User manual KYMCO GRAND DINK 150

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 FRAME Item Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upper bolt Rear shock absorber lower bolt Front shock absorber lock bolt Engine hanger bolt Left hand threads Q`ty Thread dia.(mm) 1 1 1 2 2 4 1 10 12 14 10 8 10 12 Torque (N-m) 44.1 58.8 88.2 29.4 29.4 24.5 53.9 Remarks U-nut U-nut U-nut 1-8 1. GENERAL INFORMATION SPECIAL TOOLS Tool Name Valve guide driver Valve guide reamer Valve spring compressor Lock nut wrench, 39mm Bearing driver Bearing remover, 12mm Remover shaft Remover weight Bearing remover, 15mm Bearing driver Clutch spring compressor Ball race remover extension Ball race remover Spring compressor Mechanical seal driver Kick starter spring remover Gear remover Valve adjuster Float level gauge Valve seat cutter 45° Valve seat cutter 32° Valve seat cutter 60° Cutter clip, 5mm Universal holder Bearing driver (32x35mm) Pilot, 12mm Pilot, 15mm Pilot, 17mm Flywheel puller Rear shock absorber compressor Steering head bearing remover Flywheel holder Reamer clip Fuel unit wrench Tool No. Remarks GRAND DINK 125/150 Ref. Page E027 E020 E018 E027 E014 E012 Valve guide removal/installation Valve guide grinding Valve removal Clutch disassembly Bearing removal Bearing removal Bearing removal Bearing removal Bearing removal Bearing removal Clutch disassembly Ball race removal Ball race removal Spring removal Water pump mechanical seal removal/installation Kick starter spring removal Starter gear removal Tapper adjustment Carburetor fuel level check Valve seat refacing Valve seat refacing Valve seat refacing Holding clutch for removal Bearing installation Bearing installation Bearing installation Bearing installation A.C. generator flywheel removal Rear shock absorber disassembly Steering head bearing removal A.C. generator flywheel holding Fuel unit removal E017 E014 E014 E014 E014 E003 F004 F005 E021 1-9 1. GENERAL INFORMATION LUBRICATION POINTS ENGINE Lubrication Points Valve guide/valve stem movable part Camshaft protruding surface Valve rocker arm friction surface Camshaft drive chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod/piston pin hole Connecting rod big end Crankshaft Cranksahft one-way clutch movable part Oil pump drive chain Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O-ring face Oil seal lip Starter idle gear Friction spring movable part/shaft movable part Shaft movable grooved part Starter spindle movable part Starter one-way clutch threads A.C. generator connector Transmission case breather tubee Lubricant GRAND DINK 125/150 ·Genuine KYM CO Engine Oil (SAE15W-40) ·API SE, SJ Egnine Oil High-temperature resistant grease Thread locking agent Adhesive 1-10 1. GENERAL INFORMATION GRAND DINK 125/150 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. Grease Engine Oil Speedometer Cable Throttle Cable Front Brake Lever Pivot Grease Seat Lock Speedometer Gear/ Front Wheel Bearing Grease Rear Wheel Bearing Grease 1-11 1. GENERAL INFORMATION CABLE & HARNESS ROUTING Front Brake GRAND DINK 125/150 Rear Brake Speedometer Cable Pressure Type Radiator Cap Radiator Air Vent Tube Horn Radiator 1-12 1. GENERAL INFORMATION GRAND DINK 125/150 Reserve Tank Cap Ignition Switch Fuel Filler Fuel Tank Breather Tube Fuel Tank Inlet Tube Water Hose Fuel Strainer Thermostatic Switch Front Brake Fluid Tube Water Hoses 1-13 1. GENERAL INFORMATION GRAND DINK 125/150 Front Stop Switch Rear Stop Switch Radiator Air Vent Tube Throttle Cable Fuel Filler Fuel Tank Breather Tube Fuel Tank Inlet Tube Rear Brake Fluid Tube Water Hose Wire Harness Fuel Tank Throttle Cable 1-14 1. GENERAL INFORMATION GRAND DINK 125/150 Fuel Unit Auto Bystarter Wire Fuel Tube Thermostat Ignition Coil Air Cut-off Valve (A.C.V.) Carburetor Starter Motor Starter Relay C.D.I. Regulator/ Rectifier Hazard Control Unit Battery (-) Cable Fuse Box Battery (+) Cable 1-15 1. GENERAL INFORMATION GRAND DINK 125/150 Air Cut-off Valve (A.C.V.) Ignition Coil Throttle Cable Thermostat Auto Bystarter Fuel Tube Vacuum Spark Plug Fuel Pump Vacuum Tube Regulator/ Rectifier Fuel Tube Fuel Pump Vacuum Tube Ignition Coil Fuel Pump Wire Harness Starter Relay Vacuum Fuel Unit Wire 1-16 1. GENERAL INFORMATION WIRING DIAGRAM GRAND DINK 125/150 1-17 1. GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Check if fuel reaches carburetor by loosening drain screw GRAND DINK 125/150 Symptom Probable Cause Fuel reaches carburetor Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Spark jumps Fuel does not reach carburetor ÅEmpty fuel tank ÇClogged carburetor fuel inlet tube, vacuum tube or fuel tube ÉClogged auto fuel valve ÑClogged float oil passage ÖClogged fuel tank cap breather hole ÜClogged fuel strainer áClogged fuel filter àFaulty fuel pump ÅFaulty spark plug ÇFouled spark plug ÉFaulty CDI unit ÑFaulty A.C. generator ÖBroken or shorted ignition coil ÜBroken or shorted exciter coil áFaulty ignition switch ÅStarter motor idles but crankshaft does not rotate ÇValve clearance too small ÉImproper valve and seat contact ÑWorn cylinder and piston rings ÖBlown cylinder head gasket ÜFlaws in cylinder head áSeized valve àImproper valve timing Weak or no spark Test cylinder compression Normal compression Low or no compression Start engine by following normal starting procedure Engine does not fire Engine fires but does not start ÅFaulty auto bystarter ÇAir leaking through intake pipe ÉIncorrect ignition timing ÑIncorrectly adjusted pilot screw Remove spark plug and inspect again Dry spark plug Wet spark plug ÅFlooded carburetor ÇFaulty auto bystarter ÉThrottle valve excessively open 1-18 1. GENERAL INFORMATION ENGINE LACKS POWER Inspection/Adjustment Start engine and accelerate lightly for observation Engine speed increases Check ignition timing (using a timing light) Correct timing Check valve clearance Correct Test cylinder compression Normal compression Check carburetor for clogging Not Clogged Remove spark plug and inspect Plug not fouled or discolored Remove oil dipstick and check oil level and condition Correct and not contaminated Remove cylinder head oil pipe bolt and inspect Valve train lubricated properly Check if engine overheats Engine does not overheats Rapidly accelerate or run at high speed Engine does not knock Engine knocks Engine overheats Valve train not lubricated properly Incorrect or contaminated Plug fouled or discolored Clogged Abnormal compression Incorrect Engine speed does not increase sufficiently GRAND DINK 125/150 Symptom Probable Cause ÅClogged air cleaner ÇRestricted fuel flow ÉClogged fuel line between fuel tank and carburetor ÑClogged exhaust muffler ÖFaulty auto bystarter ÜSplit carburetor vacuum piston diaphragm ÅFaulty CDI unit ÇFaulty A.C. generator ÅImproper valve clearance adjustment ÇWorn valve seat (valve stem too protruding ÅImproper valve and seat contact ÇWorn cylinder and piston rings ÉBlown cylinder head gasket ÑFlaws in cylinder head ÖImproper valve timing ÅClogged carburetor jets Incorrect timing ÅFouled spark plug ÇIncorrect heat range plug ÅOil level too high ÇOil level too low ÉOil not changed ÅClogged oil pipe ÇFaulty oil pump ÅInsufficient coolant ÇFaulty thermostat ÉWorn cylinder and piston rings ÑMixture too lean ÖPoor quality fuel ÜExcessive carbon buildup in combustion chamber áIgnition timing too early àAir in cooling system ÅExcessive carbon build-up in combustion chamber ÇPoor quality fuel ÉClutch slipping ÑMixture too lean Ö Ignition timing too early 1-19 1. GENERAL INFORMATION GRAND DINK 125/150 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Check ignition timing Symptom Probable Cause Correct timing Check carburetor pilot screw adjustment Correctly adjusted Incorrect timing ÅFaulty CDI unit ÇFaulty A.C. generator Incorrectly adjusted ÅMixture too rich (turn screw out) ÇMixture too lean (turn screw in) Check carburetor gasket for air leaks No air leak Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Good spark Check carburetor air cut-off valve Weak or intermittent spark Air leaks ÅDamaged insulator rubber ÇCarburetor not securely tightened ÉFaulty intake manifold gasket ÑDeformed carburetor O-ring ÅFaulty or fouled spark plug ÇFaulty CDI unit ÉFaulty A.C. generator ÑFaulty ignition coil ÖBroken or shorted high tension wire ÜFaulty ignition switch Good Faulty ÅDamaged air cut-off valve diaphragm ÇDamaged air cut-off valve spring 1-20 1. GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) GRAND DINK 125/150 Inspection/Adjustment Check ignition timing Symptom Probable Cause Correct timing Incorrect timing ÅFaulty CDI unit ÇFaulty A.C. generator Check valve clearance ÅImproperly adjusted valve clearance ÇWorn valve seat Correctly adjusted Incorrectly adjusted Check fuel pump for fuel supply ÅEmpty fuel tank ÇClogged fuel tube or filter ÉFaulty fuel pump ÑCracked fuel pump vacuum Fuel flows freely Check carburetor jets for clogging Not clogged Fuel flow restricted tube Clogged ÅClean and unclog Check valve timing Correct Check valve spring tension Not weakened Weak spring ÅFaulty spring Incorrect ÅCam timing gear aligning marks not aligned 1-21 1. GENERAL INFORMATION ENGINE NOISE GRAND DINK 125/150 Symptom Probable Cause Valve noise ÅValve clearance too large ÇWorn camshaft lobe ÅWorn piston rings Piston noise ÇWorn piston pin and connecting rod small end ÉExcessive carbon build-up in combustion chamber Cam chain noise ÅDamaged cam chain tensioner ÇWorn cam gear teeth ÉWorn or damaged cam chain ÑExtended cam chain Crankshaft noise ÅFaulty crankshaft bearing ÇWorn crank pin bearing Gear noise ÅWorn or damaged final reduction gears ÇWorn final reduction gear shaft splines 1-22 1. GENERAL INFORMATION CLUTCH, DRIVE AND DRIVEN PULLEYS GRAND DINK 125/150 Symptom Probable Cause ÅWorn or slipping drive belt ÇBroken ramp plate ÉBroken drive face spring ÑSeparated clutch lining ÖDamaged driven pulley shaft splines ÜDamaged final gear áSeized final gear Engine starts but motor-cycle does not move Motorcycle creeps or engine starts but soon stops or seems to rush out (Rear wheel rotates when engine idles) ÅBroken shoe spring ÇClutch outer and clutch weight stuck ÉSeized pivot Engine lacks power at start of a grade(poor slope performance) ÅWorn or slipping drive belt ÇWorn weight rollers ÉSeized drive pulley bearings ÑWeak driven face spring ÖWorn or seized driven pulley bearings Engine lacks power at high speed ÅWorn or slipping drive belt ÇWorn weight rollers ÉWorn or seized driven pulley bearings There is abnormal noise or smell while running ÅOil or grease fouled drive belt ÇWorn drive belt ÉWeak driven face spring ÑWorn or seized driven pulley bearings 1-23 1. GENERAL INFORMATION STARTER MOTOR 1. Starter motor won`t turn Inspection/Adjustment Check operation of stop switch by applying brake Check battery circuit by operating turn signals Check operation of starter relay by depressing starter button Stoplight comes on Stoplight does not come on Symptom GRAND DINK 125/150 Probable Cause ÅBurned out fuse ÇWeak or dead battery ÉFaulty stop switch ÑLoose or disconnected connectors ÖBroken or shorted ignition switch wire ÅFaulty or weak battery Signals operate properly Signals dim, remain on or don`t operate Relay does not operate Relay operates properly Connect starter motor directly to battery Starter motor turns Starter does not turn ÅPoor starter button connection ÇOpen or shorted starter relay ÉLoose or disconnected connectors ÅWorn brushes ÇOpen or shorted wires or rotor ÉOpen starter motor cable ÑLoose connectors ÅOpen wire harness 2. Starter motor turns slowly or idles Inspection/Adjustment Check battery circuit by operating turn signals Connect starter motor directly to battery Signals operate properly Signals dim, remain on or don`t operate Symptom Probable Cause ÅWeak or dead battery Starter motor turns slowly Rotate crankshaft Turns easily Starter motor turns normally ÅLoose connector or terminal ÇPoor contact in starter relay ÉFaulty starter clutch Hard to turn ÅSeized cylinder ÅBroken or shorted starter motor cable 3. Starter motor does not stop turning Inspection/Adjustment Turn ignition switch OFF Symptom Probable Cause Not stopped Stopped ÅFaulty starter pinion ÅStarter relay shorted or stuck 1-24 1. GENERAL INFORMATION NO SPARK AT SPARK PLUG Inspection/Adjustment Replace with a new spark plug and inspect again Weak or no spark Check spark plug cap and high-tension wire for looseness Not loose Check CDI unit coupler for looseness Good Measure resistance between terminals of CDI unit coupler Good Loose Good spark GRAND DINK 125/150 closed Symptom Probable Cause ÅFaulty spark plug ÅFaulty spark plug ÅPoorly connected coupler Normal Check related parts Abnormal Normal Abnormal ÅFaulty ignition switch ÇFaulty exciter coil ÉFaulty pulser coil ÑFaulty ignition coil ÅBroken wire harness ÇPoorly connected coupler Check CDI unit with a CDI unit tester Normal Check ignition coil with a CDI unit tester Abnormal ÅFaulty ignition coil Abnormal ÅFaulty CDI unit 1-25 1. GENERAL INFORMATION Undercharging Inspection/Adjustment Start engine and test limit voltage of battery terminals Normal voltage Measure resistance between AC generator coil terminals Normal Resistance too low Voltage does not increase GRAND DINK 125/150 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Symptom Probable Cause ÅFaulty AC generator ÇFaulty regulator/rectifier ÉFaulty battery ÅShorted AC generator coil ÇOpen circuit between AC generator 3 yellow wires Test output voltage of regulator/rectifier coupler red wire Normal voltage No voltage ÅFaulty regulator/rectifier ÇFaulty AC generator ÉLoose regulator/rectifier coupler ÑLimit voltage too high Overcharging Inspection/Adjustment Measure battery limit voltage with an electric tester Normal Abnormal ÅFaulty battery ÇFaulty regulator/rectifier ÉBroken or poorly connected regulator/rectifier black wire Symptom Probable Cause Check resistance between regulator/ rectifier terminals Normal Abnormal ÅLimit voltage too high 1-26 1. GENERAL INFORMATION FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Check battery circuit by operating turn signals Remove fuel unit and check operation of pointer by moving float up and down Float up: Full Float down: Empty Check operation of pointer by opening and shorting fuel unit terminal on wire harness side Check connectors for proper connection Good Faulty Signals operate properly Signals dim, remain on or don`t operate GRAND DINK 125/150 Symptom Probable Cause ÅBurned out fuse ÇWeak or dead battery ÉFaulty ignition switch ÑLoose or disconnected connectors ÖBroken wire harness Pointer does not move Pointer moves ÅFaulty float Pointer does not move Pointer moves ÅBroken or shorted fuel unit wire ÅDisconnected connector ÇIncorrectly connected connector ÉBroken or shorted wire in fuel gauge 2. Pointer fluctuates or swings (Ignition switch ON) Inspection/Adjustment Check battery circuit by operating turn signals and horn Remove fuel unit and check operation of pointer by moving float up and down Move float up and down rapidly (1 round /sec.) to check the operation of pointer Signals operate properly Signals dim, remain on or don`t operate Pointer does not move Symptom Probable Cause ÅBurned out fuse ÇWeak or dead battery ÉFaulty ignition switch ÑLoose or disconnected connector ÖBroken wire harness ÅPoor contact in fuel unit Pointer moves Pointer moves in accordance with float Pointer does not move in accordance with float ÅInsufficient damping oil in fuel gauge Check connectors for proper connection. Good Faulty ÅLoose or disconnected connector ÅBroken or shorted wire in fuel gauge 1-27 1. GENERAL INFORMATION STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause GRAND DINK 125/150 (Front and rear tire pressures are normal) Steering is heavy Front or rear wheel is wobbling Steering handlebar pulls to one side ÅSteering stem nut too tight ÇBroken steering steel balls ÅExcessive wheel bearing play ÇBent rim ÉLoose axle nut ÅMisaligned front and rear wheels ÇBent front fork POOR SUSPENSION PERFORMANCE Symptom Probable Cause (Front and rear tire pressures are normal) ÅWeak shock spring ÇExcessive load ÉShock damper oil leaking ÅBent fork tube or shock rod ÅFork tube and slider binding ÇFork spring and slider binding ÉDamaged shock stopper rubber ÑLoose steering stem nut Suspension is too soft Suspension is too hard Suspension is noisy POOR BRAKE PERFORMANCE Symptom Soft brake lever