User manual KYMCO GRAND DINK 125
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Manual abstract: user guide KYMCO GRAND DINK 125
Detailed instructions for use are in the User's Guide.
[. . . ] 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. 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. [. . . ] Starter motor rotates but engine does not start · Faulty starter clutch · Starter motor rotates reversely · Weak battery
10-2
10. GENERATOR/STARTER CLUTCH
RIGHT CRANKCASE COVER REMOVAL
Disconnect the water hoses from the right crankcase cover. Remove the nine bolts attaching the right crankcase cover and the cover.
Bolts
GRAND DINK 125/150
Water Outlet Hose
Bolts
Water Inlet Hose A. C. Generator Stator
STATOR REMOVAL
Remove the two pulser coil attaching screws and the pulser coil. When removing the pulser coil and stator, be careful not to damage them to avoid shorted or broken wire.
Screws
Pulser Coil
Bolts
FLYWHEEL REMOVAL
Hold the flywheel with a flywheel holder and remove the flywheel nut.
Flywheel Holder
Flywheel
Nut
Remove the flywheel with a flywheel puller.
Flywheel Puller
10-3
10. GENERATOR/STARTER CLUTCH
STARTER CLUTCH
REMOVAL Remove the starter idle gear and shaft.
Shaft
GRAND DINK 125/150 Starter Idle Gear
Starter Driven Gear
Remove the starter driven gear.
Starter Driven Gear
INSPECTION Inspect the starter driven gear for wear or damage. : 41. 00mm replace if below
Starter Driven Gear
Inspect the starter idle gear and shaft for wear or damage.
Starter Idle Gear
Shaft
10-4
10. GENERATOR/STARTER CLUTCH
Spring
GRAND DINK 125/150 Roller
Remove the starter one-way clutch rollers, plungers and springs. Inspect each roller and plunger for wear or damage and check for broken or weak spring.
Plunger
INSTALLATION Install the starter driven gear onto the crankshaft. Install the starter idle gear and shaft.
Shaft
Starter Idle Gear
Starter Driven Gear
FLYWHEEL INSTALLATION
Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel. · Before installation, check and make sure that the inside of the flywheel is not contaminated. Hold the flywheel with the flywheel holder and tighten the flywheel nut. Torque: 34. 3 39. 2N-m
Flywheel
Key
Groove
Flywheel Holder
10-5
10. generator stator on the right crankcase cover and secure it with the three bolts. Install the pulser coil on the right crankcase cover and secure it with the two screws. Install the wire grommet in the groove in the right crankcase cover securely. Be sure to route the stator wire under the pulser coil.
GRAND DINK 125/150
A. C. Generator Stator
Screws
Pulser Coil
Dowel Pins
RIGHT CRANKCASE COVER INSTALLATION
Install the two dowel pins and a new gasket.
Gasket
Install the right crankcase cover over the crankcase, aligning the water pump shaft groove with the oil pump shaft. ( 3-9) · Be sure to bleed air from the water jacket after filling the coolant.
Oil Pump Shaft
Right Crankcase Cover
Water Pump Shaft
10-6
11. CRANKCASE/CRANKSHAFT
GRAND DINK 125/150
11
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CRANKCASE/CRANKSHAFT
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SCHEMATIC DRAWING ---------------------------------------------- 11-1 SERVICE INFORMATION -------------------------------------------- 11-2 TROUBLESHOOTING ------------------------------------------------- 11-2 CRANKCASE SEPARATION ----------------------------------------- 11-3 CRANKSHAFT INSPECTION----------------------------------------- 11-4 CRANKCASE ASSEMBLY -------------------------------------------- 11-5
11
11-0
11. CRANKCASE/CRANKSHAFT
SCHEMATIC DRAWING
GRAND DINK 125/150
11-1
11. CRANKCASE/CRANKSHAFT
SERVICE INFORMATION
GRAND DINK 125/150
GENERAL INSTRUCTIONS · This section covers crankcase separation to service the crankshaft. [. . . ] The thermostatic switch is faulty if the cooling fan motor runs properly. If it does not start, check for voltage between the fan motor coupler wire terminals (black green). If there is no voltage, check for the following: · Blown or faulty fuse · Loose terminals or connectors · Shorted wire in the wire harness
GRAND DINK 125/150
Thermostatic Switch
Wire
TEMPERATURE GAUGE
Disconnect the wire from the thermosensor and ground it to the engine. The temperature gauge needle should move all the way to "H". [. . . ]
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