-
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.
CH
ASSIS
EQ
UIP
ME
NT
EN
GIN
E
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1. GENERAL INFORMATION
1-0
GRAND DINK 125/150
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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
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1. GENERAL INFORMATION
1-1
GRAND DINK 125/150
SERIAL NUMBER
Location of Engine Serial NumberLocation of Frame Serial
Number
Vehicle Identification Serial Number
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
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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1. GENERAL INFORMATION
1-5
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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1. GENERAL INFORMATION
1-6
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
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
1-8
GRAND DINK 125/150
TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque (N-m) Item Torque (N-m)
5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm
bolt, nut
4.99.821.634.353.9
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
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
1-10
GRAND DINK 125/150
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part
Camshaft protruding surface
Valve rocker arm friction surface
Camshaft drive chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft
Cranksahft one-way clutch movable part
Oil pump drive chain
Starter reduction gear engaging part
Countershaft gear engaging part
Final gear engaging part
Bearing movable part
O-ring face
Oil seal lip
•Genuine KYMCO Engine Oil (SAE15W-40)
•API SE, SJ Egnine Oil
Starter idle gear
Friction spring movable part/shaft movable part
Shaft movable grooved part
Starter spindle movable part
High-temperature resistant grease
Starter one-way clutch threads Thread locking agent
A.C. generator connector
Transmission case breather tubee Adhesive
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
1-12
GRAND DINK 125/150
CABLE & HARNESS ROUTING
Radiator
Front BrakeRear Brake
Speedometer Cable
Horn
PressureTypeRadiator Cap
Radiator AirVent Tube
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
1-15
GRAND DINK 125/150
Starter Relay
Fuel Tube
Battery (+) Cable
Battery (-) Cable
Ignition Coil
Auto Bystarter Wire
Thermostat
Carburetor
Air Cut-offValve (A.C.V.)
Regulator/Rectifier
C.D.I.
Fuse Box
Starter Motor
Fuel Unit
Hazard ControlUnit
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
1-17
GRAND DINK 125/150
WIRING DIAGRAM
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
1-20
GRAND DINK 125/150
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
ÅFaulty CDI unitÇFaulty A.C. generator
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
Inspection/Adjustment Symptom Probable Cause
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
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1. GENERAL INFORMATION
1-21
GRAND DINK 125/150
POOR PERFORMANCE (AT HIGH SPEED)
ÅFaulty CDI unitÇFaulty A.C. generator
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
Inspection/Adjustment Symptom Probable Cause
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
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1. GENERAL INFORMATION
1-22
GRAND DINK 125/150
ENGINE NOISE
ÅValve clearance too large
ÇWorn camshaft lobe
ÅWorn piston rings
ÇWorn piston pin and connecting 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
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1. GENERAL INFORMATION
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)
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1. GENERAL INFORMATION
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
Inspection/Adjustment
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 operate properly
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
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1. GENERAL INFORMATION
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
Inspection/Adjustment Symptom Probable Cause
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. GENERAL INFORMATION
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
Inspection/Adjustment
Inspection/Adjustment
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. GENERAL INFORMATION
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
Inspection/Adjustment
Inspection/Adjustment
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 operate properly
Signals dim, remainon or don‘toperate
Signals operate properly
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. GENERAL INFORMATION
1-28
GRAND DINK 125/150
STEERING HANDLEBAR DOES NOT TRACK STRAIGHT
(Front and rear tire pressures are normal)
ÅSteering stem nut too 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. EXHAUST MUFFLER/FRAME COVERS
2-1
GRAND DINK 125/150
SCHEMATIC DRAWING
-
2. EXHAUST MUFFLER/FRAME COVERS
2-2
GRAND DINK 125/150
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• When removing frame covers, use care not to pull them by force
because the cover joint 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. EXHAUST MUFFLER/FRAME COVERS
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. EXHAUST MUFFLER/FRAME COVERS
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. EXHAUST MUFFLER/FRAME COVERS
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. EXHAUST MUFFLER/FRAME COVERS
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. EXHAUST MUFFLER/FRAME COVERS
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. EXHAUST MUFFLER/FRAME COVERS
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. INSPECTION/ADJUSTMENT
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. INSPECTION/ADJUSTMENT
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. INSPECTION/ADJUSTMENT
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. INSPECTION/ADJUSTMENT
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
Oil Filter Screen Cap
-
3. INSPECTION/ADJUSTMENT
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. INSPECTION/ADJUSTMENT
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. INSPECTION/ADJUSTMENT
3-7
GRAND DINK 125/150
IGNITION TIMING
Remove the timing hole cap.
Check the ignition timing with a timing light.When the engine is
running at the 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. INSPECTION/ADJUSTMENT
3-8
GRAND DINK 125/150
FINAL REDUCTION GEAR OIL
Stop the engine and remove the oil check bolt.The oil level
shall be at the oil check bolt hole.If the oil level is low, add
the 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. INSPECTION/ADJUSTMENT
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. INSPECTION/ADJUSTMENT
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. INSPECTION/ADJUSTMENT
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
SERVICE INFORMATION --------------------------------------------
4-2
TROUBLESHOOTING
------------------------------------------------- 4-2
ENGINE OIL/OIL FILTER
-------------------------------------------- 4-3
OIL PUMP
REMOVAL------------------------------------------------- 4-4
OIL PUMP DISASSEMBLY -------------------------------------------
4-4
OIL PUMP INSPECTION
---------------------------------------------- 4-5
OIL PUMP
ASSEMBLY------------------------------------------------ 4-5
OIL PUMP INSTALLATION------------------------------------------
4-6
4
-
4. LUBRICATION SYSTEM
4-1
GRAND DINK 125/150
LUBRICATION SYSTEM
Oil Pump
Oil Filter Screen
Crankshaft
Rocker Arm Shaft
Oil Filter Screen
-
4. LUBRICATION SYSTEM
4-2
GRAND DINK 125/150
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• The maintenance of lubrication system can be performed with
the engine installed in the frame.• Drain the coolant before
starting any operations.• Use care when removing and installing the
oil pump not to allow dust and foreign matters to enter
the engine and oil line.• Do not attempt to disassemble the oil
pump. The oil pump must be replaced as a set when it
reaches its service limit.• After the oil pump is installed,
check each part for oil leaks.
SPECIFICATIONS
OIL PUMP
Standard (mm) Service Limit (mm)
Inner rotor-to-outer rotor clearance 0.15 0.20
Outer rotor-to-pump body clearance 0.15_ 0.20 0.25
Rotor end-to-pump body clearance 0.04_ 0.09 0.12
ENGINE OIL
Engine Oil Capacity At disassembly: 1.1 liter At change: 0.9
liter
Recommended Oil SAE15W40# API: SJ
TROUBLESHOOTING
Oil level too low Poor lubrication pressure• Natural oil
consumption • Oil level too low• Oil leaks • Clogged oil filter or
oil passage• Worn piston rings • Faulty oil pump• Worn valve guide•
Worn valve guide seal
Oil contamination• Oil not changed often enough• Faulty cylinder
head gasket• Loose cylinder head bolts
-
4. LUBRICATION SYSTEM
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
Oil Filter Screen Cap
• 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. LUBRICATION SYSTEM
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. LUBRICATION SYSTEM
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. LUBRICATION SYSTEM
4-6
GRAND DINK 125/150
Screw
Bolts
Pump Cover
Oil Separator Cover
Pump Driven Gear
Bolt
Install the pump cover by aligning the hole 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__________________________________________________________________________________
SCHEMATIC DRAWING ----------------------------------------------
5-1
SERVICE INFORMATION --------------------------------------------
5-2
ENGINE REMOVAL
--------------------------------------------------- 5-3
ENGINE INSTALLATION --------------------------------------------
5-5
5
-
5. ENGINE REMOVAL/INSTALLATION
5-1
GRAND DINK 125/150
SCHEMATIC DRAWING
-
5. ENGINE REMOVAL/INSTALLATION
5-2
GRAND DINK 125/150
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• A floor jack or other adjustable support is required to
support and maneuver the engine. 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. ENGINE REMOVAL/INSTALLATION
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. ENGINE REMOVAL/INSTALLATION
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. ENGINE REMOVAL/INSTALLATION
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. CYLINDER HEAD/VALVES
6-1
GRAND DINK 125/150
SCHEMATIC DRAWING
-
6. CYLINDER HEAD/VALVES
6-2
GRAND DINK 125/150
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• The cylinder head can be serviced with the engine installed in
the frame. Coolant in the 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. CYLINDER HEAD/VALVES
6-3
GRAND DINK 125/150
TROUBLESHOOTING• The poor cylinder head operation can be
diagnosed by a compression test or by tracing engine
top-end noises.
Poor performance at idle speed White smoke from exhaust muffler•
Compression too low • Worn valve stem or valve guide
• Damaged valve stem oil 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. CYLINDER HEAD/VALVES
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. CYLINDER HEAD/VALVES
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. CYLINDER HEAD/VALVES
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. CYLINDER HEAD/VALVES
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. CYLINDER HEAD/VALVES
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. CYLINDER HEAD/VALVES
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. CYLINDER HEAD/VALVES
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. CYLINDER HEAD/VALVES
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__________________________________________________________________________________
SCHEMATIC DRAWING ----------------------------------------------
7-1
SERVICE INFORMATION --------------------------------------------
7-2
TROUBLESHOOTING
------------------------------------------------- 7-2
CYLINDER REMOVAL------------------------------------------------
7-3
PISTON REMOVAL
---------------------------------------------------- 7-3
PISTON INSTALLATION
--------------------------------------------- 7-7
CYLINDER INSTALLATION-----------------------------------------
7-7
7
-
7. CYLINDER/PISTON
7-1
GRAND DINK 125/150
SCHEMATIC DRAWING
-
7. CYLINDER/PISTON
7-2
GRAND DINK 125/150
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• The cylinder and piston can be serviced with the engine
installed in the frame.• When installing the cylinder, use a new
cylinder gasket and make sure that the dowel pins are
correctly installed.• After disassembly, clean the removed parts
and dry them with compressed air before inspection.
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. DRIVE AND DRIVEN PULLEYS/KICK STARTER
8-1
GRAND DINK 125/150
SCHEMATIC DRAWING
-
8. DRIVE AND DRIVEN PULLEYS/KICK STARTER
8-2
GRAND DINK 125/150
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• The d