User manual KYMCO GRAND DINK 125/150

[. . . ] 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. [. . . ] · When installing the crankcase, do not use an iron hammer to tap it. · The following parts must be removed before separating the crankcase. Cylinder head ( 6-4) Cylinder/piston ( 7-3) Right crankcase cover/drive and driven pulley ( 8-3) A. C. generator/starter clutch ( 10-3) Rear wheel/rear shock absorber ( 15-4) Starter motor ( 19-3) Oil pump ( 4-4) SPECIFICATIONS Item Connecting rod big end side clearance Crankshaft Connecting rod big end radial clearance Runout TORQUE VALUES Crankcase bolt Cam chain tensioner slipper bolt SPECIAL TOOL Gear remover Standard (mm) 0. 15 0. 35 0. 0. 008 æ Service Limit (mm) 0. 6 0. 05 0. 10 7. 8 7. 8 10. 8N-m 11. 8N-m TROUBLESHOOTING Excessive engine noise · Excessive bearing play · Excessive crankpin bearing play · Worn piston pin and piston pin hole 11-2 11. CRANKCASE/CRANKSHAFT CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt. Remove the cam chain tensioner slipper and cam chain. Remove the two right crankcase attaching bolts. GRAND DINK 125/150 Cam Chain Tensioner Slipper Bolt Bolts Cam Chain Remove the five left crankcase bolts. Left Crankcase Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase. · Never use a driver to pry the crankcase mating surfaces apart. Right Crankcase Remove the gasket and dowel pins. Left Crankcase Remove the crankshaft from the left crankcase. Crankshaft Left Crankcase 11-3 11. CRANKCASE/CRANKSHAFT Oil Seal GRAND DINK 125/150 Remove the oil seal from the left crankcase. Left Crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0. 6mm replace if over Measure the connecting rod small end I. D. Service Limit: 15. 06mm replace if over 11-4 11. CRANKCASE/CRANKSHAFT Measure the crankshaft runout. Service Limit: 0. 10mm replace if over GRAND DINK 125/150 Measure the crankshaft bearing play. Service Limits: Axial : 0. 20mm replace if over Radial : 0. 05mm replace if over Play Play Axial Radial CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces. · Avoid damaging the crankcase mating surfaces. Install a new oil seal into the left crankcase. Oil Seal Left Crankcase 11-5 11. CRANKCASE/CRANKSHAFT Place the left crankcase down and install the crankshaft into the left crankcase. · · Avoid damaging the oil seal. Apply grease to the lip of the oil GRAND DINK 125/150 seal. Install the two dowel pins and a new gasket. Dowel Pins Gasket Place the right crankcase over the crankshaft and onto the left crankcase. · Install the right crankcase squarely and do not tap it with an iron or plastic hammer. Right Crankcase Left Crankcase Install and tighten the right and left crankcase attaching bolts. Torque: 7. 8 10. 8N-m Bolts 11-6 11. CRANKCASE/CRANKSHAFT Install the cam chain. [. . . ] ( 2-5) Disconnect the instrument wire couplers and connectors. Disconnect the speedometer cable. GRAND DINK 125/150 Speedometer Cable Remove the four instrument cover and leg shield screws. Remove the instruments. DISASSEMBLY/ASSEMBLY Remove the three instrument holder nuts. Remove the four screws to disassemble the instruments and instrument cover . [. . . ]