KYMCO GRAND DINK 250 User manual

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
8
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
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 /
T HERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
19
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
CHASSIS EQUIPMENT
ENGINE

1. GENERAL INFORMATION
1-0
GRAND DINK 250
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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

1. GENERAL INFORMATION
1-1
GRAND DINK 250
SERIAL NUMBER
Location of Engine Serial Number
Location of Frame Serial Number
Vehicle Identification Serial Number

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/cm_)
15±2
Max. output (kw/rpm)
13.4/7000
Max. torque (N.m/rpm)
19.6/5500
BTDC
8°
Port
Intake
ABDC
42°
timin
g
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
Front
2.00
Tire pressure
(kg/cm_)
Rear
2.25
Turning
Left
45°
angle
Right
45°
Front
Disk brake
Brake system
type
Rear
Disk brake
Suspension
Front
Telescope
type
Rear
Double swing
Shock absorber
Front
Telescope
type
Rear
Double swing
Frame type
Under bone
Tires
Engine
System
Fuel System
Carburetor
Electrical
Ignition System
Power Drive System
Transmis- sion Gear Reduction
Gear
Moving Device Damping
Device

1. GENERAL INFORMATION
1-3
GRAND DINK 250
SERVICE PRECAUTIONS
nMake sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
nWhen tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
nUse genuine parts and lubricants.
nWhen servicing the motorcycle, be sure to
use special tools for removal and
installation.
nAfter disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
nApply or add designated greases and
lubricants to the specified lubrication
points.
nAfter reassembly, check all parts for
proper tightening and operation.
nWhen two persons work together, pay
attention to the mutual working safety.
nDisconnect the battery negative (-) terminal
before operation.
nWhen using a spanner or other tools, make
sure not to damage the motorcycle surface.
nAfter operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
nWhen connecting the battery, the positive
(+) terminal must be connected first.
nAfter connection, apply grease to the
battery terminals.
nTerminal caps shall be installed securely.

1. GENERAL INFORMATION
1-4
GRAND DINK 250
nIf the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
nAfter operation, terminal caps shall be
installed securely.
nWhen taking out the connector, the lock on
the connector shall be released before
operation.
nHold the connector body when connecting
or disconnecting it.
nDo not pull the connector wire.
nCheck if any connector terminal is bending,
protruding or loose.
nThe connector shall be inserted
completely.
nIf the double connector has a lock, lock
it at the correct position.
nCheck if there is any loose wire.
nBefore connecting a terminal, check for
damaged terminal cover or loose negative
terminal.
nCheck the double connector cover for
proper coverage and installation.
nInsert the terminal completely.
nCheck the terminal cover for proper
coverage.
nDo not make the terminal cover opening
face up.
nSecure 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
nAfter clamping, check each wire to make
sure it is secure.
nDo not squeeze wires against the weld or
its clamp.
nAfter clamping, check each harness to make
sure that it is not interfering with any
moving or sliding parts.
nWhen fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
nRoute wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
nRoute wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
nRoute harnesses so they are neither
pulled tight nor have excessive slack.
nProtect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
nWhen rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
nDo not break the sheath of wire.
nIf a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
nWhen installing other parts, do not press or
squeeze the wires.
Do not pull
too tightð
No Contact
Do not press
or squeeze the
wire

1. GENERAL INFORMATION
1-6
GRAND DINK 250
nAfter routing, check that the wire harnesses
are not twisted or kinked.
nWire harnesses routed along with handlebar
should not be pulled tight, have excessive
slack or interfere with adjacent or
surrounding parts in all steering positions.
nWhen a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
nBe careful not to drop any parts.
nWhen rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
nSymbols:
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
Rustð

1. GENERAL INFORMATION
1-7
GRAND DINK 250
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
4.9
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
2
2
1
2
4
2
1
1
1
1
1
2
4
1
1
1
8
8
30
8
8
5
6
12
12
12
14
5
6
10
6
8
8.9
8.9
14.7
8.8
24.5
8.8
8.8
12.7
53.9
53.9
58.8
3.9
11.8
17.2
11.8
11.8
Double end bolt
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
1
1
1
2
2
4
1
10
12
14
10
8
10
12
44.1
68.6
127.4
29.4
29.4
24.5
53.9
U-nut
U-nut
U-nut

1. GENERAL INFORMATION
1-8
GRAND DINK 250
SPECIAL TOOLS
Tool Name
Tool No.
Remarks
Ref. Page
Valve guide driver
Valve guide removal/installation
Valve guide reamer
Valve guide grinding
Valve spring compressor
Valve removal
Lock nut wrench, 39mm
E027
Clutch disassembly
Bearing driver
Bearing removal
Bearing remover,
10,12,15,18mm
E037
Bearing removal
Clutch spring compressor
E027
Clutch disassembly
Ball race remover extension
Ball race removal
Ball race remover
Ball race removal
Spring compressor
E038
Spring removal
Mechanical seal driver
E014
Water pump mechanical seal
removal/installation
Kick starter spring remover
Kick starter spring removal
Gear remover
Starter gear removal
Valve adjuster
E012
Tapper adjustment
Float level gauge
Carburetor fuel level check
Valve seat cutter 45°
Valve seat refacing
Valve seat cutter 32°
Valve seat refacing
Valve seat cutter 60°
Valve seat refacing
Cutter clip, 5mm
Universal holder
E017
Holding clutch for removal
Bearing driver (32x35mm)
E014
Bearing installation
Pilot, 12mm
E014
Bearing installation
Pilot, 15mm
E014
Bearing installation
Pilot, 17mm
E014
Bearing installation
Flywheel puller
E003
A.C. generator flywheel removal
Rear shock absorber compressor
F004
Rear shock absorber disassembly
Steering head bearing remover
F005
Steering head bearing removal
Flywheel holder
E021
A.C. generator flywheel holding
Reamer clip
Fuel unit wrench
Fuel unit removal

1. GENERAL INFORMATION
1-9
GRAND DINK 250
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 KYM CO Engine Oil (SAE15W-40)
•API SE, SF or SG Egnine Oil
Starter idle gear
Friction springmovable 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

1. GENERAL INFORMATION
1-10
GRAND DINK 250
FRAME
The 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 avoid
abnormal noise and rise the durability of the motorcycle.
Seat Lock
Rear Wheel Bearing
Grease
Speedometer Cable
Throttle Cable
Speedometer Gear/
Front Wheel Bearing
Engine Oil
Grease
Grease
Grease
Front Brake Lever Pivot

1. GENERAL INFORMATION
1-11
GRAND DINK 250
CABLE & HARNESS ROUTING
Front Stop Brake
Rear Stop Brake
Throttle Cable
Radiator
Front Brake Fluid Tube
Front / Rear Brake
Master Cylinder
Speedometer Cable
Horn
Pressure Type
Radiator Cap
Radiator Air
Ventilated Tube

1. GENERAL INFORMATION
1-12
GRAND DINK 250
Front Brake Fluid Tube
Fuel Tank
Inlet Tube
Water Hose
Ignition Switch
Fuel Filler
Water Hoses
Fuel Tank
Breather Tube
Left Brake Fluid Tube
Ventilated Hose
Reserve Tank

1. GENERAL INFORMATION
1-13
GRAND DINK 250
Throttle Cable
Speedometer Cable
Radiator Air
Ventilated Tube
Rear Brake Fluid
Tube
Fuel Tank Inlet
Tube
Water Hose
Fuel Filler
Fuel Tank
Breather Tube
Throttle Cable
Wire Harness
Fuel Tank
Rear-view Mirror
Control Relay

1. GENERAL INFORMATION
1-14
GRAND DINK 250
Starter Relay
Fuel Tube
Battery (-) Cable
Battery (+) Cable
Ignition Coil
Thermosensor Wire
Thermostat
Carburetor
Regulator/
Rectifier
CDI Unit
Fuse Box
Starter Motor
Oil Vapor
Recovery Tube

1. GENERAL INFORMATION
1-15
GRAND DINK 250
Fuel Tube
Ignition Coil
Thermostat
Carburetor
Fuel Tube
Auto Bystarter
Spark Plug Cap
Fuel
Pump
Wire Harness
Spark Plug Cap
Throttle Cable
Fuel Pump Vacuum Tube
Oil Vapor
Recovery Tube
Fuel Pump Vacuum Tube
Ignition Coil
Starter Relay
T.P.S
Oil Vapor
Recovery Tube

1. GENERAL INFORMATION
1-16
GRAND DINK 250
WIRING DIAGRAM

1. GENERAL INFORMATION
1-17
GRAND DINK 250
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
ÅEmpty fuel tank
ÇClogged carburetor fuel inlet
tube, vacuum tube or fuel tube
ÉClogged auto fuel valve
ÑClogged float oil passage
ÖClogged fuel tank cap
breather hole
ÜClogged fuel strainer
áClogged fuel filter
àFaulty fuel pump
ÅFaulty spark plug
ÇFouled spark plug
ÉFaulty CDI unit
ÑFaulty A.C. generator
ÖBroken or shorted ignition coil
ÜBroken or shorted exciter
coil
áFaulty ignition switch
ÅStarter motor idles but
crankshaft does not rotate
ÇValve clearance too small
ÉImproper valve and seat
contact
ÑWorn cylinder and piston rings
ÖBlown cylinder head gasket
ÜFlaws in cylinder head
áSeized valve
àImproper valve timing
ÅFaulty auto bystarter
ÇAir leaking through intake
pipe
ÉIncorrect ignition timing
ÑIncorrectly adjusted pilot
screw
ÅFlooded carburetor
ÇFaulty auto bystarter
ÉThrottle valve excessively
open
Check if fuel reaches
carburetor by
loosening drain screw
Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to 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 cylinder
compression
Start engine by follow-
ing normal starting
procedure
Remove spark plug and
inspect again
Symptom
Fuel reaches
carburetor
Fuel does not
reach carburetor
Wet spark plug
Dry spark plug

1. GENERAL INFORMATION
1-18
GRAND DINK 250
ENGINE LACKS POWER
ÅClogged air cleaner
ÇRestricted fuel flow
ÉClogged fuel line between fuel
tank and carburetor
ÑClogged exhaust muffler
ÖFaulty auto bystarter
ÜSplit carburetor vacuum piston
diaphragm
ÅFaulty CDI unit
ÇFaulty A.C. generator
ÅImproper valve clearance
adjustment
ÇWorn valve seat (valve stem too
protruding
ÅImproper valve and seat contact
ÇWorn cylinder and piston rings
ÉBlown cylinder head gasket
ÑFlaws in cylinder head
ÖImproper valve timing
ÅClogged carburetor jets
ÅFouled spark plug
ÇIncorrect heat range plug
ÅOil level too high
ÇOil level too low
ÉOil not changed
ÅClogged oil pipe
ÇFaulty oil pump
ÅInsufficient coolant
ÇFaulty thermostat
ÉWorn cylinder and piston rings
ÑMixture too lean
ÖPoor quality fuel
ÜExcessive carbon buildup in
combustion chamber
áIgnition timing too early
àAir in cooling system
ÅExcessive carbon build-up in
combustion chamber
ÇPoor quality fuel
ÉClutch slipping
ÑMixture too lean
ÖIgnition timing too early
Start engine and accelerate
lightly 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 for
clogging
Rapidly accelerate or run
at high speed
Remove spark plug and
inspect
Check if engine overheats
Check valve clearance
Correct
Incorrect
Normal
compression
Abnormal
compression
Not Clogged
Clogged
Remove oil dipstick and
check oil level and condition
Remove cylinder head oil
pipe 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 lubricated
properly
Valve train not
lubricated properly
Engine does not knock
Engine knocks