User manual KYMCO GRAND DINK 125

[. . . ] 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 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ 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". [. . . ]