KYMCO GRAND DINK 250 Manuel utilisateur

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

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

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

ENGINE CHASSIS

ELECTRICAL

UIPMENT

The information and contents included in

this manual may be different from the

motorcycle in case specifications are

changed.

GRAND DINK 250

1. GENERAL INFORMATION

1-0

GRAND DINK 250

__________________________________________________________________________________

GENERAL INFORMATION

__________________________________________________________________________________

ENGINE SERIAL NUMBER------------------------------------------------ 1-1

SPECIFICATION-------------------------------------------------------------- 1-2

SERVICE PRECAUTIONS-------------------------------------------------- 1-3

TORQUE VALUES ----------------------------------------------------------- 1-7

TOOLS -------------------------------------------------------------------------- 1-8

LUBRICATION POINTS ---------------------------------------------------- 1-9

CABLE&HARNESS ROUTING--------------------------------------------1-11

WIRING DIAGRAM ---------------------------------------------------------------1-16

TROUBLESHOOTING------------------------------------------------------1-17

1. GENERAL INFORMATION

1-1

GRAND DINK 250

SERIAL NUMBER

Location of Engine Serial Numbe

Location of Frame Serial Numbe

Vehicle Identification Serial Numbe

1. GENERAL INFORMATION

1-2

GRAND DINK 250

SPECIFICATIONS

Name & Model No. SH50DA

Motorcycle Name & Type GRAND DINK 250

Overall length 2060mm

Overall width 770mm

Overall height 1360mm

Wheel base 1435mm

Engine type Water cooled 4-stroke,

OHC engine

Displacement 249cc

Fuel Used 92# nonleaded gasoline

Front wheel 58

Net weight (kg) Rear wheel 92

Total 150

Front wheel 63.5

Gross weight(kg) Rear wheel 99.5

Total 163

Front wheel 120/70-12

Rear wheel 140/70-12

Ground clearance 140mm

Perform- Braking distance (m) 7.0m/30km/hr

ance Min. turning radius 2350mm

Starting system Starting motor

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C.

Bore x stroke (mm) 72.7 x 60

Compression ratio 10.3:1

Compression pressure

(kg/cm²) 15±2

Max. output (kw/rpm) 13.4/7000

Max. torque (N.m/rpm) 19.6/5500

BTDC 8°

Port Intake ABDC 42°

timing BBDC 33°

Exhaust ATDC 1°

Valve Intake 0.1

clearance (cold) Exhaust 0.1

Idle speed (rpm) 1700±100rpm

Lubrication type Forced pressure &

wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Oil capacity 1.1 liters

Cooling Type Water cooling

Air cleaner type & No Paper element, wet

Fuel capacity 9.1 liters

Type CVK

Piston dia. 30

Venturi dia. 30 equivalent

Throttle type Butterfly type

Type CDI

Ignition timing repeatedly

Contact breaker Non-contact point type

Spark plug NGK

DPR7EA-9

Spark plug gap 0.9mm

Battery Capacity 12V10AH

Clutch Type Dry multi-disc clutch

Type Non-stage transmission

Operation Automatic centrifugal

Type

Type Two-stage reduction

Reduction 1st 0.83~2.2

ratio 2nd 6.98

Front Caster angle 27°

Axle Connecting rod

Fron

2.00

Tire pressure

(kg/cm²) Rear 2.25

Turning Left 45°

angle Right 45°

Front Disk brake

Brake system

type Rear Disk brake

Sus

ension Fron

Telesco

type Rear Double swing

Shock absorbe

Front Telescope

type Rear Double swing

Frame type Under bone

Tires

ine

Lubrication

stem

Fuel S

stem

Carbureto

Electrical E

ment

nition S

stem

Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving Device Damping

Device

1. GENERAL INFORMATION

1-3

GRAND DINK 250

SERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when

reassembling.

When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

Use genuine parts and lubricants.

When servicing the motorcycle, be sure to

use special tools for removal and

installation.

After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

Apply or add designated greases and

lubricants to the specified lubrication

points.

After reassembly, check all parts for proper

tightening and operation.

When two persons work together, pay

attention to the mutual working safety.

Disconnect the battery negative (-) terminal

before operation.

When using a spanner or other tools, make

sure not to damage the motorcycle surface.

After operation, check all connecting

points, fasteners, and lines for proper

connection and installation.

When connecting the battery, the positive

(+) terminal must be connected first.

After connection, apply grease to the

battery terminals.

Terminal caps shall be installed securely.

1. GENERAL INFORMATION

1-4

GRAND DINK 250

If the fuse is burned out, find the cause and

repair it. Replace it with a new one

according to the specified capacity.

After operation, terminal caps shall be

installed securely.

When taking out the connector, the lock on

the connector shall be released before

operation.

Hold the connector body when connecting

or disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is bending,

protruding or loose.

The connector shall be inserted

completely.

If the double connector has a lock, lock

it at the correct position.

Check if there is any loose wire.

Before connecting a terminal, check for

damaged terminal cover or loose negative

terminal.

Check the double connector cover for

proper coverage and installation.

Insert the terminal completely.

Check the terminal cover for proper

coverage.

Do not make the terminal cover opening

face up.

Secure wire harnesses to the frame with

their respective wire bands at the

designated locations.

Tighten the bands so that only the insulated

surfaces contact the wire harnesses.

Confirm

Capacity

1. GENERAL INFORMATION

1-5

GRAND DINK 250

After clamping, check each wire to make

sure it is secure.

Do not squeeze wires against the weld or

its clamp.

After clamping, check each harness to

make sure that it is not interfering with any

moving or sliding parts.

When fixing the wire harnesses, do not

make it contact the parts which will

generate high heat.

Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of

bolts and screws.

Route wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

Route harnesses so they are neither

pulled tight nor have excessive slack.

Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or

corner.

When rubber protecting cover is used to

protect the wire harnesses, it shall be

installed securely.

Do not break the sheath of wire.

If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape

or replace it.

When installing other parts, do not press or

squeeze the wires.

Do not pull

too tight

No Contact

Do not press or

squeeze the

1. GENERAL INFORMATION

1-6

GRAND DINK 250

After routing, check that the wire harnesses

are not twisted or kinked.

Wire harnesses routed along with

handlebar should not be pulled tight, have

excessive slack or interfere with adjacent

or surrounding parts in all steering

positions.

When a testing device is used, make sure to

understand the operating methods

thoroughly and operate according to the

operating instructions.

Be careful not to drop any parts.

When rust is found on a terminal, remove

the rust with sand paper or equivalent

before connecting.

Symbols:

The following symbols represent the

servicing methods and cautions included in

this service manual.

: Apply engine oil to the

specified points. (Use

designated engine oil for

lubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

Special

Engine Oil

Grease

Gear Oil



Do you understand

the instrument

Remove Rust

1. GENERAL INFORMATION

1-7

GRAND DINK 250

TORQUE VALUES

STANDARD TORQUE VALUES

Ite

Torque (N-m) Ite

Torque (N-m)

5mm bolt, nut

6mm bolt, nut

8mm bolt, nut

10mm bolt, nut

12mm bolt, nut

4.9

9.8

21.6

34.3

53.9

5mm screw

6mm screw, SH bolt

6mm flange bolt, nut

8mm flange bolt, nut

10mm flange bolt, nut

3.9

8.8

11.8

26.5

39.2

Torque specifications listed below are for important fasteners.

ENGINE

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

Cylinder head bolt A

Cylinder head bolt B

Oil filter screen cap

Exhaust muffler joint lock nut

Cylinder head cap nut

Valve adjusting lock nut

Cam chain tensioner slipper bolt

Oil bolt

Clutch outer nut

Clutch drive plate nut

Flywheel nut

Oil pump bolt

Cylinder head cover bolt

Spark plug

Cam chain tensioner bolt

Water pump impeller

8.9

14.7

8.8

24.5

8.8

12.7

53.9

58.8

3.9

11.8

17.2

11.8

Double end bolt

Apply oil to

threads

Left hand threads

FRAME

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

Steering stem lock nut

Front axle nut

Rear axle nut

Rear shock absorber upper bolt

Rear shock absorber lower bolt

Front shock absorber lock bolt

Engine hanger bolt

44.1

68.6

127.4

29.4

24.5

53.9

U-nut

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