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KYMCO GRAND DINK 250 User Manual

KYMCO GRAND DINK 250
224 pages
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GRAND DINK 250
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO Grand Dink
250.
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/
THERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
19
ENGINE CHASSIS
ELECTRICAL
E
Q
UIPMENT
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.

Table of Contents

Other manuals for KYMCO GRAND DINK 250

Questions and Answers:

KYMCO GRAND DINK 250 Specifications

General IconGeneral
Displacement249.1 cc
Cooling SystemLiquid-cooled
Fuel SystemElectronic Fuel Injection
TransmissionCVT
Front SuspensionTelescopic fork
Rear SuspensionDual shock absorbers
Front BrakeDisc
Rear BrakeDisc
Front Tire120/70-12
Rear Tire130/70-12
Seat Height780 mm
Engine Type4-stroke, Single-cylinder

Summary

GENERAL INFORMATION

ENGINE SERIAL NUMBER

Identifies the engine serial number location.

SPECIFICATIONS

Detailed technical specifications for the motorcycle.

SERVICE PRECAUTIONS

Important safety and maintenance precautions for servicing.

TORQUE VALUES

Specified torque values for important fasteners.

TOOLS

Special tools required for maintenance and repair.

LUBRICATION POINTS

Identifies specific points for lubrication and required lubricants.

CABLE & HARNESS ROUTING

Illustrates proper routing of cables and wire harnesses.

WIRING DIAGRAM

Provides the complete electrical system wiring diagram.

TROUBLESHOOTING

Guidance for diagnosing and resolving common operational issues.

EXHAUST MUFFLER/FRAME COVERS

SCHEMATIC DRAWING

Exploded view of exhaust muffler and frame cover components.

SERVICE INFORMATION

General instructions, torque values, and troubleshooting for covers/muffler.

FRAME COVERS REMOVAL

Procedures for removing various frame covers.

EXHAUST MUFFLER REMOVAL

Detailed instructions for removing the exhaust muffler.

INSPECTION/ADJUSTMENT

MAINTENANCE SCHEDULE

Periodic maintenance tasks based on mileage.

ENGINE MAINTENANCE

Fuel, oil, air, spark plug, valve, compression, gear oil, drive belt services.

CHASSIS AND SUSPENSION CHECKS

Headlight, clutch, cooling, brakes, wheels, tires, steering, suspension checks.

LUBRICATION SYSTEM

SERVICE INFORMATION

General instructions and specifications for the lubrication system.

ENGINE OIL & FILTER SERVICE

Checking and changing engine oil and filter.

OIL PUMP SERVICE

Oil pump removal, inspection, assembly, and installation.

ENGINE REMOVAL/INSTALLATION

SERVICE INFORMATION

General instructions, specs, and torque values for engine removal.

ENGINE REMOVAL

Step-by-step procedure for removing the engine from the motorcycle.

ENGINE INSTALLATION

Step-by-step procedure for installing the engine into the motorcycle.

CYLINDER HEAD/VALVES

SERVICE INFORMATION

General instructions, specifications, torque values, and special tools.

TROUBLESHOOTING

Diagnosing issues related to cylinder head operation.

CYLINDER HEAD & CAMSHAFT SERVICE

Removal, inspection, assembly, and installation of cylinder head and camshaft.

CYLINDER/PISTON

SERVICE INFORMATION

General instructions and specifications for cylinder and piston.

TROUBLESHOOTING

Diagnosing issues related to cylinder and piston.

CYLINDER & PISTON SERVICE

Removal, inspection, and installation of cylinder and piston.

DRIVE AND DRIVEN PULLEYS/KICK STARTER

SERVICE INFORMATION

General instructions, specs, torque values, special tools, troubleshooting.

DRIVE PULLEY SERVICE

Removal, inspection, and assembly of the drive pulley.

CLUTCH/DRIVEN PULLEY SERVICE

Removal, inspection, disassembly, assembly, and replacement of clutch/driven pulley.

FINAL REDUCTION

SERVICE INFORMATION

General instructions, specs, torque values, special tools, troubleshooting.

FINAL REDUCTION SERVICE

Disassembly, inspection, bearing replacement, assembly, and filling.

A.C. GENERATOR/STARTER CLUTCH

SERVICE INFORMATION

General instructions, specs, and troubleshooting for generator/clutch.

GENERATOR & CLUTCH SERVICE

Removal, installation, inspection, and assembly of generator and starter clutch.

CRANKCASE/CRANKSHAFT

SERVICE INFORMATION

General instructions, specs, torque values, special tool, troubleshooting.

CRANKCASE SEPARATION

Steps to separate the crankcase halves.

CRANKSHAFT INSPECTION

Inspecting crankshaft for runout, play, and clearances.

CRANKCASE ASSEMBLY

Cleaning and assembling the crankcase halves.

COOLING SYSTEM

SERVICE INFORMATION

General instructions, special tool, torque values, troubleshooting.

COOLING SYSTEM TESTING

Testing the radiator cap and system for leaks.

RADIATOR SERVICE

Inspecting, removing, disassembling, and installing the radiator.

WATER PUMP SERVICE

Inspecting, removing, disassembling, and installing the water pump.

THERMOSENSOR & THERMOSTAT SERVICE

Inspecting and installing thermosensor and thermostat.

FUEL SYSTEM/CARBURETOR/FUEL PUMP/FUEL TANK

FUEL SYSTEM OVERVIEW

General layout and schematic of the fuel system.

CARBURETOR SERVICE

Jet operation, disassembly, inspection, cleaning, assembly, and installation.

FUEL PUMP SERVICE

Fuel pump construction, removal, inspection, assembly, and installation.

FUEL TANK & STRAINER SERVICE

Fuel tank removal and fuel strainer service.

STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK

SERVICE INFORMATION

General instructions, specs, torque values, special tools.

TROUBLESHOOTING

Diagnosing issues with steering, suspension, and brakes.

STEERING HANDLEBAR SERVICE

Removal and installation of the handlebar.

FRONT WHEEL SERVICE

Removal, inspection, and installation of the front wheel.

FRONT BRAKE SERVICE

Master cylinder and caliper service, fluid refill, and bleeding.

FRONT SHOCK ABSORBER SERVICE

Removal, disassembly, inspection, assembly, and installation.

FRONT FORK SERVICE

Removal, replacement of races, and installation of the front fork.

REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER

SERVICE INFORMATION

General instructions, specs, torque values, special tools, troubleshooting.

REAR BRAKE SERVICE

Caliper removal, disassembly, and assembly.

REAR FORK SERVICE

Removal and inspection of the rear fork and its bearings.

REAR WHEEL SERVICE

Removal, inspection, and installation of the rear wheel.

REAR SHOCK ABSORBER SERVICE

Removal and installation of rear shock absorbers.

BATTERY/CHARGING SYSTEM

CHARGING SYSTEM LAYOUT

Overview of charging system components and circuit.

SERVICE INFORMATION

General instructions and specifications for battery and charging.

TROUBLESHOOTING

Diagnosing power and charging system issues.

BATTERY SERVICE

Procedures for inspecting and charging the battery.

CHARGING SYSTEM TESTING

Testing charging system current and performance.

A.C. GENERATOR INSPECTION

Testing the A.C. generator output and continuity.

REGULATOR/RECTIFIER INSPECTION

Testing regulator/rectifier continuity and voltage regulation.

IGNITION SYSTEM

IGNITION SYSTEM LAYOUT

Overview of ignition system components and circuit.

SERVICE INFORMATION

General instructions, specifications, and troubleshooting for ignition system.

IGNITION COIL INSPECTION

Inspecting ignition coil continuity and resistance.

A.C. GENERATOR/EXCITER/PULSER COIL INSPECTION

Testing exciter and pulser coil resistance.

CDI UNIT INSPECTION

Measuring CDI unit resistance between terminals.

STARTING SYSTEM

SERVICE INFORMATION

General instructions and specifications for starting system.

TROUBLESHOOTING

Diagnosing starting system issues.

STARTER MOTOR SERVICE

Removal, disassembly, inspection, assembly, and installation of the starter motor.

STARTER RELAY INSPECTION

Inspecting and testing the starter relay.

SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH/TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS

ELECTRICAL EQUIPMENT LAYOUT

Overview of electrical components.

SERVICE INFORMATION

General instructions, testing instrument, special tool, troubleshooting, specifications.

SWITCHES INSPECTION

Inspecting ignition, headlight, starter, stop, horn, turn signal, dimmer switches.

FUEL UNIT & METER INSPECTION

Inspecting the fuel unit and fuel meter operation.

THERMOSTATIC SWITCH INSPECTION

Inspecting the thermostatic switch for fan operation.

INSTRUMENTS SERVICE

Removal, disassembly/assembly, and installation of instruments.

LIGHTS REPLACEMENT

Headlight, position, turn signal, and taillight bulb replacement.

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