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KYMCO GRAND DINK 125 User Manual

KYMCO GRAND DINK 125
224 pages
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GRAND DINK 125/150
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO GRAND
DINK 125/150.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.
Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 5 through 13 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 14 is the
removal/ installation of chassis. Section
16 states the testing and measuring
methods of electrical equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
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 TANK
13
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 /
T HERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
19
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
CHASSIS
EQUIPMENT
ENGINE

Table of Contents

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KYMCO GRAND DINK 125 Specifications

General IconGeneral
Displacement124.6 cc
TransmissionCVT
Front SuspensionTelescopic fork
Front BrakeDisc
Rear BrakeDrum
Seat Height780 mm
Starting SystemElectric
Cooling SystemLiquid-cooled

Summary

1. General Information

Motorcycle Specifications

Technical specifications of the motorcycle.

Service Precautions

Important safety and operational precautions.

Torque Values

Specified torque values for fasteners.

Wiring Diagram

Electrical wiring diagram for the motorcycle.

Troubleshooting Guide

Troubleshooting guide for common issues.

Starter Motor Troubleshooting

Troubleshooting starter motor problems.

No Spark at Spark Plug Troubleshooting

Troubleshooting no spark issues at the spark plug.

Charging System Troubleshooting

Troubleshooting battery charging issues.

Steering Alignment Troubleshooting

Troubleshooting steering alignment issues.

Suspension Performance Troubleshooting

Troubleshooting suspension performance issues.

Brake Performance Troubleshooting

Troubleshooting brake performance issues.

2. Exhaust Muffler and Frame Covers

Exhaust and Frame Covers Troubleshooting

Troubleshooting exhaust and frame cover issues.

Frame Covers Removal Procedures

Procedures for removing frame covers.

Exhaust Muffler Removal Procedure

Procedure for removing the exhaust muffler.

3. Inspection and Adjustment

Periodic Maintenance Schedule

Schedule for periodic maintenance.

Engine Oil and Filter Maintenance

Inspection and maintenance of engine oil and oil filter.

Valve Clearance Inspection and Adjustment

Inspection and adjustment of valve clearance.

Ignition Timing Check

Checking and adjusting ignition timing.

Cylinder Compression Test

Testing cylinder compression.

Cooling System Maintenance

Inspection and maintenance of the cooling system.

Coolant Replacement Procedure

Procedure for replacing engine coolant.

Brake System Inspection

Inspection and maintenance of the brake system.

Brake Fluid Check and Refill

Checking and refilling brake fluid.

Brake Disc and Pad Inspection

Inspecting brake discs and pads for wear.

4. Lubrication System

Lubrication System Troubleshooting

Troubleshooting lubrication system issues.

Engine Oil and Oil Filter Maintenance

Maintenance of engine oil and oil filter.

Oil Pump Removal Procedure

Procedure for removing the oil pump.

Oil Pump Disassembly Procedure

Disassembly of the oil pump.

Oil Pump Inspection Procedure

Inspection of the oil pump components.

Oil Pump Assembly Procedure

Assembly of the oil pump.

Oil Pump Installation Procedure

Installation of the oil pump.

5. Engine Removal and Installation

Engine Removal Procedure

Procedure for removing the engine.

Engine Installation Procedure

Procedure for installing the engine.

6. Cylinder Head and Valves

Cylinder Head and Valves Troubleshooting

Troubleshooting cylinder head and valve issues.

Cylinder Head Cover Removal Procedure

Procedure to remove the cylinder head cover.

Camshaft Removal Procedure

Procedure to remove the camshaft.

Cylinder Head Removal Procedure

Procedure to remove the cylinder head.

Cylinder Head Disassembly Procedure

Disassembly of the cylinder head.

Cylinder Head Assembly Procedure

Assembly of the cylinder head.

Cylinder Head Installation Procedure

Installation of the cylinder head.

Camshaft Installation Procedure

Installation of the camshaft.

Cylinder Head Cover Installation Procedure

Installation of the cylinder head cover.

Camshaft Inspection

Inspecting the camshaft for wear and measuring lobe height.

Camshaft Holder Disassembly

Disassembly of the camshaft holder.

Camshaft Holder Inspection

Inspecting camshaft holder, rocker arms, and shafts.

Cylinder Head Inspection

Checking cylinder head for cracks, warpage.

Valve and Valve Guide Inspection

Inspecting valves and guides for wear.

7. Cylinder and Piston

Cylinder and Piston Troubleshooting

Troubleshooting cylinder and piston issues.

Cylinder Removal Procedure

Procedure for removing the cylinder.

Piston Removal Procedure

Procedure for removing the piston.

Piston Installation Procedure

Procedure for installing the piston.

Cylinder Installation Procedure

Procedure for installing the cylinder.

Piston Inspection

Inspecting piston, rings and measuring clearances.

Cylinder Inspection

Inspecting cylinder bore for wear, roundness, and cylindricity.

8. Drive and Driven Pulleys / Kick Starter

Pulleys and Kick Starter Troubleshooting

Troubleshooting pulley and kick starter issues.

Left Crankcase Cover Service

Removal and installation of the left crankcase cover.

Drive Pulley Service

Service and inspection of the drive pulley.

Clutch and Driven Pulley Service

Service and inspection of the clutch and driven pulley.

Kick Starter Service

Service and inspection of the kick starter.

Driven Pulley Face Bearing Replacement

Replacing bearings in the driven pulley face.

Clutch Disassembly Procedure

Disassembly of the clutch assembly.

Clutch Assembly Procedure

Assembly of the clutch components.

9. Final Reduction

Final Reduction Troubleshooting

Troubleshooting final reduction issues.

Final Reduction Disassembly Procedure

Procedure for disassembling the final reduction.

Final Reduction Inspection Procedure

Inspecting final reduction gears and bearings.

Final Reduction Assembly Procedure

Assembly of the final reduction gears.

Transmission Case Cover Bearing Replacement

Replacing bearings in the transmission case cover.

Left Crankcase Cover Bearing Replacement

Replacing bearings in the left crankcase cover.

10. A.C. Generator and Starter Clutch

A.C. Generator/Starter Clutch Troubleshooting

Troubleshooting A.C. generator and starter clutch issues.

Right Crankcase Cover Removal

Procedure to remove the right crankcase cover.

Stator Removal Procedure

Procedure to remove the stator.

Flywheel Removal Procedure

Procedure to remove the flywheel.

Starter Clutch Service

Service and inspection of the starter clutch.

Flywheel Installation Procedure

Installation of the flywheel.

Stator Installation Procedure

Installation of the stator.

11. Crankcase and Crankshaft

12. Cooling System

13. Fuel System, Carburetor, Fuel Pump, Fuel Tank

14. Steering Handlebar, Front Wheel, Front Brake, Front Shock Absorber, Front Fork

15. Rear Brake, Rear Fork, Rear Wheel, Rear Shock Absorber

16. Battery and Charging System

17. Ignition System

18. Starting System

19. Switches, Horn, Fuel Unit, Thermostatic Switch, Temperature Gauge, Instruments, Lights

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