Kymco GRAND DINK 150 User Manual

GRAND DINK 125/15 0

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/

T HERMO-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

1. GENERAL INFORMATION

1-0

GRAND DINK 125/15 0

__________________________________________________________________________________

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. GENERAL INFORMATION

1-1

GRAND DINK 125/15 0

SERIAL NUMBER

Location of Engine Serial Number

Location of Frame Serial Number

Vehicle Identification Serial Number

1. GENERAL INFORMATION

1-2

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-3

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-4

GRAND DINK 125/15 0

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.

1. GENERAL INFORMATION

1-5

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-6

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-7

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-8

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-9

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-10

GRAND DINK 125/15 0

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 KYM CO 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

1. GENERAL INFORMATION

1-11

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-12

GRAND DINK 125/15 0

CABLE & HARNESS ROUTING

Radiator

Front Brake

Rear Brake

Speedometer Cable

Horn

Pressure Type Radiator Cap

Radiator Air Vent Tube

1. GENERAL INFORMATION

1-13

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-14

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-15

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-16

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-17

GRAND DINK 125/15 0

WIRING DIAGRAM

1. GENERAL INFORMATION

1-18

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-19

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-20

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-21

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-22

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-23

GRAND DINK 125/15 0

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)

1. GENERAL INFORMATION

1-24

GRAND DINK 125/15 0

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 bat t ery circuit by operating turn signals

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

1. GENERAL INFORMATION

1-25

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-26

GRAND DINK 125/15 0

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/rect ifier 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

1. GENERAL INFORMATION

1-27

GRAND DINK 125/15 0

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

1. GENERAL INFORMATION

1-28

GRAND DINK 125/15 0

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

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