KYMCO GRAND DINK 125 User Manual

Page 1

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.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

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

A.C. GENERATOR/STARTER CLUTCH

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/ THERMO-STATIC SWITCH/TEMPERATURE GAUGE/INSTRUMENTS/ LIGHTS

The information and contents included in this manual may be different from the motorcycle in case specifications are changed.

CHASSIS

EQUIPMENT

ENGINE

Page 2

1. GENERAL INFORMATION

1-0

GRAND DINK 125/150

__________________________________________________________________________________

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

Page 3

1. GENERAL INFORMATION

1-1

GRAND DINK 125/150

SERIAL NUMBER

Location of Engine Serial Number

Location of Frame Serial Number

Vehicle Identification Serial Number

Page 4

1. GENERAL INFORMATION

1-2

GRAND DINK 125/150

SPECIFICATIONS

Name & Model No.

SH25DA Motorcycle Name & Type Overall length

2060mm Overall width

770mm

Overall height

1360mm Wheel base

1435mm Engine type

Water cooled 4-stroke, OHC engine

Displacement

124.6cc

Fuel Used

92# nonleaded gasoline

Front wheel

Net weight (kg)

Rear wheel

Total

140

Front wheel

Gross weight(kg)

Rear wheel

Total

155

Front wheel

120/70-12

Rear wheel

140/70-12

Ground clearance Perform

Braking distance (m)

30km/hr7.0m

ance

Min. turning radius

2350mm

Starting system

Starting motor &

Kick starter

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

O.H.C.

Bore x stroke (mm)

52.4 x 57.8

Compression ratio

10:1

Compression pressure (kg/cm_-rpm)

Max. output (kw/rpm)

8.4/7500

Max. torque (N.m/rpm)

9.8/6000

Intake

Open

BTDC 12°

Port

(1mm)

ATDC 35°

timin g

Exhaust

Open

BDDC 28°

(1mm)

0°

Valve

Intake

0.1mm

clearance (cold)

Exhaust

0.1mm

Idle speed (rpm)

1700rpm

Lubrication type

Forced pressure &

Wet sump

Oil pump type

Inner/outer rotor

type

Oil filter type

Full-flow filtration

Oil capacity

1.1 liters

Cooling Type

Water cooling

Air cleaner type & No

Paper element, wet

Fuel capacity

9.0 liters

Type

Piston dia.

Venturi dia.

26 equivalent

Throttle type

Butterfly type

Type

CDI

Ignition timing

10°±1.5°/1000rpm

Contact breaker

Non-contact point

type

Spark plug

NGK

DPR7EA-9

Spark plug gap

0.8~0.9mm

Battery

Capacity

12V8AH

Clutch

Type

Dry multi-disc clutch Type

Non-stage transmission

Operation

Automatic centrifugal

Type

Two-stage reduction

Reduction

1st

2.8~1.0

ratio

2nd

8.82

Front

Caster angle

Axle

Connecting rod

Front

1.75

Tire pressure (kg/cm_)

Rear

2.25

Turning

Left

42.5°

angle

Right

42.5°

Front

Disk brake

Brake system type

Rear

Disk brake

Front

Telescope

Suspension type

Rear

Double swing

Shock absorber

Front

Telescope

type

Rear

Double swing

Frame type

Under bone

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Damping

Device

Page 5

1. GENERAL INFORMATION

1-3

GRAND DINK 125/150

SPECIFICATIONS

Name & Model No.

SH30DA Motorcycle Name & Type Overall length

2060mm Overall width

770mm

Overall height

1360mm Wheel base

1435mm Engine type

Water cooled 4-stroke, OHC engine

Displacement

149.5

Fuel Used

92# nonleaded gasoline

Front wheel

Net weight (kg)

Rear wheel

Total

140

Front wheel

Gross weight(kg)

Rear wheel

Total

155

Front wheel

120/70-12

Rear wheel

140/70-12

Ground clearance Perform

Braking distance (m)

30km/hr7.0m

ance

Min. turning radius

2350mm

Starting system

Starting motor &

kick starter

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

O.H.C.

Bore x stroke (mm)

57.4 x 57.8

Compression ratio

10.6:1

Compression pressure (kg/cm_-rpm)

Max. output (kw/rpm)

8.8/7500

Max. torque (N.m/rpm)

11.76/6000

Intake

Open

BTDC 12°

Port

(1mm)

ATDC 35°

timin g

Exhaust

Open

BDDC 28°

(1mm)

0°

Valve

Intake

0.1mm

clearance (cold)

Exhaust

0.1mm

Idle speed (rpm)

1700rpm

Lubrication type

Forced pressure &

wet sump

Oil pump type

Inner/outer rotor

type

Oil filter type

Full-flow filtration

Oil capacity

1.1 liters

Cooling Type

Water cooling

Air cleaner type & No

Paper element, wet

Fuel capacity

9.0 liters

Type

Piston dia.

Venturi dia.

26 equivalent

Throttle type

Butterfly type

Type

CDI

Ignition timing

10°±1.5°/1000RPM

Contact breaker

Non-contact point

type

Spark plug

NGK

DP7EA-9

Spark plug gap

0.8~0.9mm

Battery

Capacity

12V8AH

Clutch

Type

Dry multi-disc clutch Type

Non-stage transmission

Operation

Automatic centrifugal

Type

Two-stage reduction

Reduction

1st

2.8~1.0

ratio

2nd

8.82

Front

Caster angle

Axle

Connecting rod

Front

2.00

Tire pressure (kg/cm_)

Rear

2.25

Turning

Left

42.5°

angle

Right

42.5°

Front

Disk brake

Brake system type

Rear

Disk brake

Front

Telescope

Suspension type

Rear

Double swing

Shock absorber

Front

Telescope

type

Rear

Double swing

Frame type

Under bone

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Damping

Device

Page 6

1. GENERAL INFORMATION

1-4

GRAND DINK 125/150

SERVICE PRECAUTIONS

n Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when reassembling.

n When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.

n Use genuine parts and lubricants.

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 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 two persons work together, pay

attention to the mutual working safety.

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 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.

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1. GENERAL INFORMATION

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GRAND DINK 125/150

n If the fuse is burned out, find the cause and

repair it. Replace it with a new one according to the specified capacity.

n After operation, terminal caps shall be

installed securely.

n When taking out the connector, the lock on

the connector shall be released before operation.

n Hold the connector body when connecting

or disconnecting it.

n Do not pull the connector wire.

n Check if any connector terminal is bending,

protruding or loose.

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 Before connecting a terminal, check for

damaged terminal cover or loose negative terminal.

n Check the double connector cover for

proper coverage and installation.

n Insert the terminal completely. n Check the terminal cover for proper

coverage.

n Do not make the terminal cover opening

face up.

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.

Confirm Capacity

Page 8

1. GENERAL INFORMATION

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GRAND DINK 125/150

n After clamping, check each wire to make

sure it is secure.

n Do not squeeze wires against the weld or

its clamp.

n After clamping, check each harness to make

sure that it is not interfering with any moving or sliding parts.

n When fixing the wire harnesses, do not

make it contact the parts which will generate high heat.

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 Route harnesses so they are neither

pulled tight nor have excessive slack.

n Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or corner.

n When rubber protecting cover is used to

protect the wire harnesses, it shall be installed securely.

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 When installing other parts, do not press or

squeeze the wires.

Do not pull too tightð

No Contact

Do not press or squeeze the wire

Page 9

1. GENERAL INFORMATION

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GRAND DINK 125/150

n After routing, check that the wire harnesses

are not twisted or kinked.

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.

n When a testing device is used, make sure to

understand the operating methods thoroughly and operate according to the operating instructions.

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.

n Symbols:

The following symbols represent the servicing methods and cautions included in this service manual.

:Apply engine oil to the

specified points. (Use designated engine oil for lubrication.)

:Apply grease for lubrication.

:Transmission Gear Oil (90#)

:Use special tool.

:Caution

:Warning

Special

Engine Oil

Grease

Gear Oil

＊

Do you understand the instrument？

Remove Rustð

Page 10

1. GENERAL INFORMATION

1-8

GRAND DINK 125/150

TORQUE VALUES

STANDARD TORQUE VALUES

Item

Torque (N-m)

Item

Torque (N-m)

5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut

4.9

9.8

21.6

34.3

53.9

5mm screw 6mm screw, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut

3.9

8.8

11.8

26.5

39.2 Torque specifications listed below are for important fasteners.

ENGINE

Item

Q‘ty

Thread dia.(mm)

Torque (N-m)

Remarks

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

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

2 2 1 2 4 2 1 1 1 1 1 2 4 1 1 1

8 8

8 8 5

6 12 12 12 14

6 10

21.6

14.7

8.8

21.6

8.8

12.7

53.9

3.9

11.8

8.8

13.7

Double end bolt Double end bolt Apply oil to

threads

Left hand threads

FRAME

Item

Q‘ty

Thread dia.(mm)

Torque (N-m)

Remarks

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

1 1 1 2 2 4 1

10 12 14 10

8 10 12

44.1

58.8

88.2

29.4

24.5

53.9

U-nut U-nut U-nut

Page 11

1. GENERAL INFORMATION

1-9

GRAND DINK 125/150

SPECIAL TOOLS

Tool Name

Tool No.

Remarks

Ref. Page

Valve guide driver

Valve guide removal/installation

Valve guide reamer

Valve guide grinding

Valve spring compressor

Valve removal

Lock nut wrench, 39mm

E027

Clutch disassembly

Bearing driver

Bearing removal

Bearing remover, 12mm

E020

Bearing removal

Remover shaft

Bearing removal

Remover weight

Bearing removal

Bearing remover, 15mm

E018

Bearing removal

Bearing driver

Bearing removal

Clutch spring compressor

E027

Clutch disassembly

Ball race remover extension

Ball race removal

Ball race remover

Ball race removal

Spring compressor

Spring removal

Mechanical seal driver

E014

Water pump mechanical seal removal/installation

Kick starter spring remover

Kick starter spring removal

Gear remover

Starter gear removal

Valve adjuster

E012

Tapper adjustment

Float level gauge

Carburetor fuel level check

Valve seat cutter 45°

Valve seat refacing

Valve seat cutter 32°

Valve seat refacing

Valve seat cutter 60°

Valve seat refacing Cutter clip, 5mm Universal holder

E017

Holding clutch for removal Bearing driver (32x35mm)

E014

Bearing installation Pilot, 12mm

E014

Bearing installation Pilot, 15mm

E014

Bearing installation Pilot, 17mm

E014

Bearing installation Flywheel puller

E003

A.C. generator flywheel removal Rear shock absorber compressor

F004

Rear shock absorber disassembly Steering head bearing remover

F005

Steering head bearing removal Flywheel holder

E021

A.C. generator flywheel holding Reamer clip Fuel unit wrench

Fuel unit removal

Page 12

1. GENERAL INFORMATION

1-10

GRAND DINK 125/150

LUBRICATION POINTS

ENGINE

Lubrication Points

Lubricant

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

•Genuine KYMCO Engine Oil (SAE15W-40)

•API SE, SJ Egnine Oil

Starter idle gear Friction spring movable part/shaft movable part Shaft movable grooved part Starter spindle movable part

High-temperature resistant grease

Starter one-way clutch threads

Thread locking agent

A.C. generator connector Transmission case breather tubee

Adhesive

Page 13

1. GENERAL INFORMATION

1-11

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.

Seat Lock

Rear Wheel Bearing

Grease

Speedometer Cable Throttle Cable

Speedometer Gear/ Front Wheel Bearing

Engine Oil

Grease

Front Brake Lever Pivot

Page 14

1. GENERAL INFORMATION

1-12

GRAND DINK 125/150

CABLE & HARNESS ROUTING

Radiator

Front Brake

Rear Brake

Speedometer Cable

Horn

Pressure Type Radiator Cap

Radiator Air Vent Tube

Page 15

1. GENERAL INFORMATION

1-13

GRAND DINK 125/150

Front Brake Fluid Tube

Fuel Strainer

Fuel Tank Inlet Tube

Water Hose

Ignition Switch

Fuel Filler

Water Hoses

Thermostatic Switch

Fuel Tank Breather Tube

Reserve Tank Cap

Page 16

1. GENERAL INFORMATION

1-14

GRAND DINK 125/150

Throttle Cable

Radiator Air Vent Tube

Rear Brake Fluid Tube

Fuel Tank Inlet Tube

Water Hose

Fuel Filler

Fuel Tank Breather Tube

Throttle Cable

Front Stop Switch

Wire Harness

Fuel Tank

Rear Stop Switch

Page 17

1. GENERAL INFORMATION

1-15

GRAND DINK 125/150

Starter Relay

Fuel Tube

Battery (+) Cable

Battery (-) Cable

Ignition Coil

Auto Bystarter Wire

Thermostat

Carburetor

Air Cut-off Valve (A.C.V.)

Regulator/ Rectifier

C.D.I.

Fuse Box

Starter Motor

Fuel Unit

Hazard Control Unit

Page 18

1. GENERAL INFORMATION

1-16

GRAND DINK 125/150

Fuel Tube

Ignition Coil

Thermostat

Air Cut-off Valve (A.C.V.)

Fuel Tube

Auto Bystarter

Spark Plug

Fuel Pump

Fuel Unit Wire

Wire Harness

Throttle Cable

Vacuum

Fuel Pump Vacuum Tube

Ignition Coil

Starter Relay

Regulator/ Rectifier

Page 19

1. GENERAL INFORMATION

1-17

GRAND DINK 125/150

WIRING DIAGRAM

Page 20

1. GENERAL INFORMATION

1-18

GRAND DINK 125/150

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

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

ÅFaulty auto bystarter ÇAir leaking through intake

pipe

ÉIncorrect ignition timing ÑIncorrectly adjusted pilot

screw

ÅFlooded carburetor ÇFaulty auto bystarter ÉThrottle valve excessively

open

Check if fuel reaches carburetor by loosening drain screw

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground

Inspection/Adjustment

Probable Cause

Spark jumps

Normal compression

Engine does not fire

Weak or no spark

Low or no compression

Engine fires but does not start

Test cylinder compression

Start engine by following normal starting procedure

Remove spark plug and inspect again

Symptom

Fuel reaches carburetor

Fuel does not reach carburetor

Wet spark plug

Dry spark plug

Page 21

1. GENERAL INFORMATION

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GRAND DINK 125/150

ENGINE LACKS POWER

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

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

Start engine and accelerate lightly for observation

Inspection/Adjustment

Symptom

Probable Cause

Engine speed increases

Correct timing

Engine speed does not increase sufficiently

Incorrect timing

Check ignition timing (using a timing light)

Test cylinder compression

Check carburetor for clogging

Rapidly accelerate or run at high speed

Remove spark plug and inspect

Check if engine overheats

Check valve clearance

Correct

Incorrect

Normal

compression

Abnormal compression

Not Clogged

Clogged

Remove oil dipstick and check oil level and condition

Remove cylinder head oil pipe bolt and inspect

Engine overheats

Engine does not overheats

Plug not fouled or discolored

Plug fouled or discolored

Correct and not contaminated

Incorrect or contaminated

Valve train lubricated properly

Valve train not lubricated properly

Engine does not knock

Engine knocks

Page 22

1. GENERAL INFORMATION

1-20

GRAND DINK 125/150

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

ÅFaulty CDI unit ÇFaulty A.C. generator

ÅMixture too rich (turn screw

out)

ÇMixture too lean (turn screw

in)

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

ÅDamaged air cut-off valve

diaphragm

ÇDamaged air cut-off valve

spring

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing

Check carburetor air cut-off valve

Check carburetor gasket for air leaks

Check carburetor pilot screw adjustment

Correct timing

Incorrect timing

Correctly adjusted

No air leak

Air leaks

Good spark

Weak or inter mittent spark

Good

Faulty

Incorrectly adjusted

Page 23

1. GENERAL INFORMATION

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GRAND DINK 125/150

POOR PERFORMANCE (AT HIGH SPEED)

ÅFaulty CDI unit ÇFaulty A.C. generator

ÅImproperly adjusted valve

clearance

ÇWorn valve seat

ÅEmpty fuel tank ÇClogged fuel tube or filter ÉFaulty fuel pump ÑCracked fuel pump vacuum

tube

ÅClean and unclog

ÅCam timing gear aligning

marks not aligned

ÅFaulty spring

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing

Check carburetor jets for clogging

Check fuel pump for fuel supply

Correct timing

Incorrect timing

Check valve spring tension

Check valve clearance

Fuel flows freely

Fuel flow restricted

Correct

Incorrect

Not clogged

Clogged

Correctly adjusted

Incorrectly adjusted

Not weakened

Weak spring

Check valve timing

Page 24

1. GENERAL INFORMATION

1-22

GRAND DINK 125/150

ENGINE NOISE

ÅValve clearance too large ÇWorn camshaft lobe

ÅWorn piston rings ÇWorn piston pin and connecting rod

small end

ÉExcessive carbon build-up in combustion

chamber

ÅDamaged cam chain tensioner ÇWorn cam gear teeth ÉWorn or damaged cam chain ÑExtended cam chain

ÅFaulty crankshaft bearing ÇWorn crank pin bearing

ÅWorn or damaged final reduction gears ÇWorn final reduction gear shaft splines

Valve noise

Symptom

Probable Cause

Crankshaft noise

Gear noise

Piston noise

Cam chain noise

Page 25

1. GENERAL INFORMATION

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GRAND DINK 125/150

CLUTCH, DRIVE AND DRIVEN PULLEYS

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

ÅBroken shoe spring ÇClutch outer and clutch weight stuck ÉSeized pivot

ÅWorn or slipping drive belt ÇWorn weight rollers ÉSeized drive pulley bearings ÑWeak driven face spring ÖWorn or seized driven pulley bearings

ÅWorn or slipping drive belt ÇWorn weight rollers ÉWorn or seized driven pulley bearings

ÅOil or grease fouled drive belt ÇWorn drive belt ÉWeak driven face spring ÑWorn or seized driven pulley bearings

Engine starts but motor-cycle does not move

Engine lacks power at start of a grade(poor slope performance)

Symptom

Probable Cause

Engine lacks power at high speed

There is abnormal noise or smell while running

Motorcycle creeps or engine starts but soon stops or seems to rush out (Rear wheel rotates when engine idles)

Page 26

1. GENERAL INFORMATION

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GRAND DINK 125/150

STARTER MOTOR

1. Starter motor won‘t turn

ÅBurned out fuse ÇWeak or dead battery ÉFaulty stop switch ÑLoose or disconnected

connectors

ÖBroken or shorted ignition

switch wire

ÅFaulty or weak battery

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

ÅWeak or dead battery

ÅLoose connector or terminal ÇPoor contact in starter relay ÉFaulty starter clutch

ÅSeized cylinder

ÅBroken or shorted starter

motor cable

3. Starter motor does not stop turning

ÅFaulty starter pinion ÅStarter relay shorted or stuck

Inspection/Adjustment

Symptom

Check operation of stop switch by applying brake

Stoplight does not come on

Stoplight comes

Check battery circuit by operating turn signals

Turn ignition switch

OFF

Probable Cause

Signals operate properly

Signals dim, remain on or don‘t operate

Check operation of starter relay by depressing starter button

Connect starter motor directly to battery

Starter motor turns slowly

Starter motor turns normally

Signals operate properly

Signals dim, remain on or don‘t operate

Not stopped

Stopped

Rotate crankshaft

Starter motor

Starter does not

turn

Relay operates properly

Relay does not operate

Turns easily

Hard to turn

Page 27

1. GENERAL INFORMATION

1-25

GRAND DINK 125/150

closed

NO SPARK AT SPARK PLUG

ÅFaulty spark plug

ÅPoorly connected coupler

ÅFaulty ignition switch ÇFaulty exciter coil ÉFaulty pulser coil ÑFaulty ignition coil

ÅBroken wire harness ÇPoorly connected coupler

ÅFaulty CDI unit

ÅFaulty ignition coil

Replace with a new spark plug and inspect again

Check CDI unit coupler for looseness

Inspection/Adjustment

Symptom

Probable Cause

Normal

Abnormal

Normal

Abnormal

Normal

Abnormal

Measure resistance between terminals of CDI unit coupler

Check related parts

Check ignition coil with a CDI unit tester

Weak or no spark

Not loose

Good spark

Loose

Good

Check spark plug cap and high-tension wire for looseness

Check CDI unit with a CDI unit tester

Page 28

1. GENERAL INFORMATION

1-26

GRAND DINK 125/150

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging

ÅFaulty AC generator ÇFaulty regulator/rectifier ÉFaulty battery

ÅShorted AC generator coil ÇOpen circuit between AC

generator 3 yellow wires

ÅFaulty regulator/rectifier ÇFaulty AC generator ÉLoose regulator/rectifier

coupler

ÑLimit voltage too high

Overcharging

ÅFaulty battery ÇFaulty regulator/rectifier ÉBroken or poorly

connected

regulator/rectifier black wire

ÅLimit voltage too high

Start engine and test limit voltage of battery terminals

Measure battery limit voltage with an electric tester

Test output voltage of regulator/rectifier coupler red wire

Inspection/Adjustment

Symptom

Probable Cause

Normal voltage

Normal

Voltage does not

increase

Abnormal

Resistance too

Normal voltage

No voltage

Measure resistance between AC generator coil terminals

Check resistance between regulator/ rectifier terminals

Normal

Abnormal

Page 29

1. GENERAL INFORMATION

1-27

GRAND DINK 125/150

FUEL GAUGE

1. Pointer does not register correctly (Ignition switch ON)

ÅBurned out fuse ÇWeak or dead battery ÉFaulty ignition switch ÑLoose or disconnected

connectors

ÖBroken wire harness

ÅFaulty float

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)

ÅBurned out fuse ÇWeak or dead battery ÉFaulty ignition switch ÑLoose or disconnected

connector

ÖBroken wire harness

ÅPoor contact in fuel unit

ÅInsufficient damping oil in

fuel gauge

ÅLoose or disconnected

connector

ÅBroken or shorted wire in

fuel gauge

Inspection/Adjustment

Symptom

Remove fuel unit and check operation of pointer by moving float up and down

Signals operate properly

Signals dim, remain on or don‘t operate

Signals operate properly

Signals dim, remain on or don‘t operate

Check battery circuit by operating turn signals

Check battery circuit by operating turn signals and horn

Probable Cause

Pointer does not move

Pointer moves

Pointer does not move

Check operation of pointer by opening and shorting fuel unit terminal on wire harness side

Move float up and down rapidly (1 round /sec.) to check the operation of pointer

Pointer does not move

Pointer moves

Pointer does not move in accordance with float

Pointer moves in accordance with float

Good

Faulty

Check connectors for proper connection

Check connectors for proper connection.

Good

Faulty

Float up: Full Float down: Empty

Page 30

1. GENERAL INFORMATION

1-28

GRAND DINK 125/150

STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

(Front and rear tire pressures are normal)

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

(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

POOR BRAKE PERFORMANCE

ÅWorn brake linings ÇForeign matter on brake linings ÉRough brake drum contacting area

ÅWorn brake linings ÇWorn brake cam contacting area on

ÅWorn brake linings ÇForeign matter on brake linings

ÅSluggish or elongated brake cables ÇBrake shoes improperly contact ÉWater and mud in brake system ÑOil or grease on brake linings

Steering is heavy

Suspension is too soft

Soft brake lever

Hard brake lever

Poor brake performance

Front or rear wheel is wobbling

Symptom

Probable Cause

Steering handlebar pulls to one side

Suspension is too hard

Suspension is noisy

Brake squeaks

Hard to brake

Page 31

2. EXHAUST MUFFLER/FRAME COVERS

2-0

GRAND DINK 125/150

__________________________________________________________________________________

EXHAUST MUFFLER/FRAME COVERS

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 2-1 SERVICE INFORMATION -------------------------------------------- 2-2 TROUBLESHOOTING ------------------------------------------------- 2-2 FRAME COVERS REMOVAL----------------------------------------- 2-3 EXHAUST MUFFLER REMOVAL----------------------------------- 2-6

Page 32

2. EXHAUST MUFFLER/FRAME COVERS

2-1

GRAND DINK 125/150

SCHEMATIC DRAWING

Page 33

2. EXHAUST MUFFLER/FRAME COVERS

2-2

GRAND DINK 125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged.

• Make sure to route cables and harnesses according to the Cable & Harness Routing.

TORQUE VALUES

Exhaust muffler lock bolt 34.3N-m Exhaust muffler joint lock nut 11.8N-m

TROUBLESHOOTING

Noisy exhaust muffler

• Damaged exhaust muffler

• Exhaust muffler joint air leaks

Lack of power

• Caved exhaust muffler

• Clogged exhaust muffler

• Exhaust muffler air leaks

Page 34

2. EXHAUST MUFFLER/FRAME COVERS

2-3

GRAND DINK 125/150

FRAME COVERS REMOVAL

REAR CARRIER & HAND RAIL REMOVAL

Remove the met-in box: First remove the three bolts and two nuts attaching the met-in box. Remove the met-in box.

Remove the hand rail right and left lock hex bolts. Remove the two hex bolts Remove the rear carrier and hand rail.

FRAME BODY COVER REMOVAL

Remove the two screws on the center cover. Remove the center cover.

Remove the three bolts on the back fender. Remove the back fender.

Nuts

Bolts

Bolt

Bolts

Center Cover

Screws

Bolts

Page 35

2. EXHAUST MUFFLER/FRAME COVERS

2-4

GRAND DINK 125/150

Remove the two screws on the molding covers. Remove the molding covers.

Remove the two nuts and one bolt on the back taillight.

Remove the left and right sides screws on the frame body cover. Remove the frame body cover.

FLOOR BOARD REMOVAL

Remove the blot on the front right and left side covers.

Screws

Molding Cover

Nuts

Screws

Bolt

Side Cover

Blot

Page 36

2. EXHAUST MUFFLER/FRAME COVERS

2-5

GRAND DINK 125/150

Remove the left and right side screws on the side cover. Remove the side cover.

Remove the four bolts on the floor board. Remove the floor board.

FRONT UPPER COVER REMOVAL

Remove the two screws on the front upper cover. Remove the front upper cover.

Remove the four bolts on the front windshield. Remove the front windshield.

Bolts

Screws

Bolts

Bolt

Page 37

2. EXHAUST MUFFLER/FRAME COVERS

2-6

GRAND DINK 125/150

FRONT COVER REMOVAL

First remove the front upper cover. Remove the two bolts attaching the front cover.

Remove the six screws on the back of the front cover.

Disconnect the right/left turn signal light wire connectors.

Remove the front cover The installation sequence is the reverse of

removal.

Remove the six screws on the front lower cover. Remove the front lower cover.

BACK COVER REMOVAL

Remove the front cover. Remove the key moldings. Remove the fuel cap moldings. Remove the back cover bolt. Remove the back cover.

Bolts

Key Moldings

Screws

Fuel Cap Moldings

Screws

Bolts

Page 38

2. EXHAUST MUFFLER/FRAME COVERS

2-7

GRAND DINK 125/150

Remove the three screws attaching fuel tank inlet tube join. Remove the back cover.

BOTTOM COVER REMOVAL

Remove the side stand. Remove the four bolts attaching the bottom cover. Remove the bottom cover.

FRONT FENDER REMOVAL

Remove the two bolts attaching the fender. Remove the front fender cover. The installation sequence is the reverse of removal.

EXHAUST MUFFLER REMOVAL

Remove the two exhaust muffler joint lock nuts. Remove the three exhaust muffler lock bolts to remove the exhaust muffler. Remove the exhaust muffler joint packing collar. The installation sequence is the reverse of removal.

Torque:

Exhaust muffler joint lock nut:11.8N-m Exhaust muffler lock bolt: 34.3N-m

Screws

Fuel Tank Inlet Tube

Bolts

Bottom Cover

Side Stand

Bolts

Lock Bolts

Page 39

2. EXHAUST MUFFLER/FRAME COVERS

2-8

GRAND DINK 125/150

HANDLEBAR COVER REMOVAL

First remove the three screws attaching the handlebar under cover. Remove the handlebar under cover.

Remove the screw from the handlebar upper cover.

Remove the screw from the bottom of handlebar upper cover. Remove the handlebar upper cover.

Screws

Screw

Page 40

3. INSPECTION/ADJUSTMENT

3-0

GRAND DINK 125/150

__________________________________________________________________________________

INSPECTION/ADJUSTMENT

__________________________________________________________________________________

SERVICE INFORMATION -------------------------------------------- 3- 1 MAINTENANCE SCHEDULE ---------------------------------------- 3- 2 FUEL LINE/FUEL FILTER ------------------------------------------- 3- 3 THROTTLE OPERATION--------------------------------------------- 3- 3 ENGINE OIL ------------------------------------------------------------ 3- 4 AIR CLEANER---------------------------------------------------------- 3- 5 SPARK PLUG ----------------------------------------------------------- 3- 5 VALVE CLEARANCE ------------------------------------------------- 3- 6 CARBURETOR IDLE SPEED----------------------------------------- 3- 6 IGNITION TIMING----------------------------------------------------- 3- 7 CYLINDER COMPRESSION------------------------------------------ 3- 7 FINAL REDUCTION GEAR OIL ------------------------------------- 3- 8 DRIVE BELT------------------------------------------------------------ 3- 8 HEADLIGHT AIM------------------------------------------------------ 3- 9 CLUTCH SHOE WEAR ------------------------------------------------ 3- 9 COOLING SYSTEM---------------------------------------------------- 3- 9 BRAKE SYSTEM ------------------------------------------------------- 3-10 NUTS/BOLTS/FASTENERS------------------------------------------- 3-11 WHEELS/TIRES -------------------------------------------------------- 3-11 STEERING HANDLEBAR--------------------------------------------- 3-11 SUSPENSION ----------------------------------------------------------- 3-11

Page 41

3. INSPECTION/ADJUSTMENT

3-1

GRAND DINK 125/150

SERVICE INFORMATION

GENERAL

ð WARNING

•Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people.

•Gasoline is extremely flammable and is explosive under some conditions. The working area must be well-ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area.

SPECIFICATIONS

ENGINE Throttle grip free play : 2_ 6mm Spark plug : NGK: DPR7EA9 Spark plug gap : 0.9mm Valve clearance : IN: 0.1mm EX: 0.1mm

Idle speed : 1700rpm

Engine oil capacity: Cylinder compression : 15±2kg/cm_ At disassembly : 1.1 liter Ignition timing : BTDC 10°±3°/1500rpm At change : 0.9 liter Coolant capacity : 1400±20cc Gear oil capacity : R adiator capacity : 1000±20cc At disassembly : 0.20 liter Reserve tank capacity : 400±20cc At change : 0.18 liter

CHASSIS Front/rear brake free play: 20_ 30mm

TIRE

1 Rider

2 Riders

Front

1.75kg/cm_

1.75kg/cm_ Rear

2.00kg/cm_

2.25kg/cm_

TIRE SPECIFICATION: Front : 120/70-12 56J Rear : 140/70-12 59J

TORQUE VALUES

Front axle nut : 14.8_ 68.6N-m Rear axle nut : 107.8_ 127.4N-m

Page 42

3. INSPECTION/ADJUSTMENT

3-2

GRAND DINK 125/150

MAINTENANCE SCHEDULE

Perform the periodic maintenance at each scheduled maintenance period. I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary. A: Adjust C: Clean R: Replace T : Tighten

Regular Service Mileage (km)

Frequency

Item

comes first

1000

2000

4000

6000

8000

10000

Engine oil

New

motorcycle

300km

RRRRR

Engine oil filter screen

Replace at every 6000 km(R)

Fuel filter screen

Gear oil

Note 3

New

motorcycle

300km

Valve clearance

AAA

Carburetor

Air Cleaner

Note 2,3

IRR

Spark plug

Clean at every 3000km and replace if necessary

Brake system

IIIII

Drive belt

Suspension

Nut, bolt, fastener

I TireII Steering head bearing

III

Brake fluid

Perform pre-ride inspection daily

Radiator coolant

Replace every year or at every 10000km (R)

Radiator core

Radiator cap

I Brake leverII Brake shoe wear

I Shock absorber

• In the interest of safety, we recommend these items be serviced only by an authorized KYMCO motorcycle dealer.

Note: 1. For higher odometer readings, repeat at the frequency interval established here.

2. Service more frequently when riding in dusty or rainy areas.

3. Service more frequently when riding in rain or at full throttle.

Whichever

Page 43

3. INSPECTION/ADJUSTMENT

3-3

GRAND DINK 125/150

FUEL LINE/FUEL FILTER

Remove the center cover. Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. Check for dirty or clogged fuel filter and replace with a new one if it is clogged.

THROTTLE OPERATION

Check the throttle grip for smooth movement. Measure the throttle grip free play.

Free Play: 2_ 6mm

Major adjustment of the throttle grip free play is made with the adjusting nut at the carburetor side. Adjust by loosening the lock nut and turning the adjusting nut.

Minor adjustment is made with the adjusting nut at the throttle grip side. Slide the rubber cover out and adjust by loosening the lock nut and turning the adjusting nut.

Lock Nut

Adjusting Nut

Fuel Filter

• Do not smoke or allow flames or sparks in your working area.

＊

Fuel Line

Lock Nut

Adjusting Nut

Page 44

3. INSPECTION/ADJUSTMENT

3-4

GRAND DINK 125/150

ENGINE OIL

OIL LEVEL INSPECTION

Stop the engine and support the motorcycle upright on level ground. Wait for 2_ 3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when making this check.

OIL CHANGE

Remove the oil drain bolt to drain the engine oil. Install the aluminum washer and tighten the oil drain bolt. Torque: 14.7N-m

Pour the recommended oil through the oil filler hole.

Oil Capacity:

At disassembly: 1.1 liter At change: 0.9 liter

Recommended Oil:

SAE: 15W40# API: SJ Start the engine and check for oil leaks.

Stop the engine and recheck the oil level.

OIL FILTER SCREEN INSPECTION

Drain the engine oil. Remove the oil filter screen cap. Clean the oil filter screen. Install the oil filter screen, and filter screen cap. Fill the engine with recommended engine oil.

• Drain the oil while the engine is warm.

＊

• Replace the aluminum washer with a new one if it is deformed or damaged.

＊

Oil Dipstick

Oil Filter Screen Cap

Oil Filter Screen

Oil Filter Screen Cap

Page 45

3. INSPECTION/ADJUSTMENT

3-5

GRAND DINK 125/150

AIR CLEANER

Remove the seven air cleaner case cover screws and the cover.

Remove the air cleaner element. Check the element and replace it if it is excessively dirty or damaged.

CHANGE INTERVAL

More frequent replacement is required when riding in unusually dusty or rainy areas.

SPARK PLUG

Remove the frame center cover. Remove the spark plug cap and spark plug. Check the spark plug for wear and fouling deposits. Clean any fouling deposits with a spark plug cleaner or a wire brush.

Specified Spark Plug: NGK: DP7EA9 Measure the spark plug gap.

Spark Plug Gap: 0.9mm

Torque: 7.8_ 9.8N-m

｝

Gap Wear Fouling Deposits

Spark Plug

Cracks Damage

• The air cleaner element has a

viscous type paper element. Do not clean it with compressed air.

• Be sure to install the air cleaner

element and cover securely.

＊

• When installing, first screw in the spark plug by hand and then tighten it with a spark plug wrench.

＊

Screws

Air Cleaner Case Cover

Air Cleaner Element

Deformation

0.9mm

Page 46

3. INSPECTION/ADJUSTMENT

3-6

GRAND DINK 125/150

VALVE CLEARANCE

Remove the cylinder head cover.

Turn the A.C. generator flywheel to the top dead center (TDC) on the compression stroke so that the “T” mark on the flywheel aligns with the index mark on the left crankcase cover.

Inspect and adjust valve clearance. Valve Clearance: IN: 0.1mm

EX: 0.1mm

Loosen the lock nut and adjust by turning the adjusting nut

Valve Wrench

CARBURETOR IDLE SPEED

Lift up the seat and remove the inspection cover. Warm up the engine before this operation. Start the engine and connect a tachometer. Turn the throttle stop screw to obtain the specified idle speed. Idle Speed: 1700rpm When the engine misses or run erratic, adjust the pilot screw.

Throttle Stop Screw

Pilot Screw

Feeler Gauge

• Inspect and adjust valve clearance while the engine is cold (below 35℃ ).

＊

• Check the valve clearance again after the lock nut is tightened.

＊

• The engine must be warm for accurate idle speed inspection and adjustment.

＊

Cylinder Head Cover

Bolts

“T” Mark

Top Dead Center

Valve Wrench

Special

Page 47

3. INSPECTION/ADJUSTMENT

3-7

GRAND DINK 125/150

IGNITION TIMING

Remove the timing hole cap.

Check the ignition timing with a timing light. When the engine is running at the specified idle speed, the ignition timing is correct if the “F” mark on the flywheel aligns with the index mark on the crankcase cover. Also use a timing light to check the advance. Raise the engine speed to 4,000rpm. The index mark should be between the advance marks.

CYLINDER COMPRESSION

Warm up the engine before compression test. Remove the center cover and spark plug cap. Remove the spark plug . Insert a compression gauge. Open the throttle valve fully and push the starter button to test the compression.

Compression: 15±2kg/cm_ If the compression is low, check for the

following:

_Leaky valves _Valve clearance to small _Leaking cylinder head gasket _Worn pistons _Worn piston/cylinder

If the compression is high, it indicates that carbon deposits have accumulated on the combustion chamber and the piston head.

Compression Gauge

Timing Light

• The CDI unit is not adjustable.

• If the ignition timing is incorrect, check

the ignition system,

＊

Timing Hole Cap

“F” Mark

Page 48

3. INSPECTION/ADJUSTMENT

3-8

GRAND DINK 125/150

FINAL REDUCTION GEAR OIL

Stop the engine and remove the oil check bolt. The oil level shall be at the oil check bolt hole. If the oil level is low, add the recommended oil SAE90# to the proper level.

Install the oil check bolt.

OIL CHANGE

Remove the oil check bolt. Remove the oil drain bolt and drain the oil thoroughly. Install the oil drain bolt. Torque: 9.8N-m

Fill the final reduction with the recommended oil SAE90#.

Gear Oil Capacity: At disassembly : 200cc At change : 180cc Reinstall the oil check bolt and check for oil

leaks.

DRIVE BELT

Remove the left crankcase cover. Inspect the drive belt for cracks or excessive wear. Replace the drive belt with a new one if necessary and in accordance with the Maintenance Schedule.

Drive Belt

Oil Check Bolt Hole/Oil Filler

• Place the motorcycle on its main stand on level ground.

＊

Oil Drain Bolt/Sealing Washer

• Make sure that the sealing washer is in good condition.

＊

• Make sure that the sealing washer is in good condition.

＊

Page 49

3. INSPECTION/ADJUSTMENT

3-9

GRAND DINK 125/150

HEADLIGHT AIM

Turn the ignition switch ON. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting bolt.

CLUTCH SHOE WEAR

Start the engine and check the clutch operation by increasing the engine speed gradually. If the motorcycle tends to creep, or the engine stalls, check the clutch shoes for wear and replace if necessary.

COOLING SYSTEM

COOLANT LEVEL INSPECTION

Place the motorcycle on its main stand on level ground. Check the coolant level of the reserve tank and the level should be between the upper and lower level lines. If necessary, fill the reserve tank with recommended coolant to the “F” level line.

Recommended Coolant: SIGMA Coolant (Standard Concentration 30%)

COOLANT REPLACEMENT

Remove the front cover. Remove the radiator cap. Remove the drain bolt to drain the coolant and tilt the motorcycle to the right and the coolant will drain more easily. Drain the coolant in the reserve tank. Reinstall the drain bolt. Fill the radiator with the specified coolant.

Lower Line

Headlight Aim Adjusting Bolt

Upper Line

Radiator Cap

• The coolant level does not change no matter the engine is warm or cold. Fill to the “F” (upper) line.

＊

• The coolant freezing point should be 5℃ lower than the temperature of the riding area.

＊

• Perform this operation when the engine is cold.

＊

Reserve Tank

Page 50

3. INSPECTION/ADJUSTMENT

3-10

GRAND DINK 125/150

Coolant capacity : 1400±20cc Radiator capacity : 1000±20cc Reserve tank capacity : 400±20cc Start the engine and check if there is no

bubbles in the coolant and the coolant level is stable. Reinstall the radiator cap. If there are bubbles in the coolant, bleed air from the system. Fill the reserve tank with the recommended coolant up to the upper line.

BRAKE SYSTEM

BRAKE LEVER

Measure the front and rear brake lever free plays.

BRAKE FLUID

Turn the steering handlebar upright and check if the front/rear brake fluid level is at the upper limit. If the brake fluid is insufficient, fill to the upper limit.

Specified Brake Fluid: DOT-4

BRAKE DISK/BRAKE PAD

Check the brake disk surface for scratches, unevenness or abnormal wear. Check if the brake disk runout is within the specified service limit. Check if the brake pad wear exceeds the wear indicator line.

Wear Indicator Line

Drain Bolt

Rear Brake Reservoir

Brake Disk

• The brake fluid level will decrease if the brake pads are worn.

＊

• Keep grease or oil off the brake disk to avoid brake failure.

＊

Front Brake Reservoir

Page 51

3. INSPECTION/ADJUSTMENT

3-11

GRAND DINK 125/150

NUTS/BOLTS/FASTENERS

Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found.

WHEELS/TIRES

Check the tires for cuts, imbedded nails or other damages. Check the tire pressure.

Tire Pressure

1 Rider

2 Riders

Front

1.75kg/cm_

Rear

2.00kg/cm_

2.25kg/cm_

STEERING HANDLEBAR

Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing.

SUSPENSION

Check the action of the front/rear shock absorbers by compressing them several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn. Replace the engine hanger bushings if there is any looseness.

• Tire pressure should be checked when tires are cold.

＊

Pressure Gauge

Page 52

4. LUBRICATION SYSTEM

4-0

GRAND DINK 125/150

__________________________________________________________________________________

LUBRICATION SYSTEM

__________________________________________________________________________________

LUBRICATION SYSTEM DIAGRAM-------------------------------- 4-1 SERVICE INFORMATION -------------------------------------------- 4-2 TROUBLESHOOTING ------------------------------------------------- 4-2 ENGINE OIL/OIL FILTER -------------------------------------------- 4-3 OIL PUMP REMOVAL------------------------------------------------- 4-4 OIL PUMP DISASSEMBLY------------------------------------------- 4-4 OIL PUMP INSPECTION---------------------------------------------- 4-5 OIL PUMP ASSEMBLY------------------------------------------------ 4-5 OIL PUMP INSTALLATION ------------------------------------------ 4-6

Page 53

4. LUBRICATION SYSTEM

4-1

GRAND DINK 125/150

LUBRICATION SYSTEM

Oil Pump

Oil Filter Screen

Crankshaft

Rocker Arm Shaft

Oil Filter Screen

Page 54

4. LUBRICATION SYSTEM

4-2

GRAND DINK 125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The maintenance of lubrication system can be performed with the engine installed in the frame.

• Drain the coolant before starting any operations.

• Use care when removing and installing the oil pump not to allow dust and foreign matters to enter

the engine and oil line.

• Do not attempt to disassemble the oil pump. The oil pump must be replaced as a set when it reaches its service limit.

• After the oil pump is installed, check each part for oil leaks.

SPECIFICATIONS OIL PUMP

Standard (mm)

Service Limit (mm)

Inner rotor-to-outer rotor clearance

0.15

0.20

Outer rotor-to-pump body clearance

0.15_ 0.20

0.25

Rotor end-to-pump body clearance

0.04_ 0.09

0.12

ENGINE OIL

Engine Oil Capacity

At disassembly: 1.1 liter At change: 0.9 liter

Recommended Oil

SAE15W40# API: SJ

TROUBLESHOOTING

Oil level too low Poor lubrication pressure

• Natural oil consumption • Oil level too low

• Oil leaks • Clogged oil filter or oil passage

• Worn piston rings • Faulty oil pump

• Worn valve guide

• Worn valve guide seal

Oil contamination

• Oil not changed often enough

• Faulty cylinder head gasket

• Loose cylinder head bolts

Page 55

4. LUBRICATION SYSTEM

4-3

GRAND DINK 125/150

ENGINE OIL/OIL FILTER

Remove the oil dipstick and check the oil level with the oil dipstick. If the level is near the lower level, fill to the upper level with the recommended engine oil.

OIL CHANGE

Remove the oil drain bolt located at the left side of the engine to drain the engine oil. After the oil has been completely drained, install the aluminum washer and tighten the oil drain bolt. Torque: 14.7N-m Pour the recommended oil through the oil filler hole.

OIL FILTER SCREEN

Drain the engine oil. Remove the oil filter screen cap. Remove the oil filter screen and spring. Check the oil filter screen for clogging or damage and replace if necessary. Check the filter screen O-ring for damage and replace if necessary. Install the oil filter screen, spring, O-ring and filter screen cap. Torque: 14.7N-m

Recommended Oil: SAE15W40# API: SG/CD Oil Capacity:

At disassembly: 1.1 liter At change: 0.9 liter Start the engine and check for oil leaks. Start

the engine and let it idle for few minutes, then recheck the oil level.

Oil Dipstick

Oil Drain Bolt

Oil Filter Screen Cap

• Place the motorcycle upright on level ground for engine oil level check.

• Run the engine for 2_ 3 minutes and check the oil level after the engine is stopped for 2_ 3 minutes.

＊

• The engine oil will drain more easily while the engine is warm.

＊

Page 56

4. LUBRICATION SYSTEM

4-4

GRAND DINK 125/150

Circlip

Bolts

Oil Pump Driven Gear

Oil Separator

OIL PUMP REMOVAL

First drain the coolant. Remove the right crankcase cover. (!10-3) Remove the A.C. generator starter driven gear. (!10-4) Remove the attaching bolt and oil separator cover.

Pry the circlip off and remove the oil pump driven gear, then remove the oil pump drive chain.

Remove the two oil separator bolts to remove the oil pump.

OIL PUMP DISASSEMBLY

Remove the screw and disassemble the oil pump as shown.

Oil Separator Cover

Oil Pump

Page 57

4. LUBRICATION SYSTEM

4-5

GRAND DINK 125/150

Outer Rotor

Inner Rotor

Outer Rotor

Inner Rotor

Dowel Pin

Pump Body

Rotor End

Pump Body

Pump Shaft

OIL PUMP INSPECTION

Measure the pump body-to-outer rotor clearance.

Service Limit: 0.25mm replace if over

Measure the inner rotor-to-outer rotor clearance.

Service Limit: 0.20mm replace if over

Measure the rotor end-to-pump body clearance.

Service Limit: 0.12mm replace if over

OIL PUMP ASSEMBLY

Install the outer rotor, inner rotor and pump shaft into the pump body.

There is one mark on the surface of the inner rotor and outer rotor.

The mark is upside.

Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor. Install the dowel pin.

＊

Pump Body

Page 58

4. LUBRICATION SYSTEM

4-6

GRAND DINK 125/150

Screw

Bolts

Pump Cover

Oil Separator Cover

Pump Driven Gear

Bolt

Install the pump cover by aligning the hole in the cover with the dowel pin. Tighten the screw to secure the pump cover. Make sure that the pump shaft rotates freely without binding.

OIL PUMP INSTALLATION

Install the oil pump and oil separator and tighten the two bolts. Make sure that the pump shaft rotates freely. The arrow of oil pump is upside.

Install the pump drive chain and driven gear, then set the circlip securely on the pump shaft.

Install the oil separator cover properly.

Install the A.C. generator starter driven gear. (!10-5)

Circlip

Fit the tab of the separator cover into the slit in the separator.

＊

Dowel Pin

Hole

Oil Separator

Pump Drive Chain

Arrow Mark

Page 59

5. ENGINE REMOVAL/INSTALLATION

5-0

GRAND DINK 125/150

__________________________________________________________________________________

ENGINE REMOVAL/INSTALLATION

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 5-1 SERVICE INFORMATION -------------------------------------------- 5-2 ENGINE REMOVAL --------------------------------------------------- 5-3 ENGINE INSTALLATION -------------------------------------------- 5-5

Page 60

5. ENGINE REMOVAL/INSTALLATION

5-1

GRAND DINK 125/150

SCHEMATIC DRAWING

Page 61

5. ENGINE REMOVAL/INSTALLATION

5-2

GRAND DINK 125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal.

• Use shop towels to protect the motorcycle body during engine removal.

• Drain the coolant before removing the engine.

• After the engine is installed, fill the cooling system with coolant and be sure to bleed air from the

water jacket. Start the engine to check for coolant leaks.

• Before removing the engine, the rear brake caliper must be removed first. Be careful not to bend or twist the brake fluid tube.

SPECIFICATIONS

Engine dry weight: 30kg Engine oil capacity: at disassembly: 1.1 liter

: at change 0.9 liter

Coolant capacity:

Total capacity : 1400±20cc Radiator capacity : 1000±20cc Reserve tank capacity : 400±20cc

TORQUE VALUES

Engine mounting bolt 49N-m Rear shock absorber upper mount bolt 39.2N-m

Page 62

5. ENGINE REMOVAL/INSTALLATION

5-3

GRAND DINK 125/150

ENGINE REMOVAL

Disconnect the battery negative cable. Remove the frame body cover. (!2-3) Disconnect the engine negative cable. Disconnect all of the A.C. generator, auto bystarter, spark plug, thermosensor wire couplers and connectors. Disconnect the engine fuel tube. Drain the coolant. (!3-9) Disconnect the water hose.

Disconnect the starter motor wire that goes to the starter relay.

Disconnect the fuel tube and vacuum tube that go to the carburetor from the fuel pump. Disconnect the vacuum tube from the air cutoff valve (ACV). Disconnect the throttle cable from the carburetor.

Remove the brake fluid tube bolt of the rear brake caliper. Remove the rear brake caliper bolt and the rear brake caliper.

Starter Relay

Wire Connectors

Rear Brake Caliper

ACV Vacuum Tube

Fuel Tube

Throttle Cable

Fuel Pump Vacuum Tube

Brake Fluid Tube

Rear Brake Caliper

Page 63

5. ENGINE REMOVAL/INSTALLATION

5-4

GRAND DINK 125/150

Remove the right/left rear shock absorber upper mount bolts.

Remove the two engine mounting bolts and pull out the engine with the engine hanger backward.

ENGINE HANGER REMOVAL

Remove the engine hanger bolts to remove the engine hanger.

Inspect the engine hanger bushings and stopper rubber for wear or damage.

Bushings

Rear Shock Absorber Upper Mount Bolts

Engine Hanger Bolt

Stopper Rubber

Bolt

Engine Hanger

Page 64

5. ENGINE REMOVAL/INSTALLATION

5-5

GRAND DINK 125/150

ENGINE INSTALLATION

Install the engine in the reverse order of removal. Tighten the engine mounting bolts.

Torque: 49N-m

Tighten the rear shock absorber upper mount bolts.

Torque: 39.2N-m After installation, inspect and adjust the

following:

• Throttle grip free play (!3-3)

• Fill the rear brake reservoir with brake fluid

and bleed air from the rear brake.

• Fill the cooling system with coolant and start the engine to bleed air from the system.

Engine Hanger Bolt

Rear Shock Absorber Upper Mount Bolts

Page 65

6. CYLINDER HEAD/VALVES

6-0

GRAND DINK 125/150

6 .

__________________________________________________________________________________

CYLINDER HEAD/VALVES

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 6- 1 SERVICE INFORMATION -------------------------------------------- 6- 2 TROUBLESHOOTING ------------------------------------------------- 6- 3 CYLINDER HEAD COVER REMOVAL----------------------------- 6- 4 CAMSHAFT REMOVAL----------------------------------------------- 6- 4 CYLINDER HEAD REMOVAL --------------------------------------- 6- 6 CYLINDER HEAD DISASSEMBLY --------------------------------- 6- 7 CYLINDER HEAD ASSEMBLY-------------------------------------- 6- 8 CYLINDER HEAD INSTALLATION -------------------------------- 6- 9 CAMSHAFT INSTALLATION---------------------------------------- 6-10 CYLINDER HEAD COVER INSTALLATION---------------------- 6-11

Page 66

6. CYLINDER HEAD/VALVES

6-1

GRAND DINK 125/150

SCHEMATIC DRAWING

Page 67

6. CYLINDER HEAD/VALVES

6-2

GRAND DINK 125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first.

• When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.

• The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages. Clean and unclog the oil passages before assembling the cylinder head.

• After disassembly, clean the removed parts and dry them with compressed air before inspection.

• After removal, mark and arrange the removed parts in order. When assembling, install them in the

reverse order of removal.

SPECIFICATIONS

Standard (mm)

Service Limit (mm)

Item

SH30DA

SH25DA

SH30DA

SH25DA

0.10

Cylinder head compression pressure

15kg/cm_

Cylinder head warpage

0.05

0.05IN30.8763

30.8763

30.75

30.75EX30.4081

30.4081

30.26

10.00_ 10.018

10.10

10.00_ 10.018

10.10

Valve rocker arm shaft

9.972_ 9.987

9.9

O.D.EX9.972_ 9.987

9.972_ 9.987

9.9

9.9IN1.2

1.2

1.8

1.8EX1.2

1.2

1.8

4.990_ 4.975

4.925

4.970_ 4.955

4.915

5.00_ 5.012

5.03

5.00_ 5.012

5.03

Valve stem-to-guide

0.010_ 0.037

0.08

clearance

0.030_ 0.057

0.10

TORQUE VALUES

Cylinder head cap nut 19.6N-m Apply engine oil to threads Valve clearance adjusting nut 8.8N-m Apply engine oil to threads Cylinder head cover bolt 7.8_ 11.8N-m

SPECIAL TOOLS

Valve spring compressor Valve seat cutter, 24.5mm 45° IN-EX Valve seat cutter, 25mm Plane cutter 37.5° EX Valve seat cutter, 22mm Plane cutter 37.5° EX Valve seat cutter, 26mm Plane cutter 63.5° IN/EX Cutter clip Valve guide driver Valve guide reamer

Valve clearance (cold)

Valve rocker arm I.D.

Valve stem O.D.

Valve guide I.D.

Camshaft cam height

Valve seat width

Page 68

6. CYLINDER HEAD/VALVES

6-3

GRAND DINK 125/150

TROUBLESHOOTING

• The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises.

Poor performance at idle speed White smoke from exhaust muffler

• Compression too low • Worn valve stem or valve guide

• Damaged valve stem oil seal

Compression too low

• Incorrect valve clearance adjustment Abnormal noise

• Burned or bend valves • Incorrect valve clearance adjustment

• Incorrect valve timing • Sticking valve or broken valve spring

• Broken valve spring • Damaged or worn camshaft

• Poor valve and seat contact • Worn cam chain tensioner

• Leaking cylinder head gasket • Worn camshaft and rocker arm

• Warped or cracked cylinder head

• Poorly installed spark plug

Compression too high

• Excessive carbon build-up in combustion chamber

Page 69

6. CYLINDER HEAD/VALVES

6-4

GRAND DINK 125/150

CYLINDER HEAD COVER REMOVAL

Remove the center cover. (!2-3) Remove the met-in box. (!2-3) Remove the cylinder head cover four bolts and then remove the cylinder head cover.

CAMSHAFT REMOVAL

Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke. Remove the two bolts attaching cam chain tensioner and the tensioner.

First remove the two bolts between the cylinder head and cylinder. Then, remove the four cap nuts attaching the cylinder head.

Remove the camshaft holder and dowel pins.

Cylinder Head Cover

Bolt

Cam Chain Tensioner

Round Hole

Camshaft Holder

Bolts

• Diagonally loosen the cylinder head cap nuts in 2 or 3 times.

＊

Camshaft Holder

Cap Nuts

Page 70

6. CYLINDER HEAD/VALVES

6-5

GRAND DINK 125/150

Remove the camshaft gear from the cam chain to remove the camshaft.

CAMSHAFT INSPECTION

Check each cam lobe for wear or damage. Measure the cam lobe height.

Service Limits:

SH30DA

IN: 30.75mm replace if below

SH25DA

EX:30.26mm replace if below

Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play.

CAMSHAFT HOLDER DISASSEMBLY

Take out the valve rocker arm shafts using a 6mm bolt. Remove the valve rocker arms.

Cam Chain

Camshaft Gear

Camshaft Bearings

6mm Bolt

Valve Rocker Arms

Rocker Arm Shafts

Page 71

6. CYLINDER HEAD/VALVES

6-6

GRAND DINK 125/150

CAMSHAFT HOLDER INSPECTION

Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage.

Measure the I.D. of each valve rocker arm. Service Limits: IN: 10.10mm replace if over

EX: 10.10mm replace if over

Measure each rocker arm shaft O.D. Service Limits: IN: 9.90mm replace if below

EX: 9.90mm replace if below

CYLINDER HEAD REMOVAL

First drain the coolant from the radiator and water jacket, then remove the thermostat water hose. Remove the camshaft. (!6-4) Remove the carburetor and intake manifold. Remove the bolt attaching the thermostat housing and the thermostat housing. Remove the cylinder head.

Remove the dowel pins and cylinder head gasket. Remove the cam chain guide. Remove all gasket material from the cylinder head mating surface.

Bolt

Intake Manifold

Cam Chain Tensioner Slipper

Camshaft Holder

If the valve rocker arm contact surface is worn, check each cam lobe for wear or damage.

＊

Be careful not to drop any gasket material into the engine.

＊

Rocker Arm Shafts

Cylinder

Cylinder Head Gasket

Page 72

6. CYLINDER HEAD/VALVES

6-7

GRAND DINK 125/150

CYLINDER HEAD DISASSEMBLY

Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor.

Remove carbon deposits from the exhaust port and combustion chamber.

Valve Spring Compressor

Cylinder Head

• Be sure to compress the valve springs with a valve spring compressor.

• Mark all disassembled parts to ensure correct reassembly.

＊

Be careful not to damage the cylinder head mating surface.

＊

Exhaust Port

Combustion Chamber

Page 73

6. CYLINDER HEAD/VALVES

6-8

GRAND DINK 125/150

INSPECTION

CYLINDER HEAD Check the spark plug hole and valve areas for

cracks. Check the cylinder head for warpage with a straight edge and feeler gauge.

Service Limit: 0.05mm repair or replace if

over

VALVE SPRING FREE LENGTH Measure the free length of the inner and outer

valve springs. Service Limits:

Inner (IN, EX) : 29.3mm replace if below Outer (IN, EX): 32.0mm replace if below

VALVE /VALVE GUIDE Inspect each valve for bending, burning,

scratches or abnormal stem wear. Check valve movement in the guide.

Measure each valve stem O.D. Service Limits: IN: 4.925mm replace if

below EX: 4.915mm replace if below

CYLINDER HEAD ASSEMBLY

Install the valve spring seats and stem seals. Lubricate each valve stem with engine oil and

insert the valves into the valve guides. Be sure to install new valve stem seals.

Straight Edge

Feeler Gauge

Valve Spring Compressor

Page 74

6. CYLINDER HEAD/VALVES

6-9

GRAND DINK 125/150

Tap the valve stems gently with a plastic hammer to firmly seat the cotters.

CYLINDER HEAD INSTALLATION

Install the cam chain guide. Install the dowel pins and a new cylinder head gasket.

Install the cylinder head and take out the cam chain

Assemble the camshaft holder. First install the intake and exhaust valve rocker arms; then install the rocker arm shafts.

Gasket

Cam Chain Guide

Valve Rocker Arms

Plastic Hammer

Cam Chain

Cylinder Head

Camshaft Holder

Be careful not to damage the valves.

＊

Dowel Pins

• Install the exhaust valve rocker arm shaft on the “EX” side of the camshaft holder and the exhaust rocker arm shaft is shorter.

• Clean the intake valve rocker arm shaft off any grease before installation.

• Align the cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder.

＊

Page 75

6. CYLINDER HEAD/VALVES

6-10

GRAND DINK 125/150

CAMSHAFT INSTALLATION

Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface (Position the intake and exhaust cam lobes down.) and install the cam chain over the camshaft gear.

Install the dowel pins.

Install the camshaft holder, washers and nuts on the cylinder head. Tighten the four cylinder head nuts and the two bolts between the cylinder head and cylinder.

Torque: Cylinder head cap nut: 19.6N-m

Cylinder & cylinder head bolt:

7.8_ 11.8N-m

Dowel Pins

Nut

Washer

Punch Marks

Bolts

Cam Chain

Round Hole

• Apply engine oil to the threads of the cylinder head cap nuts.

• Diagonally tighten the cylinder head cap nuts in 2_ 3 times.

• First tighten the cylinder head cap nuts and then tighten the bolts between the cylinder and cylinder head to avoid cracks.

＊

Page 76

6. CYLINDER HEAD/VALVES

6-11

GRAND DINK 125/150

Install a new cam chain tensioner gasket. Release the lock pawl and push the push rod

all the way in.

Install the cam chain tensioner and tighten the two bolts. Install the tensioner spring and tighten the sealing bolt.

Torque: 2.9_ 5.8N-m

CYLINDER HEAD COVER INSTALLATION

Adjust the valve clearance. (!3-6) Install a new cylinder head cover O-ring and install the cylinder head cover.

Install and tighten the cylinder head cover bolts.

Torque: 7.8_ 11.8N-m

Cam Chain Tensioner

Sealing Bolt

Bolt

Lock Pawl

Push Rod

Gasket

Cam Chain Tensioner

Spring

Cylinder Head Cover

O-ring

Be sure to install the O-ring into the groove properly.

＊

Page 77

7. CYLINDER/PISTON

7-0

GRAND DINK 125/150

__________________________________________________________________________________

CYLINDER/PISTON

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 7-1 SERVICE INFORMATION -------------------------------------------- 7-2 TROUBLESHOOTING ------------------------------------------------- 7-2 CYLINDER REMOVAL------------------------------------------------ 7-3 PISTON REMOVAL---------------------------------------------------- 7-3 PISTON INSTALLATION--------------------------------------------- 7-7 CYLINDER INSTALLATION ----------------------------------------- 7-7

Page 78

7. CYLINDER/PISTON

7-1

GRAND DINK 125/150

SCHEMATIC DRAWING

Page 79

7. CYLINDER/PISTON

7-2

GRAND DINK 125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The cylinder and piston can be serviced with the engine installed in the frame.

• When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are

correctly installed.

• After disassembly, clean the removed parts and dry them with compressed air before inspection.

SPECIFICATIONS

Standard (mm)

Service Limit (mm)

Item

SH30DA

SH25DA

SH30DA

SH25DA

I.D.

57.405_ 57.

52.400_ 52.

57.50

52.50

Warpage

0.01

0.05

Cylindricity

0.01

0.05

True roundness

0.01

0.05

Ring-to-groove

top

0.015_ 0.05

0.09

clearance

Second

0.015_ 0.05

0.09

top

0.15_ 0.30

0.50

Piston,

Ring end gap

Second

0.15_ 0.30

0.50

piston ring

Oil side rail

0.2_ 0.9

Piston O.D.

57.375_ 57.

52.370_ 52.

57.30

52.30

Piston O.D. measuring position

9mm from

Piston-to-cylinder clearance

0.010_ 0.04

0.01

Piston pin hole I.D.

15.002_ 15.

15.04

Piston pin O.D

14.994_ 15.

14.96

Piston-to-piston pin clearance

0.002_ 0.01

0.02

Connecting rod small end I.D. bore

15.016_ 15.

15.06

TROUBLESHOOTING

• When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.

Compression too low or uneven compression Excessive smoke from exhaust muffler

• Worn or damaged cylinder and piston rings • Worn or damaged piston rings

• Worn, stuck or broken piston rings • Worn or damaged cylinder and piston

Compression too high Abnormal noisy piston

• Excessive carbon build-up in combustion • Worn cylinder, piston and piston rings chamber or on piston head • Worn piston pin hole and piston pin

• Incorrectly installed piston

Cylinder

Page 80

7. CYLINDER/PISTON

7-3

GRAND DINK 125/150

CYLINDER REMOVAL

Remove the cylinder head. (!6-7) Remove the water hose from the cylinder. Remove the cylinder base bolt.

Remove the cam chain guide. Remove the cylinder.

Remove the cylinder gasket and dowel pins. Clean any gasket material from the cylinder surface.

PISTON REMOVAL

Remove the piston pin clip. Press the piston pin out of the piston.

Water Hose

Dowel Pins

Cam Chain Guide

Gasket

Shop Towel

Cylinder

Piston Pin

Piston

Piston Rings

Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase.

＊

Page 81

7. CYLINDER/PISTON

7-4

GRAND DINK 125/150

Inspect the piston, piston pin and piston rings. Remove the piston rings.

Clean carbon deposits from the piston ring grooves.

Install the piston rings onto the piston and measure the piston ring-to-groove clearance.

Service Limits:

Top: 0.09mm replace if over 2nd: 0.09mm replace if over

Remove the piston rings and insert each piston ring into the cylinder bottom.

Measure the piston ring end gap. Service Limit: 0.5mm replace if over

Measure the piston pin hole I.D. Service Limit: 15.04mm replace if over

• Take care not to damage or break the piston rings during removal.

＊

• Use the piston head to push each piston ring into the cylinder.

＊

Page 82

7. CYLINDER/PISTON

7-5

GRAND DINK 125/150

Measure the piston pin O.D. Service Limit: 14.96mm replace if below

Measure the piston O.D.

Service Limit: 57.90mm replace if below

SH30DA

57.30mm replace if below

SH25DA

52.30mm replace if below Measure the piston-to-piston pin clearance.

Service Limit: 0.02mm replace if over

CYLINDER INSPECTION

Inspect the cylinder bore for wear or damage. Measure the cylinder I.D. at three levels of top, middle and bottom at 90° to the piston pin (in both X and Y directions).

Service Limit: 58.10mm repair or replace if

below

SH30DA

57.50mm repair or replace if over

SH25DA

52.50mm repair or replace if over Measure the cylinder-to-piston clearance.

Service Limit: 0.1mm repair or replace if

over

The true roundness is the difference between the values measured in X and Y directions. The cylindricity (difference between the values measured at the three levels) is subject to the maximum value calculated.

Service Limits: True Roundness: 0.05mm repair or replace

if over

Cylindricity: 0.05mm repair or replace if over

• Take measurement at 9mm from the bottom and 90° to the piston pin hole.

＊

Middle

Bottom

Top

Page 83

7. CYLINDER/PISTON

7-6

GRAND DINK 125/150

Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over

Measure the connecting rod small end I.D.

Service Limit: 15.06mm replace if over

PISTON RING INSTALLATION

Install the piston rings onto the piston. Apply engine oil to each piston ring.

Second

Side Rail

Top

• Be careful not to damage the

piston and piston rings during assembly.

• All rings should be installed with

the markings facing up.

• After installing the rings, they

should rotate freely without sticking.

• Stagger the ring end gaps as the

figure shown.

＊

Second

Top

Side Rail

Oil Ring

Page 84

7. CYLINDER/PISTON

7-7

GRAND DINK 125/150

PISTON INSTALLATION

Remove any gasket material from the crankcase surface.

Install the piston, piston pin and a new piston pin clip.

CYLINDER INSTALLATION

Install the dowel pins and a new cylinder gasket on the crankcase.

Coat the cylinder bore, piston and piston rings with clean engine oil. Carefully lower the cylinder over the piston by compressing the piston rings.

Gasket

Cylinder

Dowel Pin

• Be careful not to drop foreign matters into the crankcase.

＊

• Position the piston “IN” mark

on the intake valve side.

• Place a clean shop towel in the

crankcase to keep the piston pin clip from falling into the crankcase.

＊

• Be careful not to damage or break

the piston rings.

• The piston ring end gaps should

not be parallel with or at 90° to the piston pin.

＊

Piston

Piston Pin Clip

Piston Pin

Page 85

7. CYLINDER/PISTON

7-8

GRAND DINK 125/150

Tighten the cylinder base bolt.

Install the cam chain guide.

Connect the water hose to the cylinder. Install the cylinder head. (!6-9) Tighten the cylinder base bolt.

• Insert the tab on the cam chain guide into the cylinder groove.

＊

Cylinder Base Bolt

Cam Chain Guide

Page 86

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-0

GRAND DINK 125/150

__________________________________________________________________________________

DRIVE AND DRIVEN PULLEYS/

KICK STARTER

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 8- 1 SERVICE INFORMATION -------------------------------------------- 8- 2 TROUBLESHOOTING ------------------------------------------------- 8- 2 LEFT CRANKCASE COVER------------------------------------------ 8- 3 DRIVE PULLEY -------------------------------------------------------- 8- 4 CLUTCH/DRIVEN PULLEY ------------------------------------------ 8- 8 KICK STARTER -------------------------------------------------------- 8-15

Page 87

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-1

GRAND DINK 125/150

SCHEMATIC DRAWING

Page 88

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-2

GRAND DINK 125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The drive pulley, clutch and driven pulley can be serviced with the engine installed.

• Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from

them to minimize the slipping of drive belt and drive pulley.

SPECIFICATIONS

Item

Standard (mm)

Service Limit (mm)

Movable drive face bushing I.D.

33.000_ 33.025

33.06

Drive face collar O.D.

32.006_ 32.009

31.90

Drive belt width

19.0

17.5

Clutch lining thickness

3.963_ 4.037

2.0

Clutch outer I.D.

130.0_ 130.2

130.5

Driven face spring free length

88.3

83.2

Driven face O.D.

33.965_ 33.985

33.94

Movable driven face I.D.

34.00_ 34.025

34.06

Weight roller O.D.

16.99_ 17.00

16.00

TORQUE VALUES

Drive face nut 49.0_ 58.8N-m Clutch outer nut 49.0_ 58.8N-m Clutch drive plate nut 49.0_ 58.8N-m

SPECIAL TOOLS

Universal holder Clutch spring compressor Bearing driver Lock nut wrench, 39mm

Kick starter spring remover

TROUBLESHOOTING

Engine starts but motorcycle won‘t move Lack of power

• Worn drive belt • Worn drive belt

• Broken ramp plate • Weak driven face spring

• Worn or damaged clutch lining • Worn weight roller

• Broken driven face spring • Faulty driven face

Engine stalls or motorcycle creeps

• Broken clutch weight spring

Page 89

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-3

GRAND DINK 125/150

LEFT CRANKCASE COVER

REMOVAL

Loosen the drive belt air tube band screw.

Remove the left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins.

INSTALLATION

Install the dowel pins and the gasket.

Install the left crankcase cover.

Install the cable clamp to the specified location. Install and tighten the left crankcase cover bolts.

Kick Lever

Left Crankcase Cover

Air Tube Band

Bolts

• Do not pull out the kick starter spindle. Press in the kick starter spindle when installing the left crankcase cover.

＊

Dowel Pins

Gasket

Left Crankcase Cover

Page 90

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-4

GRAND DINK 125/150

Install the drive belt air tube and tighten the tube band screw.

DRIVE PULLEY

REMOVAL

Remove the left crankcase cover. Hold the drive pulley using an universal holder and remove the drive face nut and washer. Remove the drive pulley face.

Universal Holder

Remove the drive belt from the movable drive face.

INSPECTION

Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width.

Service Limit: 17.5mm replace if below

Drive Pulley Face

Universal Holder

• Use specified genuine parts for

replace-ment.

＊

Movable Drive Face

Drive Belt

Tube Band Screw

Special

Page 91

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-5

GRAND DINK 125/150

Remove the movable drive face assembly. Remove the drive pulley collar.

DISASSEMBLY

Remove the ramp plate.

Remove the weight rollers.

INSPECTION

Check each weight roller for wear or damage. Measure each weight roller O.D.

Service Limit: 16.00mm replace if below

Drive Pulley Collar

Ramp Plate

Weight Roller

Movable Drive Face Assembly

Page 92

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-6

GRAND DINK 125/150

Measure the movable drive face bushing assemblyy I.D.

Service Limit: 27.20mm replace if over

Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface.

Service Limit: 26.90mm replace if below

ASSEMBLY

Install the weight rollers into the movable drive face.

Weight Roller

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8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-7

GRAND DINK 125/150

Install the ramp plate.

Insert the drive pulley collar into the movable drive face.

INSTALLATION

Install the movable drive face onto the crankshaft.

Lay the drive belt on the driven pulley. Set the drive belt on the drive pulley collar.

Drive Pulley Collar

Ramp Plate

Driven Pulley

Movable Drive Face Assembly

Drive Pulley Collar

Drive Belt

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8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

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GRAND DINK 125/150

Install the drive pulley face, washer and drive face nut.

Hold the drive pulley with the universal holder and tighten the drive face nut.

Torque: 49.0_ 58.5N-m

Universal Holder

CLUTCH/DRIVEN PULLEY

Remove the left crankcase cover. (!8-3) Remove the drive pulley and drive belt. (!8-

4) Hold the clutch outer with the universal holder and remove the clutch outer nut.

Universal Holder Remove the clutch outer.

INSPECTION

Inspect the clutch outer for wear or damage. Measure the clutch outer I.D.

Service Limit: 130.5mm replace if over

Drive Pulley Face

Washer

Special

• Do not get oil or grease on the

drive belt or drive pulley faces.

＊

Clutch Outer

Drive Face Nut

Drive Pulley

Universal Holder

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8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

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Check the clutch shoes for wear or damage. Measure the clutch lining thickness.

Service Limit: 2.0mm replace if below

CLUTCH/DRIVEN PULLEY DISASSEMBLY

Hold the clutch/driven pulley assembly with the clutch spring compressor.

Clutch Spring Compressor Set the tool in a vise and remove the clutch

drive plate nut.

Lock Nut Wrench, 39mm Loosen the clutch spring compressor and

disassemble the clutch/driven pulley assembly. Remove the seal collar.

Clutch/Driven Pulley

Special

Clutch Spring Compressor

• Be sure to use a clutch spring

compressor to avoid spring damage.

＊

Lock Nut Wrench

Page 96

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-10

GRAND DINK 125/150

Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face.

Remove the oil seal from the movable driven face.

INSPECTION

Measure the driven face spring free length. Service Limit: 83.2mm replace if below

Check the driven face assembly for wear or damage. Measure the driven face O.D.

Service Limit: 33.94mm replace if below

Movable Driven Face

Guide Roller Pin

O-ring

Guide Roller

Oil Seal

Page 97

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

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GRAND DINK 125/150

Check the movable driven face for wear or damage. Measure the movable driven face I.D.

Service Limit: 34.06mm replace if over

DRIVEN PULLEY FACE BEARING REPLACEMENT

Check the bearings for play and replace them if they have excessive play. Drive the inner needle bearing out of the driven pulley face.

Remove the snap ring and drive the outer bearing out of the driven face.

Apply grease to the outer bearing. Drive a new outer bearing into the driven face with the sealed end facing up.

Bearing Driver

Seat the snap ring in its groove. Apply grease to the driven face bore areas.

Snap Ring

Inner Bearing

Outer Bearing

• Discard the removed bearing and

replace with a new one.

＊

Pack all bearing cavities with 9_ 9.5g grease.

＊

• Discard the removed bearing and

replace with a new one.

＊

Special

Page 98

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-12

GRAND DINK 125/150

Press a new needle bearing into the driven face.

Bearing Driver

CLUTCH DISASSEMBLY

Remove the circlips and retainer plate to disassemble the clutch.

Circlips

Retainer Plate

Special

• Keep grease off the clutch

linings.

＊

Clutch Lining

Page 99

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

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GRAND DINK 125/150

CLUTCH ASSEMBLY

Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips.

CLUTCH/DRIVEN PULLEY ASSEMBLY

Clean the pulley faces and remove any grease from them. Apply grease to the O-rings and install them onto the moveable driven face.

Circlips

Drive Plate

Movable Driven Face

Page 100

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

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GRAND DINK 125/150

Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face.

Install the seal collar. Remove any excessive grease.

Set the driven pulley assembly, driven face spring and clutch assembly onto the clutch spring compressor.

Compress the tool and install the drive plate nut. Set the tool in a vise and tighten the drive plate nut to the specified torque.

Torque: 49.0_ 58.8N-m

Clutch Spring Compressor Outer Driver, 32x35mm

INSTALLATION

Install the clutch/driven pulley onto the drive shaft.

• Be sure to clean the driven face

off any grease.

＊

• Align the flat surface of the driven

face with the flat on the clutch drive plate.

＊

• Keep grease off the drive shaft.

＊

Movable Driven Face

Guide Roller Pin

Seal Collar

Guide Roller

Clutch/Driven Pulley

Driven Face

Clutch Spring Compressor

Lock Nut Wrench

• Be sure to use a clutch spring

compressor to avoid spring damage.

＊

Special