KYMCO GRAND DINK 150 Manuals

Manuals and User Guides for KYMCO GRAND DINK 150. We have 1 KYMCO GRAND DINK 150 manual available for free PDF download: Service Manual

KYMCO GRAND DINK 150 Service Manual

KYMCO GRAND DINK 150 Service Manual (224 pages)

Brand: KYMCO | Category: Scooter | Size: 23.2 MB

Table of Contents

Preface

1
- Table of Contents
  1
- General Information
  2
- Engine Serial Number
  3
- General Information
  3
- Specification
  4
- Service Precautions
  6
- Torque Values
  10
- Special Tools
  11
- Lubrication Points
  12
- Cable & Harness Routing
  14
  - Rear View
    15
- Wiring Diagram
  19
- Troubleshooting
  20
- Inspection/Adjustment
  26
2. Exhaust Muffler/Frame Covers 2

31
- Schematic Drawing
  32
- Service Information
  33
- Troubleshooting
  33
- Frame Covers Removal
  34
  - Front Cover Removal
    37
  - Back Cover Removal
    37
  - Bottom Cover Removal
    38
  - Front Fender Removal
    38
- Exhaust Muffler Removal
  38
3. Inspection/Adjustment 3

40
- Service Information
  41
- Maintenance Schedule
  42
- Fuel Line/Fuel Filter
  43
- Throttle Operation
  43
- Engine Oil
  44
  - Oil Filter Screen Inspection
    44
- Air Cleaner
  45
- Spark Plug
  45
- Carburetor Idle Speed
  46
- Valve Clearance
  46
- Cylinder Compression
  47
- Ignition Timing
  47
- Drive Belt
  48
- Final Reduction Gear Oil
  48
- Clutch Shoe Wear
  49
- Cooling System
  49
- Headlight Aim
  49
- Brake System
  50
- Nuts/Bolts/Fasteners
  51
- Steering Handlebar
  51
- Suspension
  51
- Wheels/Tires
  51
4. Lubrication System 4

52
- Lubrication System
  52
  - Lubrication System Diagram
    53
  - Service Information
    54
  - Troubleshooting
    54
  - Engine Oil/Oil Filter
    55
  - Oil Pump Removal
    56
  - Oil Pump Disassembly
    56
  - Oil Pump Inspection
    57
  - Oil Pump Assembly
    57
  - Oil Pump Installation
    58
Engine Removal/Installation

59
- Engine Removal/Installation
  60
- Schematic Drawing
  60
- Service Information
  61
- Engine Removal
  62
- Engine Installation
  64
Cylinder Head/Valves

65
- Cylinder Head/Valves
  66
- Schematic Drawing
  66
- Service Information
  67
- Specifications
  67
- Troubleshooting
  68
- Camshaft Removal
  69
- Cylinder Head Cover Removal
  69
- Cylinder Head Removal
  71
- Cylinder Head Disassembly
  72
- Cylinder Head Assembly
  73
- Cylinder Head Installation
  74
- Camshaft Installation
  75
- Cylinder Head Cover Installation
  76
7 Cylinder/Piston

77
- Cylinder/Piston
  78
- Schematic Drawing
  78
- Service Information
  79
- Troubleshooting
  79
- Cylinder Removal
  80
- Piston Removal
  80
  - Cylinder Inspection
    82
  - Piston Ring Installation
    83
- Cylinder Installation
  84
- Piston Installation
  84
Kick Starter 8

86
- Drive and Driven Pulleys/Kick Starter
  86
  - Drive and Driven Pulleys/ Kick Starter
    87
  - Schematic Drawing
    87
  - Service Information
    88
  - Troubleshooting
    88
  - Left Crankcase Cover
    89
  - Drive Pulley
    90
  - Clutch/Driven Pulley
    94
  - Kick Starter
    95
9. Final Reduction 9

104
- Final Reduction
  104
  - Final Reduction
    105
  - Schematic Drawing
    105
  - Service Information
    106
  - Troubleshooting
    106
  - Final Reduction Disassembly
    107
  - Final Reduction Inspection
    107
  - Final Reduction Assembly
    110
10. A.C. Generator/Starter Clutch 10

113
- Generator/Starter Clutch
  113
  - Generator/Starter Clutch
    114
  - Schematic Drawing
    114
  - Service Information
    115
  - Troubleshooting
    115
  - Right Crankcase Cover Removal
    116
  - Stator Removal
    116
  - Flywheel Removal
    116
  - Starter Clutch
    117
  - Flywheel Installation
    118
  - Stator Installation
    119
  - Right Crankcase Cover Installation
    119
11. Crankcase/Crankshaft 11

120
- Crankcase/Crankshaft
  120
  - Crankcase/Crankshaft
    121
  - Schematic Drawing
    121
  - Service Information
    122
  - Troubleshooting
    122
  - Crankcase Separation
    123
  - Crankshaft Inspection
    124
  - Crankcase Assembly
    125
12. Cooling System 12

128
- Cooling System
  128
  - Cooling System
    129
  - Schematic Drawing
    129
  - Service Information
    130
  - Troubleshooting
    130
  - Cooling System Testing
    132
  - Radiator
    132
  - Water Pump
    137
  - Thermosensor
    143
  - Thermostat
    144
13. Fuel System/Carburetor/ Fuel Pump/ Fuel Tank 13

146
- Fuel System/Carburetor/Fuel Pump Fuel Tank
  147
  - Fuel System/Carburetor/Fuel Pump
    147
  - Fuel System
    147
  - Schematic Drawing
    148
  - Operation of Carburetor Jets
    149
  - Service Information
    151
  - Carburetor Removal
    153
  - Vacuum Chamber Disassembly
    153
  - Float Chamber Disassembly
    155
  - Auto Bystarter Inspection/Removal
    157
  - Air Cut-Off Valve (A.C.V.)
    158
  - Auto Bystarter Installation
    160
  - Float Chamber Assembly
    161
  - Float Level Inspection
    162
  - Vacuum Chamber Assembly
    162
  - Carburetor Installation
    163
  - Fuel Pump Removal/Disassembly
    164
  - Fuel Pump Inspection
    165
  - Fuel Pump Assembly
    165
  - Fuel Pump Installation
    166
  - Fuel Tank Removal
    166
Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork

168
- Steering Handlebar/Front Wheel/Front Brake/Front
  168
  - Schematic Drawing
    169
  - Service Information
    170
  - Troubleshooting
    171
  - Steering Handlebar
    172
  - Front Wheel
    173
  - Front Brake
    176
  - Front Shock Absorber
    182
  - Front Fork
    182
Rear Brake/Rear Fork/Rear Wheel/ Rear Shock Absorber

187
- Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
  187
  - Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
    188
  - Schematic Drawing
    188
  - Rear Brake
    188
  - Rear Fork
    191
  - Rear Wheel
    191
  - Rear Shock Absorber
    192
16. Battery/Charging System 16

193
- Battery/Charging System
  193
  - Battery/Charging System
    194
  - Charging System Layout
    194
  - Service Information
    195
  - Troubleshooting
    196
  - Battery
    197
  - Charging System
    198
  - A.C. Generator Inspection
    198
  - Regulator/Rectifier Inspection
    199
17. Ignition System 17

200
- Ignition System
  200
- Ignition System Layout
  201
- Service Information
  202
- Troubleshooting
  202
- Ignition Coil Inspection
  203
- Spark Plug
  203
- A .C. Generator Inspection
  204
- CDI Unit Resistance Inspection
  205
- Starting System
  206
  - Starting System
    207
  - Starting System Layout
    207
  - Service Information
    208
  - Troubleshooting
    208
  - Starter Motor
    209
  - Starter Clutch Inspection
    211
  - Starter Relay Inspection
    212
- Switches/Horn/Fuel Unit/Thermostatic
  213
  - Electrical Equipment Layout
    214
  - Service Information
    215
  - Troubleshooting
    215
  - Switches
    216
  - Horn Inspection
    218
  - Fuel Unit
    218
  - Thermostatic Switch
    219
  - Temperature Gauge
    219
  - Instruments
    220
  - Lights
    221
  - Heater Wiring Diagram
    222

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