GRAND DINK 125/150 PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO GRAND DINK 125/150. Section 1 contains the precautions for all operations stated in this manual. Read them carefully before any operation is started. Section 2 is the removal/installation procedures for the frame covers which are subject to higher removal/installation frequency during maintenance and servicing operations. Section 3 describes the inspection/ adjustment procedures, safety rules and service information for each part, starting from periodic maintenance. Sections 5 through 13 give instructions for disassembly, assembly and adjustment of engine parts. Section 14 is the removal/ installation of chassis. Section 16 states the testing and measuring methods of electrical equipment. Most sections start with an assembly or system illustration and troubleshooting for the section. The subsequent pages give detailed procedures for the section. The information and contents included in this manual may be different from the motorcycle in case specifications are changed. ENGINE CHASSIS EQUIPMENT TABLE OF CONTENTS GENERAL INFORMATION EXHAUST MUFFLER/FRAME COVERS INSPECTION/ADJUSTMENT LUBRICATION SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES CYLINDER/PISTON DRIVE AND DRIVEN PULLEYS/KICK STARTER FINAL REDUCTION 1 2 3 4 5 6 7 8 9 A.C. GENERATOR/STARTER CLUTCH 10 CRANKCASE/CRANKSHAFT COOLING SYSTEM FUEL SYSTEM/CARBURETOR/FUEL PUMP FUEL TANK STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER` BATTERY/CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM SWITCHES/HORN/FUEL UNIT / T HERMO-STATIC SWITCH/TEMPERATURE GAUGE/INSTRUMENTS/ LIGHTS 11 12 13 14 15 16 17 18 19 KWANG YANG MOTOR CO., LTD. OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION 1. GENERAL INFORMATION GRAND DINK 125/150 1 1 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ ENGINE SERIAL NUMBER--------------------------------------------- 1-1 SPECIFICATION---------------------------------------------------------- 1-2 SERVICE PRECAUTIONS----------------------------------------------- 1-4 TORQUE VALUES ------------------------------------------------------- 1-8 SPECIAL TOOLS --------------------------------------------------------- 1-9 LUBRICATION POINTS------------------------------------------------1-10 CABLE & HARNESS ROUTING-----------------------------------------1-12 WIRING DIAGRAM-------------------------------------------------------------------1-17 TROUBLESHOOTING --------------------------------------------------1-18 1-0 1. GENERAL INFORMATION SERIAL NUMBER GRAND DINK 125/150 Vehicle Identification Serial Number Location of Frame Serial Number Location of Engine Serial Number 1-1 1. GENERAL INFORMATION SPECIFICATIONS Name & Model No. Motorcycle Name & Type Overall length Overall width Overall height Wheel base Engine type Displacement Fuel Used Front wheel Net weight (kg) Rear wheel Total Front wheel Gross weight(kg) Rear wheel Total Front wheel Tires Rear wheel Ground clearance Perform Braking distance (m) ance Min. turning radius Starting system Type Cylinder arrangement Combustion chamber type Valve arrangement Bore x stroke (mm) Compression ratio Compression pressure (kg/cm_-rpm) Max. output (kw/rpm) Max. torque (N.m/rpm) Intake Open Port (1mm) Close timin Exhaust Open g (1mm) Close Intake Valve clearance (cold) Exhaust Idle speed (rpm) Lubrication type Oil pump type Oil filter type Oil capacity System SH25DA 2060mm 770mm 1360mm 1435mm Water cooled 4-stroke, OHC engine GRAND DINK 125/150 Cooling Type Water cooling 124.6cc 92# nonleaded gasoline 58 82 140 60 95 155 120/70-12 140/70-12 30km/hr7.0m Air cleaner type & No Paper element, wet Fuel capacity 9.0 liters Type VE Piston dia. 22 Venturi dia. 26 equivalent Throttle type Butterfly type Type CDI Ignition timing 10°±1.5°/1000rpm Contact breaker Non-contact point type Carburetor Ignition System Spark plug NGK DPR7EA-9 0.8~0.9mm 12V8AH Dry multi-disc clutch Non-stage transmission Fuel System Electrical Power Drive System Moving Device Spark plug gap Battery Capacity Clutch Type Transmission Gear 2350mm Starting motor & Kick starter Gasoline, 4-stroke Single cylinder Semi-sphere O.H.C. 52.4 x 57.8 10:1 15 8.4/7500 9.8/6000 BTDC 12° ATDC 35° BDDC 28° 0° 0.1mm 0.1mm 1700rpm Forced pressure & Wet sump Inner/outer rotor type Full-flow filtration 1.1 liters Type Operation Type Automatic centrifugal Type Two-stage reduction 2.8~1.0 8.82 Reduction 1st ratio 2nd Front Caster angle Axle Connecting rod Front Tire pressure (kg/cm_) Rear Turning Left angle Right Front Brake system type Rear Front Suspension type Rear Shock absorber Front type Rear Frame type Damping Device Reduction Gear 1.75 2.25 42.5° 42.5° Disk brake Disk brake Telescope Double swing Telescope Double swing Under bone Engine 1-2 1. GENERAL INFORMATION SPECIFICATIONS Name & Model No. Motorcycle Name & Type Overall length Overall width Overall height Wheel base Engine type Displacement Fuel Used Front wheel Net weight (kg) Rear wheel Total Front wheel Gross weight(kg) Rear wheel Total Front wheel Tires Rear wheel Ground clearance Perform Braking distance (m) ance Min. turning radius Starting system Type Cylinder arrangement Combustion chamber type Valve arrangement Bore x stroke (mm) Compression ratio Compression pressure (kg/cm_-rpm) Max. output (kw/rpm) Max. torque (N.m/rpm) Intake Open Port (1mm) Close timin Exhaust Open g (1mm) Close Intake Valve clearance (cold) Exhaust Idle speed (rpm) Lubrication type Oil pump type Oil filter type Oil capacity System SH30DA 2060mm 770mm 1360mm 1435mm Water cooled 4-stroke, OHC engine GRAND DINK 125/150 Cooling Type Water cooling 149.5 92# nonleaded gasoline 58 82 140 60 95 155 120/70-12 140/70-12 30km/hr7.0m 2350mm Starting motor & kick starter Gasoline, 4-stroke Single cylinder Semi-sphere O.H.C. 57.4 x 57.8 10.6:1 15 8.8/7500 11.76/6000 BTDC 12° ATDC 35° BDDC 28° 0° 0.1mm 0.1mm 1700rpm Forced pressure & wet sump Inner/outer rotor type Full-flow filtration 1.1 liters Air cleaner type & No Paper element, wet Fuel capacity 9.0 liters Type VE Piston dia. 22 Venturi dia. 26 equivalent Throttle type Butterfly type Type CDI Ignition timing 10°±1.5°/1000RPM Contact breaker Non-contact point type Carburetor Ignition System Spark plug NGK DP7EA-9 0.8~0.9mm 12V8AH Dry multi-disc clutch Non-stage transmission Reduction 1st ratio 2nd Front Caster angle Axle Connecting rod Front Tire pressure (kg/cm_) Rear Turning Left angle Right Front Brake system type Rear Front Suspension type Rear Shock absorber Front type Rear Frame type Moving Device Damping Device Fuel System Electrical Power Drive System Spark plug gap Battery Capacity Clutch Type Transmission Gear Reduction Gear Type Operation Type Automatic centrifugal Type Two-stage reduction 2.8~1.0 8.82 2.00 2.25 42.5° 42.5° Disk brake Disk brake Telescope Double swing Telescope Double swing Under bone 1-3 Engine 1. GENERAL INFORMATION SERVICE PRECAUTIONS n Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. GRAND DINK 125/150 n Apply or add designated greases and lubricants to the specified lubrication points. n After reassembly, check all parts for proper tightening and operation. n When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally. n When two persons work together, pay attention to the mutual working safety. n Use genuine parts and lubricants. n Disconnect the battery negative (-) terminal before operation. n When using a spanner or other tools, make sure not to damage the motorcycle surface. n When servicing the motorcycle, be sure to use special tools for removal and installation. n After disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly. n After operation, check all connecting points, fasteners, and lines for proper connection and installation. n When connecting the battery, the positive (+) terminal must be connected first. n After connection, apply grease to the battery terminals. n Terminal caps shall be installed securely. 1-4 1. GENERAL INFORMATION n If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. Confirm Capacity GRAND DINK 125/150 n The connector shall be inserted completely. n If the double connector has a lock, lock it at the correct position. n Check if there is any loose wire. n After operation, terminal caps shall be installed securely. n Before connecting a terminal, check for damaged terminal cover or loose negative terminal. n When taking out the connector, the lock on the connector shall be released before operation. n Check the double connector cover for proper coverage and installation. n Hold the connector body when connecting or disconnecting it. n Do not pull the connector wire. n Insert the terminal completely. n Check the terminal cover for proper coverage. n Do not make the terminal cover opening face up. n Check if any connector terminal is bending, protruding or loose. n Secure wire harnesses to the frame with their respective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wire harnesses. 1-5 1. GENERAL INFORMATION n After clamping, check each wire to make sure it is secure. GRAND DINK 125/150 n Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight n Do not squeeze wires against the weld or its clamp. n Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. n After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts. n When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely. n When fixing the wire harnesses, do not make it contact the parts which will generate high heat. No Contact n Do not break the sheath of wire. n If a wire or harness is with a broken sheath, repair by wrapping it with protective tape or replace it. n Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws. n Route wire harnesses passing through the side of bolts and screws. Avoid the projected ends of bolts and screws. n When installing other parts, do not press or squeeze the wires. Do not press or squeeze the wire 1-6 1. GENERAL INFORMATION n After routing, check that the wire harnesses are not twisted or kinked. GRAND DINK 125/150 n Symbols: The following symbols represent the servicing methods and cautions included in this service manual. n Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions. Engine Oil : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) Grease : Apply grease for lubrication. Gear Oil : Transmission Gear Oil (90#) n When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions. Do you understand the instrument Special : Use special tool. : Caution : Warning n Be careful not to drop any parts. n When rust is found on a terminal, remove the rust with sand paper or equivalent before connecting. Remove Rust 1-7 1. GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES Item 5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut Torque (N-m) 4.9 9.8 21.6 34.3 53.9 Item 5mm screw 6mm screw, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut GRAND DINK 125/150 Torque (N-m) 3.9 8.8 11.8 26.5 39.2 Torque specifications listed below are for important fasteners. ENGINE Item Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Exhaust muffler joint lock nut Cylinder head cap nut Valve adjusting lock nut Cam chain tensioner slipper bolt Q`ty Thread dia.(mm) 2 2 1 2 4 2 1 1 1 1 1 2 4 1 1 1 8 8 30 8 8 5 6 12 12 12 14 5 6 10 6 8 Torque (N-m) 21.6 21.6 14.7 8.8 21.6 8.8 8.8 12.7 53.9 53.9 53.9 3.9 11.8 11.8 8.8 13.7 Remarks Double end bolt Double end bolt Apply oil to threads Oil bolt Clutch outer nut Clutch drive plate nut Flywheel nut Oil pump bolt Cylinder head cover bolt Spark plug Cam chain tensioner bolt Water pump impeller FR ...