PREFACE TABLE OF CONTENTSkymcoman.free.fr/revue technique/REVUE TECHNIQUE V1.0.pdf · 2006. 11. 14. · Name & Model No. SH25DA Motorcycle Name & Type Overall length 2060mm Overall

GRAND DINK 125/150

PREFACE

This Service Manual describes thetechnical features and servicingprocedures for the KYMCO GRANDDINK 125/150.

Section 1 contains the precautions forall operations stated in this manual.Read them carefully before anyoperation is started.

Section 2 is the removal/installationprocedures for the frame covers whichare subject to higher removal/installationfrequency during maintenance andservicing operations.

Section 3 describes the inspection/adjustment procedures, safety rules andservice information for each part, startingfrom periodic maintenance.

Sections 5 through 13 give instructionsfor disassembly, assembly and adjustmentof engine parts. Section 14 is theremoval/ installation of chassis. Section16 states the testing and measuringmethods of electrical equipment.

Most sections start with an assembly orsystem illustration and troubleshootingfor the section. The subsequent pagesgive detailed procedures for the section.

KWANG YANG MOTOR CO., LTD.OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

GENERAL INFORMATION 1

EXHAUST MUFFLER/FRAME COVERS 2

INSPECTION/ADJUSTMENT 3

LUBRICATION SYSTEM 4

ENGINE REMOVAL/INSTALLATION 5

CYLINDER HEAD/VALVES 6

CYLINDER/PISTON 7

DRIVE AND DRIVEN PULLEYS/KICK

STARTER

8

FINAL REDUCTION 9

A.C. GENERATOR/STARTER CLUTCH 10

CRANKCASE/CRANKSHAFT 11

COOLING SYSTEM 12

FUEL SYSTEM/CARBURETOR/FUEL

PUMP FUEL TANK13

STEERING HANDLEBAR/FRONT

WHEEL/FRONT BRAKE/FRONT

SHOCK ABSORBER/FRONT FORK

14

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER`15

BATTERY/CHARGING SYSTEM 16

IGNITION SYSTEM 17

STARTING SYSTEM 18

SWITCHES/HORN/FUEL UNIT/

THERMO-STATIC

SWITCH/TEMPERATURE

GAUGE/INSTRUMENTS/ LIGHTS

19

The information and contents included inthis manual may be different from themotorcycle in case specifications arechanged.

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ME

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1. GENERAL INFORMATION

1-0

GRAND DINK 125/150

1 __________________________________________________________________________________

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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


1-1

GRAND DINK 125/150

SERIAL NUMBER

Location of Engine Serial NumberLocation of Frame Serial Number

Vehicle Identification Serial Number


1-2

GRAND DINK 125/150

SPECIFICATIONS

Name & Model No. SH25DAMotorcycle Name & TypeOverall length 2060mmOverall width 770mmOverall height 1360mmWheel base 1435mm

Engine type Water cooled 4-stroke,OHC engineDisplacement 124.6ccFuel Used 92# nonleaded gasoline

Front wheel 58Net weight (kg) Rear wheel 82

Total 140Front wheel 60

Gross weight(kg) Rear wheel 95Total 155

Front wheel 120/70-12Rear wheel 140/70-12

Ground clearancePerform-

Braking distance (m) 30km/hr7.0m

ance Min. turning radius 2350mm

Starting systemStarting motor &

Kick starterType Gasoline, 4-strokeCylinder arrangement Single cylinderCombustion chamber type Semi-sphereValve arrangement O.H.C.Bore x stroke (mm) 52.4 x 57.8Compression ratio 10:1Compression pressure(kg/cm_-rpm) 15

Max. output (kw/rpm) 8.4/7500Max. torque (N.m/rpm) 9.8/6000

Intake Open BTDC 12°Port (1mm) Close ATDC 35°t iming

Exhaust Open BDDC 28°

(1mm) Close 0°

Valve Intake 0.1mmclearance (cold) Exhaust 0.1mmIdle speed (rpm) 1700rpm

Lubrication type Forced pressure &Wet sumpOil pump type Inner/outer rotor

typeOil filter type Full-flow filtrationOil capacity 1.1 liters

Cooling Type Water cooling

Air cleaner type & No Paper element, wetFuel capacity 9.0 liters

Type VEPiston dia. 22Venturi dia. 26 equivalentThrottle type Butterfly typeType CDIIgnition timing 10°±1.5°/1000rpmContact breaker Non-contact point

type

Spark plug NGKDPR7EA-9

Spark plug gap 0.8~0.9mmBattery Capacity 12V8AHClutch Type Dry multi-disc clutch

Type Non-stage transmission

Operation Automaticcentrifugal

Type

Type Two-stage reduction

Reduction 1st 2.8~1.0ratio 2nd 8.82

Front Caster angleAxle Connecting rod

Front 1.75Tire pressure(kg/cm_) Rear 2.25

Turning Left 42.5°angle Right 42.5°

Front Disk brakeBrake systemtype Rear Disk brake

Front TelescopeSuspensiontype Rear Double swing

Shock absorber Front Telescopetype Rear Double swing

Frame type Under bone

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power D

rive System

Transm

is-sion G

earR

eductionG

ear

Moving D

eviceD

amping

Device


1-3

GRAND DINK 125/150

SPECIFICATIONS

Name & Model No. SH30DAMotorcycle Name & TypeOverall length 2060mmOverall width 770mmOverall height 1360mmWheel base 1435mm

Engine type Water cooled 4-stroke,OHC engineDisplacement 149.5Fuel Used 92# nonleaded gasoline

Front wheel 58Net weight (kg) Rear wheel 82

Total 140Front wheel 60

Gross weight(kg) Rear wheel 95Total 155

Front wheel 120/70-12Rear wheel 140/70-12

Ground clearancePerform-

Braking distance (m) 30km/hr7.0m

ance Min. turning radius 2350mm

Starting systemStarting motor &

kick starterType Gasoline, 4-strokeCylinder arrangement Single cylinderCombustion chamber type Semi-sphereValve arrangement O.H.C.Bore x stroke (mm) 57.4 x 57.8Compression ratio 10.6:1Compression pressure(kg/cm_-rpm) 15

Max. output (kw/rpm) 8.8/7500Max. torque (N.m/rpm) 11.76/6000

Intake Open BTDC 12°Port (1mm) Close ATDC 35°t iming

Exhaust Open BDDC 28°

(1mm) Close 0°

Valve Intake 0.1mmclearance (cold) Exhaust 0.1mmIdle speed (rpm) 1700rpm

Lubrication type Forced pressure &wet sumpOil pump type Inner/outer rotor

typeOil filter type Full-flow filtrationOil capacity 1.1 liters

Cooling Type Water cooling

Air cleaner type & No Paper element, wetFuel capacity 9.0 liters

Type VEPiston dia. 22Venturi dia. 26 equivalentThrottle type Butterfly typeType CDIIgnition timing 10°±1.5°/1000RPMContact breaker Non-contact point

type

Spark plug NGKDP7EA-9

Spark plug gap 0.8~0.9mmBattery Capacity 12V8AHClutch Type Dry multi-disc clutch

Type Non-stage transmission

Operation Automaticcentrifugal

Type

Type Two-stage reduction

Reduction 1st 2.8~1.0ratio 2nd 8.82

Front Caster angleAxle Connecting rod

Front 2.00Tire pressure(kg/cm_) Rear 2.25

Turning Left 42.5°angle Right 42.5°

Front Disk brakeBrake systemtype Rear Disk brake

Front TelescopeSuspensiontype Rear Double swing

Shock absorber Front Telescopetype Rear Double swing

Frame type Under bone

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power D

rive System

Transm

is-sion G

earR

eductionG

ear

Moving D

eviceD

amping

Device


1-4

GRAND DINK 125/150

SERVICE PRECAUTIONS

nMake sure to install new gaskets, O-rings,circlips, cotter pins, etc. whenreassembling.

nWhen tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torquediagonally.

n Use genuine parts and lubricants.

nWhen servicing the motorcycle, be sure touse special tools for removal andinstallation.

n After disassembly, clean removed parts.Lubricate sliding surfaces with engine oilbefore reassembly.

n Apply or add designated greases andlubricants to the specified lubricationpoints.

n After reassembly, check all parts forproper tightening and operation.

nWhen two persons work together, payattention to the mutual working safety.

n Disconnect the battery negative (-) terminalbefore operation.nWhen using a spanner or other tools, make

sure not to damage the motorcycle surface.

n After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.nWhen 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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GRAND DINK 125/150

n If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.

n After operation, terminal caps shall beinstalled securely.

nWhen taking out the connector, the lock onthe connector shall be released beforeoperation.

n Hold the connector body when connectingor 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 insertedcompletely.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 fordamaged terminal cover or loose negativeterminal.

n Check the double connector cover forproper 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 withtheir respective wire bands at thedesignated locations.Tighten the bands so that only theinsulated surfaces contact the wireharnesses.

ConfirmCapacity


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GRAND DINK 125/150

n After clamping, check each wire to makesure it is secure.

n Do not squeeze wires against the weld orits clamp.

n After clamping, check each harness to makesure that it is not interfering with anymoving or sliding parts.

nWhen fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.

n Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends ofbolts and screws.n Route wire harnesses passing through the

side of bolts and screws. Avoid theprojected ends of bolts and screws.

n Route harnesses so they are neitherpulled tight nor have excessive slack.

n Protect wires and harnesses with electricaltape or tube if they contact a sharp edge orcorner.

nWhen rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled 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 tapeor replace it.

nWhen installing other parts, do not press orsqueeze the wires.

Do not pulltoo tight

No Contact

Do not press or squeezethe wire


1-7

GRAND DINK 125/150

n After routing, check that the wire harnessesare not twisted or kinked.

nWire harnesses routed along with handlebarshould not be pulled tight, have excessiveslack or interfere with adjacent orsurrounding parts in all steering positions.

nWhen a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.

n Be careful not to drop any parts.

nWhen rust is found on a terminal, removethe rust with sand paper or equivalentbefore connecting.

n Symbols:The following symbols represent theservicing methods and cautions included inthis service manual.

: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

Special

Engine Oil

Grease

Gear Oil

＊Do you understand theinstrument？

RemoveRust


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

4.99.821.634.353.9

5mm screw6mm screw, SH bolt6mm flange bolt, nut8mm flange bolt, nut10mm flange bolt, nut

3.98.811.826.539.2

Torque specifications listed below are for important fasteners.

ENGINE

Item Q‘ty Thread dia.(mm) Torque (N-m) Remarks

Cylinder head bolt ACylinder head bolt BOil filter screen capExhaust muffler joint lock nutCylinder head cap nutValve adjusting lock nutCam chain tensioner slipper boltOil boltClutch outer nutClutch drive plate nutFlywheel nutOil pump boltCylinder head cover boltSpark plugCam chain tensioner boltWater pump impeller

2212421111124111

8830885612121214561068

21.6

21.614.78.821.68.88.812.753.953.953.93.911.811.88.813.7

Double end boltDouble end boltApply oil tothreads

Left hand threads

FRAME

Item Q‘ty Thread dia.(mm) Torque (N-m) Remarks

Steering stem lock nutFront axle nutRear axle nutRear shock absorber upper boltRear shock absorber lower boltFront shock absorber lock boltEngine hanger bolt

1112241

1012141081012

44.158.888.229.429.424.553.9

U-nutU-nutU-nut


1-9

GRAND DINK 125/150

SPECIAL TOOLS

Tool Name Tool No. Remarks Ref. Page

Valve guide driver Valve guide removal/installationValve guide reamer Valve guide grindingValve spring compressor Valve removalLock nut wrench, 39mm E027 Clutch disassemblyBearing driver Bearing removalBearing remover, 12mm E020 Bearing removalRemover shaft Bearing removalRemover weight Bearing removalBearing remover, 15mm E018 Bearing removalBearing driver Bearing removalClutch spring compressor E027 Clutch disassemblyBall race remover extension Ball race removalBall race remover Ball race removalSpring compressor Spring removal

Mechanical seal driver E014 Water pump mechanical sealremoval/installation

Kick starter spring remover Kick starter spring removalGear remover Starter gear removalValve adjuster E012 Tapper adjustmentFloat level gauge Carburetor fuel level checkValve seat cutter 45° Valve seat refacingValve seat cutter 32° Valve seat refacingValve seat cutter 60° Valve seat refacingCutter clip, 5mmUniversal holder E017 Holding clutch for removalBearing driver (32x35mm) E014 Bearing installationPilot, 12mm E014 Bearing installationPilot, 15mm E014 Bearing installationPilot, 17mm E014 Bearing installationFlywheel puller E003 A.C. generator flywheel removalRear shock absorber compressor F004 Rear shock absorber disassemblySteering head bearing remover F005 Steering head bearing removalFlywheel holder E021 A.C. generator flywheel holdingReamer clipFuel unit wrench Fuel unit removal


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


1-11

GRAND DINK 125/150

FRAMEThe 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 avoidabnormal noise and rise the durability of the motorcycle.

Seat Lock

Rear Wheel Bearing

Grease

Speedometer CableThrottle Cable

Speedometer Gear/Front Wheel Bearing

Engine Oil

Grease

GreaseGrease

Front Brake Lever Pivot


1-12

GRAND DINK 125/150

CABLE & HARNESS ROUTING

Radiator

Front BrakeRear Brake

Speedometer Cable

Horn

PressureTypeRadiator Cap

Radiator AirVent Tube


1-13

GRAND DINK 125/150

Front Brake Fluid Tube

Fuel Strainer

Fuel TankInlet Tube

Water Hose

Ignition Switch

Fuel Filler

Water Hoses

ThermostaticSwitch

Fuel TankBreather Tube

Reserve Tank Cap


1-14

GRAND DINK 125/150

Throttle CableRadiator AirVent Tube

Rear Brake FluidTube

Fuel Tank InletTube

Water Hose

Fuel Filler

Fuel TankBreather Tube

Throttle Cable

Front StopSwitch

Wire Harness

Fuel Tank

Rear StopSwitch


1-15

GRAND DINK 125/150

Starter Relay

Fuel Tube

Battery (+) Cable

Battery (-) Cable

Ignition Coil

Auto Bystarter Wire

Thermostat

Carburetor

Air Cut-offValve (A.C.V.)

Regulator/Rectifier

C.D.I.

Fuse Box

Starter Motor

Fuel Unit

Hazard ControlUnit


1-16

GRAND DINK 125/150

Fuel Tube

Ignition Coil

Thermostat

Air Cut-offValve (A.C.V.)

Fuel Tube

Auto Bystarter

Spark Plug

FuelPump

Fuel Unit Wire

Wire Harness

Throttle Cable

Vacuum

Vacuum

Fuel Pump Vacuum Tube

Fuel PumpVacuum Tube

Ignition Coil

Starter Relay

Regulator/Rectifier


1-17

GRAND DINK 125/150

WIRING DIAGRAM


1-18

GRAND DINK 125/150

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

ÅEmpty fuel tankÇClogged carburetor fuel inlet

tube, vacuum tube or fuel tubeÉClogged auto fuel valveÑClogged float oil passageÖClogged fuel tank cap

breather holeÜClogged fuel straineráClogged fuel filteràFaulty fuel pump

ÅFaulty spark plugÇFouled spark plugÉFaulty CDI unitÑFaulty A.C. generatorÖBroken or shorted ignition coilÜBroken or shorted exciter

coiláFaulty ignition switch

ÅStarter motor idles butcrankshaft does not rotateÇValve clearance too smallÉImproper valve and seat

contactÑWorn cylinder and piston ringsÖBlown cylinder head gasketÜFlaws in cylinder headáSeized valveàImproper valve timing

ÅFaulty auto bystarterÇAir leaking through intake

pipeÉIncorrect ignition timingÑIncorrectly adjusted pilot

screw

ÅFlooded carburetorÇFaulty auto bystarterÉThrottle valve excessively

open

Check if fuel reachescarburetor byloosening drain screw

Remove spark plugand install it intospark plug cap to testspark by connecting itto 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 cylindercompression

Start engine by follow-ing normal startingprocedure

Remove spark plug andinspect again

Symptom

Fuel reaches carburetor

Fuel does not reach carburetor

Wet spark plugDry spark plug


1-19

GRAND DINK 125/150

ENGINE LACKS POWER

ÅClogged air cleanerÇRestricted fuel flowÉClogged fuel line between fuel

tank and carburetorÑClogged exhaust mufflerÖFaulty auto bystarterÜSplit carburetor vacuum piston

diaphragm

ÅFaulty CDI unitÇFaulty A.C. generator

ÅImproper valve clearanceadjustmentÇWorn valve seat (valve stem too

protruding

ÅImproper valve and seat contactÇWorn cylinder and piston ringsÉBlown cylinder head gasketÑFlaws in cylinder headÖImproper valve timing

ÅClogged carburetor jets

ÅFouled spark plugÇIncorrect heat range plug

ÅOil level too highÇOil level too lowÉOil not changed

ÅClogged oil pipeÇFaulty oil pump

ÅInsufficient coolantÇFaulty thermostatÉWorn cylinder and piston ringsÑMixture too leanÖPoor quality fuelÜExcessive carbon buildup in

combustion chamberáIgnition timing too earlyàAir in cooling system

ÅExcessive carbon build-up incombustion chamberÇPoor quality fuelÉClutch slippingÑMixture too leanÖ Ignition timing too early

Start engine and acceleratelightly 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 forclogging

Rapidly accelerate or runat high speed

Remove spark plug andinspect

Check if engine overheats

Check valve clearance

Correct Incorrect

Normal compression

Abnormal compression

Not Clogged Clogged

Remove oil dipstick andcheck oil level and condition

Remove cylinder head oilpipe 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 lubricatedproperly

Valve train notlubricated properly

Engine does not knock Engine knocks


1-20

GRAND DINK 125/150

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)


ÅMixture too rich (turn screwout)ÇMixture too lean (turn screw

in)

ÅDamaged insulator rubberÇCarburetor not securely

tightenedÉFaulty intake manifold

gasketÑDeformed carburetor O-ring

ÅFaulty or fouled spark plugÇFaulty CDI unitÉFaulty A.C. generatorÑFaulty ignition coilÖBroken or shorted high

tension wireÜFaulty ignition switch

ÅDamaged air cut-off valvediaphragmÇDamaged air cut-off valve

spring

Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground


Check ignition timing

Check carburetor aircut-off valve

Check carburetorgasket for air leaks

Check carburetor pilotscrew adjustment

Correct timing Incorrect timing

Correctly adjusted

No air leak Air leaks

Good spark Weak or inter- mittent spark

Good Faulty

Incorrectly adjusted


1-21

GRAND DINK 125/150

POOR PERFORMANCE (AT HIGH SPEED)


ÅImproperly adjusted valveclearanceÇWorn valve seat

ÅEmpty fuel tankÇClogged fuel tube or filterÉFaulty fuel pumpÑCracked fuel pump vacuum

tube

ÅClean and unclog

ÅCam timing gear aligningmarks not aligned

ÅFaulty spring


Check ignition timing

Check carburetor jetsfor clogging

Check fuel pump forfuel supply

Correct timing Incorrect timing

Check valve springtension

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


1-22

GRAND DINK 125/150

ENGINE NOISE

ÅValve clearance too large

ÇWorn camshaft lobe

ÅWorn piston rings

ÇWorn piston pin and connecting rodsmall endÉExcessive carbon build-up in combustion

chamber

ÅDamaged cam chain tensionerÇWorn cam gear teethÉWorn or damaged cam chainÑExtended 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


1-23

GRAND DINK 125/150

CLUTCH, DRIVE AND DRIVEN PULLEYS

ÅWorn or slipping drive beltÇBroken ramp plateÉBroken drive face springÑSeparated clutch liningÖDamaged driven pulley shaft splinesÜDamaged final gearáSeized final gear

ÅBroken shoe spring

ÇClutch outer and clutch weight stuck

ÉSeized pivot

ÅWorn or slipping drive beltÇWorn weight rollersÉSeized drive pulley bearingsÑWeak driven face springÖWorn or seized driven pulley bearings

ÅWorn or slipping drive beltÇWorn weight rollersÉWorn or seized driven pulley bearings

ÅOil or grease fouled drive beltÇWorn drive beltÉWeak driven face springÑWorn or seized driven pulley bearings

Engine starts butmotor-cycle does notmove

Engine lacks power atstart of a grade(poorslope performance)

Symptom Probable Cause

Engine lacks power athigh speed

There is abnormalnoiseor smell while running

Motorcycle creeps orengine starts but soonstops or seems to rushout (Rear wheelrotates when engineidles)


1-24

GRAND DINK 125/150

STARTER MOTOR1. Starter motor won‘t turn

ÅBurned out fuseÇWeak or dead batteryÉFaulty stop switchÑLoose or disconnected

connectorsÖBroken or shorted ignition

switch wire

ÅFaulty or weak battery

ÅPoor starter buttonconnectionÇOpen or shorted starter relayÉLoose or disconnected

connectors

ÅWorn brushesÇOpen or shorted wires or

rotorÉOpen starter motor cableÑLoose connectors

ÅOpen wire harness2. Starter motor turns slowly or idles

ÅWeak or dead battery

ÅLoose connector or terminalÇPoor contact in starter relayÉFaulty starter clutch

ÅSeized cylinder

ÅBroken or shorted startermotor cable

3. Starter motor does not stop turning

ÅFaulty starter pinion

ÅStarter relay shorted or stuck

Inspection/Adjustment



Symptom

Symptom

Symptom

Check operation ofstop switch byapplying brake

Stoplight does notcome on

Stoplight comesonCheck battery

circuit by operatingturn signals

Check batterycircuit by operatingturn signals

Turn ignitionswitchOFF

Probable Cause

Probable Cause

Probable Cause

Signals operate properly

Signals dim, remainon or don‘toperateCheck operation ofstarter relay by

depressing starterbutton

Connect startermotor directly tobattery

Connect startermotor directly tobattery

Starter motor turns slowly

Starter motor turns normally


Signals dim, remainon or don‘t operate

Not stopped Stopped

Rotate crankshaft

Starter motorturns

Starter does notturn

Relay operates properly

Relay does not operate

Turns easily Hard to turn


1-25

GRAND DINK 125/150

closed

NO SPARK AT SPARK PLUG

ÅFaulty spark plug

ÅFaulty spark plug

ÅPoorly connected coupler

ÅFaulty ignition switchÇFaulty exciter coilÉFaulty pulser coilÑFaulty ignition coil

ÅBroken wire harnessÇPoorly connected coupler

ÅFaulty CDI unit

ÅFaulty ignition coil

Replace with a newspark plug and inspectagain

Check CDI unitcoupler for looseness


Normal

Abnormal

Normal

Abnormal

Normal Abnormal

Abnormal

Measure resistancebetween terminals ofCDI unit coupler

Check related parts

Check ignition coilwith a CDI unit tester

Weak or no spark

Not loose

Good spark

Loose

Good Good

Check spark plug capand high-tension wirefor looseness

Check CDI unit with aCDI unit tester


1-26

GRAND DINK 125/150

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging

ÅFaulty AC generatorÇFaulty regulator/rectifierÉFaulty battery

ÅShorted AC generator coilÇOpen circuit between AC

generator 3 yellow wires

ÅFaulty regulator/rectifierÇFaulty AC generatorÉLoose regulator/rectifier

couplerÑLimit voltage too high

Overcharging

ÅFaulty batteryÇFaulty regulator/rectifierÉBroken or poorly

connectedregulator/rectifier black wire

ÅLimit voltage too high

Start engine and testlimit voltage ofbattery terminals

Measure battery limitvoltage with anelectric tester

Test output voltage ofregulator/rectifiercoupler red wire



Symptom

Symptom

Probable Cause

Probable Cause

Normal voltage

Normal

Normal

Voltage does not increase

Abnormal

Resistance toolow

Normal voltage No voltage

Measure resistancebetween AC generatorcoil terminals

Check resistancebetween regulator/rectifier terminals

Normal Abnormal


1-27

GRAND DINK 125/150

FUEL GAUGE1. Pointer does not register correctly (Ignition switch ON)

ÅBurned out fuseÇWeak or dead batteryÉFaulty ignition switchÑLoose or disconnected

connectorsÖBroken wire harness

ÅFaulty float

ÅBroken or shorted fuelunit wire

ÅDisconnected connectorÇIncorrectly connected

connectorÉBroken or shorted wire in

fuel gauge2. Pointer fluctuates or swings (Ignition switch ON)

ÅBurned out fuseÇWeak or dead batteryÉFaulty ignition switchÑLoose or disconnected

connectorÖBroken wire harness

ÅPoor contact in fuel unit

ÅInsufficient damping oil infuel gauge

ÅLoose or disconnectedconnectorÅBroken or shorted wire in

fuel gauge



Symptom

Symptom

Remove fuel unit andcheck operation ofpointer by movingfloat up and down

Remove fuel unit andcheck operation ofpointer by movingfloat up and down


Signals dim, remainon or don‘toperate


Signals dim,remainon or don‘toperate

Check battery circuitby operating turnsignals

Check battery circuitby operating turnsignals and horn

Probable Cause

Probable Cause

Pointer does not move Pointer moves

Pointer movesPointer does notmove

Check operation ofpointer by opening andshorting fuel unitterminal on wireharness side

Move float up anddown rapidly (1 round/sec.) to check theoperation of pointer

Pointer does not movePointer moves

Pointer does notmove in accord-ance with float

Pointer moves inaccordance withfloat

Good Faulty

Check connectors forproper connection

Check connectors forproper connection.

Good Faulty

Float up: FullFloat down: Empty


1-28

GRAND DINK 125/150

STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

(Front and rear tire pressures are normal)

ÅSteering stem nut too tightÇBroken steering steel balls

ÅExcessive wheel bearing playÇBent rimÉLoose axle nut

ÅMisaligned front and rear wheelsÇBent front fork

POOR SUSPENSION PERFORMANCE

(Front and rear tire pressures are normal)ÅWeak shock springÇExcessive loadÉShock damper oil leaking

ÅBent fork tube or shock rod

ÅFork tube and slider bindingÇFork spring and slider bindingÉDamaged shock stopper rubberÑLoose steering stem nut

POOR BRAKE PERFORMANCE

ÅWorn brake liningsÇForeign matter on brake liningsÉRough brake drum contacting area

ÅWorn brake liningsÇForeign matter on brake liningsÉRough brake drum contacting area

ÅWorn brake liningsÇWorn brake cam contacting area on

ÅWorn brake liningsÇForeign matter on brake linings

ÅSluggish or elongated brake cablesÇBrake shoes improperly contactÉWater and mud in brake systemÑOil or grease on brake linings

Steering is heavy

Suspension is too soft

Soft brake lever

Hard brake lever

Poor brakeperformance

Front or rear wheel iswobbling

Symptom

Symptom

Symptom

Probable Cause

Probable Cause

Probable Cause

Steering handlebar pullsto one side

Suspension is too hard

Suspension is noisy

Brake squeaks

Hard to brake

2. EXHAUST MUFFLER/FRAME COVERS

2-0

GRAND DINK 125/150

2 __________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

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

2


2-1

GRAND DINK 125/150

SCHEMATIC DRAWING


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 clawsmay 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

TROUBLESHOOTINGNoisy exhaust muffler

• Damaged exhaust muffler

• Exhaust muffler joint air leaks

Lack of power

• Caved exhaust muffler

• Clogged exhaust muffler

• Exhaust muffler air leaks


2-3

GRAND DINK 125/150

FRAME COVERS REMOVALREAR CARRIER & HAND RAILREMOVALRemove the met-in box:First remove the three bolts and two nutsattaching the met-in box.Remove the met-in box.

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

FRAME BODY COVER REMOVALRemove 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


2-4

GRAND DINK 125/150

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

Remove the two nuts and one bolt on theback taillight.

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

FLOOR BOARD REMOVALRemove the blot on the front right and leftside covers.

ScrewsMolding Cover

Nuts

Screws

Bolt

Side Cover

Blot


2-5

GRAND DINK 125/150

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

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

FRONT UPPER COVER REMOVALRemove the two screws on the front uppercover.Remove the front upper cover.

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

Bolts

Screws

Screws

Bolts

Bolt


2-6

GRAND DINK 125/150

FRONT COVER REMOVALFirst remove the front upper cover.Remove the two bolts attaching the frontcover.

Remove the six screws on the back of thefront cover.Disconnect the right/left turn signal light wireconnectors.Remove the front coverThe installation sequence is the reverse ofremoval.

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

BACK COVER REMOVALRemove 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


2-7

GRAND DINK 125/150

Remove the three screws attaching fuel tankinlet tube join.Remove the back cover.

BOTTOM COVER REMOVALRemove the side stand.Remove the four bolts attaching the bottomcover.Remove the bottom cover.

FRONT FENDER REMOVALRemove the two bolts attaching the fender.Remove the front fender cover.The installation sequence is the reverse ofremoval.

EXHAUST MUFFLER REMOVALRemove the two exhaust muffler joint locknuts.Remove the three exhaust muffler lock boltsto remove the exhaust muffler.Remove the exhaust muffler joint packingcollar.The installation sequence is the reverse ofremoval.Torque:Exhaust muffler joint lock nut:11.8N-mExhaust muffler lock bolt: 34.3N-m

Screws

Fuel Tank Inlet Tube

Bolts

Bottom Cover Side Stand

Bolts

Lock Bolts


2-8

GRAND DINK 125/150

HANDLEBAR COVER REMOVALFirst remove the three screws attaching thehandlebar under cover.Remove the handlebar under cover.

Remove the screw from the handlebar uppercover.

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

Screws

Screw

Screw

3. INSPECTION/ADJUSTMENT

3-0

GRAND DINK 125/150

3 __________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

INSPECTION/ADJUSTMENT__________________________________________________________________________________

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

3


3-1

GRAND DINK 125/150

SERVICE INFORMATION

GENERAL

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 carbonmonoxide gas which may cause death to people.

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

SPECIFICATIONS

ENGINEThrottle grip free play : 2_ 6mmSpark plug : NGK: DPR7EA9Spark plug gap : 0.9mmValve clearance : IN: 0.1mm EX: 0.1mmIdle 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±20ccGear oil capacity : Radiator capacity : 1000±20cc At disassembly : 0.20 liter Reserve tank capacity : 400±20cc At change : 0.18 liter

CHASSISFront/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


3-2

GRAND DINK 125/150

MAINTENANCE SCHEDULEPerform 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

comesfirst ! Ú

1000 2000 4000 6000 8000 10000

Engine oil R Newmotorcycle

300kmR R R R R

Engine oil filter screen Replace at every 6000 km(R)

Fuel filter screen R

Gear oil Note 3 R Newmotorcycle

300kmR R

Valve clearance A A A

Carburetor I I

Air Cleaner Note 2,3 I R R

Spark plug Clean at every 3000km and replace if necessary

Brake system I I I I I I

Drive belt I

Suspension I I

Nut, bolt, fastener I

Tire I I

Steering head bearing I I I

Brake fluid Perform pre-ride inspection daily

Radiator coolant Replace every year or at every 10000km (R)

Radiator core I I

Radiator cap I I

Brake lever I I

Brake shoe wear I I

Shock absorber I I

• In the interest of safety, we recommend these items be serviced only by an authorizedKYMCO 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


3-3

GRAND DINK 125/150

FUEL LINE/FUEL FILTERRemove the center cover.Check the fuel lines and replace any partswhich show signs of deterioration, damage orleakage.Check for dirty or clogged fuel filter andreplace with a new one if it is clogged.

THROTTLE OPERATIONCheck the throttle grip for smooth movement.Measure the throttle grip free play.Free Play: 2_ 6mm

Major adjustment of the throttle grip freeplay is made with the adjusting nut at thecarburetor side. Adjust by loosening the locknut and turning the adjusting nut.

Minor adjustment is made with the adjustingnut at the throttle grip side.Slide the rubber cover out and adjust byloosening the lock nut and turning theadjusting nut.

Lock Nut

Adjusting Nut

Fuel Filter

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

＊

Fuel Line

Lock Nut

Adjusting Nut


3-4

GRAND DINK 125/150

ENGINE OILOIL LEVEL INSPECTIONStop the engine and support the motorcycleupright on level ground.Wait for 2_ 3 minutes and check the oillevel with the dipstick. Do not screw in thedipstick when making this check.

OIL CHANGE

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

Pour the recommended oil through the oilfiller hole.Oil Capacity: At disassembly: 1.1 liter At change: 0.9 literRecommended Oil: SAE: 15W40# API: SJStart the engine and check for oil leaks.Stop the engine and recheck the oil level.

OIL FILTER SCREEN INSPECTIONDrain the engine oil.Remove the oil filter screen cap.Clean the oil filter screen.Install the oil filter screen, and filter screencap.Fill the engine with recommended engine oil.

• Drain the oil while the engine is warm.＊

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

＊

Oil Dipstick

Oil Filter Screen Cap

Oil Filter Screen



3-5

GRAND DINK 125/150

AIR CLEANERRemove the seven air cleaner case coverscrews and the cover.

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

CHANGE INTERVALMore frequent replacement is required whenriding in unusually dusty or rainy areas.

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

Specified Spark Plug: NGK: DP7EA9Measure the spark plug gap.Spark Plug Gap: 0.9mm

Torque: 7.8_ 9.8N-m ｝GapWearFoulingDeposits

Spark Plug

CracksDamage

• The air cleaner element has aviscous type paper element. Do notclean it with compressed air.

• Be sure to install the air cleanerelement and cover securely.

＊

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

＊

Screws

Air Cleaner Case Cover

Air Cleaner Element

Deformation

0.9mm


3-6

GRAND DINK 125/150

VALVE CLEARANCE

Remove the cylinder head cover.

Turn the A.C. generator flywheel to the topdead center (TDC) on the compression strokeso that the “T” mark on the flywheel alignswith the index mark on the left crankcasecover.

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

EX: 0.1mmLoosen the lock nut and adjust by turning theadjusting nut

Valve Wrench

CARBURETOR IDLE SPEED

Lift up the seat and remove the inspectioncover.Warm up the engine before this operation.Start the engine and connect a tachometer.Turn the throttle stop screw to obtain thespecified idle speed.Idle Speed: 1700rpmWhen the engine misses or run erratic, adjustthe pilot screw.

Throttle Stop Screw Pilot Screw

Feeler Gauge

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

＊

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

＊

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

＊

Cylinder Head Cover

Bolts

“T” Mark

Top Dead Center

Valve Wrench

Special


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 specifiedidle speed, the ignition timing is correct if the“F” mark on the flywheel aligns with theindex 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 theadvance marks.

CYLINDER COMPRESSIONWarm 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 thestarter button to test the compression.Compression: 15±2kg/cm_If the compression is low, check for thefollowing:_Leaky valves_Valve clearance to small_Leaking cylinder head gasket_Worn pistons_Worn piston/cylinderIf the compression is high, it indicates thatcarbon deposits have accumulated on thecombustion 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


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 recommendedoil SAE90# to the proper level.

Install the oil check bolt.

OIL CHANGERemove the oil check bolt.Remove the oil drain bolt and drain the oilthoroughly.Install the oil drain bolt.Torque: 9.8N-m

Fill the final reduction with the recommendedoil SAE90#.Gear Oil Capacity: At disassembly : 200cc At change : 180ccReinstall the oil check bolt and check for oilleaks.

DRIVE BELTRemove the left crankcase cover.Inspect the drive belt for cracks or excessivewear.Replace the drive belt with a new one ifnecessary and in accordance with theMaintenance Schedule.

Drive Belt

Oil Check Bolt Hole/Oil Filler

• Place the motorcycle on its main standon level ground.

＊

Oil Drain Bolt/Sealing Washer

• Make sure that the sealing washer is ingood condition.

＊

• Make sure that the sealing washer is ingood condition.

＊


3-9

GRAND DINK 125/150

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

CLUTCH SHOE WEARStart the engine and check the clutchoperation by increasing the engine speedgradually.If the motorcycle tends to creep, or the enginestalls, check the clutch shoes for wear andreplace if necessary.

COOLING SYSTEMCOOLANT LEVEL INSPECTIONPlace the motorcycle on its main stand onlevel ground.Check the coolant level of the reserve tankand the level should be between the upperand lower level lines.If necessary, fill the reserve tank withrecommended 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 coolantand tilt the motorcycle to the right and thecoolant 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 nomatter the engine is warm or cold. Fillto the “F” (upper) line.

＊

• The coolant freezing point should be5℃ lower than the temperature ofthe riding area.

＊

• Perform this operation when the engineis cold.

＊

Reserve Tank


3-10

GRAND DINK 125/150

Coolant capacity : 1400±20ccRadiator capacity : 1000±20ccReserve tank capacity : 400±20ccStart the engine and check if there is nobubbles in the coolant and the coolant level isstable. Reinstall the radiator cap.If there are bubbles in the coolant, bleed airfrom the system.Fill the reserve tank with the recommendedcoolant up to the upper line.

BRAKE SYSTEMBRAKE LEVERMeasure the front and rear brake lever freeplays.

BRAKE FLUIDTurn the steering handlebar upright and checkif the front/rear brake fluid level is at theupper limit. If the brake fluid is insufficient,fill to the upper limit.Specified Brake Fluid: DOT-4

BRAKE DISK/BRAKE PADCheck the brake disk surface for scratches,unevenness or abnormal wear.Check if the brake disk runout is within thespecified service limit.Check if the brake pad wear exceeds the wearindicator line.

Wear Indicator Line

Drain Bolt

Rear Brake Reservoir

Brake Disk

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

＊

• Keep grease or oil off the brake disk toavoid brake failure.

＊

Front Brake Reservoir


3-11

GRAND DINK 125/150

NUTS/BOLTS/FASTENERSCheck all important chassis nuts and bolts forlooseness.Tighten them to their specified torque valuesif any looseness is found.

WHEELS/TIRESCheck the tires for cuts, imbedded nails orother damages.Check the tire pressure.

Tire Pressure

1 Rider 2 Riders

Front 1.75kg/cm_ 1.75kg/cm_

Rear 2.00kg/cm_ 2.25kg/cm_

STEERING HANDLEBARRaise the front wheel off the ground andcheck that the steering handlebar rotatesfreely.If the handlebar moves unevenly, binds, orhas vertical movement, adjust the steeringhead bearing.

SUSPENSIONCheck the action of the front/rear shockabsorbers by compressing them several times.Check the entire shock absorber assembly foroil leaks, looseness or damage.Jack the rear wheel off the ground and movethe rear wheel sideways with force to see ifthe engine hanger bushings are worn.Replace the engine hanger bushings if there isany looseness.

• Tire pressure should be checked whentires are cold.

＊ Pressure Gauge

4. LUBRICATION SYSTEM

4-0

GRAND DINK 125/150

4 __________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

LUBRICATION SYSTEM__________________________________________________________________________________

LUBRICATION SYSTEM DIAGRAM-------------------------------- 4-1



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

4


4-1

GRAND DINK 125/150

LUBRICATION SYSTEM

Oil Pump

Oil Filter Screen

Crankshaft

Rocker Arm Shaft

Oil Filter Screen


4-2

GRAND DINK 125/150

SERVICE INFORMATION


• 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


4-3

GRAND DINK 125/150

ENGINE OIL/OIL FILTER

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

OIL CHANGE

Remove the oil drain bolt located at the leftside of the engine to drain the engine oil.After the oil has been completely drained,install the aluminum washer and tighten theoil drain bolt.Torque: 14.7N-mPour the recommended oil through the oilfiller hole.

OIL FILTER SCREENDrain the engine oil.Remove the oil filter screen cap.Remove the oil filter screen and spring.Check the oil filter screen for clogging ordamage and replace if necessary. Check thefilter screen O-ring for damage and replace ifnecessary.Install the oil filter screen, spring, O-ring andfilter screen cap.Torque: 14.7N-mRecommended Oil: SAE15W40# API: SG/CD Oil Capacity: At disassembly: 1.1 liter At change: 0.9 literStart the engine and check for oil leaks. Startthe engine and let it idle for few minutes, thenrecheck the oil level.

Oil Dipstick

Oil Drain Bolt


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

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

＊

• The engine oil will drain moreeasily while the engine is warm.

＊


4-4

GRAND DINK 125/150

Circlip

Bolts

Oil Pump Driven Gear

Oil Separator

OIL PUMP REMOVALFirst drain the coolant.Remove the right crankcase cover. (!10-3)Remove the A.C. generator starter drivengear. (!10-4)Remove the attaching bolt and oil separatorcover.

Pry the circlip off and remove the oil pumpdriven gear, then remove the oil pump drivechain.

Remove the two oil separator bolts to removethe oil pump.

OIL PUMP DISASSEMBLYRemove the screw and disassemble the oilpump as shown.

Oil Separator Cover

Oil Pump


4-5

GRAND DINK 125/150

Outer Rotor

Inner RotorOuter Rotor

Outer Rotor Inner Rotor

Dowel Pin

Pump Body Rotor End

Pump Body

Pump Shaft

OIL PUMP INSPECTIONMeasure the pump body-to-outer rotorclearance.Service Limit: 0.25mm replace if over

Measure the inner rotor-to-outer rotorclearance.Service Limit: 0.20mm replace if over

Measure the rotor end-to-pump bodyclearance.Service Limit: 0.12mm replace if over

OIL PUMP ASSEMBLYInstall the outer rotor, inner rotor and pumpshaft into the pump body.

There is one mark on the surface of the innerrotor and outer rotor.The mark is upside.

Insert the pump shaft by aligning the flaton the shaft with the flat in the innerrotor. Install the dowel pin.

＊

Pump Body


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 inthe cover with the dowel pin.Tighten the screw to secure the pump cover.Make sure that the pump shaft rotates freelywithout binding.

OIL PUMP INSTALLATIONInstall the oil pump and oil separator andtighten 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 pumpshaft.

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 theslit in the separator.

＊

Dowel Pin

Hole

Oil Separator

Pump Drive Chain

Arrow Mark

5. ENGINE REMOVAL/INSTALLATION

5-0

GRAND DINK 125/150

5 __________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

ENGINE REMOVAL/INSTALLATION__________________________________________________________________________________



ENGINE REMOVAL --------------------------------------------------- 5-3

ENGINE INSTALLATION -------------------------------------------- 5-5

5


5-1

GRAND DINK 125/150

SCHEMATIC DRAWING


5-2

GRAND DINK 125/150

SERVICE INFORMATION


• A floor jack or other adjustable support is required to support and maneuver the engine. Becareful 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: 30kgEngine oil capacity: at disassembly: 1.1 liter

: at change 0.9 literCoolant capacity:

Total capacity : 1400±20ccRadiator capacity : 1000±20ccReserve tank capacity : 400±20cc

TORQUE VALUES

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


5-3

GRAND DINK 125/150

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

Disconnect the starter motor wire that goes tothe starter relay.

Disconnect the fuel tube and vacuum tubethat go to the carburetor from the fuel pump.Disconnect the vacuum tube from the air cut-off valve (ACV).Disconnect the throttle cable from thecarburetor.

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

Starter Relay

Wire Connectors

Rear Brake Caliper

ACV Vacuum Tube

Fuel TubeThrottle Cable

Fuel Pump Vacuum Tube

Brake Fluid Tube

Rear Brake Caliper


5-4

GRAND DINK 125/150

Remove the right/left rear shock absorberupper mount bolts.

Remove the two engine mounting bolts andpull out the engine with the engine hangerbackward.

ENGINE HANGER REMOVALRemove the engine hanger bolts to remove theengine hanger.

Inspect the engine hanger bushings andstopper rubber for wear or damage.

Bushings

Rear Shock Absorber Upper Mount Bolts

Engine Hanger Bolt

Stopper Rubber

Bolt Engine Hanger


5-5

GRAND DINK 125/150

ENGINE INSTALLATIONInstall the engine in the reverse order ofremoval.Tighten the engine mounting bolts.

Torque: 49N-m

Tighten the rear shock absorber upper mountbolts.Torque: 39.2N-mAfter installation, inspect and adjust thefollowing:• 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 thesystem.

Engine Hanger Bolt

Rear Shock Absorber Upper Mount Bolts

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

6


6-1

GRAND DINK 125/150

SCHEMATIC DRAWING


6-2

GRAND DINK 125/150

SERVICE INFORMATION


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

• When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movableparts 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

IN 0.10 0.10 æ æEX 0.10 0.10 æ æ

Cylinder head compression pressure 15kg/cm_ 15kg/cm_ æCylinder head warpage æ æ 0.05 0.05

IN 30.8763 30.8763 30.75 30.75EX 30.4081 30.4081 30.26 30.26IN 10.00_ 10.018 10.00_ 10.018 10.10 10.10EX 10.00_ 10.018 10.00_ 10.018 10.10 10.10

Valve rocker arm shaft IN 9.972_ 9.987 9.972_ 9.987 9.9 9.9O.D. EX 9.972_ 9.987 9.972_ 9.987 9.9 9.9

IN 1.2 1.2 1.8 1.8EX 1.2 1.2 1.8 1.8IN 4.990_ 4.975 4.990_ 4.975 4.925 4.925EX 4.970_ 4.955 4.970_ 4.955 4.915 4.915IN 5.00_ 5.012 5.00_ 5.012 5.03 5.03EX 5.00_ 5.012 5.00_ 5.012 5.03 5.03

Valve stem-to-guide IN 0.010_ 0.037 0.010_ 0.037 0.08 0.08clearance EX 0.030_ 0.057 0.030_ 0.057 0.10 0.10

TORQUE VALUES

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

SPECIAL TOOLS

Valve spring compressorValve seat cutter, 24.5mm 45° IN-EXValve seat cutter, 25mm Plane cutter 37.5° EXValve seat cutter, 22mm Plane cutter 37.5° EXValve seat cutter, 26mm Plane cutter 63.5° IN/EXCutter clipValve guide driverValve guide reamer

Valve clearance (cold)

Valve rocker arm I.D.

Valve stem O.D.

Valve guide I.D.

Camshaft cam height

Valve seat width


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 sealCompression 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


6-4

GRAND DINK 125/150

CYLINDER HEAD COVERREMOVALRemove the center cover. (!2-3)Remove the met-in box. (!2-3)Remove the cylinder head cover four boltsand then remove the cylinder head cover.

CAMSHAFT REMOVALTurn the A.C. generator flywheel so that the“T” mark on the flywheel aligns with theindex mark on the crankcase.Hold the round hole on the camshaft gearfacing up and the location is the top deadcenter on the compression stroke.Remove the two bolts attaching cam chaintensioner and the tensioner.

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

Remove the camshaft holder and dowel pins.

Cylinder Head Cover

Bolt

Cam Chain Tensioner Round HoleCamshaft Holder

Bolts

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

＊

Camshaft Holder

Cap Nuts


6-5

GRAND DINK 125/150

Remove the camshaft gear from the cam chainto remove the camshaft.

CAMSHAFT INSPECTIONCheck 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 ordamage. Replace the camshaft assembly witha new one if the bearings are noisy or haveexcessive play.

CAMSHAFT HOLDER DISASSEMBLYTake out the valve rocker arm shafts using a6mm bolt.Remove the valve rocker arms.

Cam Chain

Camshaft Gear

Camshaft Bearings

6mm Bolt

Valve Rocker Arms

Rocker Arm Shafts


6-6

GRAND DINK 125/150

CAMSHAFT HOLDER INSPECTIONInspect the camshaft holder, valve rockerarms and rocker arm shafts for wear ordamage.

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

EX: 10.10mm replace if overMeasure each rocker arm shaft O.D.Service Limits: IN: 9.90mm replace if below

EX: 9.90mm replace if below

CYLINDER HEAD REMOVALFirst drain the coolant from the radiator andwater jacket, then remove the thermostatwater hose.Remove the camshaft. (!6-4)Remove the carburetor and intake manifold.Remove the bolt attaching the thermostathousing and the thermostat housing.Remove the cylinder head.

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

Bolt

Intake Manifold

Cam Chain Tensioner Slipper

Camshaft Holder

If the valve rocker arm contact surface isworn, check each cam lobe for wear ordamage.

＊

Be careful not to drop any gasketmaterial into the engine.

＊

Rocker Arm Shafts

Cylinder

Cylinder Head Gasket


6-7

GRAND DINK 125/150

CYLINDER HEAD DISASSEMBLYRemove the valve spring cotters, retainers,springs, spring seats and valve stem sealsusing a valve spring compressor.

Remove carbon deposits from the exhaustport and combustion chamber.

Valve Spring Compressor

Cylinder Head

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

• Mark all disassembled parts toensure correct reassembly.

＊

Be careful not to damage the cylinderhead mating surface.

＊

Exhaust Port

Combustion Chamber


6-8

GRAND DINK 125/150

INSPECTIONCYLINDER HEADCheck the spark plug hole and valve areas forcracks.Check the cylinder head for warpage with astraight edge and feeler gauge.Service Limit: 0.05mm repair or replace if

over

VALVE SPRING FREE LENGTHMeasure the free length of the inner and outervalve springs.Service Limits:

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

VALVE /VALVE GUIDEInspect 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

belowEX: 4.915mm replace ifbelow

CYLINDER HEAD ASSEMBLYInstall the valve spring seats and stem seals.Lubricate each valve stem with engine oil andinsert the valves into the valve guides.Be sure to install new valve stem seals.

Straight Edge

Feeler Gauge

Valve Spring Compressor


6-9

GRAND DINK 125/150

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

CYLINDER HEAD INSTALLATIONInstall the cam chain guide.Install the dowel pins and a new cylinderhead gasket.

Install the cylinder head and take out the camchain

Assemble the camshaft holder.First install the intake and exhaust valverocker 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 rockerarm shaft on the “EX” side of thecamshaft holder and the exhaust rockerarm shaft is shorter.

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

• Align the cutout on the exhaustvalve rocker arm shaft with the bolt ofthe camshaft holder.

＊


6-10

GRAND DINK 125/150

CAMSHAFT INSTALLATIONTurn the A.C. generator flywheel so that the“T” mark on the flywheel aligns with theindex mark on the crankcase.Keep the round hole on the camshaft gearfacing up and align the punch marks on thecamshaft gear with the cylinder head surface(Position the intake and exhaust cam lobesdown.) and install the cam chain over thecamshaft gear.

Install the dowel pins.

Install the camshaft holder, washers and nutson the cylinder head.Tighten the four cylinder head nuts and thetwo bolts between the cylinder head andcylinder.Torque: Cylinder head cap nut: 19.6N-m

Cylinder & cylinder head bolt:7.8_ 11.8N-m

Dowel Pins

NutWasher

Punch Marks

Bolts

Cam ChainRound Hole

• Apply engine oil to the threadsof the cylinder head cap nuts.

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

• First tighten the cylinder headcap nuts and then tighten the boltsbetween the cylinder and cylinder headto avoid cracks.

＊


6-11

GRAND DINK 125/150

Install a new cam chain tensioner gasket.Release the lock pawl and push the push rodall the way in.

Install the cam chain tensioner and tighten thetwo bolts.Install the tensioner spring and tighten thesealing bolt.Torque: 2.9_ 5.8N-m

CYLINDER HEAD COVERINSTALLATIONAdjust the valve clearance. (!3-6)Install a new cylinder head cover O-ring andinstall the cylinder head cover.

Install and tighten the cylinder head coverbolts.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 thegroove properly.

＊

7. CYLINDER/PISTON

7-0

GRAND DINK 125/150

7 __________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

CYLINDER/PISTON__________________________________________________________________________________




CYLINDER REMOVAL------------------------------------------------ 7-3

PISTON REMOVAL ---------------------------------------------------- 7-3

PISTON INSTALLATION --------------------------------------------- 7-7

CYLINDER INSTALLATION----------------------------------------- 7-7

7

7. CYLINDER/PISTON

7-1

GRAND DINK 125/150

SCHEMATIC DRAWING

7. CYLINDER/PISTON

7-2

GRAND DINK 125/150

SERVICE INFORMATION


• 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.

SPECIFICATIONSStandard (mm) Service Limit (mm)

Item SH30DA SH25DA SH30DA SH25DAI.D. 57.405_ 57.

415

52.400_ 52.

410

57.50 52.50

Warpage 0.01 0.01 0.05 0.05

Cylindricity 0.01 0.01 0.05 0.05

True roundness 0.01 0.01 0.05 0.05

Ring-to-groove top 0.015_ 0.050

0.015_ 0.05

0

0.09 0.09

clearance Second 0.015_ 0.050

0.015_ 0.05

0

0.09 0.09

top 0.15_ 0.30 0.15_ 0.30 0.50 0.50

Piston, Ring end gap Second 0.15_ 0.30 0.15_ 0.30 0.50 0.50

piston ring Oil side rail 0.2_ 0.9 0.2_ 0.9 æ æ

Piston O.D. 57.375_ 57.395

52.370_ 52.

390

57.30 52.30

Piston O.D. measuring position 9mm frombottom of skirt9mm from

bottom of skirt9mm frombottom ofskirt

9mm frombottom of skirt

. Piston-to-cylinder clearance 0.010_ 0.040

0.010_ 0.04

0

0.01 0.01

Piston pin hole I.D. 15.002_ 15.008

15.002_ 15.

008

15.04 15.04

Piston pin O.D 14.994_ 15.000

14.994_ 15.

000

14.96 14.96

Piston-to-piston pin clearance 0.002_ 0.014

0.002_ 0.01

4

0.02 0.02

Connecting rod small end I.D. bore 15.016_ 15.034

15.016_ 15.

034

15.06 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 unevencompression 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

7. CYLINDER/PISTON

7-3

GRAND DINK 125/150

CYLINDER REMOVALRemove 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 cylindersurface.

PISTON REMOVALRemove 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 crankcaseto keep the piston pin clip from fallinginto the crankcase.

＊

7. CYLINDER/PISTON

7-4

GRAND DINK 125/150

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

Clean carbon deposits from the piston ringgrooves.

Install the piston rings onto the piston andmeasure the piston ring-to-groove clearance.Service Limits:

Top: 0.09mm replace if over2nd: 0.09mm replace if over

Remove the piston rings and insert eachpiston 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 thepiston rings during removal.

＊

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

＊

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 INSPECTIONInspect the cylinder bore for wear or damage.Measure the cylinder I.D. at three levels oftop, middle and bottom at 90° to the pistonpin (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 betweenthe values measured in X and Y directions.The cylindricity (difference between thevalues measured at the three levels) is subjectto 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 thebottom and 90° to the piston pin hole.

＊

Middle

Bottom

Top

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

Second

Side Rail

Top• Be careful not to damage thepiston and piston rings duringassembly.

• All rings should be installed withthe markings facing up.

• After installing the rings, theyshould rotate freely without sticking.

• Stagger the ring end gaps as thefigure shown.

＊

Second

Top

Side RailOil Ring

7. CYLINDER/PISTON

7-7

GRAND DINK 125/150

PISTON INSTALLATIONRemove any gasket material from thecrankcase surface.

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

CYLINDER INSTALLATIONInstall the dowel pins and a new cylindergasket on the crankcase.

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

Gasket

Cylinder

Dowel Pin

• Be careful not to drop foreign mattersinto the crankcase.

＊

• Position the piston “IN” markon the intake valve side.

• Place a clean shop towel in thecrankcase to keep the piston pin clipfrom falling into the crankcase.

＊

• Be careful not to damage or breakthe piston rings.

• The piston ring end gaps shouldnot be parallel with or at 90° to thepiston pin.

＊

Piston

Piston Pin Clip Piston Pin

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 guideinto the cylinder groove.

＊

Cylinder Base Bolt

Cam Chain Guide

8. DRIVE AND DRIVEN PULLEYS/KICK STARTER

8-0

GRAND DINK 125/150

8 __________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

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

8


8-1

GRAND DINK 125/150

SCHEMATIC DRAWING


8-2

GRAND DINK 125/150

SERVICE INFORMATION


• The d

Documents

PREFACE TABLE OF CONTENTSkymcoman.free.fr/revue technique/REVUE TECHNIQUE V1.0.pdf · 2006. 11. 14. · Name & Model No. SH25DA Motorcycle Name & Type Overall length 2060mm Overall