Motorcycle Name & Type GRAND DINK 250 Fuel capacity 9.1 liters Overall length 2060mm Type Overall width 770mm Piston dia.

  • Page 6: Service Precautions

    . GENERAL INFORMATION GRAND DINK 250 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. After reassembly, check all parts for proper tightening and operation.

  • Page 7

    . GENERAL INFORMATION GRAND DINK 250 If the fuse is burned out, find the cause and The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. If the double connector has a lock, lock it at the correct position.

  • Page 8

    . GENERAL INFORMATION GRAND DINK 250 After clamping, check each wire to make Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not pull too tight Do not squeeze wires against the weld or its clamp.

  • Page 9

    . GENERAL INFORMATION GRAND DINK 250 After routing, check that the wire harnesses are not twisted or kinked. Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the Wire harnesses routed along with specified points.

  • Page 10: Torque Values

    . GENERAL INFORMATION GRAND DINK 250 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: Tools

    . GENERAL INFORMATION GRAND DINK 250 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 250 LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil (SAE15W-40) Valve guide/valve stem movable part •API SE, SF or SG Egnine Oil Camshaft protruding surface Valve rocker arm friction surface Camshaft drive chain...

  • Page 13

    . GENERAL INFORMATION GRAND DINK 250 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 250 CABLE & HARNESS ROUTING Front / Rear Brake Front Brake Fluid Tube Master Cylinder Front Stop Brake Rear Stop Brake Pressure Type Radiator Cap Radiator Air Ventilated Tube Throttle Cable Speedometer Cable Horn Radiator...

  • Page 15

    . GENERAL INFORMATION GRAND DINK 250 Ignition Switch Fuel Filler Fuel Tank Breather Tube Reserve Tank Fuel Tank Ventilated Hose Inlet Tube Water Hose Front Brake Fluid Tube Water Hoses Left Brake Fluid Tube 1-12...

  • Page 16

    . GENERAL INFORMATION GRAND DINK 250 Throttle Cable Radiator Air Ventilated Tube Fuel Filler Rear Brake Fluid Rear-view Mirror Tube Control Relay Fuel Tank Inlet Tube Speedometer Cable Fuel Tank Breather Tube Water Hose Wire Harness Fuel Tank Throttle Cable...

  • Page 17

    . GENERAL INFORMATION GRAND DINK 250 Oil Vapor Fuel Tube Recovery Tube Thermosensor Wire Thermostat Ignition Coil Carburetor Starter Relay Starter Motor CDI Unit Regulator/ Rectifier Battery (-) Cable Battery (+) Cable Fuse Box 1-14...

  • Page 18

    . GENERAL INFORMATION GRAND DINK 250 Throttle Cable Ignition Coil Spark Plug Cap Fuel Pump Vacuum Tube Carburetor Oil Vapor Recovery Tube Fuel Tube Thermostat Fuel Pump Auto Bystarter Fuel Tube Starter Relay T.P.S Fuel Pump Vacuum Tube Wire Harness...

  • Page 19: Wiring Diagram

    . GENERAL INFORMATION GRAND DINK 250 WIRING DIAGRAM 1-16...

  • Page 20: Troubleshooting

    . GENERAL INFORMATION GRAND DINK 250 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged carburetor fuel inlet tube, vacuum tube or fuel tube...

  • Page 21

    . GENERAL INFORMATION GRAND DINK 250 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and Clogged air cleaner accelerate lightly for Restricted fuel flow observation Clogged fuel line between fuel tank and carburetor Engine speed does Engine speed Clogged exhaust muffler...

  • Page 22

    . GENERAL INFORMATION GRAND DINK 250 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Incorrect timing Correct timing Faulty A.C. generator Check carburetor pilot screw adjustment Mixture too rich (turn screw...

  • Page 23

    . GENERAL INFORMATION GRAND DINK 250 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty A.C. generator Check valve clearance Improperly adjusted valve Correctly adjusted Incorrectly adjusted clearance Worn valve seat...

  • Page 24

    . GENERAL INFORMATION GRAND DINK 250 ENGINE NOISE Symptom Probable Cause Valve clearance too large Valve noise Worn camshaft lobe Worn piston rings Worn piston pin and connecting rod small Piston noise Excessive carbon build-up in combustion chamber Damaged cam chain tensioner...

  • Page 25

    . GENERAL INFORMATION GRAND DINK 250 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause Worn or slipping drive belt Broken ramp plate Broken drive face spring Engine starts but Separated clutch lining motor-cycle does not Damaged driven pulley shaft splines...

  • Page 26

    . GENERAL INFORMATION GRAND DINK 250 STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of stop switch by Burned out fuse applying brake Weak or dead battery Stoplight does not Faulty stop switch Stoplight comes on...

  • Page 27

    . GENERAL INFORMATION GRAND DINK 250 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 Faulty spark plug Check spark plug cap and high-tension wire...

  • Page 28

    . GENERAL INFORMATION GRAND DINK 250 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Faulty AC generator Voltage does not Normal voltage Faulty regulator/rectifier increase Faulty battery...

  • Page 29

    . GENERAL INFORMATION GRAND DINK 250 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals Burned out fuse Weak or dead battery Signals operate Signals dim, remain...

  • Page 30

    . GENERAL INFORMATION GRAND DINK 250 fuel gauge STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) Steering stem nut too tight Steering is heavy Broken steering steel balls Excessive wheel bearing play...

  • Page 31: Exhaust Muffler/frame Covers

    . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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: Exhaust Muffler/frame Covers

    . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 250 SCHEMATIC DRAWING...

  • Page 33: Service Information

    . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 250 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 250 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 250 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 250 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

    . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 250 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: Exhaust Muffler Removal

    . EXHAUST MUFFLER/FRAME COVERS GRAND DINK 250 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 250 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

    . INSPECTION/ADJUSTMENT GRAND DINK 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 SPARK PLUG---------------------------------------------------------------- 3- 5...

  • Page 41: Inspection/adjustment

    . INSPECTION/ADJUSTMENT GRAND DINK 250 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

    Brake lever Brake shoe wear Shock absorber • In the interest of safety, we recommend these items be serviced only by an authorized KYMCO motorcycle dealer. Note: 1. For higher odometer readings, repeat at the frequency interval established here. 2. Service more frequently when riding in dusty or rainy areas.

  • Page 43: Fuel Line/fuel Filter

    . INSPECTION/ADJUSTMENT GRAND DINK 250 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 250 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 250 Screws AIR CLEANER Remove the six 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 250 Bolts VALVE CLEARANCE • Inspect and adjust valve clearance while the engine is cold (below 35 ). Remove the cylinder head cover. Cylinder Head Cover Turn the A.C. generator flywheel to the top dead center (TDC) on the compression stroke so that the “T”...

  • Page 47: Cylinder Compression

    . INSPECTION/ADJUSTMENT GRAND DINK 250 CYLINDER COMPRESSION Warm up the engine before compression test. Remove the center cover and spark plug cap. Remove the spark plug. Insert a compression gauge. Open the throttle valves fully and pushes the starter button to test the compression.

  • Page 48: Final Reduction Gear Oil

    . INSPECTION/ADJUSTMENT GRAND DINK 250 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 checks bolt. The oil level shall be at the oil check blowhole.

  • Page 49: Headlight Aim

    . INSPECTION/ADJUSTMENT GRAND DINK 250 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 250 Coolant capacity : 1400±20cc Radiator capacity : 1000±20cc Reserve tank capacity : 400±20cc Start the engine and check if there are no bubbles in the coolant and the coolant level is stable. Reinstall the radiator cap.

  • Page 51: Nuts/bolts/fasteners

    . INSPECTION/ADJUSTMENT GRAND DINK 250 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 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 GRAND DINK 250 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...

  • Page 54: Lubrication System Diagram

    . LUBRICATION SYSTEM GRAND DINK 250 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 250 ENGINE OIL/OIL FILTER • Place the motorcycle 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 56: Oil Pump Removal

    . LUBRICATION SYSTEM GRAND DINK 250 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 250 Pump Body Outer Rotor OIL PUMP INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.25mm replace if over Outer Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.20mm replace if over Inner Rotor Measure the rotor end-to-pump body clearance.

  • Page 58: Oil Pump Installation

    . LUBRICATION SYSTEM GRAND DINK 250 Hole Pump Cover 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 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 5-1 ENGINE REMOVAL ------------------------------------------------------- 5-2 ENGINE INSTALLATION ------------------------------------------------ 5-4...

  • Page 60

    5. ENGINE REMOVAL/INSTALLATION GRAND DINK 250 SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. careful not to damage the motorcycle body, cables and wires during engine removal. • Use shop towels to protect the motorcycle body during engine removal.

  • Page 61

    . ENGINE REMOVAL/INSTALLATION GRAND DINK 250 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 62

    5. ENGINE REMOVAL/INSTALLATION GRAND DINK 250 Rear Shock Absorber Upper Mount Bolts Remove the right/left rear shock absorber upper mount bolts. Remove the engine mounting bolt and pull out the engine. Engine Mounting Nut Bolt ENGINE HANGER REMOVAL Remove the engine hanger bolts to remove the engine hanger.

  • Page 63

    . ENGINE REMOVAL/INSTALLATION GRAND DINK 250 ENGINE INSTALLATION Install the engine in the reverse order of removal. Tighten the engine mounting bolt. Torque: 49N-m Engine Mounting Nut Rear Shock Absorber Upper Mount Bolts Tighten the rear shock absorber upper mount bolts.

  • Page 64: Cylinder Head/valves

    . CYLINDER HEAD/VALVES GRAND DINK 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 65: Schematic Drawing

    . CYLINDER HEAD/VALVES GRAND DINK 250 SCHEMATIC DRAWING...

  • Page 66: Service Information

    . CYLINDER HEAD/VALVES GRAND DINK 250 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 67: Troubleshooting

    . CYLINDER HEAD/VALVES GRAND DINK 250 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 68: Cylinder Head Cover Removal

    . CYLINDER HEAD/VALVES GRAND DINK 250 CYLINDER HEAD COVER REMOVAL Cylinder Head Cover 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 69

    . CYLINDER HEAD/VALVES GRAND DINK 250 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: IN: 34.14mm replace if below EX:34.02mm replace if below...

  • Page 70: Cylinder Head Removal

    . CYLINDER HEAD/VALVES GRAND DINK 250 Rocker Arm Shafts 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 71: Cylinder Head Disassembly

    . CYLINDER HEAD/VALVES GRAND DINK 250 Cylinder Cam Chain Tensioner Slipper 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 72: Cylinder Head Assembly

    . CYLINDER HEAD/VALVES GRAND DINK 250 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 73: Cylinder Head Installation

    . CYLINDER HEAD/VALVES GRAND DINK 250 Valve Spring Compressor 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 74: Camshaft Installation

    . CYLINDER HEAD/VALVES GRAND DINK 250 Camshaft Holder 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...

  • Page 75: Cylinder Head Cover Installation

    . CYLINDER HEAD/VALVES GRAND DINK 250 Tensioner Screw Turn the cam chain tension screw counter clockwise 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 76

    . CYLINDER HEAD/VALVES GRAND DINK 250 6-12...

  • Page 77: Cylinder/piston

    . CYLINDER/PISTON GRAND DINK 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 GRAND DINK 250 SCHEMATIC DRAWING...

  • Page 79: Cylinder/piston

    . CYLINDER/PISTON GRAND DINK 250 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 250 Cylinder Cam Chain Guide CYLINDER REMOVAL Remove the cylinder head. ( 6-7) Remove the water hose from the cylinder. Water Hose Remove the cam chain guide. Remove the cylinder. Gasket Remove the cylinder gasket and dowel pins.

  • Page 81

    . CYLINDER/PISTON GRAND DINK 250 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 250 Measure the piston pin O.D. Service Limit: 16.96mm replace if below Measure the piston O.D. • Take measurement at 9mm from the bottom and 90° to the piston pin hole. Service Limit: 72.60mm replace if below Measure the piston-to-piston pin clearance.

  • Page 83: Piston Ring Installation

    . CYLINDER/PISTON GRAND DINK 250 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: 17.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston.

  • Page 84: Piston Installation

    . CYLINDER/PISTON GRAND DINK 250 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 on the intake valve side.

  • Page 85

    . CYLINDER/PISTON GRAND DINK 250 Install the cam chain guide. • Insert the tab on the cam chain guide into the cylinder groove. Dowel Pin Install the cylinder gasket and dowel pins. 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 250 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/ GRAND DINK 250 KICK STARTER SCHEMATIC DRAWING...

  • Page 88: Service Information

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 250 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.

  • Page 89: Left Crankcase Cover

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 250 KICK STARTER Air Tube Band LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw. Remove the four bolts on the left crankcase surface cover. Cover Bolts Remove the left crankcase cover bolts and left crankcase covers.

  • Page 90: Drive Pulley

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 250 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 250 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 250 KICK STARTER Measure the movable drive face bushing assembly I.D. Service Limit: 27.13mm 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 250 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 250 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

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 250 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 250 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 250 KICK STARTER Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 40.06mm 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 250 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 linings.

  • Page 99

    . DRIVE AND DRIVEN PULLEYS/ GRAND DINK 250 KICK STARTER CLUTCH ASSEMBLY 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 250 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 250 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: Final Reduction

    . FINAL REDUCTION GRAND DINK 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 103: Schematic Drawing

    . FINAL REDUCTION GRAND DINK 250 SCHEMATIC DRAWING...

  • Page 104: Service Information

    . FINAL REDUCTION GRAND DINK 250 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 105: Final Reduction Disassembly

    . FINAL REDUCTION GRAND DINK 250 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 106

    . FINAL REDUCTION GRAND DINK 250 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 107

    . FINAL REDUCTION GRAND DINK 250 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 108: Final Reduction Assembly

    . FINAL REDUCTION GRAND DINK 250 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 109

    . FINAL REDUCTION GRAND DINK 250 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 110

    . FINAL REDUCTION GRAND DINK 250 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 111: Generator/starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 112: Generator/starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 250 SCHEMATIC DRAWING 10-1...

  • Page 113: Service Information

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 250 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 114: Right Crankcase Cover Removal

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 250 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...

  • Page 115: Starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 250 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 116: Flywheel Installation

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 250 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...

  • Page 117: Stator Installation

    . A.C. GENERATOR/STARTER CLUTCH GRAND DINK 250 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 118: Crankcase/crankshaft

    . CRANKCASE/CRANKSHAFT GRAND DINK 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 119: Schematic Drawing

    . CRANKCASE/CRANKSHAFT GRAND DINK 250 SCHEMATIC DRAWING 11-1...

  • Page 120: Service Information

    . CRANKCASE/CRANKSHAFT GRAND DINK 250 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 121: Crankcase Separation

    . CRANKCASE/CRANKSHAFT GRAND DINK 250 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 122: Crankshaft Inspection

    . CRANKCASE/CRANKSHAFT GRAND DINK 250 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 123: Crankcase Assembly

    . CRANKCASE/CRANKSHAFT GRAND DINK 250 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 124

    . CRANKCASE/CRANKSHAFT GRAND DINK 250 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 125

    . CRANKCASE/CRANKSHAFT GRAND DINK 250 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 126: Cooling System

    . COOLING SYSTEM GRAND DINK 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 127

    . COOLING SYSTEM GRAND DINK 250 SCHEMATIC DRAWING 12-1...

  • Page 128: Cooling System

    . COOLING SYSTEM GRAND DINK 250 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 129

    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 130: Cooling System Testing

    . COOLING SYSTEM GRAND DINK 250 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 cap sealing surface before testing.

  • Page 131

    . COOLING SYSTEM GRAND DINK 250 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 132

    . COOLING SYSTEM GRAND DINK 250 Fan Motor Wire Coupler Thermostatic Switch Disconnect the thermostatic switch wire coupler. Disconnect the fan motor wire coupler. Thermostatic Switch Wire Radiator Remove the two bolts and one nut on the radiator. Bolts Fan/Shroud...

  • Page 133

    . COOLING SYSTEM GRAND DINK 250 Battery Check fan motor by battery. Fan Motor Thermostatic Switch CHECK THERMOSTATIC SWITCH When coolant temperature lower then 88~92 the thermostatic switch OFF. When coolant temperature over 88~92 the thermostatic switch ON. Bolts Install the fan shroud on the radiator with the three bolts.

  • Page 134

    . COOLING SYSTEM GRAND DINK 250 Radiator RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts and one nut. Bolts 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 135: Water Pump

    . COOLING SYSTEM GRAND DINK 250 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 136

    . COOLING SYSTEM GRAND DINK 250 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 Inspect the mechanical (water) seal and seal washer for wear or damage.

  • Page 137

    . COOLING SYSTEM GRAND DINK 250 Bolts WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove the eight bolts attaching the right crankcase cover. Water Pump Assembly Water Pump Assembly Inner Bearing Remove the water pump bearing snap ring from the water pump assembly.

  • Page 138

    . COOLING SYSTEM GRAND DINK 250 Water Pump Assembly MECHANICAL SEAL 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 139

    . COOLING SYSTEM GRAND DINK 250 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 Bolts Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover.

  • Page 140

    . COOLING SYSTEM GRAND DINK 250 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. Water Pump Cover Install the water pump cover and tighten the 4 bolts.

  • Page 141: Thermosensor

    . COOLING SYSTEM GRAND DINK 250 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 Thermosensor Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up.

  • Page 142: Thermostat

    . COOLING SYSTEM GRAND DINK 250 Thermostat 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 143

    . COOLING SYSTEM GRAND DINK 250 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 3.5 4.5mm...

  • Page 144: Fuel System/carburetor/fuel

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM/CARBURETOR/FUEL PUMP __________________________________________________________________________________ FUEL SYSTEM-------------------------------------------------------------- 13- 1 SCHEMATIC DRAWING ------------------------------------------------- 13- 2 OPERATION OF CARBURETOR JETS -------------------------------- 13- 3 SERVICE INFORMATION------------------------------------------------ 13- 5 CARBURETOR REMOVAL ---------------------------------------------- 13- 7...

  • Page 145

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 FUEL SYSTEM 13-1...

  • Page 146

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 SCHEMATIC DRAWING 13-2...

  • Page 147: Operation Of Carburetor Jets

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 OPERATION OF CARBURETOR JETS 1.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 148

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 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 149: Service Information

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 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 150

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 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 151: Carburetor Removal

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 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 152

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 Screws Remove the two vacuum chamber cover screws and the cover. Vacuum Chamber Cover Spring Remove the compression spring and vacuum piston. Vacuum Piston Diaphragm Vacuum Piston Remove the needle holder, spring and jet needle from the piston.

  • Page 153: Float Chamber Disassembly

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 Float Chamber FLOAT CHAMBER DISASSEMBLY Remove the three float chamber screws and the float chamber. Screws Float Remove the float pin, float and float valve. Float Valve Float Pin Float Valve...

  • Page 154

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 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 155: Auto Bystarter Inspection/removal

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 AUTO BYSTARTER INSPECTION /REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 10Ω (10 minutes minimum after stopping the engine) If the reading is not within the limit, replace the auto bystarter with a new one.

  • Page 156: Air Cut-off Valve (a.c.v.)

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 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 157

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 CARBURETOR BODY CLEANING Blow compressed air through all passages of the carburetor body. • Make sure that no fuel jet is clogged. O-ring Install the O-ring onto the air-cut-off valve body securely.

  • Page 158

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 Screws ACCELERATING PUMP DISASSEMBLY Remove the two accelerating pump cover screws and accelerating pump cover. Remove the spring and accelerating pump diaphragm. Diaphragm Cover INSPECTION Inspect the accelerating pump diaphragm for cracks, damage or deterioration.

  • Page 159: Float Chamber Assembly

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 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 160: Float Level Inspection

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 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 161: Carburetor Installation

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 Check the heater with battery. If the heater is getting hot, means the heater without problem, otherwise the heater has to be changed. Heater Air Cleaner Connecting Throttle Cable Tube Band CARBURETOR INSTALLATION Tighten the drain screw.

  • Page 162: Fuel Pump Removal/disassembly

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 Vacuum 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 163: Fuel Pump Inspection

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 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 164: Fuel Pump Installation

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 Inlet Tube Fuel Pump Outlet 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 165

    . FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK GRAND DINK 250 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. • When removing the fuel strainer, do...

  • Page 166

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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 167

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SCHEMATIC DRAWING 14-1...

  • Page 168

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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 169: Troubleshooting

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 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 •...

  • Page 170: Steering Handlebar

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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 171: Front Wheel

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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 172

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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.

  • Page 173

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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 while driving them in.

  • Page 174: Front Brake

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Holder Bolts FRONT BRAKE BRAKE MASTER CYLINDER REMOVAL Remove the handlebar covers. ( 2-6) First drain the brake fluid from the hydraulic brake system. Disconnect the front stop switch wire connector.

  • Page 175

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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: 12.64mm Before assembly, inspect the lst and 2nd rubber cups for wear.

  • Page 176

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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 177

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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.

  • Page 178

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge. Top Service Limit: 26.91mm Under Service Limit: 33.87mm Check the caliper cylinder for scratches or wear and measure the cylinder bore.

  • Page 179: Steering Handlebar/front Wheel/front Brake/front

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Fluid Tube Bolt 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 180: Front Shock Absorber

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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 181

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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 182

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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 183

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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 184

    14. STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 250 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.

  • Page 185: Rear Brake/rear Fork/rear

    . REAR BRAKE/REAR FORK/REAR GRAND DINK 250 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 ----------------------------------------------------------------- 15-5...

  • Page 186

    . REAR BRAKE/REAR FORK/REAR GRAND DINK 250 WHEEL/REAR SHOCK ABSORBER SCHEMATIC DRAWING 15-1...

  • Page 187: Wheel/rear Shock Absorber

    . REAR BRAKE/REAR FORK/REAR GRAND DINK 250 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 188

    . REAR BRAKE/REAR FORK/REAR GRAND DINK 250 WHEEL/REAR SHOCK ABSORBER 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 189

    . REAR BRAKE/REAR FORK/REAR GRAND DINK 250 WHEEL/REAR SHOCK ABSORBER 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 shop towel under the caliper to avoid contamination caused by the removed piston.

  • Page 190

    . REAR BRAKE/REAR FORK/REAR GRAND DINK 250 WHEEL/REAR SHOCK ABSORBER ASSEMBLY Clean all removed parts. Apply silicon grease to the piston and oil seal. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out.

  • Page 191

    . REAR BRAKE/REAR FORK/REAR GRAND DINK 250 WHEEL/REAR SHOCK ABSORBER Rear Brake Disk REAR WHEEL REMOVAL Remove the exhaust muffler. ( 2-6) Remove the rear brake caliper. ( 15-3) Remove the rear fork. Remove the rear axle collar. Remove the rear wheel.

  • Page 192

    . REAR BRAKE/REAR FORK/REAR GRAND DINK 250 WHEEL/REAR SHOCK ABSORBER Upper Mount Bolts REAR SHOCK ABSORBER REMOVAL Remove the rear carrier and hand rail. ( 2-3) Remove the met-in box. ( 2-3) Remove the two air cleaner bolts. Remove the rear shock absorber upper mount bolt.

  • Page 193: Battery/charging System

    . BATTERY/CHARGING SYSTEM GRAND DINK 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 16-0...

  • Page 194

    . BATTERY/CHARGING SYSTEM GRAND DINK 250 CHARGING SYSTEM LAYOUT Fuse Battery Regulator/Rectifier A.C. Generator CHARGING CIRCUIT 16-1...

  • Page 195

    . BATTERY/CHARGING SYSTEM GRAND DINK 250 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 250 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 •...

  • Page 197: Battery

    . BATTERY/CHARGING SYSTEM GRAND DINK 250 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 250 Red Wire CHARGING SYSTEM CURRENT TEST Use a fully charged battery (12.8V min.) to check the charging system. Warm up the engine before taking readings. Connect an electric tester across the battery terminals. Disconnect the red wire from the fuse terminal and connect an ammeter between the red wire lead and the fuse terminal.

  • Page 199: Regulator/rectifier Inspection

    . BATTERY/CHARGING SYSTEM GRAND DINK 250 Pulser Coil A.C. Generator Stator 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 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 CDI UNIT RESISTANCE INSPECTION-------------------------------- 17-5...

  • Page 201

    . IGNITION SYSTEM GRAND DINK 250 IGNITION SYSTEM LAYOUT CDI Unit Ignition Coil Ignition Switch A.C. Generator Pulser Coil IGNITION CIRCUIT 17-1...

  • Page 202

    . IGNITION SYSTEM GRAND DINK 250 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

    . IGNITION SYSTEM GRAND DINK 250 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. ( 2-3) Remove the ignition coil Ignition Coil Primary Coil IGNITION COIL CONTINUITY TEST Inspect the continuity of the ignition coil, primary coil and secondary coil.

  • Page 204

    . IGNITION SYSTEM GRAND DINK 250 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/white wire terminal and ground.

  • Page 205

    . IGNITION SYSTEM GRAND DINK 250 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 250 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ 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 GRAND DINK 250 STARTING SYSTEM LAYOUT Stop Switch Starter Button Starter Relay Starter Motor STARTING CIRCUIT Relay 18-1...

  • Page 208

    . STARTING SYSTEM GRAND DINK 250 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 250 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 250 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

    . STARTING SYSTEM GRAND DINK 250 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

    . STARTING SYSTEM GRAND DINK 250 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 SWITCH GRAND DINK /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 THERMOSTATIC SWITCH ---------------------------------------------- 19-6 TEMPERATURE METER ------------------------------------------------- 19-6 INSTRUMENTS ------------------------------------------------------------- 19-7 LIGHTS ----------------------------------------------------------------------- 19-8...

  • Page 214: Thermostatic

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS ELECTRICAL EQUIPMENT LAYOUT Stop Switches Headlight Instruments Dimmer Switch Turn Signal Switch Ignition Switch Horn Button Headlight Horn Switch Starter Button Fuel Unit Thermostatic Switch 19-1...

  • Page 215: Service Information

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK /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 Electric tester SPECIAL TOOL Fuel unit wrench...

  • Page 216: Switches

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 250 /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 ○...

  • Page 217

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK /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 Position FREE ○...

  • Page 218: Horn Inspection

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 250 /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 /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. Lower the water temperature to 85 check if the fan motor stops.

  • Page 220: Instruments

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS THROTTLE POSTTION SENSOR Unit:KΩ ∞ 0~5±1 ∞ 0~5±1 T.P.S. BACK MIRROR CONTROLLER Unit:Ω ∞ ∞ ∞ ∞ ∞ ∞ 5.8~11MΩ 0.2~0.8Ω ∞ 420~780KΩ 9.3~17MΩ 9.3~17MΩ ∞ ∞ ∞ 7~13MΩ ∞ ∞...

  • Page 221: Lights

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK /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. Install the bulb socket, aligning the bulb socket tab with the groove.

  • Page 222: Heater Wiring Diagram

    . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH GRAND DINK 250 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HEATER WIRING DIAGRAM 19-9...

  • Page 223

    NO.: KTI-04002 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

    YMCO ECHNICAL NFORMATION 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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