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GRAND DINK 125
KYMCO GRAND DINK 125 User Manual
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12
.
COOLING SYSTEM
12-9
G
R
A
N
D DINK
12
5/
15
0
Install
the front
upper cover.
WATER PUMP
MECHANICAL SEAL (WATER SEAL)
INSPECTION
Inspect
the
telltale hole for signs of
mechanical seal coolant leakage.
If the mechanical seal is leaking, remove the
right crankcase cover and replace the
mechanical seal.
WATER PUMP/IMPELLER REMOVAL
Remove the coolant inlet hose and outlet
hose.
Right
Crankcase
Cover
Telltale
Hole
Water
Pump
Outlet
Hose
Inlet Hose
136
138
Table of Contents
Preface
1
Table of Contents
1
General Information
2
Engine Serial Number
3
General Information
3
Specification
4
Service Precautions
6
Torque Values
10
Special Tools
11
Lubrication Points
12
Cable & Harness Routing
14
Rear View
15
Wiring Diagram
19
Troubleshooting
20
Inspection/Adjustment
26
2. Exhaust Muffler/Frame Covers 2
31
Schematic Drawing
32
Service Information
33
Troubleshooting
33
Frame Covers Removal
34
Front Cover Removal
37
Back Cover Removal
37
Bottom Cover Removal
38
Front Fender Removal
38
Exhaust Muffler Removal
38
3. Inspection/Adjustment 3
40
Service Information
41
Maintenance Schedule
42
Fuel Line/Fuel Filter
43
Throttle Operation
43
Engine Oil
44
Oil Filter Screen Inspection
44
Air Cleaner
45
Spark Plug
45
Carburetor Idle Speed
46
Valve Clearance
46
Cylinder Compression
47
Ignition Timing
47
Drive Belt
48
Final Reduction Gear Oil
48
Clutch Shoe Wear
49
Cooling System
49
Headlight Aim
49
Brake System
50
Nuts/Bolts/Fasteners
51
Steering Handlebar
51
Suspension
51
Wheels/Tires
51
4. Lubrication System 4
52
Lubrication System
52
Lubrication System Diagram
53
Service Information
54
Troubleshooting
54
Engine Oil/Oil Filter
55
Oil Pump Removal
56
Oil Pump Disassembly
56
Oil Pump Inspection
57
Oil Pump Assembly
57
Oil Pump Installation
58
Engine Removal/Installation
59
Engine Removal/Installation
60
Schematic Drawing
60
Service Information
61
Engine Removal
62
Engine Installation
64
Cylinder Head/Valves
65
Cylinder Head/Valves
66
Schematic Drawing
66
Service Information
67
Specifications
67
Troubleshooting
68
Camshaft Removal
69
Cylinder Head Cover Removal
69
Cylinder Head Removal
71
Cylinder Head Disassembly
72
Cylinder Head Assembly
73
Cylinder Head Installation
74
Camshaft Installation
75
Cylinder Head Cover Installation
76
7 Cylinder/Piston
77
Cylinder/Piston
78
Schematic Drawing
78
Service Information
79
Troubleshooting
79
Cylinder Removal
80
Piston Removal
80
Cylinder Inspection
82
Piston Ring Installation
83
Cylinder Installation
84
Piston Installation
84
Kick Starter 8
86
Drive and Driven Pulleys/Kick Starter
86
Drive and Driven Pulleys/ Kick Starter
87
Schematic Drawing
87
Service Information
88
Troubleshooting
88
Left Crankcase Cover
89
Drive Pulley
90
Clutch/Driven Pulley
94
Kick Starter
95
9. Final Reduction 9
104
Final Reduction
104
Final Reduction
105
Schematic Drawing
105
Service Information
106
Troubleshooting
106
Final Reduction Disassembly
107
Final Reduction Inspection
107
Final Reduction Assembly
110
10. A.C. Generator/Starter Clutch 10
113
Generator/Starter Clutch
113
Generator/Starter Clutch
114
Schematic Drawing
114
Service Information
115
Troubleshooting
115
Right Crankcase Cover Removal
116
Stator Removal
116
Flywheel Removal
116
Starter Clutch
117
Flywheel Installation
118
Stator Installation
119
Right Crankcase Cover Installation
119
11. Crankcase/Crankshaft 11
120
Crankcase/Crankshaft
120
Crankcase/Crankshaft
121
Schematic Drawing
121
Service Information
122
Troubleshooting
122
Crankcase Separation
123
Crankshaft Inspection
124
Crankcase Assembly
125
12. Cooling System 12
128
Cooling System
128
Cooling System
129
Schematic Drawing
129
Service Information
130
Troubleshooting
130
Cooling System Testing
132
Radiator
132
Water Pump
137
Thermosensor
143
Thermostat
144
13. Fuel System/Carburetor/ Fuel Pump/ Fuel Tank 13
146
Fuel System/Carburetor/Fuel Pump Fuel Tank
147
Fuel System/Carburetor/Fuel Pump
147
Fuel System
147
Schematic Drawing
148
Operation of Carburetor Jets
149
Service Information
151
Carburetor Removal
153
Vacuum Chamber Disassembly
153
Float Chamber Disassembly
155
Auto Bystarter Inspection/Removal
157
Air Cut-Off Valve (A.C.V.)
158
Auto Bystarter Installation
160
Float Chamber Assembly
161
Float Level Inspection
162
Vacuum Chamber Assembly
162
Carburetor Installation
163
Fuel Pump Removal/Disassembly
164
Fuel Pump Inspection
165
Fuel Pump Assembly
165
Fuel Pump Installation
166
Fuel Tank Removal
166
Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork
168
Steering Handlebar/Front Wheel/Front Brake/Front
168
Schematic Drawing
169
Service Information
170
Troubleshooting
171
Steering Handlebar
172
Front Wheel
173
Front Brake
176
Front Shock Absorber
182
Front Fork
182
Rear Brake/Rear Fork/Rear Wheel/ Rear Shock Absorber
187
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
187
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
188
Schematic Drawing
188
Rear Brake
188
Rear Fork
191
Rear Wheel
191
Rear Shock Absorber
192
16. Battery/Charging System 16
193
Battery/Charging System
193
Battery/Charging System
194
Charging System Layout
194
Service Information
195
Troubleshooting
196
Battery
197
Charging System
198
A.C. Generator Inspection
198
Regulator/Rectifier Inspection
199
17. Ignition System 17
200
Ignition System
200
Ignition System Layout
201
Service Information
202
Troubleshooting
202
Ignition Coil Inspection
203
Spark Plug
203
A .C. Generator Inspection
204
CDI Unit Resistance Inspection
205
Starting System
206
Starting System
207
Starting System Layout
207
Service Information
208
Troubleshooting
208
Starter Motor
209
Starter Clutch Inspection
211
Starter Relay Inspection
212
Switches/Horn/Fuel Unit/Thermostatic
213
Electrical Equipment Layout
214
Service Information
215
Troubleshooting
215
Switches
216
Horn Inspection
218
Fuel Unit
218
Thermostatic Switch
219
Temperature Gauge
219
Instruments
220
Lights
221
Heater Wiring Diagram
222
5
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KYMCO GRAND DINK 125 Specifications
General
Brand
KYMCO
Model
GRAND DINK 125
Category
Scooter
Language
English
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