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1. CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ e 34909 KBF 9000 00161000 LAMP A INNESTO T6 5 1 00 1 e B 35360 KBF 9000 00161951 INTERRUTTORELUCE VANO 5 68 1 e C 46514 KBF 9000 00161952 MOLLA INTERRUTTORE VANO 3 10 1 A 77235 KKC4 9000 00161420 GANCIO SERRATURA SELLA 11 36 1 e D 77240 KKC4 9000 00168908 CAVO SERRATURA SELLA 18 08 1 e H 81202 KKC4 900 00161038 BOCCOLA PORTAPACCHI 4 00 4 e 93500 04012 1H 00161039 VITE TESTA PIATTA 3 10 4 e 422 95701 06012 08 00159015 VITE FLANGIATA 6X12 1 00 2 423 83500 KKC4 900 BHP 00161017A FIANCHETTO DX BLU GARDA 149 77 1 e 423 83500 KKC4 900 N8P 0016101795 FIANCHETTO DX ARGENTO METAL 149 77 1 423 83500 KKC4 900 NFP 00161017N FIANCHETTO DX NERO SMOKE 149 77 1 423 83500 KKC4 900 R1P 00161017H FIANCHETTO DX ROSSO RAC RR004 149 77 1 424 90302 SA4 0040 00162570 INSERTO FILETTATO 4MM 3 10 1 O 425 90302 GY6 9400 00155515 VITE RONDELLA 5 x 12 1 O 426 93903 35380 00150702 VITE AUTOFILETTANTE 5 x 16 4 427 83600 KKC4 900 BHP 00161019A FIANCHETTO SX BLU GARDA 149 77 1 427 83600 KKC4 900 N8P 001610195 FIANCHETTO SX ARGENTO 149 77 1 427 83600 KKC4 900 NFP 00161019N FIANCHETTO SX NERO SMOKE 149 77 1 427 83600 KKC4 900 R1P 00161019H FIANCHETTO SX ROSSO RACING 149 77 1 428 90302 SA4 0040 00162570 INSERTO FILETTATO 4MM 3 10 1 O 429 90302 GY6 9400 00155515 VITE RONDELLA 5 x 12 1 O 4380 93903 35380 00150702 VITE AUTOFILETTANTE 5 x 16 4
2. TROUBLESHOOTING COOLING SYSTEM TESTING RADIA TOR WATER PUMP L se ee THERMOSENS OR THERMOSTAT a u 12 0 dC KYMCO GRAND DINK 125 150 12 COOLING SYSTEM SCHEMATIC DRAWING 13 7N m ON 5 SN 12 1 12 COOLING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS KYMCO GRAND DINK 125 150 The water pump must be serviced after removing the engine Other cooling system service can be done with the engine installed in the frame The engine must be cool before servicing the cooling system When the coolant temperature is over 100 C never remove the radiator cap to release the pressure because the boiling coolant may cause danger Avoid spilling coolant on painted surfaces because the coolant will corrode the painted surfaces Wash off any spilled coolant with fresh water as soon as possible After servicing the system check for leaks with a cooling system tester SPECIAL TOOL Mechanical seal driver TORQUE VALUES Water pump impeller 9 8 13 7N m Water pump cover bolt 7 8 11 6 TROUBLESHOOTING Engine temperature too high Faulty temperature gauge or thermosensor Faulty radiator cap Faulty thermostat nsufficient coolant Passage
3. 13 20 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 FUEL SYSTEM 13 1 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 SCHEMATIC DRAWING 13 2 13 FUEL SYSTEM CARBURETOR QC KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 OPERATION OF CARBURETOR JETS l LOW SPEED X Air 4 slightly Bleed Holes gt Mixture Low Speed Air Inlet X Fuel in Float Chamber Slow J Low Speed Small Jet Holes 2 MIDDLE SPEED Air Venturi halfway opened throttle TL Air Bleed Holes gt Mixture High Speed Air Jet f X Fuel in Float Chamber Main Jet Main Jet The slow jet also works Low amp Middle Speed Supplementary Device Vacuum Tube Low Speed Air Jet Pilot Screw Main Jet Bypass Jet Slow Jet Low amp Middle Speed Supplementary Fuel Inlets 13 3 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 FUEL PUMP CONSTRUCTION The fuel pump adopted for this model is a vacuum type fuel pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve FUEL PUMP CONSTRUCTION Outlet Outlet Valve Diaphragms Suction Valve Pulsating Pressure 1 from
4. engine 149 5 Fuel Used 58 10 1 5 1000RPM Contact breaker Non contact point 140 Front whel 60 Spark plug NGK 155 DP7EA 9 Tires 120 70 12 140 70 12 0 8 0 9mm Ground clearance O O O o ooo 12V8AH Perform Braking distance 30km hr7 0m Clutch Type Dry multi disc clutch Non stage transmission ance 2350mm PR Starting motor amp Operation 2 Starting system kick starter Gasoline 4 stroke Single cylinder Two stage reduction Combustion chamber type Reduction 151 2 8 1 0 ratio 2nd 8 82 Bore x stroke mm 57 4 x 57 8 Front Caster angle Axle Connecting rod ompression pressure 15 en mmt e Il 8 tine pressure Max output kw rpm 8 8 7500 kg cm 2 25 Max torque N m rpm 11 76 6000 Turning BTDC 12 angle Exhaust BDDC 28 type Disk brake amm cose Valve 2 clearance cold Shock absorber Idle speed rpm 1700rpm Double swing Lubrication type Forced pressure amp 2 wet sump S S Oil pump type Inner outer rotor type Oil filter type Full flow filtration 1 3 GRAND DINK 125 150 1 GENERAL INFORMATION m Apply or add designated greases lubricants to the specified lubrication SERVICE PRECAUTIONS points B Make sure to install new gaskets O rings circlips cotter pins etc when reassembling to 3 ra mn 2 ei IL a f B After reassembly check all
5. Kick Lever Left Crankcase Cover Dowel Pins 8 DRIVE AND DRIVEN PULLEYS KYMCO __KICK STARTER SAID Install the drive belt air tube and tighten the tube band screw Tube Band Screw Universal Holder DRIVE PULLEY REMOVAL m Remove the left crankcase cover SC Hold the drive pulley using an universal holder and remove the drive face nut and washer Remove the drive pulley face Universal Holder Drive Pulley Face Movable Drive Face Remove the drive belt from the movable drive face Drive Belt INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 17 5mm replace if below Use specified genuine parts for replace ment 8 DRIVE AND DRIVEN PULLEYS KICK STARTER Remove the movable drive face assembly Remove the drive pulley collar DISASSEMBLY Remove the ramp plate Remove the weight rollers INSPECTION Check each weight roller for wear or damage Measure each weight roller O D Service Limit 16 00mm replace if below KYMCO GRAND DINK 125 150 Movable Drive Face Assembly Ramp Plate Weight Roller 8 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER 0 Measure the movable drive face bushing assemblyy I D Service Limit 27 20mm replace if over Check the drive pulley collar for wear or damage Measure the O D of the d
6. 2 3 EXHAUST MUFFLER REMOVAL 2 6 dC KYMCO GRAND DINK 125 150 2 EXHAUST MUFFLER FRAME COVERS SCHEMATIC DRAWING KYMCO 2 EXHAUST MUFFLER FRAME COVERS GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS When removing frame covers use care not to pull them by force because the cover joint claws may be damaged Make sure to route cables and harnesses according to the Cable amp Harness Routing TORQUE VALUES Exhaust muffler lock bolt 34 3N m Exhaust muffler joint lock nut 11 8N m TROUBLESHOOTING Noisy exhaust muffler Damaged exhaust muffler Exhaust muffler joint air leaks Lack of power Caved exhaust muffler Clogged exhaust muffler e Exhaust muffler air leaks KYMCO 2 EXHAUST MUFFLER FRAME COVERS GRAND DINK 125 150 FRAME COVERS REMOVAL REAR CARRIER amp HAND RAIL REMOVAL Remove the met in box First remove the three bolts and two nuts attaching the met in box Remove the met in box Nuts Bolts Remove the hand rail right and left lock hex bolts Remove the two hex bolts Remove the rear carrier and hand rail Bolts Center Cover FRAME BODY COVER REMOVAL Remove the two screws on the center cover Remove the center cover Screws Remove the three bolts on the back fender Remove the back fender 2 3 KYMCO 2 EXHAUST MUFFLER FRAME COVERS GRAND DINK 125 150
7. EE does not Ere ES or shorted fuel V Check connectors for proper connection 2 Pointer fluctuates or SN Ignition switch ON Inspection Adjustment Check battery circuit by operating turn signals and horn Signals operate Signals dim Remove fuel unitand LELEA check operation of pointer by moving gt float up and down u Move float up and down rapidly 1 round to check the gt Operation of pointer Pointer moves Pointer does not accordance with move in accord float ance with float Check connectors for proper connection UU E 1 27 unit wire ODisconnected connector Incorrectly connected connector Broken or shorted wire in fuel gauge Probable Cause OBurned out fuse 2 Weak or dead battery Faulty ignition switch Loose or disconnected connector Broken wire harness Poor contact in fuel unit DInsufficient damping oil in fuel gauge MLoose or disconnected connector Broken or shorted wire in fuel gauge 1 GENERAL INFORMATION dC KYMCO GRAND DINK 125 150 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Steering is heavy Front or rear wheel is wobbling steering handlebar pulls e 1 gt un m A POOR SUSPENSION PERFORMANCE Symptom Suspension is too soft Suspension is too hard Suspension is noisy L i POOR BRAKE PERFO
8. 211 201 202 5 203 0593 to 205 555 215 hil 216 6 216 216 216 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ e 215 61110 KHD8 900 N8P 001549215 ANT ARGENTO 67 14 1 215 61110 KHD8 900 NFP 00154921 5 67 14 1 215 61110 KHD8 900 R1P 00154921 ANT ROSSO RACING 67 14 1 216 90110 KEB7 9000 00152575 VITE SPECIALE 6 x 14 1 00 4 F 07 GRAND DINK 125 F 07 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ e 43352 568 0030 00156983 VITE DI SPURGO 9 00 1 P 43353 461 7710 M1 00156984 CAPPUCCIO SPURGO 1 00 1 44650 KHD8 30A NJA 00156907 CERCHIO ANT COMPLETO 206 58 1 OR 45107 MN5 0070 00156994 PARAPOLVERE 2 45108 ML4 0060 00156988 MOLLA 4 65 1 e J 45109 GE2 0060 00156989 PARAPOLVERE 7 75 2 eE 45131 GE2 0060 00156893 PERNO FLOTTANTE SUPP PINZA 9 30 1 45132 166 0160 00156895 PERNO FLOTTANTE PERNO PAST 9 30 1 OG 45133 MA3 0060 00156891 PROTEZIONE PERNO PINZA 1 e B 45150 LLB5 3050 00126217 PASTIGLIE ANTERIORI COPPIA 17 56 1 eH 45209 GE2 0060 00156890 PARAPOLVERE 8 26 2 45210 KHD8 9000 00156990 SUPPORTO PINZA ANTERIORE 26 00 1 45215 KA3 7320 M1 00156898 PERNO PINZA FRENO 4 00 2 OD 45216 166 0060 00156295 RONDELLA 1 OS 45531 GR
9. 3 1 MAINTENANCE SCHEDULE 3 2 FUEL LINE FUEL FILTER 3 3 THROTTLE OPERATION 3 3 ENGINE S Eege 3 4 AIR CLEANER 3 5 SPARK PLUG 3 5 VALVE CLEARANCE 3 6 CARBURETOR IDLE SPEED 3 6 IGNITION TIMING 3 7 CYLINDER COMPRESSION 3 7 FINAL REDUCTION GEAR OIL 3 8 DRIVE 3 8 HEADLIGHT AIM 3 9 CLUTCH SHOE WEAR 3 9 COOLING SYSTEM 3 9 BRAKE SYSTEM 3 10 NUTS BOLTS FASTENERS 3 11 WHEELS TIRES 3 11 STEERING HANDLEBAR 3 11 SUSPENSION tee 21 dO KYMCO 3 INSPECTION ADJUSTMENT GRAND DINK 125 150 SERVICE INFORMATION GENERAL
10. 3 A 1 D TE ES um 4 T 4 Li a d Cylinder Chain Tensioner Slipper 6 6 dC KYMCO 6 CYLINDER HEAD VALVES GRAND DINK 125 150 Cylinder Head CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs spring seats and valve stem seals using a valve spring compressor Be sure to compress the valve springs with a valve spring compressor Mark all disassembled parts to ensure correct reassembly Valve Spring Compressor Combustion Chamber Remove carbon deposits from the exhaust port and combustion chamber Be careful not to damage the cylinder head mating surface Exhaust Port 6 7 KYMCO 6 CYLINDER HEAD VALVES __GRAND Dink 125150 Straight Edge INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 05mm repair or replace if over VALVE SPRING FREE LENGTH Measure the free length of the inner and outer valve springs Service Limits Inner IN EX 29 3mm replace if below Outer IN EX 32 0mm replace if below VALVE VALVE GUIDE Inspect each valve for bending burning scratches or abnormal stem wear Check valve movement in the guide Measure each valve stem O D Service Limits IN 4 925mm replace if below EX 4 915mm replace if below CYLINDER HEAD ASSEMBLY Install t
11. dO KYMCO GRAND DINK 125 150 Probable Cause OClogged air cleaner Restricted fuel flow Clogged fuel line between fuel tank and carburetor Clogged exhaust muffler Faulty auto bystarter Split carburetor vacuum piston diaphragm OFaulty CDI unit Faulty A C generator OImproper valve clearance adjustment Worn valve seat valve stem too protruding OImproper valve and seat contact Worn cylinder and piston rings Blown cylinder head gasket Flaws in cylinder head 5 Improper valve timing OClogged carburetor jets Fouled spark plug Incorrect heat range plug level too high 2 level too low Oil not changed D Clogged oil pipe Faulty oil pump coolant Faulty thermostat Worn cylinder and piston rings 4 Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber Ignition timing too early 8 Air in cooling system DExcessive carbon build up in combustion chamber 2 Poor quality fuel GClutch slipping 4 Mixture too lean Ignition timing too early KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause Check ignition timing gt We m DFaulty CDI unit Faulty A C generator Check carburetor pilot screw adjustment pem 4 D Mixture too rich turn screw Correctly adjusted Incorrectly ad
12. KYMCO WHEEL REAR SHOCK ABSORBER lt SPANDDINKIZS 790 SCHEMATIC DRAWING 15 1 15 REAR BRAKE REAR FORK REAR KYMCO __WHEEL REAR SHOCK ABSORBER CHAND DINK 125150 SERVICE INFORMATION GENERAL INSTRUCTIONS When performing the services stated in this section the engine and exhaust muffler must be cold to avoid scalding During servicing keep oil or grease off the brake pads and brake disk SPECIFICATIONS 35 38 ear brake master cylinder piston O D 12 657 12 684 12 645 ear brake caliper cylinder I D 25 400 25 45 25 45 ear brake caliper piston O D 25 335 25 368 25 30 TORQUE VALUES SPECIAL TOOLS Exhaust muffler lock bolt 20 4 39 2N m Rear shock absorber remover Rear axle nut 78 4 98N m Shock absorber spring compressor Rear shock absorber lower mount bolt 19 6 29 4N m Rear shock absorber upper mount bolt 39 2N m Rear damper lock nut 14 7 24 5N m apply locking agent Rear brake caliper bolt 19 06 29 4N m TROUBLESHOOTING Rear wheel wobbling Poor brake performance Bent rim Air in brake system Faulty tire Deteriorated brake fluid Axle not tightened properly Contaminated brake pad surface Worn brake pads Soft rear shock absorber Clogged brake fluid line Weak shock absorber spring Deformed brake disk Damper oil leaks Unevenly worn brake caliper Rear wheel noise Worn rear wheel axle bearings Worn rear fork bearings Deformed rear fork 15 2 15 REAR BRAKE R
13. Before running the engine make sure that the working area is well ventilated Never run the engine a closed area The exhaust contains poisonous carbon monoxide gas which may cause death to people eGasoline is extremely flammable and is explosive under some conditions The working area must be well ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2_ 6mm Spark plug NGK DPR7EA9 Spark plug gap 0 9mm Valve clearance IN 0 1mm EX 0 1mm Idle speed 1700rpm Engine oil capacity Cylinder compression 15 2kg cm_ At disassembly 1 1 liter Ignition timing BTDC 10 3 1500rpm At change 0 9 liter Coolant capacity 1400 20 Gear oil capacity R adiator capacity 1000 20cc At disassembly 0 20 liter Reserve tank capacity 400 20 At change 0 18 liter CHASSIS Front rear brake free play 20 30mm TIRE LENA Ride 1 75kg em_ 1 75 2 00kg em_ 225kplom TIRE SPECIFICATION Front 120 70 12 56J Rear 140 70 12 59 TORQUE VALUES Front axle nut 14 8 68 6N m Rear axle nut 107 8 127 4N m 3 1 QC KYMCO 3 INSPECTION ADJUSTMENT GRAND DINK 125 150 MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary A Adjust C Clean R Replace Tighten Whichever Regular Service Mi
14. Inner Bearing Water Pump Assembly Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover Tighten the 3 bolts to secure the water pump assembly When installing the water pump assembly aligning the groove on the water pump shaft with the tab on the oil pump shaft Bolts Mechanical Seal Seal Washer Porcelain WATER PUMP AIMPELLER INSTALLATION When the mechanical seal is replaced a new seal washer must be installed to the impeller Impeller 12 13 12 COOLING SYSTEM Install the impeller onto the water pump shaft Torque 9 8_ The impeller has left hand threads Install the two dowel pins and a new gasket Install the water pump cover and tighten the 4 bolts Torque 7 8 13 7N m 11 8N m GRAND DINK 125 150 Impeller Left Hand Threads s Gasket Water Pump Cover 7 L F 12 14 dC KYMCO 12 COOLING SYSTEM GRAND DINK 125 150 THERMOSENSOR THERMOSENSOR REMOVAL Thermo enso Remove the seat met in box and center cover Drain the coolant Disconnect the thermosensor wire Remove the thermosensor Wire THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistance Thermosensor 2 through the sensor as the water heats up j Cs e C THERMOSENSOR INSTALLATION Thermosensor Apply 3 BOND
15. 30km hr7 0m Clutch Type length width verall height heel base 6 VE DL CDI 0 F F 5 Z zB a L z de 3 o lt ge d e 54 ond 10391918 621129 54 uous Non stage transmission Starting motor amp Two stage reduction Combustion chamber type Semi sphere oe 28 10 Automatic centrifugal Type z 2 lt lt un e c wW uononpoy e em ME 2nd 8 82 Compression pressure Axle Connecting rod TM Front Is Tire pressure Front L Max torque N m rpm 9 8 6000 Ce 2 25 Intake BTDC 12 Turning MD oe angle ms lax now dmm Clos 8 Valve 0 1mm clearance co C oim 2 Shock absorber Idle speed rpm 1700rpm type er F d amp tvpe Oil filter type Full flow filtration NAA SUMON Uulojs qn dC KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 __ E SPECIFICATIONS Cooling Type Name amp Model No SH30DA Motorcycle Name amp Type D Overall length 2060mm Overall width Air cleaner type amp No Overall height 1360mm 54 ond 1039119220 621129 54 uous z 2 lt lt un e c wW uononpoy SUMON 1435mm VE
16. 7 000 00158942 ATTREZZI SET 9 30 1 e 363 77210 KKC4 900 TO1 00158165 POGGIASCHIENA 45 96 1 e 366 89013 KFC8 E000 00158100 REG AMMORTIZZATORE POST 8 00 1 Li 381 GRAND DINK 125 03 11 04 e G 390 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ OD 16911 KKC4 9000 00159904 TUBO FILTRO LATO SERBATOIO 1 C 16912 KKC4 9000 00159905 TUBO FILTRO LATO POMPA 7 00 1 B 1691A KEC2 E00 00159396 FILTRO CARBURANTE 4 65 1 e 17510 KKC4 9000 00159361 RACCORDO TAPPO CARBURANTE 23 76 1 OG 95002 02070 00159013 CLIP TUBO B7 1 e E 95002 02100 00161011 CLIP TUBO B10 1 00 4 O A 95002 02130 00162961 CLIP TUBO B 12 5 2 OF 95002 02080 00159014 CLIP TUBO B8 3 e 370 37802 GA7 7000 00159010 COP INDICATORE LIV CARBURANTE 4 13 1 e 371 3780A KKC3 9000 00159350 INDICATORE LIVELLO CARBURANTE 30 99 1 e 373 37801 GA7 7000 00159009 GUARN INDICATORE LIVELLO CARB 4 13 1 e 374 17500 KKC4 900 00159373 SERBATOIO CARBURANTE 92 96 1 e 375 94050 06080 00109022 DADO FLANGIATO 6mm 1 55 4 e 376 19411 KCB 9000 00159957 MORSETTO TUBO 4 65 1 e 378 17502 KKC4 9000 00159360 TUBO CARBURANTE 18 59 1 e 380 19411 KCB 9000 00159957 MORSETTO TUBO 4 65 1 e 381 17689 KBE E000 00159958 TUBO GIUNTO 3 VIE 7 23 1 O 384 95002 02130 00162961 CLIP TUBO B 12 5 1 O 385 93903 35220 00151719 VITE AUTOFILETTANTE 5 x 12 3 387 16700 7 900 00165200 CARBUR
17. Check the load of the whole charging system Do not quick charge the battery Quick charging should only be done in an emergency Remove the battery from the motorcycle for charging When replacing the battery do not use a traditional battery When charging check the voltage with an electric tester SPECIFICATIONS Voltage Battery 20 C A C Generator 0 6 1 60 TESTING INSTRUMENTS TORQUE VALUES Ammeter Pulser coil bolt 4 9N m Electric tester Coil lock bolt 5 8N m Tachometer Flywheel nut 34 3 44 1 16 2 dC KYMCO 16 BATTERY CHARGING SYSTEM GRAND DINK 125 150 SPECIAL TOOLS Universal holder Flywheel puller TROUBLESHOOTING No power Intermittent power Dead battery Loose battery cable connection Disconnected battery cable Loose charging system connection Fuse burned out Loose connection or short circuit in Faulty ignition switch ignition system Low power Charging system failure Weak battery Loose broken or shorted wire or connector Loose battery connection Faulty regulator rectifier Charging system failure Faulty A C generator Faulty regulator rectifier 16 3 N T O a KYMCO 16 BATTERY CHARGING SYSTEM GRAND DINK 125 150 Battery Cover Screw BATTERY Remove the seat and met in box 2 3 Remove the battery cover screw and the battery cover Remove the battery First disconnect the battery negative cable and then the pos
18. Starter Relay C D I Regulator Rectifier Hazard Control Unit Fuse Box CULA Battery Cable 1 15 KYMCO 1 GENERAL INFORMATION GRANDDINK125 150 Air Cut off Ignition Coil Valve Throttle Cable Thermostat Auto Bystarter Vacuum Fuel Tube Nez Spark Plug Fuel Pump Vacuum Tube Regulator Rectifier Ignition Coil Fuel Pump Vacuum Tube Wire Harness Starter Relay Vacuum Fuel Unit Wire 1 16 KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 WIRING DIAGRAM E EE is a EE ANM 1 041 ak 1 17 KYMCO GRAND DINK 125 150 1 GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment 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 engine ground Test cylinder compression Start engine by follow Ing normal starting procedure Remove spark plug and inspect again Probable Cause DEmpty fuel tank E Clogged carburetor fuel inlet tube vacuum tube or fuel tube Clogged auto fuel valve 4 Clogged float oil passage 5 Clogged fuel tank breather hole Clogged fuel strainer OClogged fuel filter 9 Faulty fuel p
19. THERMOSTAT INSTALLATION The installation sequence is the reverse of removal Replace the O ring with a new apply grease to it Thermostat Housing Thermostat Housing Fill the cooling system with the specified 444 coolant 3 9 12 17 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 FUEL SYSTEM CARBURETOR FUEL PUMP PUEICSYSTEM 13 1 C MATICO AW e 13 2 OPERATION OF CARBURETOR JETS 13 3 SERVICE INFORMATION eege 13 5 CARBURETOR REMOVAL 13 7 VACUUM CHAMBER DISASSEMBLY 13 7 FLOAT CHAMBER DISASSEMBLY 13 9 AUTO BYSTARTER INSPECTION REMOV AL 13 11 I OP P VALVE 13 12 AUTO BYSTARTER INSTALLATION 13 14 FLOAT CHAMBER ASSEMBLY 13 15 FLOAT LEVEL 13 16 VACUUM CHAMBER ASSEMBLY 13 16 CARBURETOR INSTALLATION 13 17 FUEL PUMP REMOVAL DISASSEMBLY 13 18 FUEL PUMP ING PEC TION 13 19 FUEL PUMP ASSEMBLY 13 19 FUEL PUMP INSTALLATION 13 20 FUEL TANK
20. Probable Cause Valve clearance too large 2 Worn camshaft lobe D Worn piston rings Worn piston pin and connecting rod small end Excessive carbon build up in combustion chamber Damaged cam chain tensioner Worn cam gear teeth Worn or damaged cam chain Extended cam chain Faulty crankshaft bearing 2 Worn crank pin bearing Q Worn or damaged final reduction gears Worn final reduction gear shaft splines 1 22 1 GENERAL INFORMATION CLUTCH DRIVE AND DRIVEN PULLEYS O 1 23 Engine starts but motor cycle does not move Motorcycle creeps or engine starts but soon stops or seems to rush out Rear wheel rotates when engine idles Engine lacks power at start of a grade poor slope performance Engine lacks power at high speed There is abnormal noise or smell while running KYMCO GRAND DINK 125 150 Probable Cause Worn or slipping drive belt 2 ramp plate Broken drive face spring Separated clutch lining Damaged driven pulley shaft splines Damaged final gear Seized final gear Broken shoe spring Clutch outer and clutch weight stuck Seized pivot D or slipping drive belt Worn weight rollers Seized drive pulley bearings Weak driven face spring Worn or seized driven pulley bearings Worn or slipping drive belt Worn weight rollers Worn or seized driven pulley bearings or grea
21. Probable Cause DWeak or dead battery 0 Loose connector or terminal 2 Poor contact in starter relay QG Faulty starter clutch OSeized cylinder Broken or shorted starter motor cable Probable Cause O Faulty starter pinion 0 Starter relay shorted or stuck 1 24 dC KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 closed NO SPARK AT SPARK PLUG Inspection Adjustment Probable Cause o Replace with a new spark plug and inspect 2 UUU TU TUT TTT TUTE again Faulty spark plug Good spark Check spark plug cap and high tension wire gt for looseness _ Check CDI unit i coupler for looseness connected coupler Measure resistance between terminals of CDI unit coupler 5 Faulty ignition switch Faulty exciter coil Faulty pulser coil 4 Faulty ignition coil Broken wire harness Poorly connected coupler Check CDI unit with a T q CDI unit tester Check ignition coil with a CDI unit tester D Faulty ignition coil KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment Probable Cause Start engine and test limit voltage of battery terminals OFaulty AC generator Normal voltage 2 HOST Faulty regulator rectifier Faulty battery Measure resistance between AC generat
22. SERVICE INFORMATION GENERAL INSTRUCTIONS dC KYMCO GRAND DINK 125 150 Check the ignition system according to the sequence specified in the Troubleshooting 1 28 The ignition system adopts CDI unit and the ignition timing cannot be adjusted If the timing is incorrect inspect the CDI unit and A C generator and replace any faulty parts Inspect the CDI unit with a CDI tester Loose connector and poor wire connection are the main causes of faulty ignition system Check each connector before operation Use of spark plug with improper heat range is the main cause of poor engine performance The inspections in this section are focused on maximum voltage The inspection of ignition coil resistance 1s also described this section Inspect the ignition switch according to the continuity table specified in page 20 3 nspect the spark plug referring to Section 3 Remove the A C generator and pulser coil referring to Section 10 SPECIFICATIONS Item Spark plug Spark plug eap SCH 2 F mark Ignition timing Full advance Primary coil Ignition coil resistance 20 with plug Pulser coil resistance 20 Exciter coil resistance 20 C Ignition coil primary side max voltage Pulser coil max voltage Exciter coil max voltage TESTING INSTRUMENT Electric tester TROUBLESHOOTING No spark at plug Faulty spark plug Poorly connected broken or sho
23. O D 9972 9 987 9 972 9 987 99 1 1 4 u Valve stem O D 4 990 4 975 14 990 4 975 925 ib 4 970 4 955 4 970 4 955 4 915 4 915 clearance L 99 4925 0 000 0037 0010 0 037 0 0500 0 057 10 030 04057 TORQUE VALUES Cylinder head cap nut 19 6N m Apply engine oil to threads Valve clearance adjusting out 8 8N m Apply engine oil to threads Cylinder head cover bolt 1 8 11 8N m SPECIAL TOOLS Valve spring compressor Valve seat cutter 24 5mm 45 IN EX Valve seat cutter 25mm Plane cutter 37 5 EX Valve seat cutter 22mm Plane cutter 37 5 EX Valve seat cutter 26mm Plane cutter 63 5 IN EX Cutter clip Valve guide driver Valve guide reamer 6 CYLINDER HEAD VALVES TROUBLESHOOTING dO KYMCO GRAND DINK 125 150 The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top end noises Poor performance at idle speed Compression too low Compression too low Incorrect valve clearance adjustment Burned or bend valves Incorrect valve timing Broken valve spring Poor valve and seat contact Leaking cylinder head gasket Warped or cracked cylinder head Poorly installed spark plug Compression too high Excessive carbon build up in combustion chamber White smoke from exhaust muffler Worn valve stem or valve guide Damaged valve stem oil seal Abnormal noise ncorrect valve clearance adjustment e Sticking valve or broken
24. Oil Capacity At disassembly 0 2 liter At change 0 18 liter TORQUE VALUES Transmission case cover bolt 25 5 31 4N m check bolt 9 8 14 7N m SPECIAL TOOLS Bearing remover 12mm Bearing remover 15mm Pilot 12mm Pilot 15mm TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Abnormal noise Worn seized or chipped gears Worn bearing Oil leaks Oil level too high Worn or damaged oil seal KYMCO 9 FINAL REDUCTION GRAND DINK 125 150 FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler 2 6 Remove the rear brake caliper 15 3 Remove the right rear shock absorber 15 5 Remove the rear fork 15 4 Remove the rear wheel 15 4 Remove the left crankcase cover 8 3 Remove clutch driven pulleys 8 4 Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Final Shaft Dowel Pin Drive Shaft Remove the transmission case cover Remove the gasket and dowel pins Remove the final gear and countershaft Final Gear Co ntesshaft Dowel Pin Washers FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Countershaft KYMCO 9 FINAL REDUCTION GRAND DINK 125 150 Inspect the final gear and final shaft for wear damage or seizure Drive Shaft Bearing Check the left crankcase
25. SPECIAL TOOLS Lock nut wrench Front shock absorber compressor Ball race remover Driver handle Outer driver 37x40mm Pilot 12mm Bearing remover Bearing remover head 12mm 14 2 I4 STEERING HANDLEBAR FRONT WHEEL FRONT KYMCO BRAKE FRONT SHOCK ABSORBER FR ONT FORK GRAND DINK 125 150 TROUBLESHOOTING Hard steering heavy Excessively tightened steering stem top cone race Broken steering balls nsufficient tire pressure Steers to one side or does not track straight Uneven front shock absorbers Bent front fork Bent front axle or uneven tire Poor brake performance Worn brake pads Contaminated brake pad surface Deformed brake disk Air in brake system Deteriorated brake fluid Worn brake master cylinder piston oil seal Clogged brake fluid line Unevenly worn brake caliper 14 3 Front wheel wobbling Bent rim Loose front axle Bent spoke plate Faulty tire mproperly tightened axle nut Soft front shock absorber Weak shock springs nsufficient damper oil Front shock absorber noise e Slider bending Loose fork fasteners Lack of lubrication 14 STEERING HAN DLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK GRAND DINK 125 150_ Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers 2 6 Remove the front and rear brake master cylinder attaching bolts Remove
26. Starter Driven Gear Friction Spring Kick Starter Spindle Forcing Starter Driven Gear Shaft Forcing Part Friction Spring Starting Ratchet 8 16 Kick Starter Spindle 8 DRIVE AND DRIVEN PULLEYS KICK STARTER Install the kick lever Install the left crankcase cover and tighten the cover bolts diagonally Connect the drive belt air tube and tighten the band screw LEFT CRANKCASE COVER BEARING INSPECTION Inspect the bearing into the left crankcase cove for loose wear or damage If any abnormal problem is found replace the bearing with a new one 9 17 KYMCO 9 FINAL REDUCTION GRAND DINK 125 150 FINAL REDUCTION SCHEMATIC Eeer 9 SERVICE INFORMATION 9 2 TROUBLESHOOTING 9 2 FINAL REDUCTION DISASSEMBLY 9 3 FINAL REDUCTION INSPECTION 9 3 FINAL REDUCTION ASSEMBLY 9 6 9 0 KYMCO 9 FINAL REDUCTION GRAND DINK 125 150 SCHEMATIC DRAWING 9 1 KYMCO 9 FINAL REDUCTION GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The servicing operations of this section can be made with the engine installed When replacing the drive shaft use a special tool to hold the bearing inner race for this operation SPECIFICATIONS Specified Oil SAE 90s
27. 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 Grease Engine Oil Front Brake Lever Pivot Speedometer Cable Throttle Cable d _ Grease Seat Lock Speedometer Gear Rear Wheel Bean Front Wheel Bearing E eel bearing _ WT Grease 1 11 1 GENERAL INFORMATION GRAND DINK 125 150 CABLE amp HARNESS ROUTING Front Brake Rear Brake Speedometer Cable Pressure Type Radiator Air Radiator Cap Vent Tube Horn Radiator zie 1 12 dO KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 Reserve Tank Cap Ignition Switch Fuel Filler 5 WEBB Fuel Tank Breather Tube lt Thermostatic SM Switch Fuel Tank f j Inlet Tube Water Hose Fuel Strainer Front Brake Fluid Tube Water Hoses 1 13 KYMCO GRAND DINK 125 150 1 GENERAL INFORMATION Front Stop Switch Rear Stop Switch 4 Radiator Aur Vent Tube Throttle Cable Fuel Filler Fuel Tank Fuel Tank Inlet Tube Rear Brake Fluid Tube Water Hose Wire Harness Fuel Tank Throttle Cable 1 14 KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 Fuel Unit Fuel Tube Auto Bystarter Wire Thermostat Ignition Coil Air Cut off Valve A C V Carburetor Starter Motor
28. with a micrometer gauge Service Limit 25 30mm Check the caliper cylinder for scratches or wear and measure the cylinder bore Service Limit 25 45mm ASSEMBLY Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Install the piston with its outer end protruding 3 5mm beyond the brake caliper Wipe off excessive brake fluid with a clean shop towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat INSTALLATION Install the brake caliper to the shock absorber and tighten the two bolts Torque 24 5 343 When installing the brake caliper be sure to position the brake disk between the GR Es V 1 li lt i 108 dm 1 1 N d k a m a 1 Caliper 1 14 12 two brake pads 14 STEERING HANDLEBAR FRONT WHEEL FFRONT BRAKE FRONT SHOCK ABSORBER FR ONT FORK GRAND DINK 125 150 Brake Fluid Tube Connect the brake fluid tube to the brake E caliper and tighten the fluid tube bolt Torque 24 5 34 3N m Fill the brake reservoir with the specified i brake fluid and bleed air from the brake system 14 10 When installing the brake
29. 07 00158355 VITE FLANGIATA 8 X 65 2 58 1 Li C SERE 03 11 04 516 513 CODICE CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 50505 7 000 00164982 GOMMA FERMO CAVALLETTO 4 13 1 e D 50506 7 000 00164983 BOCCOLA GOMMA FINE CORSA 9 00 1 e B 94101 08700 00168212 RONDELLA LISCIA 8MM 3 00 2 C 94251 08800 00165105 COPPIGLIA 8mm 2 00 1 510 5050A KKC3 900 00164126 CAVALLETTO CENTRALE 46 48 1 511 50502 GY6 9010 00164792 BOCCOLA CAVALLETTO CENTRALE 3 10 2 e 513 95801 10025 08 00164794 VITE FLANGIATA 10X25 3 10 2 514 50550 KKC2 E000 00164514 MOLLA CAVALLETTO CENTRALE 5 68 1 e 515 28300 2 000 00164515 LEVA AVVIAMENTO 23 76 1 e 516 95701 06022 07 00165007 VITE FLANGIATA 6X22 NERA 3 10 1 517 50530 KKC4 E00 00164517 CAVALLETTO LATERALE 24100747 20 00 1 517 50530 KKC4 E000 00164996 CAVALLETTO LATERALE 19 63 1 e 518 90108 KFC8 E000 00164918 PERNO CAVALLETTO LATERALE 4 65 1 518 90108 KKC4 900 00164518 PERNO CAVALLETTO LATERALE 24100747 5 00 1 519 50532 KGBG E000 00164979 MOLLA CAVALLETTO LATERALE 6 20 1 Li te EE Ce 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ A 11203 GC7 3010 00109006 SUPPORTO ELASTICO AMM POST 9 04 1 e B 91051 KBF 901 00165715 CUSCINETTO 21X40X12 RAD 6203LU 11 88 1 91259 KBF 9000 00165716 PARAOLIO 40 x26
30. 1 1 1 1 1 1 1 1 1 2 4 1 1 2 2 2 21 CODICE KY CODICE PIR GRAND DINK 125 03 11 04 2 2 Y 4 149 149 S DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 180 64312 KKC4 900 N1R 00154176 GRIGLIA POGGIAPIEDI DX 11 88 1 182 64322 KKC4 900 N1R 00154177 GRIGLIA POGGIAPIEDI SX 11 88 1 185 81132 KEB7 900 N1R 00154553 COP ISPEZIONE TELAIO 3 10 1 186 64317 4 9000 00152179 GUARNIZIONE SCUDO INT SUP 6 20 1 188 64309 4 9000 00154029 GRIGLIA SCUDO ANTERIORE 11 36 1 190 64311 KKC4 900 N1R 00154178 POGGIAPIEDI DX 13 94 1 e 191 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 1 O 192 93404 06016 07 00163215 VITE RONDELLA 6 x 16 2 194 64321 KKC4 900 N1R 00154179 POGGIAPIEDI SX 13 94 1 e 195 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 1 196 93404 06016 07 00163215 VITE RONDELLA 16 2 Li eS ee 03 11 04 211 200 55 TT 201 in 202 gt 203 2 15 2 B 20 x e O a 215 T 216 216 216 45 216 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ eA 45156 KCE 9000 00155000 SUPP TUBO FRENO ANT 3 00 1 e B 95701 06012 08 00159015 VITE FLANGIATA 6X12 1 00 1 O 1 51420 KKC4 9000 00155901 FODERO DX 1 O2 51520 KKC4 9000 00155902 FODERO SX
31. 14 STEERING HAN DLEBAR FRONT WHEEL FRONT __ BRAKE FRONT SHOCK ABSORBER FRONT FORK GRAND DINK 125 150_ INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race Then install the front fork Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Check that the steering stem rotates freely without vertical play Install the steering stem lock nut and tighten it while holding the top cone race Torque 78 4_ 117 6N m Install the front wheel 14 7 Install the front brake caliper 14 12 Install the front inner fender 2 6 Install the throttle grip and the right and left handlebar switches 14 5 Install the right and left brake master cylinders 14 5 Lock Nut Wrench 14 18 15 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER CP WDDINRTZ I99 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER SIE NAT DRAWING O eee 15 1 SERVICE INFORMATION 15 2 lt 15 2 BEAR Ne 15 3 REAR TORK s LEE 15 4 BEAR ee meee 15 4 REAR SHOCK ABSORBER 15 5 15 0 15 REAR BRAKE REAR FORK REAR
32. 2 lt 14 3 STEERING HANDLEBAR 14 4 FERONT WHEEL eei uenisset eee e 14 5 14 8 FRONT SHOCK 14 14 14 17 14 0 14 STEERING HANDLEBAR FRONT WHEELFRONT KYMCO ___BRAKE FRONT SHOCK ABSORBER FRONT FORK RAND DINK 125 150_ SCHEMATIC DRAWING 14 1 I4 STEERING HANDLEBAR FRONT WHEEL FRONT KYMCO BRAKE FRONTSHOCK ABSORBER FRONT FORK GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS Remove the motorcycle frame covers before removing the front wheel steering handlebar front shock absorber and front fork Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down During servicing keep oil or grease off the brake pads and brake disk SPECIFICATIONS Axle shaft runout Front wheel rim runout 2 0 0 Front shock absorber spring free length 240 6 3 0 Rail JI 2406 3 rake disk thickness 38 4 2 Item 0 2 2 2 3 rake disk runout rake master cylinder I D rake master cylinder piston O D rake caliper piston O D rake caliper cylinder I D TORQUE VALUES Steering stem lock nut 78 4 117 6N m Steering top cone race 4 9 I2 7N m Front shock absorber bolt 19 8 24 5N m Front axle nut 441 49N m Brake caliper bolt 24 5N_ 34 3N m
33. 6204 14 46 1 11 96100 62030 00 00125788 CUSCINETTO 17x40x12 RAD 6203 10 85 1 12 91202 KJ9 0040 00125789 PARAOLIO 20 x 32 x6 6 20 1 13 11102 187 0030 00109202 SUPPORTO MOTORE ELASTICO 9 55 1 14 11203 GC7 3010 00109006 SUPPORTO ELASTICO AMM POST 9 04 1 e 18 90032 KBE 9000 00121918 PRIGIONIERO B 8 mm 4 65 1 e 23 28250 KFC8 9000 00121923 ALBERINO AVVIAMENTO PEDALE 18 59 1 24 28281 GN2 6030 M1 00106012 MOLLA RITORNO AVV PEDALE 6 20 1 e 25 28255 GS6 0010 00106205 RONDELLA BATTUTA BOCCOLA 2 07 1 26 28253 GN2 6020 M1 00106011 BOCCOLA AVVIAMENTO PEDALE 7 23 1 e 27 90451 GN2 6010 00106016 RONDELLA ALBERINO AVV PED 4 13 1 e 28 94511 14000 00106119 SEEGER EST 14mm 2 00 1 e 30 28230 KBN 9010 00121130 INGRANAGGIO AVV PEDALE 20 66 1 31 90412 329 0010 00106014 RONDELLA DI SPINTA 4 00 1 e 32 28223 KBN 9010 00106209 MOLLA FRIZIONE AVV PEDALE 4 13 1 e 36 11395 KKC3 9000 00121156 GUARNIZIONE CARTER SX 19 63 1 37 11341 KKC3 900 N8A 00121157 CARTER SX 045 129 11 1 e 38 94301 08140 00121704 SPINA DI CENTRAGGIO 8 x 14 1 55 2 39 96001 06040 08 00105008 VITE FLANGIATA SH 6 x 40 4 13 8 O 47 96001 06060 08 00109030 VITE FLANGIATA SH 6 x 60 2 Cel V GRAND DINK 125 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ O 48 96001 06120 08 00121954 VITE FLANGIATA 6 x 120 1 49 95701 08012 08 00109234 VITE FLANGIATA 8 X 12 3 00 1 O 50 96001 06
34. 8 13 7N m SPECIAL TOOLS Flywheel holder Flywheel puller TROUBLESHOOTING Starter motor won t turn Lack of power Fuse burned out Weak battery Weak battery Loose wire or connection Faulty ignition switch Foreign matter stuck in starter motor Faulty starter clutch or gear Faulty front or rear stop switch Faulty starter relay Starter motor rotates but engine does Poorly connected broken or shorted wire not start Faulty starter motor Faulty starter pinion e Starter motor rotates reversely Weak battery 18 2 KYMCO 18 STARTING SYSTEM GRAND DINK 125 150 STARTER MOTOR REMOVAL Before removing the starter motor turn the ignition switch OFF and remove the battery ground Then turn on the ignition switch and push the starter button to see 1f the starter motor Operates properly Remove the seat met in box and frame center Starter Motor Cable cover 2 3 Remove the waterproof rubber jacket and Motor Case disconnect the starter motor cable Remove the two starter motor mounting bolts and the motor DISASSEMBLY Remove the two starter motor case screws front cover rear cover motor case and other parts Case Screws Front Cover INSPECTION Inspect the removed parts for wear damage or discoloration Replace if necessary Clean the commutator if there is metal powder between the segments Commutator Check for continuity between pairs of the commutator segme
35. 8 x 1 9 2 00 1 e 285 19503 KBE 9000 00129968 TUBO C ACQUA 8 26 1 286 95002 KN7 9100 00123937 FASCETTA TUBO ACQUA 1 00 2 O 287 96001 06018 08 00103008 VITEFLANGIATA SH 6 x 18 1 e 289 19211 KKC3 9000 00129902 CORPO POMPA ACQUA 40 00 1 290 94520 26000 00129980 SEEGER INT 26mm 3 62 1 291 96100 60000 00 00128975 CUSC SFERE RAD 6000 14 98 1 e 292 19231 KBE 9000 00129977 ALBERO POMPA ACQUA 37 18 1 e 293 91001 KJ9 006 00129985 CUSC SFERE RAD 6901 16 53 1 294 91201 KJ9 0040 00129984 PARAOLIO 12 x20 x4 4 65 1 e 295 19217 657 0240 00129974 GUARN MECCANICA 16 53 1 e 296 90423 KJ9 0010 00129978 RONDELLA 7 2 x 13x 1 2 4 00 1 e 297 19215 KJ9 0110 00129973 GIRANTE POMPA ACQUA 6 71 1 e 298 19221 KKC3 9000 00129906 COPERCHIO POMPA ACQUA 16 00 1 11 Cel V e 285 GRAND DINK 125 03 11 04 310 307 307 S CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ O 299 96001 06022 08 00103207 VITE FLANGIATA SH 6 x 22 2 O 300 96001 06028 08 00108016 VITE FLANGIATA SH 6 x 28 2 e 301 94301 08140 00121704 SPINA DI CENTRAGGIO 8 x 14 1 55 2 302 19229 KKC3 900 00128302 GUARNIZIONE POMPA ACQUA 4 00 1 303 91302 567 0040 00124952 O RING 27 4 x 2 4 3 10 1 304 19501 KKC3 9000 00129969 TUBO ACQUA A 10 33 1 e 305 95002 KN7 9100 00123937 FASCETTA TUBO ACQUA 1 00 1 O 307 96001 06020 08 00104004 VITE FLANGIATA SH 6 x 20 3 O 309 37720 KGB5 9000 00102020 TERRA TERMOSTATO 1 310 32101 KHD8 9000 0
36. Black Y ellow 17 5 KYMCO GRAND DINK 125 150 IGN Black Yello w E PC Green Blue Yellow E EXT SW Green White Black Red Black White KYMCO 18 STARTING SYSTEM GRAND DINK 125 150 STARTING SYSTEM STARTING SYSTEM LAYOUT 18 1 SERVICE INFORMATION 18 2 TROUBLESHOOTING 18 2 SPAPTEP MOTOR eee ean ind 18 3 STARTER CLUTCH INSPECTION 18 5 STARTER RELAY INSPECTION 18 6 4 KYMCO 18 STARTING SYSTEM GRAND DINK 125 150 STARTING SYSTEM LAYOUT Stop Switches Starter Relay Starter Motor STARTING CIRCUIT Fusce PPP Ignition SW FR Stop SW p mE Fuse 15A RR Stop SW Starter St Battery Motor Relay a 12V8AH G G L 1 18 1 dO KYMCO 18 STARTING SYSTEM GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The removal of starter motor can be accomplished with the engine installed For the starter clutch removal refer to page 10 3 After the starter clutch 1s installed be sure to add the engine oil and coolant and then bleed air from the cooling system SPECIFICATIONS Standard mm eric Lind n TORQUE VALUES Starter motor mounting bolt 6 7 10 8N m Starter motor case screw 2 9 4 9N m Starter clutch bolt 9
37. Crankcase Inlet 13 4 13 FUEL SYSTEM CARBURETOR QC KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS When working with gasoline keep away from sparks and flames Note the locations of O rings when disassembling and replace them with new ones during assembly Before float chamber disassembly drain the residual gasoline from the float chamber Do not try to disassemble the auto bystarter When assembling the vacuum chamber and air cut off valve be careful not to damage the diaphragms All cables fuel lines and wires must be routed and secured at correct locations When removing the fuel tank keep sparks and flames away from the working area When removing the fuel tank the remaining fuel in the tank must be lower than _ of the fuel tank capacity to avoid gasoline overflowing Fuel tank capacity 10 5 liters SPECIFICATIONS 125 Venturi dia mm VE26 VEOGOA VEOGIA 185 2417 1024 35 1700 pm SPECIAL TOOLS Float level gauge Fuel unit remover 13 5 13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK TROUBLESHOOTING Engine does not start No fuel in tank Restricted fuel line Too much fuel getting to cylinder Clogged air cleaner Contaminated fuel Faulty fuel pump Throttle does not open fully so engine stalls Damaged vacuum piston diaphragm Clogged diaphragm hole Lean mixture Clogged fuel jet
38. KYMCO 10 GENERA TOR STARTER CLUTCH SCHEMATIC DRAWING 10 1 KYMCO 10 GENERA TOR STARTER CLUTCH GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS All servicing operations and inspections in this section can be made with the engine installed Drain the coolant before removing the right crankcase cover Be careful not to drain the coolant when the engine temperature is high Perform this operation when the engine is cold Drain the coolant into a clean container Drain the engine oil into a clean container before removing the right crankcase cover When the right crankcase cover is installed fill with the recommended engine oil and coolant Then bleed air from the water jacket Refer to page 18 4 for A C generator inspection SPECIFICATIONS Engine SAEIS5W AOf API SJ Oil capacity at change 0 9 liter Coolant distilled water coolant concentrate Coolant capacity 1400 20 SPECIAL TOOLS Flywheel puller Flywheel holder SPECIFICATIONS Standard mm Service Limit mm Starter driven gear I D 20 025 20 045 20 15mm Starter driven gear O D 42 175 42 200 TORQUE VALUES Flywheel nut 343 44 1N m TROUBLESHOOTING Refer to page 1 27 for A C generator troubleshooting Starter motor rotates but engine does not start Faulty starter clutch Starter motor rotates reversely Weak battery 10 2 KYMCO 10 GENERA TOR START
39. KYMCO 4 LUBRICATION SYSTEM GRAND DINK 125 150 LUBRICATION SYSTEM Rocker Arm Shaft Oil Pump Oil Filter Screen 4 1 dC KYMCO 4 LUBRICATION SYSTEM GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The maintenance of lubrication system can be performed with the engine installed in the frame Drain the coolant before starting any operations Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit After the oil pump is installed check each part for oil leaks SPECIFICATIONS OIL PUMP Tos Outer rotor to pump body clearance 0 15 0 20 Rotor end to pump body clearance 0 04 0 09 ENGINE OIL Engine Oil Capacity At disassembly 1 1 liter At change 0 9 liter Recommended Oil SAE15W40 API SJ TROUBLESHOOTING Oil level too low Poor lubrication pressure Natural oil consumption Oil level too low Oil leaks Clogged oil filter or oil passage Worn piston rings Faulty oil pump Worn valve guide Worn valve guide seal Oil contamination Oil not changed often enough Faulty cylinder head gasket Loose cylinder head bolts KYMCO 4 LUBRICATION SYSTEM GRAND DINK 125 150 ENGINE OIL OIL FILTER Place the motorcycle upright on level ground for engine oil level che
40. LA 22 Cautions for Using Coolant Use coolant of specified mixing rate The mixing rate of 425cc KYMCO SIGMA coolant concentrate 975cc distilled water 1s 30 Do not mix coolant concentrate of different brands Do not drink the coolant which is poisonous The freezing point of coolant mixture shall be5 C lower than the freezing point of the riding area 12 3 KYMCO 12 COOLING SYSTEM GRAND DINK 125 150 COOLING SYSTEM TESTING Radiator Tester RADIATOR CAP INSPECTION Install the radiator cap onto the radiator tester and apply specified pressure to it It must hold specified pressure for at least six seconds Apply water to the cap sealing surface before testing Radiator Cap Relief Pressure 0 9 0 15 Radiator Install the radiator tester onto the radiator and apply specified pressure to it It must hold specified pressure for at least six seconds Check the water hoses and connectors for leaks test pressure should not exceed 1 05 kg cm_ Excessive pressure can damage the radiator and its hose connectors RADIATOR RADIATOR INSPECTION Remove the front upper cover 2 5 Remove the front lower cover 2 5 12 4 KYMCO 12 COOLING SYSTEM GRAND DINK 125 150 Inspect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with compressed air If insects etc are clogging
41. LISTINO IVA ESCL N PZ 110 14401 KDU 9000 00123110 CATENA DISTRIBUZIONE 30 99 1 e 111 14510 KBE 9000 00123913 TENDICATENA 16 53 1 112 14610 KJ9 0010 00123914 GUIDA CATENA 5 68 1 113 14531 KJ9 0010 00123916 TENDICATENA 3 62 1 116 12100 1 9000 00123947 CILINDRO 98 13 1 119 12191 KKC3 9000 00123945 GUARNIZIONE CILINDRO 3 10 1 120 94301 10160 00122773 SPINA DI CENTRAGGIO 10 x 16 1 55 2 e 121 13101 KED1 9000 00123941 PISTONE 52 4mm 36 15 1 122 13111 384 0010 00123724 SPINOTTO 3 10 1 123 94601 15000 1 00123725 FERMI SPINOTTO IN SET 15mm 2 58 2 124 13011 GY6 9000 00123728 SEGMENTI SET 52 4 mm 29 95 1 127 13000 KKC2 900 00123948 ALBERO MOTORE 273 72 1 e 128 90701 HB6 0110 00123730 CHIAVETTA 25 x 14 x 4 3 10 1 O 130 11384 KHE7 9000 00153011 MORSETTO TUBO FRENO POST A 1 131 14550 KS4 0040 M2 00103731 REGISTRO TENDICATENA 15 49 1 O 132 14552 KS4 0030 00123935 VITE REGISTRO 1 O 133 14553 KS4 0030 00103636 MOLLA VITE REGISTRO 1 e 134 90421 KM1 0030 00123934 RONDELLA 8 x 16 x 1 6 3 10 1 e 135 14555 KJ9 0010 00123932 GUARN REGISTRO TENDICAT 4 65 1 136 96001 06018 08 00103008 VITE FLANGIATA SH 6 x 18 2 137 19502 KBE 9000 00123936 TUBO B ACQUA 9 30 1 138 95002 7 9100 00123937 FASCETTA TUBO ACQUA 1 00 2 Li Gea oni EEN 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ A 91302 567 00
42. Remove the brake lever bolt and the brake lever Remove the piston rubber cover and snap ring from the brake master cylinder Remove the washer main piston and spring from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid Bolts Holder Stop Switch Wire Connector Snap Ring Snap Ring Pliers Close Master Cylinder Spring Main Piston Rubber Cover 14 8 Snap Ring 14 STEERING HANDLEBAR FRONT WHEELFRONT re BRAKEJRONT SHOCK ABSORBER FRONT FORK RAND DINK 125 150 INSPECTION Measure the brake master cylinder I D Inspect the master cylinder for scratches or cracks Service Limit 12 75mm Measure the brake master cylinder piston O D Service Limit 12 645mm Before assembly inspect the Ist and 2nd rubber cups for wear ASSEMBLY Before assembly apply brake fluid to all Master Cylinder Spring Main Piston removed parts Install the spring together with the Ist rubber cup During assembly the main piston and spring must be installed as a unit without exchange When assembling the piston soak the cups in brake fluid for a while Install the cups with the cup lips facing the correct direction 2 Snap Ring Rubber Cover Install the main piston spring and snap ring Install the rubber cover Fluid Tube Bolt Punch Mark Install the brake lever Place the brake master cylinder on the handlebar and
43. SCARICO 20 66 1 e 82 14711 KBE 9000 00122981 VALVOLA ASPIRAZIONE 13 43 1 83 12251 KED1 9010 00122992 GUARNIZIONE TESTA 8 78 1 e 84 1221A KBE 9000 00122987 SEDE ALBERO A CAMME 20 66 1 e 85 90465 4 0010 00122783 RONDELLA 8mm 3 10 4 e 86 94050 08000 00109038 DADO FLANGIATO 8mm 1 55 4 87 14450 KBE 9000 00122989 ALBERO IMMISSIONE 10 33 1 e 88 14461 KBE 9000 00122990 ALBERO SCARICO 6 20 1 89 14431 KKC1 9000 00122089 BILANCERE 36 15 2 e 90 90206 001 0010 00122792 DADO REGOLAZIONE 3 10 2 91 90012 333 0010 00122793 VITE DI REGISTRO 4 13 2 92 14100 KKC2 220 00122972 ALBERO A CAMME 103 29 1 e 93 98069 5791 00 00122997 CANDELA DPR7EA 9 4 65 1 94 91301 028 0010 00122700 O RING 27 x 2 0 4 13 1 96 17110 1 000 00122906 RACCORDO AMMISSIONE 35 12 1 O 99 92900 06045 0B 00122099 PRIGIONIERO SCARICO 6 x 45 2 100 16217 KBE 9000 00122903 FASCETTA 4 65 1 3 Cel V e GRAND DINK 125 03 11 04 108 89 Y Cu 109 Z Ba CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 104 16218 000 00122921 TUBO CARBURANTE 4 20 1 106 14761 KJ9 0030 00122976 MOLLA INTERNA 3 10 2 107 14751 KJ9 0030 00122977 MOLLA ESTERNA 3 10 2 e 108 11385 KBE 9000 00122936 MORSETTO DRENAGGIO CARB 4 13 1 109 94591 KBF 900 00128739 CLIP 2X70 1 55 1 eS eee 03 11 04 e 138 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO
44. at the three levels is subject to the maximum value calculated Service Limits True Roundness 0 5 repair or replace if over Cylindricity 0 05 mm repair or replace if over 7 5 KYMCO GRAND DINK 125 150 Middle Bottomt a KYMCO 7 CYLINDER PISTON GRAND DINK 125 150 Inspect the top of the cylinder for warpage Service Limit 0 05mm repair or replaceif over Measure the connecting rod small end I D Service Limit 15 06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring Be careful not to damage the piston and piston rings during assembly All rings should be installed with the markings facing up After installing the rings they should rotate freely without sticking Stagger the ring end gaps as the figure shown KYMCO 7 CYLINDER PISTON GRAND DINK 125 150 PISTON INSTALLATION Remove any gasket material from the crankcase surface Be careful not to drop foreign matters into the crankcase Install the piston piston pin and a new piston pin clip Position the piston IN mark on the intake valve side Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Piston Pin Clip Piston Pin Dowel Pin CYLINDER INSTALLATION uu 7 Fs Install the dowel pins and a new cylinder gasket on the crankca
45. bearings for excessive play and inspect the oil seal for wear or damage Inspect the drive shaft and gear for wear or damage Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and oil seal Drive Shaft Bearing 9 4 KYMCO 9 FINAL REDUCTION GRAND DINK 125 150 Bearing Remover 12mm BEARING REPLACEMENT TRANSMISSION CASE COVER Remove the transmission case cover bearings using the bearing remover Remove the final shaft oil seal Drive Shaft Bearing 2 Pilot 12mm Drive new bearings into the transmission 5 cOVCT BEARING REPLACEMENT LEFT CRANKCASE COVER Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using the bearing remover Bearing Remover 15mm KYMCO 9 FINAL REDUCTION GRAND DINK 125 150 Drive new bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Dive Shaft Install the final gear and final shaft into the left crankcase 9 FINAL REDUCTION GRAND DINK 125 150 Install the countershaft and gear into the left crankcase Install the resin washer onto the counter shaft Install th
46. face 9 13 8 DRIVE AND DRIVEN PULLEYS KICK STARTER Install the movable driven face onto the driven face Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face Install the seal collar Remove any excessive grease Be sure to clean the driven face off any grease Set the driven pulley assembly driven face spring and clutch assembly onto the clutch spring compressor S Align the flat surface of the driven face with the flat on the clutch drive plate nut Set the tool in a vise and tighten the drive plate nut to the specified torque Torque 49 0 58 83 Se Be sure to use a clutch spring compressor to avoid spring damage Clutch Spring Compressor Outer Driver 32x35mm INSTALLATION Install the clutch driven pulley onto the drive shaft Keep grease off the drive shaft KYMCO GRAND DINK 125 150 Guide Roller Guide Roller Pin Driven Face Movable Driven Face Seal Collar Clutch Spring Compressor Clutch Driven Pulley 8 14 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER GRAND DINK 125 150 Clutch Outer Install the clutch outer Hold the clutch outer with the universal holder Install and tighten the clutch outer nut Torque 49 0 58 8kg m Universal Holder Install the drive belt 8 7 Install the left crankcase cover 8 3 Kick Lever KICK STARTER REMOVA
47. hard When you adjust rear cushion the spring preload of rear cushions must be the same REAR SHOCK ABSORBER REMOVAL Remove the rear carrier and hand rail 2 3 Remove the met in box 2 3 Remove the two air cleaner bolts Remove the rear shock absorber upper mount bolt Remove the right left rear shock absorber upper and lower mount bolts Remove the right and left rear shock absorbers INSPECTION Install the rear shock absorbers in the reverse order of removal Torque Upper Mount Bolt 39 2N m Lower Mount Bolt 19 6 29 4N m Lower Mount Bolts 15 5 KYMCO 16 BATTERY CHARGING SYSTEM GRAND DINK 125 150 BATTERY CHARGING SYSTEM CHARGING SYSTEM LAYOUT 16 1 SERVICE INFORMATION 16 2 TROUBLESHOOTING 16 3 16 4 CHG ING S ee 16 5 A C GENERATOR INSPECTION reseter 16 5 REGULATOR RECTIFIER INSPECTION 16 6 16 0 KYMCO 16 BATTERY CHARGING SYSTEM GRAND DINK 125 150 CHARGING SYSTEM LAYOUT Fuse Battery Regulator Rectifier A C Generator CHARGING CIRCUIT R MA MAIN SW hoa Li t G G IVs AH 16 1 KYMCO 16 BATTERY CHARGING SYSTEM GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte sulfuric acid 1s poisonous and may seriously dama
48. shock absorbers onto the front fork Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Align the upper mount bolt hole with the groove on the front fork Install the front wheel 14 7 14 16 14 STEERING HANDLEBAR FRONT WHEELFRONT KYMCO __BRAKE FRONT SHOCK ABSORBER FRONT FORK RAND DINK 125 150_ Lock Nut Socket FRONT FORK REMOVAL 1 Remove the handlebar covers 2 6 E a Remove the steering handlebar 14 4 Remove the front upper cover 2 5 Remove the front lower cover 2 5 Remove the front inner fender 2 6 Remove front wheel 14 5 Remove the front brake caliper 14 11 Hold the steering stem top cone race and a T remove the steering stem lock nut Lock Nut yen A Remove the top cone race and remove the front fork Be careful not to lose the steel balls 26 on top race and 19 on bottom race Inspect the ball races cone races and steel balls for wear or damage Replace if necessary BOTTOM CONERACE REPLACEMENT Remove the bottom cone race using a chisel d Cone Race Top Drive a new bottom cone race into place with a proper driver Be careful not to damage the steering stem and front fork Bottom Cone Race Top Ball Race BALL RACE REPLACEMENT Drive out the ball races Drive in new ball races Be sure to drive the ball races into place completely 14 17
49. the front wheel and the speedometer gear unit Axle Nut INSPECTION AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge The actual runout is _ of the total indicator reading Service Limit 0 2mm replace if over 14 5 14 STEERING HANDLEBAR FRONT WHEEL FRONT KYMCO __BRAKE FRONT SHOCK ABSORBER FRONT FORK GRAND DINK 125 150_ WHEEL RIM Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over FRONT WHEEL BEARING Remove the side collar and dust seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub Wheel Bearing BEARING REPLACEMENT Remove the front wheel bearings and distance collar Special Tools Bearing Remover Bearing Remover Head 12mm 14 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK GRAND DINK 125 50 Pack all bearing cavities with grease Drive in the left bearing Install the distance collar Drive in the right bearing Do not allow the bearings to tilt while driving them in Drive in the bearing squarely with the sealed end facing out Special Tools Outer driver Driver handle INSTALLATION Apply grease to the speedometer gear unit Install the speedo
50. the radiator wash them off Carefully straighten any bent fins RADIATOR REMOVAL Drain coolant 3 9 Disconnect the air vent tube from the radiator filler Remove the overflow tube clamp and disconnect the overflow tube Air Vent Tube Upper Hose Loosen the hose band and disconnect the upper hose and lower hose from the radiator Lower Hose 12 5 12 COOLING SYSTEM Disconnect the thermostatic switch wire coupler Disconnect the fan motor wire coupler Remove the two bolts and one nut on the radiator RADIATOR DISASSEMBLY Remove the four bolts and then remove the fan shroud from the radiator KYMCO GRAND DINK 125 150 Thermostatic Switch Wire Thermostatic Switch A 08 20 AW A at d 223 P T Bolts Radiator Nut Fan Shroud 12 6 KYMCO 12 COOLING SYSTEM GRAND DINK 125 150 Battery Check fan motor by battery Fan Motor Thermostatic Switch CHECK THERMOSTATIC SWITCH When coolant temperature lower then 83 87 the thermostatic switch OFF When coolant temperature over 88 92 C the thermostatic switch ON Bolts Install the fan shroud on the radiator with the four bolts Fan Shroud Radiator 12 7 12 COOLING SYSTEM RADIATOR INSTALLATION Install the radiator on the radiator bracket with the two bolts and one nut Connect the upper and lower hoses and secure them with hose bands Connect the thermostatic swi
51. tube to check the fuel output Output 40cc 1500rpm 10 seconds FUEL TANK REMOVAL Remove the floor board 2 4 Remove the leg shield 2 5 Disconnect the fuel unit wire connector Remove the fuel tube between the fuel tank and the fuel filler Disconnect the fuel vapor tube Remove the fuel tank The installation sequence is the reverse of removal KYMCO GRAND DINK 125 150 Outlet Tube Vacuum Tube Inlet Tube Fuel Pump Fuel Strainer Outlet Tube Fuel Pump S 8 L i K 5 nas iN Container Fuel Unit Fuel Vapor Tube LY Tube to Fuel Filler 13 20 Fuel Strainer 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 FUEL STRAINER REMOVAL Remove the fuel strainer from the fuel tank INSPECTION Inspect if the fuel strainer is clogged and clean it with compressed air Replace the fuel strainer at every 6000 km When removing the fuel strainer do not allow flames or sparks near the working area and drain the residual gasoline into a container INSTALLATION Install the fuel strainer with its arrow mark toward the fuel pump Fuel Strainer 13 21 14 STEERING HANDLEBAR FRONT WHEELFRONT KYMCO BRAKEFRONT SHOCK ABSORBER FRONT FORK RAND DINK 129 190 SIEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK BEREEDEN 14 1 SERVICE INFORMATION 14
52. x 18 13 43 1 192 91002 GA7 70A 00127771 CUSC SFERE RAD 6902U 14 46 1 193 94520 28000 00127772 SEEGER INT 28mm 1 55 1 194 23220 KN7 6710 00127973 PARTE MOBILE PULEGGIA CONDOTTA 61 97 1 195 23225 GC8 0040 00127774 GUIDA 4 65 3 e 196 23226 GC8 0040 00127775 SPINA GUIDA 4 65 3 197 23233 7 6710 00127976 MOLLA PULEGGIA CONDOTTA 14 46 1 198 23237 KG8 9010 00127977 COLLARE DI TENUTA 5 68 1 200 90202 KN7 6710 00127979 DADO SPECIALE 28mm 4 13 1 201 91211 KBE 9000 00126970 PARAOLIO 34 x41 x4 4 13 2 e 202 91384 KBE 9000 00126981 O RING 38 8 x 1 9 5 00 2 e 203 22101 KBE 9000 00127982 CAMPANA FRIZIONE 29 95 1 204 94050 12080 00127704 DADO FLANGIATO 12mm 1 55 1 e 205 23100 KN7 6720 M1 00127985 CINGHIA TRASMISSIONE 20 66 1 e 207 22105 KHD4 E00 00127951 BUSSOLA SEMIPULEGGIA MOTRICE 30 99 1 208 22110 KKC3 9000 00127952 SEMIPULEGGIA MOBILE 30 99 1 210 22112 KAA 9000 H1 00126910 BOCCOLA SEMIPUL MOTRICE 1 211 94601 33000 00127701 CLIP 33mm 3 10 1 e 212 22121 KED1 9000 00127999 RULLINI CENTRIF 13 4 gr SET 10 33 6 e 213 22131 KAA 9000 00127990 PIASTRA A RAMPE 24 79 1 Cel V C Es 03 11 04 214 214 amp 213 214 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 214 22132 KN7 6700 00127991 ELEMENTO GUIDA 1 29 3 215 22102 KKC3 9000 00126216 SEMIPULEGGIA MOTRICE 61 97 1 217 94050 12080 00127704 DADO FLANGIATO 12mm 1 55 1 218 2
53. 0 US 00153122 COPERCHIO CORPO 6 00 1 O 120 93600 04012 1G 00153505 VITE 4 x 12 2 121 53178 KFC8 E10 M3A 00153977 LEVA FRENO SX ARGENTO 14 46 1 122 90114 166 0070 00154210 VITE LEVA FRENO 3 10 1 123 35350 KBN 900 00155604 CONTATTO STOP FRENO POSTERIORE 9 30 1 O 124 93893 04012 18 00154209 VITE RONDELLA 4 x 12 1 126 95701 06022 07 00165007 VITE FLANGIATA 6X22 NERA 3 10 2 127 43126 2 000 00153914 TUBO COMPLETO FRENO POST 92 96 1 128 90145 MS9 6120 M1 00154205 RACCORDO FILETTATO 10X22 4 13 2 129 90545 300 0010 00154206 GUARNIZIONE TUBO FRENO 3 10 4 Cel V GRAND DINK 125 03 11 04 149 149 67 e 8 149 A ag Pes 4 Aen V CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 64220 KKC4 9000 00151831 PARABREZZA 108 46 1 64221 KKC4 9000 00151834 GUARNIZIONE PROFILO SCUDO ANT 3 00 1 B 64222 KKC4 9000 00170113 GOMMINO PARABREZZA 0 93 4 e D 64301 4 900 00154120A PROFILO SCUDO ANT BLU GARDA 32 02 1 e D 64301 4 900 001541205 PROFILO SCUDO ANT ARGENTO MET 32 02 1 e D 64301 4 900 00154120N PROFILO SCUDO ANT NERO SMOKE 32 02 1 e D 64301 4 900 1 00154120H PROFILO SCUDO ANT ROSSO RACING 32 02 1 87508 KKC4 E00 00151832 PARABREZZA 1 90302 SA4 0040 00162570 INSERTO FILETTATO 4MM 3
54. 00 2000 Y W LAV 450 75090 450 7500 Lower Fuel Unit FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Before performing the following test operate the turn signals to determine that the battery circuit is normal Check the fuel gauge needle for correct indication by moving the fuel unit float up and down Needle Position Upper Fuel Gauge F Full E Empty Needle Position Lu The fuel gauge is normal if it operates as above indicated If not check for loosely tightened nuts poorly connected terminals or shorted wires 19 5 Needle moves from F to E 19 SWITCHESHORNEUELUNITHERMostAnicswrrar KYMCO TEMPERATUREGAUGEINSTRUMENTSI IGHIS GRAND DINK 125 150 Thermostatic Switch THERMOSTATIC SWITCH e INSPECTION Remove front covers 2 5 Start and run the engine to make the water temperature reaches 85 90 and check if cooling fan motor operates Lower the water temperature to 85 check if the fan motor stops If the fan motor does not start disconnect the wires from the thermostatic switch and then connect a jumper wire between the Wire wire harness and thermosensor wires black and green wires Turn the ignition switch ON 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
55. 0128913 CAVETTO 8 00 1 175 CODICE KY WIUWIWMWWMWWK U il CODICE PIR GRAND DINK 125 03 11 04 DESCRIZIONE DA N TELAIO LISTINO IVA ESCL 0804 E39 0000 00129993 TUBO 1 e C K350 GY6 0200 00129911 VASCHETTA COMPLETA 18 08 1 e 6510 0100 00126725 DISPOSITIVO ANTISPARO 50 61 1 5362 0080 00126707 VALVOLA A SPILLO 6 20 1 e D 35446 1210 00126708 VITE ARIA IN SET 4 65 1 A 5506 0052 00126717 FERMO SPILLO MOLLA 2 58 1 eE 5536 1050 00126719 VITE MINIMO IN SET 2 58 1 O F 57860 112 000 00129918 TUBO 1 e 2 4000 170 0000 00129916 STARTER AUTOMATICO 77 47 1 e 3 D1310 853 0110 00126704 GALLEGGIANTE 3 62 1 e 7 N413 30B00 00129007 POLVERIZZATORE 6 00 1 e 8 1001 MA1H 0351 00126722 GETTO MINIMO 35 4 65 1 e 9 N425 BVAOO 00129009 SPILLO CONICO 8 00 1 e 10 16111 KN7 7410 M1 00126718 MEMBRANA A DEPRESSIONE 46 48 1 O 13 W1561 107 9920 00129924 STAFFA SUPPORTO CAVO 1 14 16107 KJ9 0030 00126728 CAPPUCCIO 4 00 1 16 16051 KN7 7410 M1 00126724 MOLLA GHIGLIOTTINA 3 62 1 O 17 93500 04008 1H 00117046 VITE TESTA PIATTA 2 O 18 16080 KJ9 0030 00129900 VITE TESTA PIATTA 2 O 19 93500 04014 1 00129921 VITE TESTA PIATTA 4 23 1703 GJ2H 0040 00111029 FERMO STARTER 1 24 99101 393 1020 00126727 GETTO PRINCIPALE 115 3 62 1 25 1010 43BH 9900 00129905 GUIDA SPILLO 6 20 1 e 27 W1314 01
56. 1 e 3 51410 KHD8 9000 00171903 STELO 56 81 2 e 4 51401 KHD8 9000 00171904 MOLLA INFERIORE STELO 5 16 2 5 51429 KHD8 9000 00171905 TUBO CALIBRATO 2 e 6 51412 KHD8 9000 00171906 MOLLA SUPERIORE STELO 4 65 2 O 7 51422 KEC8 900 00171907 BOCCOLA 2 O 8 94605 KHD8 9000 00171908 VITE FORCELLA 2 10 51427 9000 00156317 PARAPOLVERE 6 20 2 11 51428 KAK 9000 00156315 FINE CORSA 4 65 2 12 51423 KAK 9000 00156310 PARAOLIO 33 x46 x11 6 20 2 O 13 90544 KEC8 9000 00171013 RONDELLA 2 O 14 90116 KHD8 9000 00171014 VITE A BRUGOLA 2 15 51411 KHD8 9000 00171015 SOFFIETTO STELO 6 00 2 O 16 51413 KHD8 9000 00171016 FASCETTA SOFFIETTO 2 e 200 50306 196 0010 00158205 DADO SERRAGGIO STELO STERZO 2 32 1 201 53211 GY6 9400 00158214 CONO SUPERIORE SFERE STERZO 4 39 1 e 202 96211 05000 00155025 SFERE ACCIAIO 3 9 SET 30 pz 4 65 26 e 203 96211 08000 00155753 SFERE ACCIAIO 6 3 SET 19 pz 4 65 19 204 53212 250 0110 00155754 CONO INFERIORE SFERE STERZO 8 01 1 205 53215 250 0010 00155755 RONDELLA PARAPOLVERE 1 81 1 e 206 53214 250 0010 00155756 PARAPOLVERE 3 10 1 e 207 53200 KKC2 9000 00155102 FORCELLA PORTA STELI 82 63 1 208 95801 08040 07 00158211 VITE FLANGIATA 8 x 40 2 00 4 211 51400 KKC4 E10 00155217 STELO DX COMPLETO 24100747 113 62 1 212 5150A KKC4 E10 00155218 STELO SX COMPLETO 24100747 113 62 1 215 61110 KHD8 900 BHP 00154921B PARAFANGO ANT BLU GARDA 67 14 1 23 Ce a 177 e eS ee 03 11 04 200 55
57. 1 9510 00156927 CAPPUCCIO 2 45131 166 0160 00156894 PERNO PASTIGLIA 9 30 1 45216 KW6 9020 M1 00156956 DADO SPECIALE 4 65 1 280 44301 KCX 900 00156860 PERNO RUOTA ANTERIORE 7 75 1 e 281 44311 KBE 9000 00156971 BOCCOLA LAT RUOTA ANTERIORE 3 62 1 284 90912 GC8 00B 00156030 CUSCINETTO 12X32X10 RAD 6201U 11 36 2 e 285 44620 KHD8 9000 00156973 DISTANZIALE PERNO RUOTA ANT 7 75 1 e 286 90754 GC8 0030 00156029 PARAPOLVERE 20 X32 X5 3 36 1 e 287 90105 KR3 0010 00156556 VITE DISCO 8X 24 4 65 5 e 288 45351 7 000 00156909 DISCO ANTERIORE 56 81 1 289 44710 KKC4 900 00156592 PNEUMATICO ANTERIORE 44 00 1 e 293 45200 KKC2 E00 NJA 00159029 PINZA ANTERIORE 118 79 1 296 90122 KBE 9000 00156901 VITE FLANGIATA 8 x 32 4 00 2 e 316 90306 901 00156027 DADO FLANGIATO 12MM AUTOBLOC 4 13 1 e 317 44800 KFA5 9000 00156904 INGRANAGGIO CONTA KM 18 08 1 25 Ce a 177 e GRAND DINK 125 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ EE Ce 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 43150 3060 00157900 PASTIGLIE POSTERIORI COPPIA 17 56 1 43210 KBE 900 N1A 00157977 SUPPORTO PINZA POSTERIORE 17 00 1 OB 43215 9000 00157000 SUPPORTO PASTIGLIE 2 e C 43352 568 0030 00156983 VITE DI SPURGO 9 00 1 D 43353 461 7710 M1 00156984 CAPPUCCIO S
58. 10 2 130 53204 KKC4 900 N1R 00154942 SCUDO INTERNO SUPERIORE 23 24 1 131 90302 5 4 0040 00162570 INSERTO FILETTATO 4MM 3 10 4 132 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 4 O 133 93903 GY6 900 00154705 VITE AUTOFILETTANTE 4 x 14 2 134 90302 GY6 9010 00160702 VITE RONDELLA 5X12 1 00 2 e 135 90677 GR1 0040 00154014 CLIP FILETTATA 5MM 2 00 1 137 64302 4 900 00154630A SCUDO ANT BLU GARDA 165 27 1 137 64302 KKC4 900 N8P 001546305 SCUDO ANT ARGENTO 165 27 1 137 64302 KKC4 900 NFP 00154630N SCUDO ANT NERO SMOKE 165 27 1 137 64302 KKC4 900 R1P 00154630H SCUDO ANT ROSSO RACING 165 27 1 138 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 6 O 139 93903 KEB7 9000 00154194 VITE RONDELLA 4mm 5 140 81131 KKC4 900 N1R 00154141 SCUDO INTERNO INFERIORE 98 13 1 141 90302 SA4 0040 00162570 INSERTO FILETTATO 4MM 3 10 2 O 142 93903 GY6 900 00154705 VITE AUTOFILETTANTE 4 x 14 4 143 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 10 O 144 93404 KKC2 900 00168560 VITE RONDELLA 6 x 16 1 O 146 94591 27000 00154023 CLIP 2 x 70 2 149 90302 GR2 0000 00160006 VITE RONDELLA 5 x16 3 10 4 151 81136 KKC4 900 N1R 00154143 COP VASCHETTA LIQ RAFFRED 6 71 1 20 Ce amp 177 152 GRAND DINK 125 4 149 149 S er 444 LISTINO IVA ESCL 93891 05012 07 VITE RONDELLA 5 x 12 N PZ 153 53214 KKC4 900 N1R GRIGLIA DX SCUDO INT SUPERIORE 155 53224 KKC4 900 N1R GRIGLIA
59. 10 33 1 485 8360A KKC4 9000 00162485 CAMERA FILTRO ARIA GRUPPO 50 10 1 486 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 2 493 17255 KV7 6710 00162980 COLLARINO 4 39 1 Li CODICE KY CODICE PIR GRAND DINK 125 DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ C 18293 9000 00163908 GOMMINO PROTEZIONE MARMITTA 3 10 5 e D 18294 KBE 9000 00163070 ISOLANTE PROTEZIONE MARMITTA 1 90 0 e P 18295 KCE 9000 00163902 RONDELLA 4 00 5 e 18306 8 9000 00163974 CAPPUCCIO TERMINALE MARMITTA 20 14 1 90110 KHD8 9000 00163907 VITE SPECIALE 6 x 20 0 30 5 90215 0 9100 00154908 DADO CAPPUCCIO 6MM 3 00 3 e H 94101 06800 00121325 RONDELLA PIANA 6mm 1 00 5 OM 94101 9000 00163990 RONDELLA 6mm 2 OK 94111 06800 00164407 RONDELLA 6mm 5 e 96001 06010 08 00129991 VITE FLANGIATA 6 x 10 3 10 2 e F 18305 KHD8 9000 00163960 RIVEST TERMINALE MARMITTA 13 94 1 18325 KKC1 9000 00163890 PROTEZIONE COLLETTORE 11 36 1 e B1 18317 KHD8 E000 00163972 PROTEZIONE MARMITTA 18 08 1 B2 18318 KKC1 E000 00164030 PROTEZIONE MARMITTA 20 00 1 500 18291 GC8 0010 00164001 GUARNIZIONE SCARICO 1 96 1 501 90301 GY6 9010 00163961 DADO ALTO A CAPPUCCIO 8 5 00 2 502 1830A KKC1 E0A 00163106 GRUPPO DI SCARICO 211 75 1 503 90021 GY6 900 00163543 VITE 8 x 42 3 00 1 e 505 95801 08042 07 00163764 VITE FLANGIATA 8 x 42 3 16 2 e 506 95801 08065
60. 120 08 00121954 VITE FLANGIATA 6 x 120 2 e 51 50504 KKC3 9000 00164124 FERMO CAVALLETTO 4 13 1 52 96001 06016 08 00101005 VITE FLANGIATA 6 x 16 2 O 53 11383 KDU 9000 00121052 MORSETTO DRENAGGIO CARB 1 54 9052A GY6 9500 00101633 BULLONE SPURGO 5 16 1 55 1541A KKC3 9000 00124759 ELEMENTO FILTRO OLIO 6 71 1 56 15421 KKC3 9000 00124390 COPERCHIO FILTRO OLIO 6 20 1 57 15422 KKC3 9000 00125037 O RING 53 65x2 62 4 65 2 58 15423 KKC3 9000 00124391 MOLLA COPERCHIO FILTRO OLIO 3 10 1 59 96001 06016 08 00101005 VITE FLANGIATA 6 x 16 3 Li GRAND DINK 125 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 61 12310 KBE E000 00122961 COPERCHIO TESTA 18 08 1 e 64 12391 KBE 9000 00122964 GUARN COP TESTA 4 65 1 O 65 95701 06025 08 00101203 VITE FLANGIATA SH 25 4 66 12200 KKC1 E00 00122973 TESTA 185 92 1 68 12205 KE8 3010 00122914 GUARN VITE 12mm 4 13 1 e 71 90033 GY6 9000 00122970 PRIGIONIERO 8 x 32 3 10 2 O 72 96001 06025 00 00109026 VITE FLANGIATA SH 6 x 25 2 74 94301 10160 00122773 SPINA DI CENTRAGGIO 10 x 16 1 55 2 75 14781 MA6 0000 M1 00122774 SEMICONI 4 13 4 e 76 14771 GB4 6800 00122775 SEDE MOLLA INT VALVOLA 3 10 2 e 79 14775 MA6 0000 00122778 SEDE MOLLA EST VALVOLA 2 07 2 80 12209 GB4 6820 M1 00122779 GUARNIZIONE STELO VALVOLA 6 00 2 e 81 14721 KAA 9000 00122980 VALVOLA
61. 168586 VITE 8 X25 4 13 2 588 38110 KKC3 90A 00169103 CLACSON 25 82 1 e 589 94050 08000 00109038 DADO FLANGIATO 8mm 1 55 1 590 31600 KM1 009 00168780 REG TENSIONE RADDRIZZATORE 57 84 1 e 591 94050 06080 00109022 DADO FLANGIATO 6mm 1 55 1 e 592 38300 KCE 9000 00151708 RELE SONORO FRECCE 16 53 1 594 32100 2 000 00168195 CAVO PRINCIPALE 87 80 1 e 595 30400 KN7 6710 00168923 CENTRALINA CDI 98 13 1 596 3195A KCB 9000 00168990 CENTRALINA HAZARD 46 48 1 597 35850 KHD8 9000 00168997 RELE AVVIAMENTO 36 15 1 e 598 94050 06080 00109022 DADO FLANGIATO 6mm 1 55 2 603 37720 KGBG E000 00102021 TERRA TERMOSTATO 7 75 1 605 37760 KGBG E100 00129931 CONTROLLO RISCALDAMENTO 61 97 1 606 94050 06080 00109022 DADO FLANGIATO 6mm 1 55 1 610 39100 KHD8 9000 00168999 RELE VENTOLA 20 66 1 612 31602 KKC4 9000 00150912 SUPPORTO CELLULARE 18 08 1 613 31601 KKC4 900 00150911 PRESA 12V 10 85 1 Li CODICE KY 636 CODICE PIR GRAND DINK 125 03 11 04 DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 50352 GY6 9000 00169992 GOMMA FINE CORSA 5 00 2 B 50356 7 000 00169997 BOCCOLA 15 49 2 620 50100 2 00 00169624 TELAIO 24100747 780 00 1 620 50100 2 000 00170090 TELAIO 774 69 1 621 50301 7 6710 00169701 SEDE SUPERIORE SFERE STERZO 5 68 1 622 50302 268 0110 00169702 SEDE INFERIORE SFERE STE
62. 4 9901 00126706 PERNO GALLEGGIANTE 3 62 1 29 93892 04008 18 00129917 VITE RONDELLA 4 x 8 2 43 1531 803 2000 00129925 CLIP GUIDA 1 O 87 1531 818 2000 00129087 CLIP GUIDA 1 175 1610K KKC1 E000 00128173 CARBURATORE 273 72 1 e 177 37710 KGBG E000 00129920 RISCALDATORE 21 69 1 13 Cel V CODICE KY GRAND DINK 125 03 11 04 WWW ff D 175 177 CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ ees ro 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ E B 33120 4 000 00150600 FARO ANT 1 33130 KKC4 E000 00150910 CAVO CON PORTALAMPADA 1 e D 34901 KED9 900 00150309 LAMP FARO ANT 20 00 1 e C 34903 KCP 9000 00150407 LAMPADINA 5W 12V 3 10 2 1 33100 KKC4 E000 00150909 FARO ANTERIORE COMPLETO 139 44 1 2 95701 06012 08 00159015 VITE FLANGIATA 6X12 1 00 2 O 3 93903 35380 00150702 VITE AUTOFILETTANTE 5x 16 4 Li GRAND DINK 125 34908 MB9 8710 M1 LAMPADA A INNESTO 12V 1 7W LISTINO IVA ESCL N PZ 37200 KKC1 E00 STRUMENTAZIONE COMPLETA 37203 KKC3 900 N8P CORNICE CRUSCOTTO D gt 37204 900 8 44831 4 9000 FILO 16 90302 GY6 9400 VITE RONDELLA 5 x 12 17 44830 KKC4 9000 CAVO COMPLETO CONTA KM 18 93700 05018 0H VITE OVALE 5X18 e 9 O O 9 19 372
63. 40 00124952 O RING 27 4 x 2 4 3 10 1 140 11330 KKC3 9000 00124911 CARTER BLOCCO MOTORE DX 139 44 1 141 91303 377 0010 00124941 O RING 13 8 x 2 5 3 10 1 142 11394 KBE 9000 00124942 GUARNIZIONE BLOCCO MOTORE DX 9 30 1 143 1565A KBE 9000 00124943 ASTA LIVELLO OLIO COMPLETA 9 30 1 e 145 91307 035 0010 00124745 O RING 18 x3 1 55 1 146 15421 107 0000 00124746 FILTRO OLIO 4 65 1 147 15426 GE1 9200 00124747 MOLLA FILTRO OLIO 7 75 1 158 91302 001 0210 00124748 O RING 30 8 2 00 1 159 12361 GY6 9010 00124749 TAPPO FILTRO OLIO 6 71 1 160 90084 428 0010 00124950 CAPPUCCIO ACG 4 65 1 e 161 9008A KE2 9000 00124951 CAPPUCCIO 30mm 4 65 1 162 96001 06040 08 00105008 VITE FLANGIATA SH 6 x 40 4 13 6 O 164 96001 06120 08 00121954 VITE FLANGIATA 6 x 120 1 165 94301 08140 00121704 SPINA DI CENTRAGGIO 8 x 14 1 55 2 Li KEXNE EE Es 03 11 04 330 330 S p zz 331 CODICE CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 21201 KFC8 3050 00125902 CARTER TRASMISSIONE COMPLETO 67 14 1 e B 91105 KN7 6710 M1 00121957 GABBIA A RULLI 14mm 11 88 1 OC 95002 02080 00159014 CLIP TUBO B8 1 e 322 91003 KS4 004 00121713 CUSCINETTO 12x37x12 RAD 6301 13 43 1 e 323 91255 GE0 0060 00108209 PARAOLIO 27 x42 x7 5 16 1 e 324 91009 GE0 0040 00108208 CUSCINETTO 20x42x12 RAD 6004 11 88 1 e 325 90474 333 001 00125790 RONDELLA 8mm 3 10 1 e 326 95701 08012 08 0010
64. 80 KKC3 9000 OROLOGIO DIGITALE 2 1 1 1 1 3 1 1 1 GRAND DINK 125 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 88114 KKC4 9000 00163031 STAFFA RETROVISORE 13 94 1 e B 88115 KKC4 9000 00163032 GUARNIZIONE RETROVISORE DX 3 62 1 C 88125 4 9000 00163033 GUARNIZIONE RETROVISORE SX 3 62 1 e D 88130 4 9000 00163035 VITE SPECIALE 3 10 4 O E 93500 05020 00152597 VITE TESTA PIATTA 5 x 20 4 30 88110 KKC3 900 BHP 00163036A RETROVISORE DX BLU GARDA 67 14 1 30 88110 900 00163036S RETROVISORE DX ARGENTO METAL 67 14 1 30 88110 KKC3 900 NFP 00163036N RETROVISORE DX NERO NH124 67 14 1 30 88110 KKC3 900 R1P 00163036H RETROVISORE DX ROSSO RR004 67 14 1 31 88120 KKC3 900 BHP 00163037A RETROVISORE SX BLU GARDA 67 14 1 31 88120 KKC3 900 N8P 001630375 RETROVISORE SX ARGENTO METAL 67 14 1 31 88120 KKC3 900 NFP 00163037N RETROVISORE SX NERO SMOKE 67 14 1 31 88120 KKC3 900 R1P 00163037H RETROVISORE SX ROSSO RR004 67 14 1 e 33 17910 KKC3 9000 00152934 CAVO ACCELERATORE 17 56 1 41 53140 KKC3 900 N1R 00152996 MANOPOLA ACCELERATORE 001 6 71 1 e 42 53166 KGB5 900 N1R 00152322 MANOPOLA SX 6 71 1 43 3515A KKC2 E000 00152951 GRUPPO COMANDI DX 41 32 1 56 3520A KBE 9000 00152928 GRUPPO COMANDI SX 29 95 1 e 59 53100 KKC4 9000 00152171 MANUBRIO 67 14 1 61
65. 8211 KFC8 9000 00127905 NOTTOLINO DENTATO 10 33 1 GRAND DINK 125 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ OD 31205 KN7 6700 00128941 SET VITE 2 31206 KN7 6700 00128938 O RING 3 10 1 e B 91309 425 0040 00128931 O RING 24 4 x 3 1 3 00 1 91981 KN7 6700 00128954 VITE RONDELLA 5 x 8 1 00 1 OE 94111 05800 00127950 RONDELLA 5mm 2 OF 31204 KN7 6700 00128943 MOLLA SPAZZOLA 2 228 15100 KKC3 9000 00127320 POMPA OLIO 67 14 1 O 236 92000 06028 0H 00127236 VITE FLANGIATA SH 6 x 28 2 237 15133 1 0010 00128919 CORONA MOVIM POMPA OLIO 8 26 1 238 94510 10000 00128920 SEEGER EST 10mm 3 62 1 e 239 15141 KJ9 0040 00128921 CATENA POMPA OLIO 19 63 1 240 15711 KKC3 9000 00128800 PARACATENA A 6 20 1 O 241 96001 06014 08 00101004 VITE FLANGIATA 6X14 1 e 242 15712 KBE 9000 00128923 PARACATENA B 8 26 1 e 244 32410 KDU 9000 00127159 CAVO AVVIAMENTO 10 33 1 e 245 31210 KKC3 9000 00128751 MOTORE AVVIAMENTO 77 47 1 246 96001 06016 08 00101005 VITE FLANGIATA 6 x 16 2 247 28101 KJ9 0110 00128927 RIDUZIONE INGRANAGGIO AVV 41 32 1 248 28102 KJ9 0010 00128928 PERNO INGRANAGGIO AVV 5 68 1 249 28110 KN7 6720 00128929 INGRANAGGIO USCITA AVV 36 15 1 e 250 96600 08015 10 00126361 VITE A BRUGOLA 8 x 15 4 65 3 e 252 28120 KBE 305 00128934 RUOTA LIBERA ESTERNA 8 mm 92 96 1 e 253 91101 179 7110 M1 00128733 RULL
66. 90106 GN5 9010 00172212 VITE FLANGIATA 10X50 4 13 1 62 53125 GN5 9010 00152745 SEDE VITE MANUBRIO 4 13 1 63 90304 8 0040 00153206 DADO FLANGIATO 10MM 4 13 1 64 53205 KKC4 900 N8P 00170109 COPRIMANUBRIO SUP 46 48 1 O 65 90302 KEC8 9000 00152061 VITE RONDELLA 5 X 9 1 O 66 93903 35380 00150702 VITE AUTOFILETTANTE 5 x 16 2 67 53206 4 900 00152172 COPRIMANUBRIO INF DX 7449 1 68 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 2 69 90302 GY6 9010 00160702 VITE RONDELLA 5X12 1 00 1 70 53207 KKC4 900 N1R 00152176 COPRIMANUBRIO INF SX 7 75 1 Ce amp 177 e 17 GRAND DINK 125 03 11 04 1 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ e 71 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 2 e 72 90302 GY6 9010 00160702 VITE RONDELLA 5X12 1 00 1 e 73 53208 4 900 00170111 TAPPO COPRIMANUBRIO SUP 13 94 1 e 74 53209 KKC4 9000 00152173 GUARNIZIONE COPRIMANUBRIO 7 75 1 75 53105 KFC8 9000 00152911 CONTRAPPESO MANOPOLADX 9 30 1 75 53105 KKC4 900 00152914 CONTRAPPESO MANOPOLA DX 24100747 9 30 1 e 76 90106 6 9000 00161308 VITE SPECIALE 8X75 24100747 7 75 1 76 90106 KFC2 9000 00152330 VITE SPECIALE 8 x 42 5 00 1 e 77 53106 KFC8 9000 00152912 CONTRAPPESO MANOPOLA SX 9 30 1 e 77 53106 KKC4 900 00152915 CONTRAPPESO MANOPOLA SX 24100747 9 30 1 e 78 90106 6 9000 00161308 VIT
67. 91003 VERNICE RITOCCO ROSSO RR004C 9 30 1 Li aan ain ro 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 1 35111 KHC5 3060 M2 00190005 CHIAVE GREZZA TIPO A 4 00 1 2 35111 KHC5 3050 M2 00190006 CHIAVE GREZZA 4 00 1
68. 9234 VITE FLANGIATA 8 X 12 3 00 1 e 327 21395 KFC8 9000 00125997 GUARN CARTER TRASMISSIONE 4 65 1 e 328 94301 08140 00121704 SPINA DI CENTRAGGIO 8 x 14 1 55 2 329 96001 06040 08 00105008 VITE FLANGIATA SH 6 x 40 4 13 2 O 330 96001 06035 08 00108017 VITE FLANGIATA SH 6 x 35 7 e 331 23411 KKC3 900 00129125 ALBERO PULEGGIA 61 97 1 e 332 23420 KFC8 900 00125992 CONTRALBERO 61 97 1 e 333 23431 KFC8 9000 00125993 ALBERO RUOTA 61 97 1 334 94510 20000 00108210 SEEGER EST 20mm 1 55 1 e 335 23432 KFC8 900 00125995 INGRANAGGIO USCITA 41 32 1 e 336 90411 KM1 0010 00125916 RONDELLA DI SPINTA 14 x 32 x 1 4 13 2 337 90446 357 0010 00125917 RONDELLA SPINTA 17 2mm 4 13 1 O 340 1122A KKC2 9000 00121142 TUBO DI SFIATO 1 Li Es CODICE KY CODICE PIR 03 11 04 DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 2301A KBE 9000 00127960 PULEGGIA CONDOTTA 200 00 1 e 181 22300 KN7 6710 00127961 FRIZIONE 51 13 1 O 182 22350 KN7 6700 00127962 PIATTELLO MOBILE 1 183 22401 7 6710 00127963 MOLLA FRIZIONE 3 10 3 O 184 22530 KN7 6710 00126984 SET GANASCIA FRIZIONE 3 O 185 22804 GB2 0010 00127765 GOMMINO FRIZIONE 3 O 186 22361 KN7 6710 00127966 PIASTRA LAT 1 e 187 90605 166 7210 00127767 SEEGER 7mm 3 10 3 e 189 23200 KBE 9000 00127969 SEMIPULEGGIA CONDOTTA COMPLETA 36 15 1 191 91001 GY6 90A 00127770 CUSC RULLI 20 x 29
69. ANTE 129 11 1 O 388 96001 06014 08 00101004 VITE FLANGIATA 6X14 2 390 50139 4 9000 00153115 SUPPORTO POMPA CARBURANTE 9 30 1 e 391 95701 06012 08 00159015 VITE FLANGIATA 6X12 1 00 1 392 17683 KKC4 9000 00159907 TUBO POMPA CARBURAT 4 00 1 e 393 17682 KKC4 9000 00159906 TUBO CARBURANTE 5 00 1 396 50197 KKC4 9000 00159351 SOSTEGNO PEDANA 18 00 1 e 397 94050 06080 00109022 DADO FLANGIATO 6mm 1 55 2 Li CODICE KY CODICE PIR GRAND DINK 125 03 11 04 405 DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 400 31500 KAF 9000 M1 00160700 BATTERIA GTX9 BS 61 97 1 401 38500 KHD8 9000 M1 00168930 RELE FARI 30 99 2 403 32411 KKC4 9000 00128971 CAVO BATTERIA 8 00 1 404 32412 KKC3 9000 00128973 TERRA 12 00 1 405 95701 06012 08 00159015 VITE FLANGIATA 6X12 1 00 1 406 50326 4 900 00160404 COPERCHIO SEDE BATTERIA 9 81 1 O 407 93903 GY6 900 00154705 VITE AUTOFILETTANTE 4 x 14 4 409 50328 KBN 2000 00160408 ELASTICO BATTERIA 4 00 1 410 98200 31000 00155400 FUSIBILE 10A 1 55 1 411 98200 31500 00160409 FUSIBILE 15A 1 50 1 412 98200 33000 00155401 FUSIBILE 30A 1 55 1 413 5032A KKC4 9000 00151916 SEDE BATTERIA 9 30 1 414 94050 06080 00109022 DADO FLANGIATO 6mm 1 55 1 e 415 90112 KBN 9010 00170205 VITE FLANGIATA 6mm 1 00 1 GRAND DINK 125 03 11 04
70. BLY 6 8 CYLINDER HEAD INSTALLATION 6 9 CAMSHAFT 8 6 10 CYLINDER HEAD COVER INSTALLATION 6 11 6 0 dO KYMCO 6 CYLINDER HEAD VALVES GRAND DINK 125 150 SCHEMATIC DRAWING 6 1 dC KYMCO 6 CYLINDER HEAD VALVES GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder head can be serviced with the engine installed in the frame Coolant in the radiator and water jacket must be drained first When assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages Clean and unclog the oil passages before assembling the cylinder head After disassembly clean the removed parts and dry them with compressed air before inspection After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal SPECIFICATIONS SH30DA SH25DA SH30DA SH25DA Valve clearance cold 1 4 1 010 1 040 01 2 01 2 Cylinder head compression pressure l5kegcm 1 Cylinder head warpage 005 005 E 2 29 4 Valve rocker arm shaft 9 972 9 987 9 972 9987 99
71. Blue TURN SIGNAL SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the turn signal switch wire couplers and turn on the turn signal switch Check for continuity between the wire terminals Ne E Blue Orange mt Nes DIMMER SWITCH INSPECTION Turn Signal Switch Remove the frame front covers 2 5 Disconnect the headlight dimmer switch wire couplers Turn on the dimmer switch and check for continuity between the wire terminals ome Blue Blue arsa H O rO PASSING STOP SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the front rear stop switch wire couplers Check for continuity between the wire terminals when the front brake lever is applied Med Brown Blue Green Yellow Dimmer Switch PASSING FREE APPLY O Stop Switch 19 4 19 SWITCHESHORNFUELUNIT THERMOSTATICSWITCH dO KYMCO IEMPERATUREGAUGEINSTRUMENTSI IGHIS GRAND DINK 125 150 HORN INSPECTION Remove the front upper cover 2 5 Disconnect the horn wire couplers The horn is normal if it sounds when a 12V battery 15 connected across the horn wire terminals Horn Upper FUEL UNIT FUEL UNIT INSPECTION Remove the fuel unit Disconnect the fuel unit wire connectors Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions 33 450 500 8500 L W 1400 7000 1
72. CQUA 1 00 6 660 19504 KKC4 9000 00129385 TUBO ACQUA D 6 20 1 IC Li CODICE KY CODICE PIR 03 11 04 678 DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 661 19505 KKC4 9000 00170936 TUBO ACQUA F 6 20 1 664 90913 KKC4 9000 00121003 TUBO VASCHETTA POMPA RADIATORE 18 08 1 666 19102 KKC4 9000 00159364 CONDOTTO RAFFREDDAMENTO 15 49 1 668 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 4 673 64318 4 9000 00170673 SUPP CRUSCOTTO 4 00 1 O 674 93404 06016 07 00163215 VITE RONDELLA 16 2 O 676 17228 KKC3 9000 00170670 SUPP FILTRO ARIA 1 677 95701 06012 08 00159015 VITE FLANGIATA 6X12 1 00 1 O 678 90001 GHB 6610 00123733 VITE FLANGIATA 6 x 22 1 Li 710 900 CODICE KY CODICE PIR GRAND DINK 125 03 11 04 DESCRIZIONE 725 750 714 DA N TELAIO LISTINO IVA ESCL N PZ 86102 KFA6 E00 00172300 ADESIVO K 7 75 1 710 86202 4 900 00170196 ADESIVO DINK 10 33 2 e 711 86212 KKC4 900 00170197 ADESIVO GRAND 10 33 2 713 86030 4 00 01 00171690 ADESIVO COPRIMANUBRIO KYMCO 7 75 1 725 86212 KHD4 E00 00172305 ADESIVO 125 10 33 2 e 900 45 00191016 VERNICE RITOCCO ARG M NHO45M 9 30 1 e 900 NH124 NF 00191017 VERNICE RITOCCO NERO S NH124M 9 30 1 e 900 PB183 BH 00191007 VERNICE RITOCCO BLU G PB183M 9 30 1 e 900 RRO004 H1 001
73. Check the bearings for play and replace them if they have excessive play Drive the inner needle bearing out of the driven pulley face Ss Discard the removed bearing and replace with a new one Inner Bearing Remove the snap ring and drive the outer bearing out of the driven face Discard the removed bearing and replace with a new one Apply grease to the outer bearing Drive a new outer bearing into the driven face with the sealed end facing up Outer Bearing Bearing Driver Seat the snap ring in its groove Apply grease to the driven face bore areas Pack all bearing cavities with9_ 9 56 grease 8 11 8 DRIVE AND DRIVEN PULLEYS O KYMCO _ KICK STARTER GPA DNK 125 150 Press a new needle bearing into the driven face Bearing Driver CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch Keep grease off the clutch linings Retainer Plate Clutch Lining 8 12 8 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER GRAND DINK 125 150 CLUTCH ASS EMBLY Install the damper rubbers on the drive plate Circlips pins Install the clutch weights shoes and clutch springs onto the drive plate Install the retainer plate and secure with the circlips Drive Plate Movable Driven Face CLUTCH DRIVEN PULLEY ASSEMBLY Clean the pulley faces and remove any grease from them Apply grease to the O rings and install them onto the moveable driven
74. E SPECIALE 8X75 24100747 7 75 1 78 90106 KFC2 9000 00152330 VITE SPECIALE 8 x 42 5 00 1 e 79 90656 GY6 9110 00159961 FASCETTA TUBO OLIO 3 10 2 Li GRAND DINK 125 03 11 04 mum 4 Go CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 143530 8 3050 00153979 92 96 1 e D 45517 KAK 9000 00152353 STAFFA SUPPORTO POMPA 3 62 2 45530 KFC8 E000 IT 00153962 CORPO POMPA DX 92 96 1 O 94050 06070 00172205 DADO FLANGIATO 6mm 2 O 94 43156 KKC3 9000 00153094 MORSETTO TUBO FRENO 1 96 45128 KBE 9000 00153996 SUPP TUBO FRENO ANT 1 e 97 95701 06012 08 00159015 FLANGIATA 6X12 1 00 2 O 99 43156 KKC4 9000 00153373 MORSETTO TUBO FRENO 1 105 45513 000 05 00153122 6 00 1 106 93600 04012 1G 00153505 VITE 4x 12 2 107 53175 KFA5 E10 M3A 00153960 LEVA FRENO DX ARGENTO 14 46 1 108 90114 166 0070 00154210 VITE LEVA FRENO 3 10 1 109 35340 KBN 9000 00154204 CONTATTO STOP FRENO ANTERIORE 6 97 1 O 110 93893 04012 18 00154209 VITE RONDELLA 4 x 12 1 112 95701 06022 07 00165007 VITE FLANGIATA 6X22 NERA 3 10 2 e 113 45126 KHD8 9000 00153970 TUBO FLESSIBILE FRENO ANT 61 97 1 114 90145 MS9 6120 M1 00154205 RACCORDO FILETTATO 10X22 4 13 2 e 115 90545 300 0010 00154206 GUARNIZIONE TUBO FRENO 3 10 4 119 45513 KCX M00
75. EAR FORK REAR KYMCO NHEEL REAR SHOCK ABSORBER SPANDDINKIZS 790 REAR BRAKE REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler 2 6 Remove the rear brake fluid tube bolt and disconnect the brake fluid tube Remove the two bolts attaching the rear brake caliper Remove the rear brake caliper When removing the brake fluid tube use shop towels to cover plastic parts and coated surfaces to avoid damage INSPECTION Inspect the brake pads and brake disk Visually check the brake pad thickness and it should not exceed the wear indicator mark Measure the brake disk thickness Service Limit 3 0mm replace if below DISASSEMBLY Disassemble the rear brake caliper 14 11 Inspect and assemble the rear brake caliper 14 12 Note The rear brake caliper and front brake caliper have the same specification Wear Indicator Mark INSTALLATION Install the brake caliper to the rear fork and tighten the two bolts Torque 24 5 34 3N m Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt Fill the brake reservoir with the specified brake fluid and bleed air from the brake system 14 10 Copper Washers When installing the brake fluid tube be sure to install the two copper sealing w pu washers Fluid Tube Bolt Bolts 15 3 15 REAR BRAKE REAR FORK REAR KYMCO __WHEEL REAR SHOCK ABSORBER CHAND DINK 125150 REAR FORK S
76. EDDAMENTO 29 44 1 C 19030 KHD8 9000 00170903 MOTORE VENTOLA RAFFREDDAMENTO 123 95 1 x J 19104 KKC4 9000 00129384 TUBO DRENAGGIO 6 20 1 e H 19105 KKC4 9000 00170907 TUBO SERBATOIO LIQUIDO RAFF 7 75 1 e 19210 4 900 00170020 TAPPO VASCHETTA LIQUIDO RAF 6 71 1 38773 PB9 001 00168992 GIUNTO A 3 VIE 3 5 1 00 1 OD 95001 35225 40 00170910 TUBO DRENAGGIO LIQUIDO REFRIGE 2 e 95002 02100 00161011 CLIP TUBO B10 1 00 1 OK 95002 70000 00170911 CLIP TUBO C11 2 OF 95002 02070 00159013 CLIP TUBO B7 4 633 19120 KKC4 900 00170972 TUBO A R ACQUA 41 32 1 635 94050 06080 00109022 DADO FLANGIATO 6mm 1 55 2 640 19010 KKC4 900 00170333 RADIATORE 134 28 1 641 94050 06080 00109022 DADO FLANGIATO 6mm 1 55 1 642 95701 06016 08 00169709 VITE FLANGIATA 6 x 16 1 00 2 643 37760 KHD8 9000 00170950 BULBO TERMOSTATO RADIATORE 61 97 1 644 19005 KKC4 9000 00170971 GRUPPO VENTOLA 134 28 1 645 95701 06016 08 00169709 VITE FLANGIATA 6 x 16 1 00 3 646 19101 KKC4 9000 00170018 SERBATOIO LIQUIDO RAFF 21 69 1 647 90302 GR2 0000 00160006 VITE RONDELLA 5 x16 3 10 1 648 90302 GY6 9010 00160702 VITE RONDELLA 5X12 1 00 1 649 19012 KHD8 900 00170648 SEDE TAPPO RADIATORE 18 08 1 650 19111 GE2 0040 00170967 TAPPO RADIATORE 11 36 1 651 94050 06080 00109022 DADO FLANGIATO 6mm 1 55 1 656 19506 KKC4 900 00170937 TUBO 6 20 1 657 95002 KHE7 9000 00170900 CLIP TUBO ACQUA 3 00 2 658 95002 7 9100 00123937 FASCETTA TUBO A
77. EL PUMP REMOVAL Remove the frame center cover Disconnect the fuel pump inlet outlet and vacuum tubes Remove the two fuel pump attaching bolts and the fuel pump Outlet Tube Inlet Screws FUEL PUMP DISASSEMBLY Remove the four fuel pump body screws Vacuum Tube Outlet Disassemble the fuel pump 13 18 13 FUEL SYSTEM CARBURETOR QC KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 FUEL PUMP INSPECTION Inspect the fuel pump diaphragms A for damage Inspect each gasket for damage Gaskets Outlet Relief Valve Suction Valve Inspect the suction valve outlet valve and relief valve in the fuel pump body for damage cracks or foreign matters Spring Outlet Valve Inlet Spring Dowel Pins FUEL PUMP ASSEMBLY Assemble the fuel pump in the reverse order of disassembly During assembly be sure to install the gaskets and diaphragms properly to avoid damage Do not allow any foreign matter to byw e enter the fuel pump during assembly ZY gt Fuel Pump Body Dowel Pin Holes 13 19 13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK FUEL PUMP INSTALLATION Install the fuel pump and secure it with the two bolts Connect the fuel pump inlet outlet and vacuum tubes Install the seat met in box and frame center cover Measure the fuel pump output Start the engine and disconnect the fuel outlet tube and place a clean container under the
78. ER CLUTCH GRAND DINK 125 150 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 Water Inlet Hose STATOR REMOVAL Screws A C Generator Stator Remove the two pulser coil attaching screws and the pulser coil Remove the three A C generator stator bolts and the stator When removing the pulser coil and stator be careful not to damage them to avoid shorted or broken wire Pulser Coil Bolts FLYWHEEL REMOVAL Flywheel Holder Hold the flywheel with a flywheel holder and remove the flywheel nut Flywheel 1 Nut Remove the flywheel with a flywheel puller Flywheel Puller 10 3 KYMCO 10 GENERA TOR STARTER CLUTCH GRAND DINK 125 150 Shaft Starter Idle Gear STARTER CLUTCH I REMOVAL Remove the starter idle gear and shaft Remove the starter driven gear INSPECTION Inspect the starter driven gear for wear or damage Measure the starter driven gear I D and O D Service Limits LD 20 15mm replace if over O D 41 00mm replace if below Starter Driven Gear Starter Idle Gear Inspect the starter idle gear and shaft for wear or damage Shaft 10 4 KYMCO 10 GENERA TOR STARTER CLUTCH GRAND DINK 125 150 Remove the starter one way clutch rollers plungers and springs Inspect each roller and plunger for wear or damage a
79. ERATION Check the throttle grip for smooth movement Measure the throttle grip free play Free Play 7 6mm Lock Nut Major adjustment of the throttle grip free play is made with the adjusting nut at the carburetor side Adjust by loosening the lock nut and turning the adjusting nut Minor adjustment is made with the adjusting nut at the throttle grip side Slide the rubber cover out and adjust by loosening the lock nut and turning the adjusting nut Adjusting Nut Lock Nut KYMCO 3 INSPECTION ADJUSTMENT GRAND DINK 125 150 Oil Dipstick ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the motorcycle upright on level ground Wait 2 minutes and check oil level with the dipstick Do not screw in the dipstick when making this check OIL CHANGE T Drain the oil while the engine is warm Remove the oil drain bolt to drain the engine oil Install the aluminum washer and tighten the oil drain bolt Torque 14 7N m T s Replace the aluminum washer with a new one if it is deformed or damaged Pour the recommended oil through the oil filler hole Oil Capacity At disassembly 1 1 liter At change 0 9 liter Recommended Oil SAE 15W40 SJ Start the engine and check for oil leaks Stop the engine and recheck the oil level OIL FILTER SCREEN INSPECTION Drain the engine oil Remove the oil filter screen cap Clean the oil filter screen Instal
80. ERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER BATTERY CHARGING SYSTEM IGNITION SYSTEM STARTING SYSTEM SWITCHESHORN FUEL UNIT T HERMO STATIC SWITCH TEMPERATURE GAUGE INSTRUMENTS LIGHTS Nn 515 15 23 5 KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 GENERAL INFORMATION ENGINE SERIAL NUMRBER 1 1 BEER 1 2 SERVICE 65 1 4 TOROUE EE 1 8 SPECIAL Eege 1 9 EECHER 1 10 CABLE amp HARNESS 1 12 WV MR UN AG 1 17 TROUBLESHOOTING 1 18 1 0 dC KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 SERIAL NUMBER Vehicle Identification Serial Number m x y L Le E e d a e d D i E Location of Frame Serial Number Location of Engine Serial Number 1 1 QC KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 SPECIFICATIONS SH25DA De 2060mm 770mm 1360mm 1435mm Water cooled 4 stroke OHC engine 124 6cc Fuel Used 92 nonleaded gasoline 58 140 Type 10 1 5 1000rpm Non contact point Front wheel 60 Spark plug NGK Tires 120 70 12 DPR7EA 9 140 70 12 0 8 0 9mm ve E Se distance
81. ETTANTE 4 x 10 4 33452 4 000 00166150 SCHERMO FRECCIA ANTERIORE SX 10 33 1 ON 33607 7 000 00166917 SEDE LAMPADA FRECCIA 2 e 540 33400 KKC4 E000 00166147 FRECCIA ANTERIORE DX 18 08 1 e 541 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 3 542 33450 KKC4 E000 00166149 FRECCIA ANTERIORE SX 18 08 1 543 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 3 544 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 2 545 33600 KKC4 E000 00159365 FRECCIA POSTERIORE DX 20 66 1 e 546 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 3 547 33650 KKC4 E000 00159367 FRECCIA POSTERIORE SX 20 66 1 548 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 3 Li GRAND DINK 125 SCHERMO FARO POSTERIORE 33702 KKC4 E000 LISTINO IVA ESCL N PZ 33705 KKC4 E000 BASE LUCE POST 33709 KAB 0030 GUARN LUCE TARGA 33722 KHB4 E000 33725 KHB4 E000 SCHERMO LUCE TARGA 33726 KHB4 E000 CAVO CON PORTALAMPADA 34903 KCP 9000 LAMPADINA 5W 12V 34906 KCP 9000 LAMPADA FARO POST P21 5W 12V 91508 KV7 6710 M1 VITE AUTOFILETTANTE 4 x 14 VITE AUTOFILETTANTE 4 x 12 nr A T 0 D 33706 GN3 6710 M1 COPERCHIO LUCE TARGA 550 33700 4 000 FARO POSTERIORE 552 93404 06016 07 VITE RONDELLA 16 553 90301 634 6710 DADO FLANGIATO 6MM 554 80100 KKC4 900 PARASPRUZZI POSTERIORE INF 555 90302 KFC2 9000 VITE RONDE
82. FRAME COVERS _ GRAND DINK 125 150 Remove the three screws attaching fuel tank Screws inlet tube join Remove the back cover 2 Y l Fuel Tank Inlet Tube Bolts BOTTOM COVER REMOVAL Remove the side stand Remove the four bolts attaching the bottom cover Remove the bottom cover Bottom Cover Side Stand FRONT FENDER RFMO VAL Remove the two bolts attaching the fender Remove the front fender cover The installation sequence is the reverse of removal EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts Remove the three exhaust muffler lock bolts to remove the exhaust muffler Remove the exhaust muffler joint packing collar The installation sequence is the reverse of removal Torque Exhaust muffler joint lock nut 11 8N m Exhaust muffler lock bolt 34 3N m 2 7 KN 73 TS T 4 AN rh k i d NAA Bolts Lock Bolts KYMCO 2 EXHAUST MUFFLER FRAME COVERS GRAND DINK 125 150 HANDLEBAR COVER REMOVAL First remove the three screws attaching the handlebar under cover Remove the handlebar under cover Screws Screw Remove the screw from the handlebar upper cover Remove the screw from the bottom of handlebar upper cover Remove the handlebar upper cover 2 8 KYMCO 3 INSPECTION ADJUSTMENT GRAND DINK 125 150 gt INSPECTION ADJUSTMENT SERVICE INFORMATION
83. FT REMOVAL Disconnect the water hose from the right crankcase cover Remove the 3 bolts attaching the water pump assembly Remove the water pump assembly gasket and dowel pins Remove the water pump bearing snap ring from the water pump assembly Remove the water pump shaft and shaft inner bearing Remove the water pump shaft outer bearing 12 11 dC KYMCO GRAND DINK 125 150 Water Pump Assembly Water Pump Assembly Inner Bearing gt f e BN e 4 HI Snap Ring Water Pump Shaft Water Pump Shaft O Inner Bearing KYMCO 12 COOLING SYSTEM GRAND DINK 125 150 MECHANICAL S FAL REPLACEMENT Water Pump Assembly Drive the mechanical seal out of the water pump assembly from the inside Mechanical Seal Water Seal Mechanical Seal Driver Drive in a new mechanical seal using a mechanical seal driver Apply sealant to the right crankcase cover fitting surface of a new mechanical seal and then drive the mechanical seal Outer Bearing WATER PUMP SHAFT INS TALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside Water Pump Assembly 12 12 KYMCO 12 COOLING SYSTEM GRAND DINK 125 150 Install the water pump shaft and shaft inner Snap Ring Water Pump Shaft bearing into the waster pump assembly Install the snap ring to secure the inner bearing properly
84. INO 10 x 10 3 10 3 e 254 28125 426 0010 00128734 MOLLA RUOTA LIBERA 3 10 3 e 255 28126 KDU 900 00128735 CAPPUCCIO MOLLA 3 10 3 e 256 96220 60100 00127248 GRANO 6 x 10 2 00 1 e 257 28131 KN7 6710 00128939 GUIDA INGRANAGGIO USCITA 4 65 1 O 258 96001 06014 08 00101004 VITE FLANGIATA 6X14 1 IC Li GRAND DINK 125 03 11 04 BEN ao 15 24 282 284 286 285 M 286 e CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 30301 KBE 9000 M2 00128952 PICK UP 30 99 1 O C 90478 700 0010 00123919 RONDELLA 6mm 1 e B 96001 06010 08 00129991 VITE FLANGIATA 6 x 10 3 10 1 269 94591 KBF 900 00128739 CLIP 2X70 1 55 1 e 271 31110 KBE 9000 00128946 VOLANO MAGNETE 8 mm 77 47 1 e 272 31120 KBE 90B 00128947 STATORE 98 13 1 O 273 92000 05032 OH 00128948 VITE TESTA PIATTA 5 x 32 3 O 274 93500 05016 0H 00128949 VITE TESTA PIATTA 5 x 16 2 e 275 90401 KJ9 0010 00128950 RONDELLA SPALLA 14 x28x2 3 00 1 e 276 90201 KR8 7520 M1 00128951 DADO FLANGIATO 14mm 4 13 1 279 19300 KE1 0030 M1 00129962 TERMOSTATO POMPA ACQUA 46 48 1 e 280 19310 KBE 9000 00129963 CUSTODIA TERMOSTATO POMPA ACQU 15 49 1 O 281 93500 05016 0H 00128949 VITE TESTA PIATTA 5 x 16 2 e 282 19315 KBE 9000 00129965 COPERCHIO TERMOSTATO POMPA ACQ 3 10 1 e 283 37750 PC1 0050 00129966 BULBO TERMOSTATO POMPA ACQUA 21 69 1 e 284 91301 KV7 6710 00129967 O RING 14
85. L Remove left crankcase cover 8 3 Remove the seal rubber and dowel pins Remove the kick lever Remove the circlip and washer from the kick starter spindle Kick Starter Spindle Starter Driven Gear Gently turn the kick starter spindle to remove the starter driven gear together with the friction spring Friction Spring Return Spring Remove the kick starter spindle and return spring from the left crankcase cover Remove the kick starter spindle bushing TN AD Y 2 2 165 g 5 de P Kick Starter Spindle 8 15 8 DRIVE AND DRIVEN PULLEYS KICK STARTER INSPECTION Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushings for wear or damage Inspect the starter driven gear for wear or damage Inspect the friction spring for wear or damage Inspect the kick starter spindle and starter driven gear forcing parts for wear or damage INSTALLATION Install the kick starter spindle bushings and return spring onto the left crankcase cover i When installing the return spring use a screw driver to press the inward and outward return spring hooks into their original positions respectively Install the starter driven gear and friction spring as the figure shown KYMCO GRAND DINK 125 150 Plastic Bushing Spindle Return Spring Spindle Bushing
86. LLA 5 x 25 556 90677 GR1 0040 CLIP FILETTATA 5MM 557 90302 GY6 9400 VITE RONDELLA 5 x 12 558 80101 KKC4 900 PARASPRUZZI POSTERIORE SUP 559 80105 KKC4 9000 PARAFANGO POSTERIORE SUP 560 90112 KBN 9010 VITE FLANGIATA 6mm 561 33741 KBE 9000 CATARIFRANGENTE POSTERIORE 562 DADO FLANGIATO 5mm 564 VITE AUTOFILETTANTE M4 x 12 565 80106 KKC4 9000 PARAFANGO POSTERIORE INF 566 VITE AUTOFILETTANTE M4 x 12 568 80102 KKC4 900 TENDINA PARASPRUZZI e eo O 0 O e e O e O 569 93903 7 9000 VITE RONDELLA 4mm 1 1 1 1 1 1 1 1 2 4 1 1 1 2 1 3 3 1 1 1 3 1 1 2 1 3 1 2 IC GRAND DINK 125 03 11 04 586 586 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ C 17620 5 000 2 00168582 TAPPO CARBURANTE COMPLETO 36 15 1 e D 17623 KHC4 9000 00168912 CORNICE TAPPO CARBURANTE 4 65 1 30700 KN7 6710 00168937 PIPETTA CANDELA 12 39 1 35101 KHC4 3050 00168913 ROTORE ACCENSIONE 61 97 1 e B 35102 KHC4 9000 00168910 CORNICE ROTORE ACCENSIONE 7 75 1 e 580 30510 KBE 900 00168921 BOBINA A T E CAVO CANDELA 46 48 1 O 581 90112 KDR 9000 00168581 VITE FLANGIATA 5 x 22 1 585 17520 KKC4 9000 00124155 CAVO APERTURA TAPPO CARBURANTE 8 26 1 586 95701 KHC5 E000 IT 00
87. Maintenance Schedule KYMCO GRAND DINK 125 150 Drive Belt Oil Check Bolt Hole Oil Filler dC KYMCO 3 INSPECTION ADJUSTMENT GRAND DINK 125 150 L HEADLIGHT AIM Turn the ignition switch ON Turn on the headlight switch Adjust the headlight aim by turning the headlight aim adjusting bolt CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually If the motorcycle tends to creep or the engine Stalls check the clutch shoes for wear and replace if necessary COOLING SYSTEM COOLANT LEVEL INSPECTION Place the motorcycle on its main stand on level ground Check the coolant level of the reserve tank and the level should be between the upper and lower level lines If necessary fill the reserve tank with recommended coolant to the F level line Recommended Coolant SIGMA Coolant Standard Concentration 30 The coolant level does not change no matter the engine is warm or cold Fill to the F upper line COOLANT REPLACEMENT Lower Line Perform this operation when the engine is cold Radiator Cap Remove the front cover Remove the radiator cap Remove the drain bolt to drain the coolant and tilt the motorcycle to the right and the coolant will drain more easily Drain the coolant in the reserve tank Reinstall the drain bolt Fill the radiator with the specified coolant The coolant f
88. NE SX 36 15 1 464 90106 KFC2 9000 00152330 VITE SPECIALE 8 x 42 5 00 2 e 467 33900 KBF 9000 00161745 LUCE VANO PORTAOGG 9 30 1 468 81201 4 900 00161020 SUPPORTO 24100747 20 00 1 469 90105 5 0010 00160611 VITE DISCO 6X 17 24100747 3 10 1 Li CODICE KY CODICE PIR GRAND DINK 125 03 11 04 DESCRIZIONE 416 476 Ki DA N TELAIO LISTINO IVA ESCL N PZ eL 11207 KKC4 9000 00167925 SUPPORTO PARASPRUZZI POST 9 30 1 OD 11211 KKC2 900 00162483 MANDATA TUBO SFIATO 1 e 15772 551 0000 00161001 CLIP TUBO SFIATO 1 55 1 e B 17214 KKC3 9000 00162911 GUARN COPERCHIO FILTRO ARIA 7 23 1 1723A KKC3 E000 00162976 SCATOLA FILTRO ARIA COMPLETA 41 32 1 17254 KCA POO0 00163803 TAPPO SFIATO FILTRO ARIA 2 50 1 17368 KB4 6710 00162977 CLIP TUBO 14 5 3 OE 17370 419 6700 00162978 COP TUBO SFIATO 1 OK 93891 05016 07 00154027 VITE RONDELLA 5 X16 NERA 6 OM 93903 35220 00151719 VITE AUTOFILETTANTE 5 x 12 1 O J 95002 02130 00162961 CLIP TUBO B 12 5 1 OF 17371 174 6710 00162762 CLIP TUBO SFIATO 2 474 17231 KKC3 900 00162474 COPERCHIO FILTRO ARIA 20 66 1 475 1721A KKC3 9000 00162475 ELEMENTO FILTRO ARIA 12 91 1 O 476 93903 25480 00166210 VITE AUTOFILETTANTE 5X20 6 e 478 90114 GM4 0110 00163008 VITE FLANGIATA 6X28 3 10 1 O 479 90114 KCX 9000 00163897 VITE FLANGIATA 6 x 12 1 e 484 17215 KGBG 9000 00162625 CLIP MANICOTTO
89. No 1212 sealant or equivalent to the thermosensor threads and install it into the thermostat housing Connect the thermosensor wire the radiator with coolant 3 9 Install the center cover met in box and seat 2 3 sure to bleed air from the cooling system Thermosensor Wire 12 15 KYMCO 12 COOLING SYSTEM GRAND DINK 125 150 Th Hous Bol THERMOSTAT c THERMOSTAT REMOVAL Remove the seat met in box and center cover Drain the coolant Disconnect the thermosensor wire from the thermosensor Disconnect the water hose from the thermostat housing Disconnect the air vent tube from the thermostat housing Remove the mounting bolt and the thermostat housing from the cylinder head Water ios Air Vent Tube Bolts Remove the two bolts and separate the thermostat housing halves Thermostat Thermostat Remove the thermostat from the thermostat housing 12 16 KYMCO 12 COOLING SYSTEM GRAND DINK 125 150 THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation Technical Data Thermostat Valve lift 3 5 45mm Do not let the thermostat touch the pan as it will give a false reading Replace the thermostat if the valve stays open at room temperature Test the thermostat after 1t 1s opened for about 5 minutes and holds the temperature at 70
90. O 17 IGNITION SYSTEM GRAND DINK 125 150 A C GENERATOR INSPECTION EXCITER COIL PULSER COIL INSPECTION This test is performed with the stator installed in the engine Remove the frame right cover 2 4 Disconnect the A C generator connector Measure the exciter coil resistance between the black red wire terminal and ground Black red_ Ground 50 2500 Measure the resistance in the XQ range For A C generator removal installation refer to pages 10 3 and 10 6 Disconnect the pulser coil wire coupler Measure the pulser coil resistance between the blue white and green white wire terminals Blue white_ Green white 50 1700 17 4 17 IGNITION SYSTEM CDI UNIT RESISTANCE INSPECTION Measure the resistance between the terminals Replace the CDI unit if the readings are not within the specifications in the table below Due to the semiconductor In circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings Use a Sanwa Electric Tester 07308 0020000 or Kowa Electric Tester TH 5H n this table Needle swings then returns indicates that there is a charging current applied to a condenser The needle will then remain at unless the condenser is discharged 99 Use the X KQ range for the Sanwa Tester Use the x 10002 range for the Kowa Tester Unit KQ Q Green Green White IGN
91. ONT WHEELFRONT KYMCO ___ BRAKE FRONT SHOCK ABSORBER FRONT FORK See Shock Absorber Tube INSPECTION Inspect the following items and replace if necessary Front shock absorber tube bending damage or wear Weak front shock absorber spring Damper and damper rod bending Oil seal damage or wear Measure the front shock absorber spring free length Service Limit 233mm replace if below 14 15 14 STEERING HAN DLEBAR FRONT WHEEL FRONT KYMCO BRAKE FRONTSHOCK ABSORBER FRONT FORK GRAND DINK 125 150_ ASSEMBLY Install the damper spring onto the damper rod and then install them into the front shock absorber tube Install the shock absorber spring onto the front shock absorber tube Set the front shock absorber tube in a vise and then tighten the lock nut When holding the shock absorber tube place a shop towel to protect it and do apply too much force Set the front shock absorber in a vise Insert the shock absorber tube into the shock absorber and then install the copper washer and tighten the damper rod hex bolt Apply locking agent to the washer hex bolt and install them together Add engine oil into the front shock absorber Torque 4 9 294 Specified Oil SAE30 Hex Bolt Copper Washer Circlip Dust Boot Oil Capacity 81cc Install the oil seal Install the circlip Install the dusts seal and dust boot Dust Seal INSTALLATION Install the front
92. PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO GRAND DINK 125 150 Section contains the precautions for all operations stated in this manual Read them carefully before any operation 15 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 1s 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 The information and contents included in this manual may be different from the motorcycle in case specifications are changed KWANG YANG MOTOR CO L TD OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION HNIDONH SISSVHO LNHINdIL 10H IV OTSELOH T dC KYMCO GRAND DINK 125 150 TABLE OF CONTENTS EXHAUST MUFFLER FRAME COVERS ENGINE REMOVAL INSTALLATION DRIVE AND DRIVEN PULLEYS KICK STARTER A C GENERATOR STARTER CLUTCH 1 x PUMP FUEL TANK STE
93. PURGO 1 00 1 OQ 45107 MN5 0070 00156994 PARAPOLVERE 2 e E 45108 ML4 0060 00156988 MOLLA 4 65 1 45131 166 0160 00156894 PASTIGLIA 9 30 1 J 45131 GE2 0060 00156893 PERNO FLOTTANTE SUPP PINZA 9 30 1 45132 166 0160 00156895 PERNO FLOTTANTE PERNO PAST 9 30 1 OH 45133 0060 00156891 PROTEZIONE PERNO PINZA 1 e 45209 GE2 0060 00156890 PARAPOLVERE 8 26 2 e P 45216 KW6 9020 M1 00156956 DADO SPECIALE 4 65 1 OR 45531 1 9510 00156927 CAPPUCCIO 2 45109 GE2 0060 00156989 PARAPOLVERE 7 75 2 45215 KA3 7320 M1 00156898 PERNO PINZA FRENO 4 00 2 e 331 42601 KHD8 90B NJA 00157990 CERCHIO POSTERIORE 206 58 1 e 332 90105 KR3 0010 00156556 VITE DISCO 8X 24 4 65 5 333 43351 7 00 00156976 DISCO POSTERIORE 61 97 1 334 42710 KKC4 900 00157330 PNEUMATICO POSTERIORE 48 00 1 e 337 90305 KW6 9120 M1 00157413 DADO FLANGIATO 16MM 5 68 1 338 43100 KBE 910 N1A 00157336 PINZA POSTERIORE 118 79 1 O 339 90131 GWO 9110 00159217 VITE FLANGIATA 8 x 35 2 e 349 42311 KFC8 9000 00157997 BOCCOLA ASSE POSTERIORE 13 43 1 e 350 42312 KBE 9000 00157938 DISTANZIALE ASSE POSTERIORE 6 20 1 Li GRAND DINK 125 03 11 04 361 361 366 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 77220 KKC4 910 T01 00158995 SCHIENALE SELLA 21 69 1 e 360 77200 4 10 01 00158164 SELLA 149 77 1 361 94050 06080 00109022 DADO FLANGIATO 6mm 1 55 2 362 89010
94. RMANCE Symptom Soft brake lever Hard brake lever Hard to brake Brake squeaks 2 Sr 2 CH Probable Cause Front and rear tire pressures are normal Q Steering stem nut too tight Broken steering steel balls Excessive wheel bearing play 2 Bent rim Loose axle nut D Misaligned front and rear wheels 2 Bent front fork Probable Cause Front and rear tire pressures are normal DWeak shock spring Excessive load Shock damper oil leaking Bent fork tube or shock rod Fork tube and slider binding Fork spring and slider binding GO Damaged shock stopper rubber Loose steering stem nut Probable Cause Q Worn brake linings 2 Foreign matter on brake linings Rough brake drum contacting area Q Worn brake linings 2 Foreign matter on brake linings Rough brake drum contacting area DWorn brake linings 2 Worn brake cam contacting area on Q Worn brake linings 2 Foreign matter on brake linings OSluggish or elongated brake cables 2 Brake shoes improperly contact Water and mud in brake system or grease on brake linings 1 28 KYMCO 2 EXHAUST MUFFLER FRAME COVERS GRAND DINK 125 150 2 EXHAUST MUFFLER FRAME COVERS SCHEMATIC DRAWN G e 2 1 SERVICE INFORMATION 2 2 TROUBLESHOOTING 222 FRAME COVERS REMOVAL
95. RZO x 4 65 1 623 50350 KKC3 9000 00170091 SUPPORTO OSCILLANTE MOTORE 87 80 1 624 90106 KHE7 E000 00170017 VITE FLANGIATA 12X59 6 20 2 e 625 90121 KHE7 E000 00156978 DISTANZIALE 6 20 1 e 626 90117 KED9 900 00169621 VITE FLANGIATA 10X265 7 00 1 627 90304 GE8 0040 00153206 DADO FLANGIATO 10MM AUTOBLOC 4 13 1 628 50613 KKC4 900 00170103 PROTEZIONE INFERIORE A NH001 16 53 1 629 95701 06012 08 00159015 VITE FLANGIATA 6X12 1 00 4 630 64315 KKC4 900 00154959 SUPPORTO SCUDO ANTERIORE 108 46 1 631 95701 08050 07 00164504 VITE FLANGIATA 8 x 50 3 10 2 632 95701 08012 08 00109234 VITE FLANGIATA 8 X 12 3 00 1 636 11345 2 000 00169630 10 33 1 638 11346 KKC3 9000 00169965 FASCETTA 1 654 50151 4 9000 00169654 SEDE SUPP PORTAPACCHI 12 00 1 O 670 50191 KKC4 9000 00169670 SUPPORTO 1 O 680 50185 KKC4 9000 00169680 SUPP FIANCH DX 1 682 50186 KKC4 9000 00169682 SUPP FIANCH SX 4 00 1 683 50614 KKC3 900 00169683 PROTEZIONE INFERIORE 24100747 12 00 1 684 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 3 Li GRAND DINK 125 03 11 04 635 658 633 4 658 0677 45 678 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 19015 KKC4 9000 00159362 CAMERA VENTOLA RAFFREDDAMENTO 19 63 1 e B 19020 KED9 900 00159363 VENTOLA RAFFR
96. Remove the two screws on the molding covers Remove the molding covers Molding Cover Screws Remove the two nuts and one bolt on the back taillight Nuts Blot Remove the left and right sides screws on the frame body cover Remove the frame body cover Bolt FLOOR BOARD REMOVAL Remove the blot on the front right and left side covers Side Cover KYMCO Remove the left and right side screws on the side cover Remove the side cover Remove the four bolts on the floor board Remove the floor board FRONT UPPER COVER REMOVAL Remove the two screws on the front upper cover Remove the front upper cover Remove the four bolts on the front windshield Remove the front windshield 2 5 _ Screws Bolt vx 4 Screws dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS GRAND DINK 125 150 FRONT COVER REMOVAL First remove the front upper cover Remove the two bolts attaching the front cover Remove the six screws on the back of the front cover Disconnect the right left turn signal light wire connectors Remove the front cover The installation sequence is the reverse of removal Screws Screws Remove the six screws on the front lower cover Remove the front lower cover BACK COVER REMOVAL Remove the front cover Remove the key moldings Remove the fuel cap moldings Remove the back cover bolt Remove the back cover KYMCO 2 EXHAUST MUFFLER
97. SX SCUDO INT SUPERIORE 157 81137 KKC4 900 N1R GRIGLIA DX SCUDO INT INFERIORE 158 VITE AUTOFILETTANTE M4 x 12 159 81147 KKC4 900 N1R GRIGLIA SX SCUDO INT INFERIORE 160 VITE AUTOFILETTANTE M4 x 12 161 64400 KKC4 900 BHP SPOILER BLU GARDA 161 64400 KKC4 900 N8P SPOILER ARGENTO METAL 161 64400 KKC4 900 NFP SPOILER NERO SMOKE 161 64400 KKC4 900 R1P SPOILER ROSSO RACING 165 64305 KKC4 900 BHP FASCIONE ANT DX BLU 165 64305 KKC4 900 N8P FASCIONE ANT DX ARGENTO METAL 165 64305 KKC4 900 NFP FASCIONE ANT DX NERO SMOKE 165 64305 4 900 1 FASCIONE ANT DX ROSSO RACING 166 90302 GY6 9400 VITE RONDELLA 5 x 12 167 64306 KKC4 900 BHP FASCIONE ANT SX BLU GARDA 167 64306 KKC4 900 N8P FASCIONE ANT SX ARGENTO METAL 167 64306 KKC4 900 NFP FASCIONE ANT SX NERO SMOKE 167 64306 KKC4 900 R1P FASCIONE ANT SX ROSSO RACING 168 90302 GY6 9400 VITE RONDELLA 5 x 12 170 64310 KKC4 900 N1R 171 90302 SA4 0040 INSERTO FILETTATO 4MM 172 93404 06020 07 VITE RONDELLA 6 x 20 173 64320 4 900 COPRIPEDANA 174 8376A KBE 900 GANCIO PORTABORSA 175 93903 GY6 900 VITE AUTOFILETTANTE 4 x 14 178 33741 GY6 C300 CATARIFRANGENTE LATERALE e O O 0808 000 0 O 179 DADO FLANGIATO 6mm 1 1 1 1 3 1 3 1 1 1 1 1 1
98. UBL UNE 19 5 EE ER TEMPERATURE GAUGE 19 6 LNS Ipu P NI 2222 2032 55 19 7 IER 19 8 HEATER WIRING DIAGRAM 19 9 19 0 19 KYMCO SWITCHESHORNFUEL IEMPERATUREGAUGEINSTRUMENTSI IGHIS GRAND DINK 125 150 ELECTRICAL EQUIPMENT LAYOUT Stop Switches Headlight Dimmer Switch Turn Signal Switch Instruments Horn Button Auto Bystarter Headlight Switch Starter Button Thermostatic Switch Thermosensor 19 1 19 SWITCHESHORNFUBELUNIDTHERMOSTATICSWITCH KYMCO IEMPERATUREGAUGEINSTRUMENTSI IGHIS GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS After installation of each switch a continuity check must be performed A continuity check can usually be made without removing the part from the motorcycle TESTING INSTRUMENT Electric tester SPECIAL TOOL Fuel unit wrench TROUBLESHOOTING Lights do not come on when ignition Temperature gauge does not register switch is ON Burned bulb Faulty switch correctly Faulty temperature gauge Faulty thermosensor Poorly connected broken or shorted wire Broken or shorted wire between temperature gauge and thermosensor Fuel gauge pointer does not move or register correctly Faulty fuel gauge Faulty fuel unit Poorly connected wire between fuel gauge and fuel unit Fu
99. aphragm spring and cover Install and tighten the two screws attaching the air cut off valve cover Connect the hose Screws AUTO BYSTARTER INSTALLATION Auto Bystarter Screws Install the auto bystarter and set plate Install and tighten the two screws Insert the auto bystarter into the carburetor body until it bottoms and position the set plate into the upper eroove in the bystarter nstall the set plate with its round face facing down Set Plate 13 14 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 FLOAT CHAMBER ASSEMBLY Slow Jet Main Jet Install the main jet Install the slow jet Install the pilot screw Be sure to record the rotating turns when it is removed Pilot Screw Install the float valve float and float pin Float Valve Float Pin 13 15 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 FLOAT LEVEL INSPECTION Measure the float level at the location of the main jet just contacting the float valve Float Level 18 5 1 0mm Replace the float if the level is incorrect Check the operation of the float and then reinstall the float chamber Float Vacuum Piston VACUUM CHAMBER ASSEMBLY First install the jet needle and spring into the vacuum chamber and then install the needle holder 1 Jet Needle Spring Needle Holder Vacuum Piston Install the vacuum pis
100. attaching bolt and oil separator cover Pry the circlip off and remove the oil pump driven gear then remove the oil pump drive chain Remove the two oil separator bolts to remove the oil pump OIL PUMP DISASSEMBLY Remove the screw and disassemble the oil pump as shown Oil Pump Driven Gear Oil Pump KYMCO 4 LUBRICATION SYSTEM GRAND DINK 125 150 Pump Body Outer Rotor OIL PUMP INSPECTION Measure the pump body to outer rotor clearance Service Limit 0 25mm replace if over Outer Rotor Inner Rotor Measure the inner rotor to outer rotor clearance Service Limit 0 20mm replace if over Measure the rotor end to pump body clearance Service Limit 0 12mm replace if over Pump Body Rotor End Dowel Pin Pump Body OIL PUMP ASSEMBLY Install the outer rotor inner rotor and pump shaft into the pump body Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor Install the dowel pin There is one mark on the surface of the inner rotor and outer rotor The mark is upside 4 5 Outer Rotor Inner Rotor Pump Shaft dC KYMCO 4 LUBRICATION SYSTEM GRAND DINK 125 150 Pump Cover Hole Screw Install the pump cover by aligning the hole in the cover with the dowel pin Tighten the screw to secure the pump cover Make sure that the pump shaft rotates freely without binding Dowel Pin Arrow Mark OIL PUMP INSTALLATION Install the pum
101. ck Run engine for2_ 3 minutes and check the oil level after the engine is stopped for 2_ 3 minutes Remove the oil dipstick and check the oil level with the oil dipstick If the level 1s near the lower level fill to the upper level with the recommended engine oil OIL CHANGE The engine oil will drain more easily while the engine is warm Remove the oil drain bolt located at the left side of the engine to drain the engine oil After the oil has been completely drained install the aluminum washer and tighten the oil drain bolt Torque 14 7N m Pour the recommended oil through the oil filler hole OIL FILTER SCREEN Drain the engine oil Remove the oil filter screen cap Remove the oil filter screen and spring Check the oil filter screen for clogging or damage and replace if necessary Check the filter screen O ring for damage and replace if necessary Install the oil filter screen spring O ring and Pe filter screen cap Torque 14 7N m 21 Recommended SAE15W40 API SG CD Oil Filter Screen Cap Oil Capacity At disassembly 1 1 liter At change 0 9 liter Start the engine and check for oil leaks Start the engine and let it idle for few minutes then recheck the oil level 4 3 4 LUBRICATION SYSTEM OIL PUMP REMOVAL First drain the coolant Remove the right crankcase cover 10 3 Remove the A C generator starter driven gear 10 4 Remove the
102. ck nut Cam chain tensioner slipper bolt Cylinder head cover bolt Spark plug Cam chain tensioner bolt ater pump impeller 2 1 2 4 2 1 1 1 1 1 2 4 1 1 1 Left hand threads Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upp er bolt Rear shock absorber lower bolt Front shock absorber lock bolt Engine hanger bolt 1 GENERAL INFORMATION SPECIAL TOOLS dC KYMCO GRAND DINK 125 150 Valve guide driver Valve guide reamer Valve spring compressor Lock nut wrench 39mm Bearing driver Bearing remover 12mm Remover shaft Remover weight Bearing remover 15mm Bearing driver Clutch spring compressor Ball race remover extension Ball race remover Spring compressor Mechanical seal driver Kick starter spring remover Gear remover Valve adjuster Float level gauge Valve seat cutter 45 Valve seat cutter 32 Valve seat cutter 60 Cutter clip 5mm niversal holder Bearing driver 32x35mm Pilot 12mm Rear shock absorber compressor Steering head bearing remover Fuel unit wrench 1 9 Valve guide removal installation Valve guide grinding Valve removal Clutch disassembly Bearing removal Bearing removal Bearing removal Bearing removal Bearing removal Bearing removal Clutch disassembly Ball race removal Ball race removal Spring removal Water pump mechanical seal removal installation Kick starter spring removal Starter gear removal Tapper adjustmen
103. duce the braking effect Clean the brake pads and brake disk with a high quality brake degreaser Fully apply the brake lever and then loosen the brake caliper bleed valve to drain the brake fluid until there 1s no air bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system 15 free of air 14 STEERING HANDLEBAR FRONT WHEEL FFRONT BRAKE FRONT SHOCK ABSORBER FR ONT FORK GRAND DINK 125 150 Bleed Valve BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system Remove the brake fluid tube bolt Remove the two bolts attaching the brake caliper Remove the brake caliper DISASSEMBLY Remove the two brake pads dowel pins from the brake caliper Remove the brake pads Dowel Pin Remove the piston from the brake caliper If necessary use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Push the piston oil seal outward to remove it Clean the oil seal groove with brake fluid Be careful not to damage the piston surface Piston Oil Seal 14 11 14 STEERING HANDLEBAR FRONT WHEELFRONT BRAKE FRONTSHOCK ABSORBER FRONT FORK GRAND DINK 125 150_ Check the piston for scratches or wear Measure the piston O D
104. e 431 81260 KKC4 9000 00161014 VANO PORTA OGGETTI 92 96 1 432 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 2 O 433 90381 GZ5 0010 00161930 VITE SPECIALE 6mm 2 434 90215 GMO0 9100 00154908 DADO A CAPPUCCIO 6MM 3 00 2 e 435 90111 187 0010 00154504 VITE FLANGIATA 6 MM 1 03 2 436 80151 KKC4 900 N1R 00161923 SCUDO CENTRALE NERO 50 61 1 437 93903 34380 00153009 VITE AUTOFILETTANTE M4 x 12 1 00 2 Cel e CODICE KY CODICE PIR 426 426 4 GRAND DINK 125 08 11 04 426 426 DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ e 438 90305 GK8 0010 00162025 CLIP FILETTATA 6mm 3 10 1 441 81151 KKC4 9000 00161441 ISOLANTE SCUDO INT 20 00 1 448 83750 KKC4 900 BHP 00161391A CODINO BLU GARDA PB183 47 51 1 448 83750 KKC4 900 N8P 00161391S CODINO ARGENTO METAL 045 47 51 1 448 83750 KKC4 900 NFP 00161391N CODINO NERO SMOKE NH124 47 51 1 448 83750 KKC4 900 R1P 00161391H CODINO ROSSO RACING RR004 47 51 1 O 449 93903 GY6 900 00154705 VITE AUTOFILETTANTE 4 x 14 2 450 8120A KKC4 900 00161450 PORTAPACCHI 82 63 1 O 451 90105 KEC8 9000 00161451 VITE RONDELLA 8mm 4 O 451 90106 KKC4 900 00161452 VITE RONDELLA 8mm 24100747 4 455 81257 KKC4 800 00162065 COPERCHIO ACCESSO CARBURATORE 11 88 1 460 81400 KKC4 900 N1R 00161015 MANIGLIONE DX 36 15 1 461 90105 KBN 9010 00163214 VITE SPECIALE 8MM 3 36 4 463 81500 KKC4 900 N1R 00161016 MANIGLIO
105. e dowel pins and a new gasket Countershaft Washer Install the transmission case cover Transmission Case Cover Install and tighten the transmission case cover bolts Install the clutch driven pulley Install other removed parts in the reverse order of removal 9 7 9 FINAL REDUCTION GRAND DINK 125 150 After installation fill the transmission case with the specified oil Place the motorcycle on its main stand on level ground Check the oil sealing washer for wear or damage Specified Gear Oil SAE90f Oil Capacity At disassembly 0 2 liter At change 0 18 liter Install and tighten the oil check bolt Torque 98 14 7N m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper level if the oil level is low Drain Bolt KYMCO 10 GENERA TOR STARTER CLUTCH GRAND DINK 125 150 GENERA TOR STARTER CLUTCH SCHEMATIC DRAWING eee 10 1 SERVICE INFORMATION ee 10 2 TROOPER TIN 55 52 2555 aac 10 2 RIGHT CRANKCASE COVER REMOVAL 10 3 10 3 FLYWHEEL 10 3 STARTER CEUTCEI 10 4 FLYWHEEL INSTALLATION 10 5 STATOR te ecco 10 6 RIGHT CRANKCASE COVER INSTALLATION 10 6 10 0 GRAND DINK 125 150
106. e wire harnesses do not make it contact the parts which will generate high heat T mc mm 4 lt Contact ru RN s ro AN 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 PNE uta s x H ZE hee Fa 7X E 23 Route harnesses so they are neither pulled tight nor have excessive slack es Do not pul gt n tight Se M DE 4 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 B Do not break the sheath of wire B If a wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it wi X E e 7 4 A na a m A B When installing other parts do not press or squeeze the wires Do not press squeeze phe wire 1 58 12 1 GENERAL INFORMATION B After routing check that the wire harnesses are not twisted or kinked O X wie 7 x p S m n m a d in 1225 ee ke Wi B Wire harnesses routed along with
107. emove the carburetor VACUUM CHAMBER DISASSEMBLY Loosen the drain screw and drain the fuel from the float chamber 13 7 KYMCO GRAND DINK 125 150 Auto Bystarter Wire Auto Bystarter Air Cleaner Connecting Tube Band Drain Screw 13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK Remove the two vacuum chamber cover screws and the cover Remove the compression spring and vacuum piston Remove the needle holder spring and jet needle from the piston Be careful not to damage the vacuum piston diaphragm VACUUM PISTON INSPECTION Inspect the vacuum piston and jet needle for wear or damage Inspect the diaphragm for deterioration and tears dC KYMCO GRAND DINK 125 150 Screws Vacuum Chamber Cover Spring Vacuum Piston Vacuum Piston Diaphragm Jet Needle Spring Needle Holder 13 8 13 FUEL SYSTEM CARBURETOR QC KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 FLOAT CHAMBER DISASSEMBLY Remove the four float chamber screws and the float chamber Remove the float pin float and float valve Float Pin Float Valve Float Valve FLOAT VALVE INSPECTION Inspect the float valve seat contact area for wear Float Valve Seat 13 9 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 JETS SCREWS REMOVAL Before removing the pilot screw turn the pilot screw clockwise until 1t seats light
108. er and spark plug cap Remove the spark plug Insert a compression gauge Open the throttle valve fully and push the starter button to test the compression Compression 15 2k cm_ If the compression 1s low check for the following _Leaky valves Valve clearance to small _Leaking cylinder head gasket _Worn pistons _Worn piston cylinder If the compression 15 high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head Compression Gauge 3 INSPECTION ADJUSTMENT FINAL REDUCTION GEAR OIL s Place the motorcycle on its main stand on level ground Stop the engine and remove the oil check bolt The oil level shall be at the oil check bolt hole If the oil level 1s low add the recommended oil SAE9O to the proper level Install the oil check bolt Make sure that the sealing washer is in good condition OIL CHANGE Remove the oil check bolt Remove the oil drain bolt and drain the oil thoroughly Install the oil drain bolt Torque 9 8N m m Make sure that the sealing washer is in good condition Fill the final reduction with the recommended oil SAE90 Gear Oil Capacity At disassembly 200cc At change 180cc Reinstall the oil check bolt and check for oil leaks DRIVE BELT Remove the left crankcase cover Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new one if necessary and in accordance with the
109. etor body Set Plate 13 11 13 FUEL SYSTEM CARBURETOR QC KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks wear or damage If any faulty part is found replace the auto bystarter with a new one Bystarter Needle Bystarter Valve Air Cut off Valve Cover AIR CUT OFF VALVE A C V A C V REMOVAL Remove the two screws and the air cut off valve cover Screws Diaphragm Remove the spring diaphragm and O rings Inspect the diaphragm and spring for wear or damage Spring 13 12 13 FUEL SYSTEM CARBURETOR QC KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 Disconnect the hose at the valve seat Hose Air Cut off Valve Body Remove the two screws and the air cut off valve body Screws CARBURETOR BODY CLEANING Blow compressed air through all passages of the carburetor body Make sure that no fuel jet is clogged A C V ASSEMBLY Install the O ring onto the air cut off valve body and then install the valve body to the carburetor with the two screws EE Install the O ring with the flat face toward the valve body side O ring 13 13 13 FUEL SYSTEM CARBURETOR QC KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 Diaphragm O ring Install the O ring onto the air cut off valve body securely Install the O ring with the flat face toward the valve body side Install the di
110. f necessary Apply grease to the O ring and install it to the starter motor Tighten the two mounting bolts O ring Starter Motor Cable STARTER CLUTCH INSPECTION Refer to pages 10 4 and 10 5 for the starter clutch removal inspection and installation 18 5 dO KYMCO 18 STARTING SYSTEM GRAND DINK 125 150 STARTER RELAY INSPECTION Disconnect the starter relay wire connector Check for continuity between the yellow red wire terminal and ground There should be continuity when the starter button is depressed If there is no continuity check the starter button for continuity and inspect the wire OPERATION TEST Connect the electric tester to the starter relay larger terminals that connect to the battery positive cable and the starter motor cable Connect a fully charged battery across the starter relay yellow red and green yellow wire terminals Check for continuity between the starter relay large terminals The relay is normal if there 15 continuity 18 6 19 SWITCHESHORNFUELUNITTHERMOSTATICSWITCH TEMPER ATUREGAUGEINSTRUMENISUGHIS GRAND DINK 125 150 SWITCHES HORN FUEL UNIT THERMOSTATIC SWITCH TEMPERATURE GAUGE INSTRUMENTS LIGHTS ELECTRICAL EQUIPMENT LAYOUT 19 1 SERVICE INFORMATION 19 2 TROUBLESHOOTING 19 2 19 3 pi COIN 19 5 P
111. fied torque values if any looseness is found WHEELS TIRES Check the tires for cuts imbedded nails or other damages Check the tire pressure Pressure Gauge Tire pressure should be checked when S Ug tires are cold Tire Pressure 75kg cm 1 75kg cm_ Rear 2 00kg cm _ 2 25kg cm STEERING HANDLEBAR Raise the front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing SUSPENSION Check the action of the front rear shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn Replace the engine hanger bushings if there 15 any looseness 3 11 KYMCO 4 LUBRICATION SYSTEM GRAND DINK 125 150 Ee LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 1 SERVICE INFORMATION 4 2 TROUBLESHOOTING 4 2 ENGINE FILTER eee 4 3 OD I I REMOVA 4 4 OH POMP DICAS ee 4 4 OIL PUMP INSPECTION 4 5 OIL PUMP 55 4 5 OIL PUMP INSTALLATION 4 6 4 0
112. fluid tube be sure to install the two sealing washers Fluid Tube Bo It Washers 14 13 14 STEERING HANDLEBAR FRONT WHEEL FRONT KYMCO BRAKE FRONT SHOCK ABSORBER FRONT FORK GRAND DINK 125 150_ FRONT SHOCK ABSORBER REMOVAL Remove the front upper cover 2 5 Remove the front lower cover 2 5 Remove front wheel 14 5 Remove the front brake caliper 14 11 Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers DISASSEMBLY Remove the dust boot Remove the dust seal Remove the circlip Set the front shock absorber in a vise Remove the damper rod hex bolt and copper washer Pull out the front shock absorber tube After the hex bolt is removed place a container under the front shock absorber to drain the engine oil from it Set the front shock absorber tube in a vise Remove the lock nut on the front shock absorber tube Take out the shock absorber spring and damper rod When holding the shock absorber tube place a shop towel to protect it and do apply too much force Front Fork P P Fidtr gd T Ai i mmm iliam PT es oe n Shock Absorber M Bolts Dust Boot Circlip Dust Seal Copper Washer Hex Bolt Lock Nut Shock Absorber Tube 14 14 14 STEERING HANDLEBAR FR
113. ge the skin and eyes Avoid contact with skin eyes or clothing In case of contact flush with water and get prompt medical attention The battery can be charged and discharged repeatedly discharged battery is not used for a long time its service life will be shortened Generally the capacity of a battery will decrease after itis used for 2_ years A capacity decreased battery will resume its voltage after it 1s recharged but its voltage decreases suddenly and then increases when a load is added When a battery 15 overcharged some symptoms can be found If there 15 a short circuit inside the battery no voltage is produced on the battery terminals If the rectifier won t operate the voltage will become too high and shorten the battery service life f a battery 1s not used for a long time it will discharge by itself and should be recharged every 3 months A new battery filled with electrolyte will generate voltage within a certain time and it should be recharged when the capacity 1s insufficient Recharging a new battery will prolong its service life Inspect the charging system according to the sequence specified in the Troubleshooting Do not disconnect and soon reconnect the power of any electrical equip ment because the electronic parts in the regulator rectifier will be damaged Turn off the ignition switch before operation t is not necessary to check the MF battery electrolyte or fill with distilled water
114. h a new one if the bearings are noisy or have excessive play CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 6mm bolt Remove the valve rocker arms 6mm Bolt Rocker Arm Shafts 6 CYLINDER HEAD VALVES CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder valve rocker arms and rocker arm shafts for wear or damage If the valve rocker arm contact surface is worn check each cam lobe for wear or damage Measure the I D of each valve rocker arm Service Limits IN 10 10mm replace if over EX 10 10mm replace if over Measure each rocker arm shaft O D Service Limits IN 9 90mm replace if below EX 9 90mm rep lace if below CYLINDER HEAD REMOVAL First drain the coolant from the radiator and water jacket then remove the thermostat water hose Remove the camshaft 6 4 Remove the carburetor and intake manifold Remove the bolt attaching the thermostat housing and the thermostat housing Remove the cylinder head Remove the dowel pins and cylinder head gasket Remove the cam chain guide Remove all gasket material from the cylinder head mating surface 5 Be careful not to drop any gasket material into the engine KYMCO GRAND DINK 125 150 Camshaft Holder Rocker Arm Shafts Intake Manifold pom 7 1 j E H 8 CA A p gl a 114 Bolt Cylinder Head Gasket um
115. handlebar should not be pulled tight have excessive slack or interfere with adjacent or surrounding parts in all steering positions When a testing device 15 used make sure to understand the operating methods thoroughly and operate according to the operating instructions I Do you e the L instrument B When rust is found on a terminal remove the rust with sand paper or equivalent before connecting Za i Remove Rust as KYMCO GRAND DINK 125 150 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 Engine Oil E Grease Apply grease for lubrication m Transmission Gear Oil 90 Gear Oil E Use special tool Special Caution V Warning dO KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 TORQUE VALUES STANDARD TORQUE VALUES 5mm bolt nut I 5mm screw 6mm bolt nut I 6mm screw SH bolt Smm bolt nut 6mm flange bolt nut 10mm bolt nut 8mm flange bolt nut 12mm bolt nut 10mm flange bolt nut Torque specifications listed below are for important fasteners ENGINE Double bolt Double end bolt Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Exhaust muffler joint lock nut Cylinder head cap nut Valve adjusting lo
116. harged battery 12 8V min to check the charging system Warm up the engine after connecting a fully charged battery Connect an electric tester across the battery terminals Disconnect the red wire from the fuse terminal and connect an ammeter between the red wire lead and the fuse terminal Attach a tachometer to the engine Start the engine and gradually increase the engine speed to measure the limit voltage and current Limit Voltage Current 14 15V 0 5A max 5000rpm max If the limit voltage is not within the specified range check the regulator rectifier PERFORMANCE TEST Engine Speed 2500rpm 5000rpm Charging Current When measuring the charging current disconnect the black wire from the regulator rectifier wire coupler If the readings do not meet the specified values check the regulator rectifier A C GENERATOR INSPECTION This test can be made without removing the stator from the engine Disconnect the yellow wire from the auto bystarter Remove the frame center cover Disconnect the A C generator connector Check the continuity between the yellow wires and ground There should be continuity between the yellow wires and no continuity between each yellow wire and ground Resistance 16 5 dC KYMCO GRAND DINK 125 150 Red Wire A C Generator Connector 16 BATTERY CHARGING SYSTEM A C GENERATOR REMOVAL A C generator removal 10 3 A C gene
117. he valve spring seats and stem seals Lubricate each valve stem with engine oil and insert the valves into the valve guides Be sure to install new valve stem seals KYMCO 6 CYLINDER HEAD VALVES GRAND DINK 125 150 Plastic Hammer Tap the valve stems gently with a plastic hammer to firmly seat the cotters Be careful not to damage the valves Cylinder Head Gasket CYLINDER HEAD INSTALLATION d Install the cam chain guide Install the dowel pins and a new cylinder head gasket x ErWUE D Kat CH 1 a E 1 4 l as m Cam Chain Guide vy Dowel Pins Install the cylinder head and take out the cam chain A B H DL d m Cann Cnn Assemble the camshaft holder Valve Rocker Arms First install the intake and exhaust valve rocker arms then install the rocker arm shafts Install the exhaust valve rocker arm shaft on the side of the camshaft holder and the exhaust rocker arm shaft 1s shorter Clean the intake valve rocker arm shaft off any grease before Installation Align the cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder Camshaft Holder 6 9 dO KYMCO 6 CYLINDER HEAD VALVES GRAND DINK 125 150 Punch Marks e CAMSHAFT INSTALLATION Turn the A C generator flywheel so that the mark on the flywheel aligns with the index mark on the cran
118. hock Absorber Low er Mount Bolt REMOVAL Remove the exhaust muffler 2 6 E Remove the rear brake caliper 15 3 TN Remove the right rear shock absorber lower mount Remove rear axle nut and remove collar Remove the rear fork The installation sequence is the reverse of removal Axle Nut Rear Fork Turn the inner race of each bearing with your finger to see if they turn smoothly and Collar quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn ws ee quietly or if they fit loosely in the e REAR WHEEL REMOVAL Remove the exhaust muffler 2 6 Remove the rear brake caliper 15 3 Remove the rear fork Remove the rear axle collar Remove the rear wheel INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over 15 4 15 REAR BRAKE REAR FORK REAR dC KYMCO WHEEL REAR SHOCK ABSORBER GRAND DINK 125 150 INSTALLATION The installation sequence is the reverse of removal Torque Rear shock absorber lower mount bolt 19 6 29 4N m Rear axle nut 78 4 95 ADJUSTABLE REAR CUSHION To suit scooter behaviour to load condition rear cushion could be adjusted in spring prelocad It is possible to adjust rear cushion in three positions A position soft B position medium C position
119. ied coolant 3 9 sure to bleed air from the water Jacket after filling the coolant Oil Pump Shaft Water Pump Shaft 10 6 KYMCO 11 CRANKCASE CRANKSHAFT GRAND DINK 125 150 CRANKCASE CRANKSHAFT SCHEMATIC DRAWING 11 1 SERVICE INFORMATION 11 2 TROUBLESHOOTING 11 2 CRANKCASF SEPARATION u ul uu uento 11 3 CRANK ATT INSPECCION 11 4 CRANECASE ASSEMEBIY oere 5 11 5 140 KYMCO 11 CRANKCASE CRANKSHAFT GRAND DINK 125 150 SCHEMATIC DRAWING 11 1 KYMCO 11 CRANKCASE CRANKSHAFT GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS This section covers crankcase separation to service the crankshaft The engine must be removed for this operation When separating the crankcase never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces When installing the crankcase do not use an iron hammer to tap it The following parts must be removed before separating the crankcase Cylinder head 6 4 Cylinder piston 7 3 Right crankcase cover drive and driven pulley 8 3 A C generator starter clutch 10 3 Rear wheel rear shock absorber 15 4 Starter motor 19 3 Oil pump 4 4 SPECIFICATIONS lem Standard mm Service Limit mm Connecting r
120. install the holder with the up mark facing up Also align the punch mark with the holder joint seam First tighten the upper bolt and then tighten the lower bolt Torque 9 8 13 7N m Install the brake fluid tube with the attaching bolt and two sealing washers 14 9 14 STEERING HANDLEBAR FRONT WHEELFRONT KYMCO __BRAKE FRONT SHOCK ABSORBER FRONT FORK GRAND DINK 125 150_ Connect the front stop switch wire connector Install the handlebar covers 2 6 BRAKE FLUID REFILLING Keep the handlebar upright and remove the brake reservoir cover and diaphragm Add DOT 4 brake fluid to the brake reservoir When bleeding be careful not to allow air in the brake reservoir flowing into the brake system When using a brake bleeder follow the manufacturer s instructions Never use dirty or unspecified brake fluid or mix different brake fluids be cause it will damage the brake system BRAKE FLUID BLEEDING Keep the handlebar upright and remove the brake reservoir cover and diaphragm Add the specified brake fluid to the upper limit Do not allow dust or water to enter the brake system during refilling When servicing the brake system use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid In order to avoid spilling brake fluid connect a transparent hose to the bleed valve Brake fluid spilled on brake pads or brake disk will re
121. itive cable When disconnecting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the fuel The installation sequence is the reverse of removal First connect the positive cable and then negative cable to avoid short circuit BATTERY VOLTAGE INSPECTION OPEN CIRCUIT VOLTAGE Disconnect the battery cables Measure the voltage between the battery terminals Fully charged 13 2V Undercharged 12 3V max 5 Battery charging inspection must be performed with a voltmeter CHARGING Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal Keep flames and sparks away from a charging battery Turn power ON OFF at the charger not at the battery terminals to prevent sparks near the battery Charge the battery according to the current specified on the battery During quick charging the battery temperature should not exceed 45 C uuo H game I 022 Wan Quick charging should only be done in an emergency Measure the voltage 30 minutes after the battery 1s charged Charging current Standard 0 9A Quick 4A Charging time Standard 5_ 10 hours Quick 30 minutes After charging Open circuit voltage 12 5V min 16 4 16 BATTERY CHARGING SYSTEM CHARGING SYSTEM CURRENT TEST 5 Use a fully c
122. justed out 2 Mixture too lean turn screw in Check carburetor gasket for air leaks UU ui Damaged insulator rubber 2Carburetor not securely tightened Faulty intake manifold gasket Deformed carburetor O ring Remove spark plug and install it into Spark plug to test 2 spark by connecting it to engine ground 0 Faulty or fouled spark plug 2 Faulty CDI unit Faulty A C generator Faulty ignition coil 5 Broken or shorted high tension wire Faulty ignition switch Weak or inter mittent spark Good spark Check carburetor air cut off valve Damaged air cut off valve diaphragm 2 Damaged air cut off valve spring 1 20 1 GENERAL INFORMATION POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Check fuel pump for fuel supply oe Check carburetor jets for clogging Check valve spring tension 4 1 21 dO KYMCO GRAND DINK 125 150 Probable Cause Faulty CDI unit 2 Faulty A C generator DImproperly adjusted valve clearance 2 Worn valve seat D Empty fuel tank 2 Clogged fuel tube or filter 3 Faulty fuel pump A Cracked fuel pump vacuum tube Clean and unclog DCam timing gear aligning marks not aligned DFaulty spring 1 GENERAL INFORMATION ENGINE NOISE O Symptom Piston noise Cam chain noise Crankshaft noise Gear noise dC KYMCO GRAND DINK 125 150
123. kcase Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the cam chain over the camshaft gear i n Round Hole Cam Chain Install the dowel pins 26 Dowel Pins Washer Nut Install the camshaft holder washers and nuts on the cylinder head Tighten the four cylinder head nuts and the two bolts between the cylinder head and cylinder Torque Cylinder head cap nut 19 0N m Cylinder amp cylinder head bolt 7 8 1 8N m Apply engine oil to the threads of the cylinder head cap nuts Diagonally tighten the cylinder head cap nutsin2_ 3 times First tighten the cylinder head cap nuts and then tighten the bolts between the cylinder and cylinder head to avoid cracks 6 10 KYMCO 6 CYLINDER HEAD VALVES GRAND DINK 125 150 Gasket mu Lock Pawl Install a new cam chain tensioner gasket Release the lock pawl and push the push rod all the way in Ld E Cam Chain Tensioner Push Rod Sealing Bolt Chain Tensioner D 4 ES i C t Install the cam chain tensioner and tighten the two bolts Install the tensioner spring and tighten the sealing bolt Torque 2 5 8N m Spring Bolt Cylinder Head Cover CYLINDER HEAD COVER INSTALLATION Adjust the valve clearance 3 6 Install a new cylinder head cover O ring and install
124. l the oil filter screen and filter screen cap Fill the engine with recommended engine oil Oil Filter Screen KYMCO 3 INSPECTION ADJUSTMENT GRAND DINK 125 150 AIR CLEANER Remove the seven air cleaner case cover screws and the cover Remove the air cleaner element Check the element and replace it if it is excessively dirty or damaged CHANGE INTERVAL More frequent replacement is required when riding in unusually dusty or rainy areas The air cleaner element has a viscous type paper element Do not clean it with compressed air Be sure to install the air cleaner element and cover securely SPARK PLUG Remove the frame center cover Remove the spark plug cap and spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug NGK DP7EA9 Measure the spark plug gap 1 Spark Plug Gap 0 9mm Damage When installing first screw in the spark plug by hand and then tighten it with a Deformaton spark plug wrench Gap Torque 7 5 9 8N m Wear Fouling Deposit 3 5 KYMCO 3 INSPECTION ADJUSTMENT GRAND DINK 125 150 VALVE CLEARANCE Inspect and adjust valve clearance while the engine is cold below 35 C Remove the cylinder head cover Cylinder Head Cover Mark Turn the A C generator flywheel to the top dead center TDC on the co
125. leage km comes FS m EFE mm Engine oil TN MEE Engine oil filter screen oe at ESES oo Fuel filter screen E ED gt t OC m tt NrCeme Fail 1 R L 1 0 Spark plug Clean at every 3000km and replace if necessary Brake system P I Pj ry ry 1 j 1 Suspension J jJ roy o Nue fastener 1 _ sens Brake fluid Perform pre ride inspection daily Radiator coolant TI Replaceevery year or at every 10000km R Radiatorcore o o Io Radiatorcap Brakelever S o Io Brake shoewear fJ I f o Io Shock absorber TI S IC In the Interest of safety we recommend these items be serviced only by an authorized KYMCO motorcycle dealer Note 1 For higher odometer readings repeat at the frequency interval established here 2 Service more frequently when riding in dusty or rainy areas 3 Service more frequently when riding in rain or at full throttle KYMCO 3 INSPECTION ADJUSTMENT GRAND DINK 125 150 FUEL LINE FUEL FILTER Remove the center cover Check the fuel lines and replace any parts which show signs of deterioration damage or leakage Check for dirty or clogged fuel filter and replace with a new one if it is clogged Do not smoke or allow flames or sparks in your working area THROTTLE OP
126. ly and record the rotating turns Do not force the pilot screw against its seat to avoid seat damage Pilot Screw P S Main Jet Remove the main jet needle jet holder and needle jet Remove the slow jet Slow Jet Needle Jet Slow Jet Clean the removed the main jet needle jet holder needle jet and slow jet with detergent oil Be sure to use clean detergent oil Pilot Screw Needle Jet Holder Main Jet 13 10 13 FUEL SYSTEM CARBURETOR QO KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 AUTO BYSTARTER INSPECTION REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 10 10 minutes minimum after stopping the engine If the reading 1s not within the limit replace the auto bystarter with a new one Connect a hose to the fuel enriching circuit of the carburetor Connect the auto bystarter yellow wire to the positive 4 terminal of a battery and green wire to the negative terminal Wait 5 minutes and blow the hose with mouth If the passage is blocked the auto bystarter is normal Disconnect the auto bystarter from the battery Wait 30 minutes and blow the hose with mouth If air can be blown into the hose the auto bystarter is normal zm Green En Yellow Hose Auto Bystarter Screws AUTO BYSTARTER REMOVAL Remove the two set plate screws and set plate and then remove the auto bystarter from the carbur
127. m to minimize the slipping of drive belt and drive pulley SPECIFICATIONS Movable drive face bushing I D 33 000 33 025 33 06 Drive face collar O D 32 006 32 009 31 90 Drive belt width 17 5 Clutch lining thickness 3 963 4 037 TORQUE VALUES Drive face nut 49 58 8N m Clutch outer nut 49 58 8N m Clutch drive plate nut 49 0 58 8N m SPECIAL TOOLS Universal holder Clutch spring compressor Bearing driver Lock nut wrench 39mm Kick starter spring remover TROUBLESHOOTING Engine starts but motorcycle won t move Lack of power Worn drive belt Worn drive belt Broken ramp plate Weak driven face spring Worn or damaged clutch lining Worn weight roller Broken driven face spring Faulty driven face Engine stalls or motorcycle creeps Broken clutch weight spring 8 DRIVE AND DRIVEN PULLEYS KICK STARTER LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw Remove the left crankcase cover bolts and left crankcase cover Remove the seal rubber and dowel pins INSTALLATION Install the dowel pins and the gasket Install the left crankcase cover d Do not pull out the kick starter spindle Press in the kick starter spindle when installing the left crankcase cover Install the cable clamp to the specified location Install and tighten the left crankcase cover bolts 8 3 KYMCO GRAND DINK 125 150 Air Tube Band ir F u E T
128. meter gear unit by aligning its retaining pawl with the hub cutout If not aligned the retaining pawl will be deformed when the axle nut is tightened After installing the axle turn the wheel to make sure that the speedometer drive shaft rotates freely Install the front wheel by aligning the speedometer gear unit groove with the front shock absorber tab Insert the axle and tighten the axle nut When installing the front wheel position the brake disk between the two brake pads Torque 44 1 49N m 14 7 ji F T L d Les ke p 4 LS Driver Handle Outer Driver Speedometer Gear Unit gt Hub Cutout Pawl L 7 L Speedometer Gear Unit Groove I4 STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONTSHOCK ABSORBER FRONT FORK GRAND DINK 125 150_ FRONT BRAKE BRAKE MASTER CYLINDER REM OVAL Remove the handlebar covers 2 6 First drain the brake fluid from the hydraulic brake system Disconnect the front stop switch wire connector Remove the brake fluid tube bolt Remove the two bolts attaching the brake master cylinder Remove the brake master cylinder When servicing the brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid When removing the brake fluid tube bolt be sure to plug the tube end to avoid brake fluid leakage DISASSEMBLY
129. mm replace if over 8 DRIVE AND DRIVEN PULLEYS O KYMCO __ STARTER Check the clutch shoes for wear or damage Measure the clutch lining thickness Service Limit 2 0mm replace if below CLUTCH DRIVEN PULLEY DISASSEMBLY Clutch Driven Pulle Hold the clutch driven pulley assembly with the clutch spring compressor s Be sure to use a clutch spring compressor to avoid spring damage Clutch Spring Compressor Set the tool in a vise and remove the clutch drive plate nut Lock Nut Wrench Lock Nut Wrench 39mm Loosen the clutch spring compressor and disassemble the clutch driven pulley assembly Remove the seal collar 8 DRIVE AND DRIVEN PULLEYS O KYMCO KICK STARTER GRAND DINK 125 150 Guide Roller Pin Guide Roller Pull out the guide roller pins and guide rollers Remove the movable driven face from the driven face Movable Driven Face O ring Remove the oil seal from the movable driven Oil Seal face INSPECTION Measure the driven face spring free length Service Limit 83 2mm replace if below Check the driven face assembly for wear or damage Measure the driven face O D Service Limit 33 94mm replace if below 8 10 8 DRIVE AND DRIVEN PULLEYS __ STARTER CII Check the movable driven face for wear or damage Measure the movable driven face I D Service Limit 34 06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT
130. mpression stroke so that the T mark on the flywheel aligns with the index mark on the left crankcase cover Inspect and adjust valve clearance Valve Clearance IN 0 1mm EX 0 1mm Loosen the lock nut and adjust by turning the adjusting nut Valve Wrench Check the valve clearance again after the lock nut is tightened CARBURETOR IDLE SPEED 9 The engine must be warm for accurate idle speed inspection and adjustment Lift up the seat and remove the inspection cover Warm up the engine before this operation Start the engine and connect a tachometer Turn the throttle stop screw to obtain the specified idle speed Idle Speed 1700rpm When the engine misses or run erratic adjust the pilot screw Throttle Stop Screw Pilot Screw 3 6 KYMCO 3 INSPECTION ADJUSTMENT GRAND DINK 125 150 Timing Hole Can IGNITION TIMING The CDI unit is not adjustable f the ignition timing is incorrect check the ignition system Remove the timing hole cap Check the ignition timing with a timing light When the engine 1s running at the specified idle speed the ignition timing 1s correct if the F mark on the flywheel aligns with the index mark on the crankcase cover Also use a timing light to check the advance Raise the engine speed to 4 000rpm The index mark should be between the advance marks CYLINDER COMPRESSION Warm up the engine before compression test Remove the center cov
131. nd check for broken or weak spring INSTALLATION Install the starter driven gear onto the crankshaft Install the starter idle gear and shaft 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 1s not contaminated Hold the flywheel with the flywheel holder and tighten the flywheel nut Torque 343 39 2 10 5 Spring Roller Plunger Shaft Starter Idle Gear Key Groove Flywheel Holder KYMCO 10 GENERA TOR STARTER CLUTCH GRAND DINK 125 150 STATOR INSTALLATION A C A Stator Screws Install the A C 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 d Be sure to route the stator wire under the pulser coil RIGHT CRANKCASE COVER INSTALLATION Install the two dowel pins and a new gasket Gasket Right Crankcase Cover Install the right crankcase cover over the crankcase aligning the water pump shaft groove with the oil pump shaft Tighten the nine right crankcase cover bolts Connect the water hoses to the right crankcase cover Add the recommended engine oil 4 3 Fill the cooling system with the specif
132. nector 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 dC KYMCO GRAND DINK 125 150 B The connector shall be inserted completely B If the double connector has a lock lock it at the correct position Check if there is any loose wire r 1 1245 __ e prm E 14 e Kai TI C a 4 ar ey Ag d p B Before connecting a terminal check for damaged terminal cover or loose negative terminal TE B Check double connector cover for proper coverage and installation B Insert the terminal completely B Check the terminal cover for proper coverage B 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 oux I 4 212 1 GENERAL INFORMATION dC KYMCO GRAND DINK 125 150 B After clamping check each wire to make sure it 1s secure Q X 2 9 od 3800 B Do not squeeze wires against the weld or its clamp X B After clamping check each harness to make sure that it 1s not interfering with any moving or sliding parts B When fixing th
133. nts and there should be continuity Also make a continuity check between individual commutator segments and the armature shaft There should be no continuity 18 3 KYMCO 18 STARTING SYSTEM GRAND DINK 125 150 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover Also check for the continuity between the wire terminal and each brush Replace if necessary Wire Terminal Measure the length of the brushes Service Limit 8 5mm replace if below Check for continuity between the brushes If there is continuity replace with new ones Check if the needle bearing in the front cover turns freely and has no excessive play Replace if necessary Check the dust seal for wear or damage Dust Seal 18 4 KYMCO 18 STARTING SYSTEM GRAND DINK 125 150 ASSEMBLY Apply grease to the dust seal in the front cover Install the brushes onto the brush holders Apply a thin coat of grease to the two ends of the armature shaft Insert the commutator into the front cover Front Cover Tab Groove O ring Install a new O ring to the front cover Install the starter motor case aligning the tab on the motor case with the groove on the front cover Tighten the starter motor case screws Motor Case INSTALLATION Connect the starter motor cable Check the O ring for wear or damage and replace 1
134. od big end side clearance 0 15 0 35 Crankshaft Connecting rod big end radial clearance 0 008 Runout Raw o E lee TORQUE VALUES Crankcase bolt Cam chain tensioner slipper bolt SPECIAL TOOL Gear remover TROUBLESHOOTING Excessive engine noise Excessive bearing play Excessive crankpin bearing play Worn piston pin and piston pin hole 11 2 KYMCO 11 CRANKCASE CRANKSHAFT GRAND DINK 125 150 Cam Chain Tensioner Slippe CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt Remove the cam chain tensioner slipper and cam chain Remove the two right crankcase attaching bolts Remove the five left crankcase bolts Left Crankcase Right Crankcase Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase o N ever use a driver to pry the crankcase mating surfaces apart Remove the gasket and dowel pins Left Crankcase Remove the crankshaft from the left Crankshaft crankcase Left Crankcase 11 3 KYMCO 11 CRANKCASE CRANKSHAFT GRAND DINK 125 150 Oil Seal Remove the oil seal from the left crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over Measure the connecting rod small end I D Service Limit 15 06mm replace if over 11 4 KYMCO 11 CRANKCASE CRANKSHAFT GRAND DINK 125 150 Measure the crankshaft runou
135. oke is found it means that the piston rings are worn stuck or broken Compression too low or uneven compression Excessive smoke from exhaust muffler Worn or damaged cylinder and piston rings Worn or damaged piston rings Worn stuck or broken piston rings Worn or damaged cylinder and piston Compression too high Abnormal noisy piston Excessive carbon build up in combustion Worn cylinder piston and piston rings chamber or on piston head Worn piston pin hole and piston pin ncorrectly installed piston 7 2 KYMCO 7 CYLINDER PISTON GRAND DINK 125 150 Cylinder CYLINDER REMOVAL EU Remove the cylinder head 6 7 Remove the water hose from the cylinder Remove the cylinder base bolt 17 Chain Guide Water Hose Remove the cam chain guide Remove the cylinder Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface d Dowel Pins Shop Towel Piston Rings PISTON REMOVAL Remove the piston pin clip Press the piston pin out of the piston Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase B Piston Pin Piston 7 3 7 CYLINDER PISTON Inspect the piston piston pin and piston rings Remove the piston rings Take care not to damage or break the piston rings during removal Clean carbon deposits from the piston ring grooves In
136. or gt coll terminals DShorted AC generator coil 2 circuit between AC generator 3 yellow wires Test output voltage of regulator rectifier coupler red wire OFaulty regulator rectifier Faulty AC generator Normal voltage Loose regulator rectifier coupler Limit voltage too high Overcharging Inspection Adjustment Probable Cause O Measure battery limit voltage with an electric tester DFaulty battery 2 Faulty regulator rectifier Broken or poorly regulator rectifier black wire Check resistance between regulator rectifier terminals Normal Limit voltage too high 1 26 1 GENERAL INFORMATION FUEL GAUGE 1 Pointer does not correctly Ignition switch ON Inspection Adjustment Check battery circuit by operating turn signals Signals operate Signals dim remain 2 inan roperl on or don t Remove fuel unit and ee operate check operation of pointer by moving gt float up and down Float up Full Float down Empty Pointer does not Pointer m nave ointe oves Check operation of pointer by opening shorting fuel unit terminal wire dO KYMCO GRAND DINK 125 150 Probable Cause out fuse Weak or dead battery Faulty ignition switch Loose or disconnected connectors Broken wire harness MO Faulty float harness
137. p and oil separator and tighten the two bolts Make sure that the pump shaft rotates freely The arrow of oil pump is upside Install the pump drive chain and driven gear then set the circlip securely on the pump shaft Install the oil separator cover properly Fit the tab of the separator cover into the slit in the separator Install the A C generator starter driven gear 10 5 Oil Separator Cover 4 6 KYMCO 5 ENGINE REMOVAL INSTALLATION GRAND DINK 125 150 ENGINE REMOVAL INSTALLATION SCHEMATIC DRAMWINGO eee 5 1 SERVICE INFORMATION 5 2 EROINE PEMOVA L eee 5 3 ENGINE INSTALLATION 5 5 5 0 dO KYMCO 5 ENGINE REMOVAL INSTALLATION GRAND DINK 125 150 SCHEMATIC DRAWING KYMCO GRAND DINK 125 150 5 ENGINE REMOVAL INSTALLATION SERVICE INFORMATION GENERAL INSTRUCTIONS A floor jack or other adjustable support is required to support and maneuver the engine Be careful not to damage the motorcycle body cables and wires during engine removal Use shop towels to protect the motorcycle body during engine removal Drain the coolant before removing the engine After the engine is installed fill the cooling system with coolant and be sure to bleed air from the water Jacket Start the engine to check for coolant leaks Before removing the engine the rear brake caliper must be removed first Be careful not to bend or twi
138. parts for proper tightening and operation CH CH When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque When two persons work together pay diagonally attention to the mutual working safety C w Disconnect the battery negative terminal Use genuine ES and lubricants before operation When using a spanner or other tools make sure not to damage the motorcycle surface When servicing the motorcycle be sure to use special tools for removal and installation 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 B Terminal caps shall be installed securely After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembl S an KS Yos dry ES I Bes T 14161 ar 3 y f ete Ben 1 PNA 1 4 1 GENERAL INFORMATION B If the fuse 1s burned out find the cause and repair it Replace it with a new one according to the specified capacity E ee Confirm r4 ee re p B After operation terminal caps shall be installed securely en When taking out the con
139. place with new ones The installation sequence is the reverse of removal KYMCO GRAND DINK 125 150 19 SWITCHESHORNFUEL UNIDTHERMOSTATICSWITCH EBS EE HEATER WIRING DIAG CORA SM i 2 KA j r rA hot HEALER i ki Je Lk a E CES i a ee 2 In e 3 n F 1 d QU RK i ta P3 b l K 5 rp 2 2 1 HEATER L CARBLURETNYN 19 9 OSDINAM OD RI CAMBI LC CN Y lt a 2 or O GRAND DINK 125 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ 11200 3150 00121155 BLOCCO MOTORE SX 165 27 1 e B 91009 KKC3 9000 00108214 CUSCINETTO 10X35X11 RAD 6000ZZ 11 36 1 1 11100 KKC1 3050 00121010 BLOCCO MOTORE DX 139 44 1 e 2 11102 187 0030 00109202 SUPPORTO MOTORE ELASTICO 9 55 1 O 3 96001 06050 08 00105009 VITE FLANGIATA 6 x 50 2 e 4 94301 08140 00121704 SPINA DI CENTRAGGIO 8 x 14 1 55 2 e 5 90031 KBE 900 00121905 PRIGIONIERO A 8 mm 4 65 3 e 6 11192 KKC3 9000 00121106 GUARNIZIONE BLOCCO MOTORE 8 26 1 e 9 91261 415 0040 00121912 PARAOLIO 25 x 40 x8 4 65 1 10 91104 KN7 6710 00121913 CUSCINETTO 20x47x14 RAD
140. rator installation 10 6 REGULATOR RECTIFIER INSPECTION Remove the frame front cover 2 5 Remove the regulator rectifier wire coupler Check the continuity between the wire terminals Normal Direction Continuity 7 1 Probe O Pro Reverse Direction No Continuity Probe O Probe VOLTAGE REGULATION TEST Connect a voltmeter across the battery terminals Start the engine and gradually increase the engine speed The battery terminal voltage should be within 14 0 15 0V KYMCO GRAND DINK 125 150 Generator Stator Pulser Coil d Normal Direction Reverse Direction 16 6 KYMCO 17 IGNITION SYSTEM GRAND DINK 125 150 IGNITION SYSTEM IGNITION SYSTEM LAYOUT 17 1 SERVICE INFORMATION 17 2 TROUBLESHOOTING 17 2 SPARR TUG 17 3 IGNITION INSPECTION 17 3 A C GENERATOR INSPECTION ressis scnnni 17 4 CDI UNIT RESISTANCE INSPECTION 17 5 17 0 KYMCO 17 IGNITION SYSTEM GRAND DINK 125 150 IGNITION SYSTEM LAYOUT CDI Unit Ignition Coil Li Ignition Switch j A Pulser Coil A C Generator IGNITION CIRCUIT HL BREW LG Y G Ignition Coil A C Generator 17 1 17 IGNITION SYSTEM
141. reezing point should be 5C lower than the temperature of nay IC the riding area Reserve Tank KYMCO 3 INSPECTION ADJUSTMENT GRAND DINK 125 150 Coolant capacity 1400 20cc Radiator capacity 1000 20 Reserve tank capacity 400 20 Start the engine and check if there is no bubbles in the coolant and the coolant level is stable Reinstall the radiator cap If there are bubbles in the coolant bleed air from the system Fill the reserve tank with the recommended coolant up to the upper line Drain Bolt BRAKE SYSTEM BRAKE LEVER Measure the front and rear brake lever free plays Rear Brake Reservoir Front Brake Reservoir BRAKE FLUID Turn the steering handlebar upright and check if the front rear brake fluid level is at the upper limit If the brake fluid 18 insufficient fill to the upper limit Specified Brake Fluid DOT 4 She brake fluid level will decreases the brake pads are worn BRAKE DISK BRAKE PAD Check the brake disk surface for scratches unevenness or abnormal wear Check if the brake disk runout 15 within the specified service limit Check if the brake pad wear exceeds the wear indicator line Keep grease or oil off the brake disk to avoid brake failure Brake Disk Wear Indicator Line 3 10 dO KYMCO 3 INSPECTION ADJUSTMENT GRAND DINK 125 150 NUTS BOLTS FASTENERS Check all important chassis nuts and bolts for looseness Tighten them to their speci
142. rive pulley collar sliding surface Service Limit 26 90mm replace if below ASSEMBLY Install the weight rollers into movable drive face Weight Roller 9 6 8 DRIVE AND DRIVEN PULLEYS KYMCO __ STARTER Ramp Plate Install the ramp plate Drive Pulley Collar Insert the drive pulley collar into the movable drive face INSTALLATION Install the movable drive face onto the crankshaft N Movable Drive Face Assembly Drive Pulley Collar Driven Pulle Lay the drive belt on the driven pulley d Set the drive belt on the drive pulley collar Drive Belt 8 DRIVE AND DRIVEN PULLEYS KYMCO __KICK STARTER Drive Pulley Face Install the drive pulley face washer and drive face nut Washer Drive Face Nut Universal Holder Hold the drive pulley with the universal holder and tighten the drive face nut Torque 49 0 58 5N m Universal Holder Do not get oil or grease on the drive belt or drive pulley faces Drive Pulley Clutch Outer CLUTCH DRIVEN PULLEY Remove the left crankcase cover 8 3 Remove the drive pulley and drive belt 8 4 Hold the clutch outer with the universal holder and remove the clutch outer nut Universal Holder Remove the clutch outer Universal Holder INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 130 5
143. rted wire Faulty ignition switch Faulty ignition coil Faulty CDI unit Faulty A C generator Secondary without plug cap Standard NGK DP7EA9 NGK DP6EA9 NGK DP8EA9 0 5 0 9mm BTDC 10 1 5 BTDC 27 2 0 16 10 36 4 6KQ 7 0 9 6 0 50 1700 50 3500 244V 10 5V 244V Engine starts but turns poorly Ignition primary circuit Faulty ignition coil Poorly connected wire or connector Poorly contacted ignition switch Ignition secondary circuit Faulty ignition coil Faulty spark plug Faulty high tension wire Poorly insulated plug cap Improper ignition timing Faulty A C generator Stator not installed properly Faulty CDI unit 17 2 dC KYMCO 17 IGNITION SYSTEM GRAND DINK 125 150 SPARK PLUG Ignition Coil For spark plug inspection and adjustment refer to page 3 5 IGNITION COIL INSPECTION Remove the seat and met in box 2 3 Remove the ignition coil IGNITION COIL CONTINUITY TEST Inspect the continuity of the ignition coil primary coil and secondary coil Ignition Coil Primary Coil This is a general test Accurate ignition coil test must be performed with a CDI tester Measure the ignition coil resistances at 20 C Ignition Coil Secondary Coil SECONDARY COIL WITH PLUG CAP Secondary coil without plug cap 3 4 4 6K Secondary coil with plug cap 7 6_ 9 6KQ SECONDARY COIL WITHOUT PLUG CAP 17 3 KYMC
144. s Clogged fuel tank cap breather hole Clogged fuel filter Bent kinked or restricted fuel line Faulty float valve Float level too low Faulty fuel pump or insufficient output Engine is hard to start No fuel in tank Restricted fuel line Clogged fuel strainer Faulty fuel pump Broken or clogged vacuum tube Faulty or clogged charcoal canister Lean mixture Clogged charcoal canister Bent kinked or restricted fuel line Clogged fuel strainer Float level too low KYMCO GRAND DINK 125 150 Engine idles roughly stalls or runs poorly ncorrect idle speed Rich mixture Lean mixture Clogged air cleaner ntake air leak Contaminated fuel Faulty air cut off valve Damaged vacuum tube and connectors Damaged carburetor insulator Rich mixture Auto bystarter valve opens excessively Faulty float valve Float level too high Clogged air jets Auto bystarter valve set plate installed in the wrong groove Clogged air cleaner 13 6 13 FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK CARBURETOR REMOVAL Remove the seat met in box and center cover Disconnect the fuel tube and vacuum tube at the carburetor Disconnect the auto bystarter wire Loosen the throttle cable adjusting nut and lock nut and disconnect the throttle cable from the carburetor Loosen the air cleaner connecting tube band and carburetor intake manifold band and then r
145. s blocked in hoses or water jacket Clogged radiator fins Passages blocked in radiator Faulty water pump Temperature gauge pointer does not register the correct coolant temperature Faulty temperature gauge or thermosensor Faulty thermostat Coolant leaks Faulty pump mechanical water seal Deteriorated O rings Damaged or deteriorated water hoses 12 2 KYMCO 12 COOLING SYSTEM GRAND DINK 125 150 SPECIFICATIONS Radiator cap relief pressure 0 9 0 15 Www 80 2 C po Thermostat temperature Full open EE Valve lift 3 5 4 5mm mM 1000 20 Coolant capacity Total system Reserve tank 400 20cc 1400 20 COOLANT GRAVITY concentration 107 027 1 026 1 025 03 1 047 05 07 06 07 07 Los 092 1 089 SIS GO NO m 4 10 15 20 25 30 35 40 45 50 55 60 N C D UA pesi lt ee SIS E 95 olo I CA ON es E UA 92 C UA m N m E oclo ON CA QN oo olo ON olo 4 95 olo Kam Slo ON ON Go 2 4 ON 4 EN lt 4 N 4 SIS NO CA ON Ee I wll olo NO N Silo CoO Fa
146. se D M p g7 1 i Gasket Cylinder Coat the cylinder bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Be careful not to damage or break the piston rings The piston ring end gaps should not be parallel with or at 90 to the piston pin 1 1 7 CYLINDER PISTON Tighten the cylinder base bolt Install the cam chain guide Insert tab cam chain guide into the cylinder groove Connect the water hose to the cylinder Install the cylinder head 6 9 Tighten the cylinder base bolt Cam Chain Guide 7 5 8 DRIVE AND DRIVEN PULLEYS KYMCO __KICK STARTER SIND DRIVE AND DRIVEN PULLEYS KICK STARTER SCHEMATIC DRAWN Gee 8 1 SERVICE INFORMATION 8 2 IROUBLESHOCOTIN uU 2 8 2 LEFT CRANKCASE 8 3 DRP 8 4 CLUTCH UDRIVEN PULLEY 8 8 KICK Eege 8 15 8 DRIVE AND DRIVEN PULLEYS O KYMCO __ KICK STARTER SCHEMATIC DRAWING 8 1 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER GRAND DINK 125 150 SERVICE INFORMATION GENERAL INSTRUCTIONS The drive pulley clutch and driven pulley can be serviced with the engine installed Avoid getting grease and oil on the drive belt and pulley faces Remove any oil or grease from the
147. se burned out SPECIFICATIONS Fuse Headlight bulb Turn signal light bulb Stoplight taillight License plate light Instrument light Position light Turn signal indicator light 20A 15A 10 12V 60W 55W 12V 10W 12V 21 5W 12V 5W 12V 1 7W 12V 5W 12V 3 4W 19 2 19 SWITCHESHORNEUBLUNITHERMosTATICswirar KYMCO IEMPERATUREGAUGEINSTRUMENTSILIGHIS GRAND DINK 125 150 SWITCHES IGNITION SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the ignition switch wire couplers Check for continuity between the wire terminals HEADLIGHT SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the headlight switch wire couplers Check for continuity between the wire terminals BRA STARTER SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the starter switch wire couplers Depress the starter button and check for continuity between the wire terminals FREE PUSH Or HAZARD SWITCH Remove the front upper cover 2 5 Disconnect the headlight switch wire couplers Check for continuity between the hazard switch wire terminals 19 SWICHESHORNFUELUNIDIHERMosTAncswircH QO KYMCO IEMPERATUREGAUGEINSTRUMENTSI IGHIS GRAND DINK 125 150 HORN BUTTON INSPECTION SSS Remove the frame front covers 2 5 Disconnect the horn wire couplers Depress the horn button and check for continuity between the wire terminals Light Green Brown
148. se fouled drive belt 2 Worn drive belt Weak driven face spring Worn or seized driven pulley bearings 1 GENERAL INFORMATION STARTER MOTOR 1 Starter motor won t turn Inspection Adjustment Check operation stop switch b applying brake Check battery circuit by operating turn signals Signals dm remain on or don t operate starter relay by depressing starter button Relay operates Relay does not properly operate Connect starter motor directly to battery 2 Starter motor turns or idles Inspection Adjustment Check battery circuit by turn signals Signals dim remain on or don t operate Connect starter motor directly to x nnnm batter BN UO Starter motor Starter motor turns slowly turns normally Rotate crankshaft L sene 3 Starter motor does not stop turning O Inspection Adjustment IO OH switch OFF u Hard to turn dC KYMCO GRAND DINK 125 150 Probable Cause 5 Burned out fuse 2 Weak or dead battery Faulty stop switch Loose or disconnected connectors Broken or shorted ignition switch wire Faulty or weak battery Poor starter button connection 2 Open or shorted starter relay Q Loose or disconnected connectors Worn brushes 2 or shorted wires or rotor Open starter motor cable Loose connectors DOpen wire harness
149. st the brake fluid tube SPECIFICATIONS Engine dry weight 30kg Engine oil capacity at disassembly 1 1 liter at change 0 9 liter Coolant capacity Total capacity 1400 20cc Radiator capacity 1000 20 Reserve tank capacity 400 20 TORQUE VALUES Engine mounting bolt 49N m Rear shock absorber upper mount bolt 39 2N m 5 2 KYMCO 5 ENGINE REMOVAL INSTALLATION GRAND DINK 125 150 Wire Connectors ENGINE REMOVAL Disconnect the battery negative cable Remove the frame body cover 2 3 Disconnect the engine negative cable Disconnect all of the A C generator auto bystarter spark plug thermosensor wire couplers and connectors Disconnect the engine fuel tube Drain the coolant 3 9 Disconnect the water hose Rear Brake Caliper Starter Rela Disconnect the starter motor wire that goes to the starter relay Disconnect the fuel tube and vacuum tube that go to the carburetor from the fuel pump Disconnect the vacuum tube from air cut off valve ACV Disconnect the throttle cable from the carburetor 4 ACV Vacuum Tube Fuel Pump Vacuum Tube Remove the brake fluid tube bolt of the rear brake caliper Remove the rear brake caliper bolt and the rear brake caliper qO KYMCO 5 ENGINE REMOVAL INSTALLATION GRAND DINK 125 150 Rear Shock Absorber Upper Mount Bolts Remove the right left rear shock absorber M 5 upper mount bolts Remove the
150. stall the piston rings onto the piston and measure the piston ring to groove clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom s Use the piston head to push each piston ring into the cylinder Measure the piston ring end gap Service Limit 0 5mm replace if over Measure the piston pin hole I D Service Limit 15 04mm replace if over GRAND DINK 125 150 7 4 7 CYLINDER PISTON Measure the piston pin O D Service Limit 14 96mm replace if below Measure the piston O D Take measurement at 9mm from the bottom and 90 to the piston pin hole Service Limit 57 90mm replace if below SH30DAJ 57 30mm replace if below SH25DA 52 30mm replace if below Measure the piston to piston pin clearance Service Limit 0 02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder I D at three levels of top middle and bottom at 90 to the piston pin in both X and Y directions Service Limit 58 10mm repair or replace if below SH30DAJ 57 50mm repair or rep lace if over SH25DA 52 50mmr rep ar or rep lace if over Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if Over The true roundness 1s the difference between the values measured in X and Y directions The cylindricity difference between the values measured
151. t Service Limit 0 10mm replace if over Measure the crankshaft bearing play Service Limits Axial 0 20mm replace if over Radial 0 05mm replace if over Radial CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces Avoid damaging the crankcase mating surfaces Install a new oil seal into the left crankcase Left Crankcase 11 5 11 CRANKCASE CRANKSHAFT Place the left crankcase down and install the crankshaft into the left crankcase Avoid damaging the oil seal Apply grease to the lip of the oil seal Install the two dowel pins and a new gasket Place the right crankcase over the crankshaft and onto the left crankcase Install the right crankcase squarely and do not tap it with an iron or plastic hammer Install and tighten the right and left crankcase attaching bolts Torque 78 10 6 ai f d KYMCO GRAND DINK 125 150 Dowel Pins Gasket Right Crankcase Left Crankcase Bolt S 11 CRANKCASE CRANKSHAFT GRAND DINK 125 150 Cam Chain Tensioner Slipper G5 Install the cam chain Install the cam chain tensioner slipper Install and tighten the cam chain tensioner slipper bolt Torque 78 11 8N m 11 7 KYMCO 12 COOLING SYSTEM GRAND DINK 125 150 COOLING SYSTEM SCHEMATIC DRAWING SERVICE INFORMATION
152. t Carburetor fuel level check Valve seat refacing Valve seat refacing Valve seat refacing Holding clutch for removal Bearing installation Bearing installation Bearing installation Bearing installation A C generator flywheel removal Rear shock absorber disassembly Steering head bearing removal A C generator flywheel holding Fuel unit removal KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 LUBRICATION POINTS ENGINE Valve guide valve stem movable part e Genuine CO Engine Oil SAEI5W 40 Camshaft protruding surface e API SE SJ Egnine 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 Starter idle gear Friction spring movable part shaft movable part High temperature resistant grease Shaft movable grooved part Starter spindle movable part Starter one way clutch threads Thread locking agent A C generator connector Adhesive Transmission case breather tubee 1 10 dO KYMCO 1 GENERAL INFORMATION GRAND DINK 125 150 FRAME The following is the lubrication points for the frame
153. tch wire and fan motor wire couplers Connect the overflow tube and secure with the tube clamp Connect the vent tube to the radiator filler the radiator with coolant 3 9 After installation check for coolant leaks KYMCO GRAND DINK 125 150 Bolts Radiator KS H sa EMI mmm 2 d Switch Lower Hose Thermostatic Wire Overflow Tube Air Vent Tube 12 8 KYMCO 12 COOLING SYSTEM GRAND DINK 125 150 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 Telltale Hole Inlet Hose 4 o lt Ps VA WATER PUMP IMPELLER REMOVAL Remove the coolant inlet hose and outlet ft hose Ge 202 M gt Outlet ese 12 9 12 COOLING SYSTEM GRAND DINK 125 150 Remove the four bolts and the water pump cover gasket and 2 dowel pins Remove the water pump impeller The impeller has left hand threads Inspect the mechanical water seal and seal washer for wear or damage The mechanical seal and seal washer must be replace as a set Mechanical Seal _Seal Washer Porcelain Impeller 12 10 12 COOLING SYSTEM WATER PUMP SHA
154. terminals black green If there 1s no voltage check for the following Blown or faulty fuse Loose terminals or connectors Shorted wire the wire harness TEMPERATURE GAUGE Disconnect the wire from the thermosensor and ground it to the engine Turn the ignition switch ON The temperature gauge needle should move all the way to H Do not leave the thermosensor wire grounded for longer than 5 seconds or the temperature gauge will be damaged HEATER CONTROLER UNIT INS PECTION 18 Open ignition switch to check if the black wire of it is enough voltage 2 Put the heater controler unit in refrigerator Start engine after keeping the temperatureunder10 4 3 Check if the yellow wire of heater controler unit has output voltage Start engine and if the temp erature of heater controler unit is under 102 4 C Check if the white blue wire of heater controler unit has output voltage If it has not any voltage It 1s damaged 19 6 19 SWITCHESHORNFUELUNITTHERMOSTATICSWITCH O KYMCO IEMPERATUREGAUGEINSIRUMENTSI IGHIS GRAND DINK 125 150 INSTRUMENTS Speedometer Cable REMOVAL Remove the front upper cover 2 5 Disconnect the instrument wire couplers and connectors Disconnect the speedometer cable Remove the four instrument cover and leg shield screws Remove the instruments DISASSEMBLY ASSEMBLY Remove the three instrument holder nuts Remove the holder Remo
155. the cylinder head cover Be sure to install the O ring into the groove properly Install and tighten the cylinder head cover bolts Torque 7 5 11 6 6 11 KYMCO 7 CYLINDER PISTON GRAND DINK 125 150 CY LINDER PISTON SCHEMATIC DRAWING 7 1 SERVICE INFORMATION 12 TROUBLESHOOTING 72 CYLINDER RENOV E 73 PISTON REMOY pete 5 ce 73 PITON ENG TAU TN 29 CYLINDER INSTALLATION 7 0 KYMCO GRAND DINK 125 150 7 CYLINDER PISTON SCHEMATIC DRAWING T 5 i Fi UJ XGA Wa dC KYMCO GRAND DINK 125 150 7 CYLINDER PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS The cylinder and piston can be serviced with the engine installed in the frame When installing the cylinder use a new cylinder gasket and make sure that the dowel pins are correctly installed After disassembly clean the removed parts and dry them with compressed air before inspection SPECIFICATIONS Cylinder Ring to groove top nz 0050015_ 005 009 0 09 _ clearance Second 0015 0 050 015 005 009 0 09 Piston Ring end gap piston ring Oil side rail 02 09 02 09 TROUBLESHOOTING When hard starting or poor performance at low speed occurs check the crankcase breather for white smoke If white sm
156. the front upper cover 2 5 Remove the front lower cover 2 5 Remove the floor board 2 4 Remove the leg shield 2 5 Bolts Throttle Grip Remove the four screws attaching the right and left handlebar switches Disconnect the throttle cable from the throttle grip and remove the throttle grip from the handlebar Screws Throttle Cable Remove the handlebar lock nut and take out the bolt 1 Es Remove the handlebar 1 c 4 w F lt i al We m a ex mae w INSTALLATION Install the handlebar onto the steering stem and install the handlebar collar lock nut and bolt Tighten the bolt to the specified torque Torque 39 2 49 Collar 14 4 14 STEERING HANDLEBAR FRONT WHEEL FRONT KYMCO BRAKE FRONT SHOCK ABSORBER FR ONT FORK GRAND DINK 125 150 Throttle Grip Throttle Cable Lubricate the throttle grip front end with _ grease and then install the throttle grip Connect the throttle cable to the throttle grip Install the right and left handlebar switches and tighten the screws Adjust throttle grip free play to specified range of 6mm Brake Master Cylinder Install the front and rear brake master cylinders Install the brake master cylinders aligning the index marks FRONT WHEEL REMOVAL Jack the motorcycle front wheel off the ground Remove the front axle nut to pull out the axle Remove
157. ton into the carburetor body Align the hole in the diaphragm with the hole in the carburetor body Install the spring Install the vacuum chamber cover and tighten it with the two screws Be careful not to let the diaphragm slip f the diaphragm cannot be positioned correctly because of expansion dry the _ 8 j diaphragm before installation Spring Diaphragm 13 16 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 Check the heater with battery If the heater is getting hot means the heater without problem otherwise the heater has to be changed Heater Throttle Cable CARBURETOR INSTALLATION Tighten the drain screw Install the carburetor onto the intake manifold and tighten the band Install the air cleaner connecting tube and tighten the band Connect the throttle cable to the carburetor After connecting the throttle cable adjust the throttle grip free play to 2 6mm Intake Manifold Band Air Cleaner Connecting Tube Band Fuel Tube Connect the auto bystarter wire gt Connect fuel tube and vacuum tube to the carburetor x Perform the following Inspections and adjustments Throttle grip free play 3 3 Idle speed 3 6 Install the seat met in box and frame center cover Auto Bystarter Wire 13 17 13 FUEL SYSTEM CARBURETOR KYMCO FUEL PUMP FUEL TANK GRAND DINK 125 150 FU
158. two engine mounting bolts and pull out the engine with the engine hanger backward L 42 1 L Engine Hanger Bolt ENGINE HANGER REMOVAL Remove the engine hanger bolts to remove the engine hanger 7 Stopper Rubber Bolt Engine Hanger Inspect the engine hanger bushings and stopper rubber for wear or damage Bushings dC KYMCO 5 ENGINE REMOVAL INSTALLATION GRAND DINK 125 150 ENGINE INSTALLATION Install the engine in the reverse order of removal Tighten the engine mounting bolts Torque 49N m Engine Hanger Bolt SS the rear shock absorber upper mount Rear Shock Absorber Upper Mount Bolts Torque 39 2N m After installation inspect and adjust the following Throttle grip free play 3 3 Fill the rear brake reservoir with brake fluid and bleed air from the rear brake Hill the cooling system with coolant and start the engine to bleed air from the system KYMCO 6 CYLINDER HEAD VALVES GRAND DINK 125 150 CYLINDER HEAD VALVES SCHEMATIC eee 6 1 SERVICE INFORMATION 6 2 TROUBLESHOOTING 6 3 CYLINDER HEAD COVER REMOVAL 6 4 ETA REMO VA 6 4 CYLINDER HEAD REMOVAL 6 6 CYLINDER HEAD DISASSEMBLY 6 7 CYLINDER HEAD ASSEM
159. ump gt DFaulty spark plug 2 Fouled spark plug Faulty CDI unit Faulty A C generator Broken or shorted ignition coil Broken or shorted exciter coil Faulty ignition switch Spark jumps Weak or no spark Starter motor idles but crankshaft does not rotate 2 Valve clearance too small 3 Improper valve and seat contact 4 Worn cylinder and piston rings 5 Blown cylinder head gasket 6 Flaws in cylinder head Seized valve Improper valve timing Normal Low or no compression compression D Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing 4 Incorrectly adjusted pilot screw Engine fires but does not start Engine does not fire Dry spark plug DFlooded carburetor Faulty auto bystarter 3 Throttle valve excessively open Wet spark plug 1 18 1 GENERAL INFORMATION ENGINE LACKS POWER Inspection Adjustment Start engine and accelerate lightly for observation Engine speed increases Check ignition timing using a timing light Check carburetor for Clogging Remove spark plug and inspect Remove oil dipstick and check oil level and condition Remove cylinder head oil pipe bolt and inspect Rapidly accelerate or run at high speed 1 19 Engine speed does Correct timing Incorrect timing Engine does not knock Engine knocks
160. valve spring Damaged or worn camshaft Worn cam chain tensioner Worn camshaft and rocker arm dO KYMCO 6 CYLINDER HEAD VALVES GRAND DINK 125 150 Cylinder Head Cover CYLINDER HEAD COVER REMOVAL Remove the center cover 2 3 Remove the met in box 2 3 Remove the cylinder head cover four bolts and then remove the cylinder head cover CAMSHAFT REMOVAL Turn the A C generator flywheel so that the mark on the flywheel aligns with the index mark on the crankcase Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke Remove the two bolts attaching cam chain tensioner and the tensioner Cam Chain Tensioner Round Hole Camshaft Holder First remove the two bolts between the cylinder head and cylinder Then remove the four cap nuts attaching the cylinder head Diagonally loosen the cylinder head cap nuts in 2 or 3 times Remove the camshaft holder and dowel pins KYMCO 6 CYLINDER HEAD VALVES GRAND DINK 125 150 Cam Chain Ya 8 Remove the camshaft gear from the cam chain to remove the camshaft ls CAMSHAFT INSPECTION Check each cam lobe for wear or damage Measure the cam lobe height Service Limits SH30DAJ IN 30 75mm replace if below SH25DAJEX 30 26mm replace if below Check each camshaft bearing for play or damage Replace the camshaft assembly wit
161. ve the four screws to disassemble the instruments and instrument cover Assemble the instruments the reverse order of disassembly INSTALLATION The installation sequence is the reverse of removal HAZARD INSPECTION 19 SWITCHESHORNFUELUNI THERMOSTATICSWITCH KYMCO JJEMPERATUREGAUGEINSTRUMENTSILIGHIS GRAND DINK 125 150 LIGHTS HEADLIGHT BULB REPLACEMENT Remove the front upper cover 2 5 Disconnect the headlight and turn signal light wire couplers Remove the rubber boot from the bulb socket Remove the bulb socket and replace the bulb Install the bulb socket aligning the bulb socket tab with the groove Install the rubber boot Install the front cover in the reverse order of removal Wire FRONT POSITION LIGHT BULB REPLACEMENT Remove the front upper cover 2 5 Disconnect the headlight and turn signal light wire couplers Remove the bulb sockets by turning them counterclockwise Remove the bulbs and replace them with new ones FRONT TURN SIGNAL LIGHT BULB REPLACEMENT Remove the one screw attaching the turn signal light shell and remove the light shell Remove the turn signal fixer two screws Remove the bulb protector screw Remove the bulb and replace with a new one Screw TAILLIGHT REAR TURN SIGNAL LIGHT o BULB REPLACEMENT Remove the rear protective cover 2 3 Remove the two screws attaching the rear light shell and remove the light shell Remove the bulbs and re
162. x5 5 16 2 O D 94524 42000 00165000 SEEGER INT 42mm 1 530 52400 KKC2 E00 F1S 00165134 AMMORTIZZATORE POST DX 01 72 30 1 530 52500 2 00 15 00165135 AMMORTIZZATORE POST SX 01 72 30 1 O 531 95701 08030 02 00153394 VITE FLANGIATA 8 x 30 2 e 533 95801 10035 08 00165711 VITE FLANGIATA 10X35 3 10 2 e 535 52000 KKC3 900 NJA 00170092 FORCELLA POSTERIORE ARGENTO HT 77 47 1 e 536 90131 KAF 9000 00157770 VITE FLANGIATA 8X42 3 10 2 Li F 17 GRAND DINK 125 03 11 04 CODICE KY CODICE PIR DESCRIZIONE DA N TELAIO LISTINO IVA ESCL N PZ e B 33402 KKC4 E000 00166148 SCHERMO FRECCIA ANTERIORE DX 10 33 1 OD 33403 4 000 00166911 PARABOLA FRECCIA ANT DX 1 O 33407 4 000 00166910 SEDE LAMPADA FRECCIA DX 1 OH 33453 KKC4 E000 00166913 PARABOLA FRECCIA ANT SX 1 33457 KKC4 E000 00166912 SEDE LAMPADA FRECCIA SX 1 e J 33602 KKC4 E000 00159366 SCHERMO FRECCIA POSTERIORE DX 9 30 1 OK 33603 4 000 00166914 PARABOLA FRECCIA POST DX 1 OL 33606 4 000 00166915 CAVO CON PORTALAMPADA 2 e 33652 KKC4 E000 00159368 SCHERMO FRECCIA POSTERIORE SX 9 30 1 OR 33653 4 000 00166919 PARABOLA FRECCIA POST SX 1 34905 KCP 9000 00168407 LAMPADA A BAIONETTA 12V R10W 4 93901 32220 00166918 VITE AUTOFILETTANTE 3 x 10 8 O E 93901 32320 00166901 VITE AUTOFILETTANTE 3 x 12 2 OM 93901 34220 00166916 VITE AUTOFIL

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