KYMCO GRAND DINK 250 Manuals

Manuals and User Guides for KYMCO GRAND DINK 250. We have 2 KYMCO GRAND DINK 250 manuals available for free PDF download: Service Manual, Manual

KYMCO GRAND DINK 250 Service Manual

KYMCO GRAND DINK 250 Service Manual (265 pages)

Brand: KYMCO | Category: Scooter | Size: 32.58 MB
Table of contents
Table Of Contents1................................................................................................................................................................
Grand Dink 2504................................................................................................................................................................
Service Precautions5................................................................................................................................................................
Torque Values9................................................................................................................................................................
Frame9................................................................................................................................................................
Special Tools10................................................................................................................................................................
Lubrication Points11................................................................................................................................................................
Cable & Harness Routing13................................................................................................................................................................
Wiring Diagram18................................................................................................................................................................
Troubleshooting19................................................................................................................................................................
General Information23................................................................................................................................................................
Exhaust Muffler/frame Covers30................................................................................................................................................................
Schematic Drawing31................................................................................................................................................................
Service Information32................................................................................................................................................................
Frame Covers Removal33................................................................................................................................................................
Exhaust Muffler Removal37................................................................................................................................................................
Inspection/adjustment39................................................................................................................................................................
Maintenance Schedule41................................................................................................................................................................
Fuel Line/fuel Filter42................................................................................................................................................................
Throttle Operation42................................................................................................................................................................
Engine Oil43................................................................................................................................................................
Air Cleaner44................................................................................................................................................................
Spark Plug44................................................................................................................................................................
Valve Clearance45................................................................................................................................................................
Carburetor Idle Speed45................................................................................................................................................................
Cylinder Compression46................................................................................................................................................................
Final Reduction Gear Oil47................................................................................................................................................................
Drive Belt47................................................................................................................................................................
Headlight Aim48................................................................................................................................................................
Clutch Shoe Wear48................................................................................................................................................................
Cooling System48................................................................................................................................................................
Brake System49................................................................................................................................................................
Nuts/bolts/fasteners50................................................................................................................................................................
Wheels/tires50................................................................................................................................................................
Steering Handlebar50................................................................................................................................................................
Suspension50................................................................................................................................................................
Lubrication System53................................................................................................................................................................
Lubrication System Diagram53................................................................................................................................................................
Engine Oil/oil Filter54................................................................................................................................................................
Oil Pump Removal55................................................................................................................................................................
Oil Pump Disassembly55................................................................................................................................................................
Oil Pump Inspection56................................................................................................................................................................
Oil Pump Assembly56................................................................................................................................................................
Oil Pump Installation57................................................................................................................................................................
Engine Removal60................................................................................................................................................................
Engine Removal/installation62................................................................................................................................................................
Cylinder Head/valves63................................................................................................................................................................
Cylinder Head Cover Removal67................................................................................................................................................................
Camshaft Removal67................................................................................................................................................................
Cylinder Head Removal69................................................................................................................................................................
Cylinder Head Disassembly70................................................................................................................................................................
Cylinder Head Assembly71................................................................................................................................................................
Cylinder Head Installation72................................................................................................................................................................
Camshaft Installation73................................................................................................................................................................
Cylinder Head Cover Installation74................................................................................................................................................................
Cylinder/piston75................................................................................................................................................................
Cylinder Removal78................................................................................................................................................................
Piston Removal78................................................................................................................................................................
Piston Installation82................................................................................................................................................................
Cylinder Installation82................................................................................................................................................................
Drive And Driven Pulleys/kick Starter84................................................................................................................................................................
Drive And Driven Pulleys/ Kick Starter86................................................................................................................................................................
Left Crankcase Cover87................................................................................................................................................................
Drive Pulley88................................................................................................................................................................
Clutch/driven Pulley92................................................................................................................................................................
Final Reduction103................................................................................................................................................................
Final Reduction Disassembly103................................................................................................................................................................
Final Reduction Inspection103................................................................................................................................................................
Final Reduction Assembly106................................................................................................................................................................
Generator/starter Clutch109................................................................................................................................................................
Right Crankcase Cover Removal112................................................................................................................................................................
Stator Removal112................................................................................................................................................................
Flywheel Removal112................................................................................................................................................................
Starter Clutch113................................................................................................................................................................
Flywheel Installation114................................................................................................................................................................
Stator Installation115................................................................................................................................................................
Right Crankcase Cover Installation115................................................................................................................................................................
Crankcase/crankshaft116................................................................................................................................................................
Crankcase Separation119................................................................................................................................................................
Crankshaft Inspection120................................................................................................................................................................
Crankcase Assembly121................................................................................................................................................................
Cooling System Testing128................................................................................................................................................................
Radiator128................................................................................................................................................................
Water Pump133................................................................................................................................................................
Thermosensor139................................................................................................................................................................
Thermostat140................................................................................................................................................................
Fuel System/carburetor/fuel Pump Fuel Tank142................................................................................................................................................................
Fuel System/carburetor/fuel Pump145................................................................................................................................................................
Fuel System145................................................................................................................................................................
Operation Of Carburetor Jets145................................................................................................................................................................
Fuel Pump146................................................................................................................................................................
Carburetor Removal149................................................................................................................................................................
Vacuum Chamber Disassembly149................................................................................................................................................................
Float Chamber Disassembly151................................................................................................................................................................
Auto Bystarter Inspection/removal153................................................................................................................................................................
Air Cut-off Valve (a.c.v.)154................................................................................................................................................................
Float Chamber Assembly157................................................................................................................................................................
Float Level Inspection158................................................................................................................................................................
Vacuum Chamber Assembly158................................................................................................................................................................
Carburetor Installation159................................................................................................................................................................
Fuel Pump Removal/disassembly160................................................................................................................................................................
Fuel Pump Inspection161................................................................................................................................................................
Fuel Pump Assembly161................................................................................................................................................................
Fuel Pump Installation162................................................................................................................................................................
Fuel Tank Removal162................................................................................................................................................................
Steering Handlebar/front164................................................................................................................................................................
Steering Handlebar/front Wheel/front Brake/front168................................................................................................................................................................
Front Wheel169................................................................................................................................................................
Front Brake172................................................................................................................................................................
Front Shock Absorber178................................................................................................................................................................
Front Fork180................................................................................................................................................................
Rear Brake/rear Fork/rear183................................................................................................................................................................
Wheel/rear Shock Absorber185................................................................................................................................................................
Rear Brake186................................................................................................................................................................
Rear Fork188................................................................................................................................................................
Rear Wheel189................................................................................................................................................................
Rear Shock Absorber190................................................................................................................................................................
Battery/charging System192................................................................................................................................................................
Battery195................................................................................................................................................................
Charging System196................................................................................................................................................................
Generator Inspection196................................................................................................................................................................
Regulator/rectifier Inspection197................................................................................................................................................................
Ignition System198................................................................................................................................................................
Ignition Coil Inspection201................................................................................................................................................................
A .c. Generator Inspection202................................................................................................................................................................
Cdi Unit Resistance Inspection203................................................................................................................................................................
Starting System206................................................................................................................................................................
Starter Motor207................................................................................................................................................................
Starter Clutch Inspection209................................................................................................................................................................
Starter Relay Inspection210................................................................................................................................................................
Switches/horn/fuel Unit/thermostatic211................................................................................................................................................................
Electrical Equipment Layout212................................................................................................................................................................
Switches214................................................................................................................................................................
Horn Inspection216................................................................................................................................................................
Fuel Unit216................................................................................................................................................................
Thermostatic Switch217................................................................................................................................................................
Temperature Meter217................................................................................................................................................................
Instruments218................................................................................................................................................................
Lights219................................................................................................................................................................
Heater Wiring Diagram220................................................................................................................................................................

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KYMCO GRAND DINK 250 Manual

KYMCO GRAND DINK 250 Manual (224 pages)

Brand: KYMCO | Category: Scooter | Size: 38.37 MB
Table of contents
Table Of Contents1................................................................................................................................................................
General Information3................................................................................................................................................................
Specification5................................................................................................................................................................
Service Precautions6................................................................................................................................................................
Torque Values10................................................................................................................................................................
Tools11................................................................................................................................................................
Lubrication Points12................................................................................................................................................................
Cable & Harness Routing14................................................................................................................................................................
Wiring Diagram19................................................................................................................................................................
Troubleshooting20................................................................................................................................................................
Exhaust Muffler/frame Covers31................................................................................................................................................................
Schematic Drawing32................................................................................................................................................................
Service Information33................................................................................................................................................................
Frame Covers Removal34................................................................................................................................................................
Exhaust Muffler Removal38................................................................................................................................................................
Inspection/adjustment40................................................................................................................................................................
Maintenance Schedule42................................................................................................................................................................
Fuel Line/fuel Filter43................................................................................................................................................................
Throttle Operation43................................................................................................................................................................
Engine Oil44................................................................................................................................................................
Oil Change44................................................................................................................................................................
Oil Filter Screen Inspection44................................................................................................................................................................
Air Cleaner45................................................................................................................................................................
Spark Plug45................................................................................................................................................................
Valve Clearance46................................................................................................................................................................
Carburetor Idle Speed46................................................................................................................................................................
Cylinder Compression47................................................................................................................................................................
Final Reduction Gear Oil48................................................................................................................................................................
Drive Belt48................................................................................................................................................................
Headlight Aim49................................................................................................................................................................
Clutch Shoe Wear49................................................................................................................................................................
Cooling System49................................................................................................................................................................
Brake System50................................................................................................................................................................
Nuts/bolts/fasteners51................................................................................................................................................................
Wheels/tires51................................................................................................................................................................
Steering Handlebar51................................................................................................................................................................
Suspension51................................................................................................................................................................
Lubrication System52................................................................................................................................................................
Lubrication System Diagram54................................................................................................................................................................
Engine Oil/oil Filter55................................................................................................................................................................
Oil Pump Removal56................................................................................................................................................................
Oil Pump Disassembly56................................................................................................................................................................
Oil Pump Inspection57................................................................................................................................................................
Oil Pump Assembly57................................................................................................................................................................
Oil Pump Installation58................................................................................................................................................................
Engine Removal/installation59................................................................................................................................................................
Cylinder Head/valves64................................................................................................................................................................
Cylinder Head Cover Removal68................................................................................................................................................................
Camshaft Removal68................................................................................................................................................................
Cylinder Head Removal70................................................................................................................................................................
Cylinder Head Disassembly71................................................................................................................................................................
Cylinder Head Assembly72................................................................................................................................................................
Cylinder Head Installation73................................................................................................................................................................
Camshaft Installation74................................................................................................................................................................
Cylinder Head Cover Installation75................................................................................................................................................................
Cylinder/piston77................................................................................................................................................................
Cylinder Removal80................................................................................................................................................................
Piston Removal80................................................................................................................................................................
Cylinder Inspection82................................................................................................................................................................
Piston Ring Installation83................................................................................................................................................................
Piston Installation84................................................................................................................................................................
Cylinder Installation84................................................................................................................................................................
Drive And Driven Pulleys/kick Starter86................................................................................................................................................................
Kick Starter88................................................................................................................................................................
Left Crankcase Cover89................................................................................................................................................................
Drive Pulley90................................................................................................................................................................
Clutch/driven Pulley94................................................................................................................................................................
Final Reduction102................................................................................................................................................................
Final Reduction Disassembly105................................................................................................................................................................
Final Reduction Inspection105................................................................................................................................................................
Final Reduction Assembly108................................................................................................................................................................
Generator/starter Clutch111................................................................................................................................................................
Right Crankcase Cover Removal114................................................................................................................................................................
Stator Removal114................................................................................................................................................................
Flywheel Removal114................................................................................................................................................................
Starter Clutch115................................................................................................................................................................
Flywheel Installation116................................................................................................................................................................
Stator Installation117................................................................................................................................................................
Right Crankcase Cover Installation117................................................................................................................................................................
Crankcase/crankshaft118................................................................................................................................................................
Crankcase Separation121................................................................................................................................................................
Crankshaft Inspection122................................................................................................................................................................
Crankcase Assembly123................................................................................................................................................................
Cooling System Testing130................................................................................................................................................................
Radiator130................................................................................................................................................................
Water Pump135................................................................................................................................................................
Thermosensor141................................................................................................................................................................
Thermostat142................................................................................................................................................................
Fuel System/carburetor/fuel144................................................................................................................................................................
Operation Of Carburetor Jets147................................................................................................................................................................
Carburetor Removal151................................................................................................................................................................
Vacuum Chamber Disassembly151................................................................................................................................................................
Float Chamber Disassembly153................................................................................................................................................................
Auto Bystarter Inspection/removal155................................................................................................................................................................
Air Cut-off Valve (a.c.v.)156................................................................................................................................................................
Float Chamber Assembly159................................................................................................................................................................
Float Level Inspection160................................................................................................................................................................
Vacuum Chamber Assembly160................................................................................................................................................................
Carburetor Installation161................................................................................................................................................................
Fuel Pump Removal/disassembly162................................................................................................................................................................
Fuel Pump Inspection163................................................................................................................................................................
Fuel Pump Assembly163................................................................................................................................................................
Fuel Pump Installation164................................................................................................................................................................
Fuel Tank Removal164................................................................................................................................................................
Front Wheel171................................................................................................................................................................
Front Brake174................................................................................................................................................................
Steering Handlebar/front Wheel/front Brake/front179................................................................................................................................................................
Front Shock Absorber180................................................................................................................................................................
Rear Brake/rear Fork/rear185................................................................................................................................................................
Wheel/rear Shock Absorber187................................................................................................................................................................
Battery/charging System193................................................................................................................................................................
Battery197................................................................................................................................................................
Charging System198................................................................................................................................................................
A.c. Generator Inspection198................................................................................................................................................................
Regulator/rectifier Inspection199................................................................................................................................................................
Ignition System200................................................................................................................................................................
Starting System206................................................................................................................................................................
Starter Motor209................................................................................................................................................................
Thermostatic214................................................................................................................................................................
Switches/horn/fuel Unit/thermostatic Switch/temperature Gauge/ Instruments/lights214................................................................................................................................................................
Electrical Equipment Layout214................................................................................................................................................................
Switches216................................................................................................................................................................
Horn Inspection218................................................................................................................................................................
Fuel Unit218................................................................................................................................................................
Thermostatic Switch219................................................................................................................................................................
Temperature Meter219................................................................................................................................................................
Instruments220................................................................................................................................................................
Lights221................................................................................................................................................................
Heater Wiring Diagram222................................................................................................................................................................

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