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/
THERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
19
ENGINE CHASSIS
ELECTRICAL
E
Q
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
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 Numbe
r
Location of Frame Serial Numbe
r
Vehicle Identification Serial Numbe
r

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
t
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
p
ension Fron
t
Telesco
p
e
type Rear Double swing
Shock absorbe
r
Front Telescope
type Rear Double swing
Frame type Under bone
Tires
En
g
ine
Lubrication S
y
stem
Fuel S
y
stem
Carbureto
r
Electrical E
q
ui
p
ment
I
g
nition S
y
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
i

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
m
Torque (N-m) Ite
m
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 KYMCO Engine Oil (SAE15W-40)
•API SE, SF or SG Egnine Oil
Starter idle gear
Friction spring movable 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 Loc
k
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
Radiato
r
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 B
r
ake Fluid Tube
Fuel Tank
Inlet Tube
Water Hose
Ignition Switch
Fuel Fille
r
Water Hoses
Fuel Tank
Breather Tube
Left Brake Fluid Tube
Ventilate
d
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 Fille
r
Fuel Tank
Breather Tube
Throttle Cable
Wire Harness
Fuel Tan
k
Rea
r
-view Mirro
r
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 Moto
r
Oil Vapor
Recover
y
Tube

1. GENERAL INFORMATION
1-15
GRAND DINK 250
Fuel Tube
Ignition Coil
Ther
m
ostat
Carbureto
r
Fuel Tube
Auto Bystarte
r
Spark Plug Cap
Fuel Pump
Wire Harness
Spark Plug Cap
Throttle Cable
Fuel Pump Vacuum Tube
Oil Vapor
Recover
y
Tube
Fuel Pump Vacuum Tube
Ignition Coil
Starter Relay T.P.S
Oil Vapor
Recover
y
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
cEmpty fuel tank
dClogged carburetor fuel inlet
tube, vacuum tube or fuel tube
eClogged auto fuel valve
fClogged float oil passage
gClogged fuel tank cap
breather hole
hClogged fuel strainer
iClogged fuel filter
jFaulty fuel pump
cFaulty spark plug
dFouled spark plug
eFaulty CDI unit
fFaulty A.C. generator
gBroken or shorted ignition coil
hBroken or shorted exciter coil
iFaulty ignition switch
cStarter motor idles but
crankshaft does not rotate
dValve clearance too small
eImproper valve and seat contact
fWorn cylinder and piston rings
gBlown cylinder head gasket
hFlaws in cylinder head
iSeized valve
jImproper valve timing
cFaulty auto bystarter
dAir leaking through intake
pipe
eIncorrect ignition timing
fIncorrectly adjusted pilot screw
cFlooded carburetor
dFaulty auto bystarter
eThrottle 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
startin
g
p
rocedure
Remove spark plug and
inspect again
Symptom
Fuel reaches
carburetor Fuel does not
reach carburetor
Wet spark plug
Dry spark plug