KYMCO GRAND DINK 50 Service Manual

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Table Of Contents

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Table of Contents

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Download this manual See also: Driver Manual, Owner's Manual

This Service Manual describes the technical features and

servicing procedures for the KYMCO GRAND DINK 50.

In this manual, many illustrations and drawings are used to help

servicemen have better understanding.

Section 2 contains the service precautions for all operations and

Troubleshooting stated in this manual. Read them carefully before

starting any operation.

Section 3 describes the inspection/adjustment procedures, safety

rules and service information for each part, starting from periodic

maintenance.

Sections 4 through 16 give instructions for disassembly, assembly

and inspection of lubrication system, engine, fuel system and

Electrical Equipment.

Section 17 is the maintenance and inspection directions for the

evaporative/ exhaust emission control system. 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, specifications, and

illustrations included in this manual

may be different from the motorcycle

in case specifications are changed.

PREFACE

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

OCTOBER 2004

Table of Contents

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Summary of Contents for KYMCO GRAND DINK 50

Page 1 PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO GRAND DINK 50. In this manual, many illustrations and drawings are used to help servicemen have better understanding. Section 2 contains the service precautions for all operations and troubleshooting stated in this manual.
Page 2: Table Of Contents
1.SPECIFICATIONS GRAND DINK 50 TABLE OF CONTENTS SPECIFICATIONS................1 GENERAL INFORMATION..............2 INSPECTION/ADJUSTMENT .............. 3 LUBRICATION SYSTEM ..............4 ENGINE REMOVAL/INSTALLATION..........5 CYLINDER HEAD/CYLINDER/PISTON..........6 A.C. GENERATOR................7 KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY... 8 FINAL REDUCTION................9 CRANKCASE/CRANKSHAFT ............. 10 CARBURETOR ..................11 FRAME COVERS.................
Page 3: Specifications
1.SPECIFICATIONS GRAND DINK 50 SPECIFICATIONS Name & Model SF10JA(LDA5) Lubrication oil capacity (liter) Overall length (mm) 2045 Air cleaner type & No. Wet, single Overall width (mm) Fuel capacity (liter) Overall height (mm) 1360 Type Plunger type Wheel base (mm) 1435 Carburetor Piston dia.
Page 4: Table Of Contents
GRAND DINK 50 . GENERAL INFORMATION ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION ________________________________________________________________________________ ENGINE SERIAL NUMBER/IDENTIFICATION ............ 2- 1 SERVICE PRECAUTIONS ................... 2- 2 SERVICE INFORMATION ..................2- 10 TORQUE VALUES ....................2- 12 SPECIAL TOOLS ....................2- 13 LUBRICATION POINTS ..................
Page 5: Engine Serial Number/Identification
. GENERAL INFORMATION GRAND DINK 50 ENGINE SERIAL NUMBER/IDENTIFICATION Location of Engine Serial Number...
Page 6: Service Precautions
GRAND DINK 50 . GENERAL INFORMATION SERVICE PRECAUTIONS „ Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. „ When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
Page 7 . GENERAL INFORMATION GRAND DINK 50 „ Apply or add designated greases and lubricants to the specified lubrication points. „ After reassembly, check all parts for proper tightening and operation. „ When two persons work together, pay attention to the mutual working safety.
Page 8: General Information
GRAND DINK 50 . GENERAL INFORMATION „ If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. Confirm Capacity „ After operation, terminal caps shall be installed securely.
Page 9 . GENERAL INFORMATION GRAND DINK 50 „ The connector shall be inserted completely. Snapping! „ If the double connector has a lock, lock it at the correct position. „ Check if there is any loose wire. „ Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
Page 10 GRAND DINK 50 . GENERAL INFORMATION „ After clamping, check each wire to make sure it is secure. „ Do not squeeze wires against the weld or its clamp. „ After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
Page 11 . GENERAL INFORMATION GRAND DINK 50 „ Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! „ Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.
Page 12 GRAND DINK 50 . GENERAL INFORMATION „ After routing, check that the wire harnesses are not twisted or kinked. „ Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
Page 13 . GENERAL INFORMATION GRAND DINK 50 „ 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 : Apply grease for lubrication.
Page 14: Service Information
GRAND DINK 50 . GENERAL INFORMATION SERVICE INFORMATION ENGINE Standard (mm) Service Limit (mm) GRAND DINK 50 GRANK DINK 50 Item 0.10 Cylinder head warpage 38.970 38.955 38.90 Piston O.D.(5mm from bottom of piston skirt) 0.10 Cylinder-to- piston clearance 12.002 12.008 12.03...
Page 15 . GENERAL INFORMATION FRAME Standard (mm) Service Limit (mm) Item GRANK DINK 50 GRANK DINK 50 Axle shaft runout Radial Front wheel rim runout Axial Front shock absorber spring free length 200.0 182.8 Rear wheel rim runout Brake drum I.D. Front/rear Brake lining thickness Front/rear...
Page 16: Torque Values
GRAND DINK 50 . GENERAL INFORMATION TORQUE VALUES ENGINE Item Thread dia. (mm) Torque (kg-m) Remarks Cylinder head bolt BF7x115 1.5 1.7 (cold) Clutch drive plate nut 3.5 4.0 Clutch outer nut NH10 3.5 4.5 Drive face nut NH12 5.0 6.0 Oil check bolt 1.0 1.5...
Page 17: Special Tools
. GENERAL INFORMATION SPECIAL TOOLS Tool Name Tool No. Remarks Universal bearing puller Crankshaft bearing removal Lock nut wrench, 39mm Drive pulley disassembly/assembly Lock nut socket wrench Top cone race holding Lock nut wrench, Stem lock nut tightening Crankcase puller Crankcase disassembly Bearing remover set, 12mm Drive shaft bearing removal/installation...
Page 18 GRAND DINK 50 . GENERAL INFORMATION Tool Name Tool No. Remarks Drive shaft bearing installation Final shaft Bearing outer driver, 37x40mm bearing installation Crankshaft bearing installation Outer driver, 24x26mm Driven pulley bearing installation Pilot, 10mm Front wheel bearing installation Bearing driver pilot, 17mm...
Page 19: Lubrication Points
. GENERAL INFORMATION LUBRICATION POINTS ENGINE Lubrication Points Lubricant Remarks Crankcase sliding & movable JASO-FC or API-TC Cylinder movable parts Transmission gear (final gear) SAE-90# Kick starter spindle bushing Grease Drive pulley movable parts Grease Starter pinion movable parts Grease FRAME Apply clean engine oil or grease to cables and movable parts not specified.
Page 20: Wiring Diagram
GRAND DINK 50 . GENERAL INFORMATION GRAND DINK 50 WIRING DIAGRAM 2-16...
Page 21: Cable & Harness Routing
. GENERAL INFORMATION CABLE & HARNESS ROUTING Front Brake Reservoir Rear Stop Brake Throttle Cable Ignition Switch Rear Brake Cable Speedometer Cable Front Brake Fluid Tube Horn 2-17...
Page 22 GRAND DINK 50 . GENERAL INFORMATION Front Brake Reservoir Rear Brake Cable Fuel Filler Fuel Tank Inlet Tube Throttle Cable Fuel Tank Breather Tube Front Brake Fluid Tube Wire Harness Speedometer Cable 2-18...
Page 23 . GENERAL INFORMATION Air Injection Control Valve C.D.I. Unit Throttle Cable Fuel Pump Regulator/Rectifier Fuel Tube Ignition Coil Battery Resistance Oil Tank Ignition Coil Oil Tube Fuel Filter Spark Plug 2-19...
Page 24 GRAND DINK 50 . GENERAL INFORMATION Fuel Pump Fuel Tube Spark Plug Cap Seat Cable Oil Tube Fuel Pump Oil Pump Vacuum Tube A.C.G Connect wire Auto Bystarter Battery (-) Cable Oil Tank Cap Battery (+) Cable 2-20...
Page 25: Troubleshooting
. GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw. c Empty fuel tank d Clogged float valve Fuel reaches Fuel does not e Clogged charcoal canister carburetor reach carburetor f Clogged fuel filter...
Page 26 GRAND DINK 50 . GENERAL INFORMATION ENGINE STOPS IMMEDIATELY AFTER IT STARTS Symptom Inspection/Adjustment Probable Cause Check if fuel reaches carburetor by loosening drain screw. c Empty fuel tank d Clogged float valve Fuel reaches Fuel does not e Clogged charcoal canister...
Page 27 . GENERAL INFORMATION Symptom Inspection/Adjustment Probable Cause Check carburetor gasket for air leaks. c Carburetor not securely tightened No air leak Air leaks d Faulty intake manifold gasket e Deformed or broken carburetor O-ring Remove auto bystarter connecting wire and check if bypass fuel line is clogged.
Page 28 GRAND DINK 50 . GENERAL INFORMATION ENGINE LACKS POWER Symptom Inspection/Adjustment Probable Cause Start engine and accelerate lightly for observation. c Clogged air cleaner Engine speed d Clogged fuel filter Engine speed does not increase e Clogged exhaust muffler increases...
Page 29 . GENERAL INFORMATION POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Symptom Inspection/Adjustment Probable Cause Check ignition timing. c Faulty CDI unit Incorrect timing Correct timing d Faulty A.C. generator Check carburetor air screw adjustment. c Mixture too rich (turn screw Correctly adjusted Incorrectly adjusted out)
Page 30 GRAND DINK 50 . GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) Symptom Inspection/Adjustment Probable Cause Check ignition timing. c Faulty CDI unit Correct timing Incorrect timing d Loose A.C.G. stator e Faulty A.C. generator Check auto fuel valve for fuel supply.
Page 31 . GENERAL INFORMATION CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause c Worn or slipping drive belt d Broken ramp plate e Broken driven face spring Engine starts but f Separated clutch lining motor-cycle does not g Damaged driven pulley shaft splines move h Damaged final gear i Seized final gear...
Page 32 GRAND DINK 50 . GENERAL INFORMATION POOR SUSPENSION PERFORMANCE Symptom Probable Cause (Front and rear tire pressures are normal) c Weak shock spring Suspension is too soft d Excessive load e Shock damper oil leaking c Bent fork tube or shock rod...
Page 33 . GENERAL INFORMATION OIL METER 1. Motor oil indicator light does not come on when there is no motor oil (Ignition switch ON) Symptom Inspection/Adjustment Probable Cause Check battery circuit by operating turn c Burned out fuse signals. d Weak or dead battery Signals dim, remain Signals operate e Faulty ignition switch...
Page 34 GRAND DINK 50 . GENERAL INFORMATION FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Symptom Probable Cause Inspection/Adjustment Check battery circuit by operating turn signals. c Burned out fuse d Weak or dead battery Signals operate Signals dim, remain...
Page 35 . GENERAL INFORMATION STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of c Burned out fuse stop switch by d Weak or dead battery applying brake. e Faulty stop switch Stoplight does Stoplight comes on f Loose or disconnected not come on connector...
Page 36: Table Of Contents
. INSPECTION/ADJUSTMENT GRAND DINK 50 __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ __________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________ INSPECTION AND MAINTENANCE SCHEDULE .....3- 1 BRAKE SYSTEM ...............3- 4 MOVING DEVICE ..............3- 6 DAMPING DEVICE ..............3- 7 POWER DRIVE SYSTEM............3- 7 ELECTRICAL EQUIPMENT............3- 8 ENGINE ..................3- 9...
Page 37: Inspection And Maintenance Schedule
. INSPECTION/ADJUSTMENT GRAND DINK 50 INSPECTION AND MAINTENANCE SCHEDULE (Note) 1. means time for inspection. means regular replacement for the specified parts. This inspection and maintenance schedule is based upon average riding conditions. Machines subjected to serve use, or ridden in unusually dusty areas, require more frequent servicing.
Page 38 . INSPECTION/ADJUSTMENT GRAND DINK 50 Frequency Inspection & Maintenance Item Judgment Standards Remarks Every 6 Every 12 Prior month months months Tire crack and damage Groove Depth: Tire groove and Front: 0.8mm abnormal wear Rear : 0.8mm Imbedded objects, gravel, etc.
Page 39 . INSPECTION/ADJUSTMENT GRAND DINK 50 Frequency Inspection & Maintenance Item Judgment Standards Remarks Every 6 Every 12 Prior month months months Performance and abnormal noise Conditions at low and high Body speeds Exhaust smoke Air cleaner ˆ Oil level indicator...
Page 40: Brake System
. INSPECTION/ADJUSTMENT GRAND DINK 50 Fuel Line 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.
Page 41 . INSPECTION/ADJUSTMENT GRAND DINK 50 <Rear> “ ” Marks BRAKE DRUM/SHOE Brake Shoe Wear Replace the brake shoes if the arrow on the brake arm aligns with reference mark“ ” on the brake panel when the brake is fully applied.
Page 42: Moving Device
. INSPECTION/ADJUSTMENT GRAND DINK 50 MOVING DEVICE TIRES Tire Pressure Check the tire pressure. Tire pressure should be checked when tires are cold. Tire Pressure (one rider) Front: 1.75 kg/cm² Rear: 2.25 kg/cm² Tire Size Front 120/70 12 Rear...
Page 43: Damping Device
. INSPECTION/ADJUSTMENT GRAND DINK 50 DAMPING DEVICE SHOCK ABSORBERS Oil Leak/Damage Fully apply the front brake and check the action of the front shock absorber by compressing it several times. Check the entire shock absorber assembly for looseness or damage.
Page 44: Electrical Equipment
. INSPECTION/ADJUSTMENT GRAND DINK 50 ELECTRICAL EQUIPMENT Gap, Wear and IGNITION APPARATUS Fouling Deposits 0.6-0.7mm Spark Plug Remove the frame center cover. Remove the spark plug cap and spark plug. Check the spark plug for wear, fouling and carbon deposits.
Page 45: Engine
. INSPECTION/ADJUSTMENT GRAND DINK 50 Throttle Stop Screw ENGINE BODY At High and Low Speeds The engine must be warm for accurate idle speed adjustment. Adjust the idle speed to the specified range by turning the throttle stop screw and air screw.
Page 46: Lubrication System
. INSPECTION/ADJUSTMENT GRAND DINK 50 Wash the air cleaner element in detergent Squeeze out oil, squeeze out and allow to dry. excess oil dry Never use gasoline or organic vaporable oil with acid or alkali for washing. After washing, soak the element in clean engine oil SAE 15W-40# and squeeze out excess oil.
Page 47 . INSPECTION/ADJUSTMENT GRAND DINK 50 Filter Screen Clean the oil filter screen with compressed air. Install the oil filter in the reverse order of removal and fill the oil tank with specified oil up to the proper level. Bleed air from the oil pump and oil lines.
Page 48: Others
. INSPECTION/ADJUSTMENT GRAND DINK 50 FUEL SYSTEM Throttle Grip Free Play Measure the throttle grip free play. Free Play: 2 6mm Lock Nut If the throttle grip free play does not fall within the specified range, adjust by loosening the lock nut and turning the adjusting nut.
Page 49 . LUBRICATION SYSTEM GRAND DINK 50 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ LUBRICATION SYSTEM ________________________________________________________________________________ SERVICE INFORMATION ..................4-2 TROUBLESHOOTING..................4-2 OIL PUMP REMOVAL ..................4-3 OIL PUMP INSPECTION..................4-3 OIL PUMP INSTALLATION .................. 4-4 OIL PUMP BLEEDING..................4-5 OIL TANK ......................4-6...
Page 50 . LUBRICATION SYSTEM GRAND DINK 50 LUBRICATION SYSTEM...
Page 51 . LUBRICATION SYSTEM GRAND DINK 50 SERVICE INFORMATION GENERAL INSTRUCTIONS x Use care when removing and installing the oil pump not to allow dust and dirt to enter the engine and oil line. x Do not attempt to disassemble the oil pump.
Page 52: Lubrication System
. LUBRICATION SYSTEM GRAND DINK 50 Oil Pump Control Cable OIL PUMP REMOVAL • • Do not allow foreign matters to enter the crankcase. Before removing the oil pump, clean the oil pump and crankcase surfaces. Remove the met-in box. ( Ö 12-4)
Page 53 . LUBRICATION SYSTEM GRAND DINK 50 OIL PUMP INSTALLATION • • x Lubricate the O-ring with grease or engine oil before installation. x Make sure that the oil pump is inserted into the crankcase. x Apply molybdenum disulfide or grease to the pump pinion.
Page 54 . LUBRICATION SYSTEM GRAND DINK 50 Intake Manifold Oil Outlet Line OIL PUMP BLEEDING • • x Air in the oil lines will block oil flow and result in severe engine damage. x Bleed air from the oil lines and oil...
Page 55 . LUBRICATION SYSTEM GRAND DINK 50 Oil Meter OIL TANK OIL TANK REMOVAL Remove the met-in box. ( Ö 12-5) Remove the frame body cover. ( Ö 12-5) Remove the rear carrier. ( Ö 12-5) Remove the two bolts, four nuts attaching the stay comp fuel tank.
Page 56: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION GRAND DINK 50 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION ________________________________________________________________________________ SERVICE INFORMATION ..................5-1 ENGINE REMOVAL....................5-2 ENGINE INSTALLATION..................5-4...
Page 57 GRAND DINK 50 . ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL INSTRUCTIONS x 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.
Page 58 . ENGINE REMOVAL/INSTALLATION GRAND DINK 50 Carburetor Cap Air Cleaner Case ENGINE REMOVAL Remove the frame body cover. ( Ö 12-5) Remove the two bolts attaching the air cleaner case. Loosen the band between the air cleaner and carburetor to remove the air cleaner case.
Page 59 GRAND DINK 50 . ENGINE REMOVAL/INSTALLATION Rear Shock Absorber Lower Mount Bolt Remove the rear brake adjusting nut and disconnect the brake cable from the crankcase. Remove the rear brake cable clamp and rear brake cable. Remove the cooling air tube band on the left crankcase cover and disconnect the cooling air tube.
Page 60 . ENGINE REMOVAL/INSTALLATION GRAND DINK 50 Engine Hanger ENGINE HANGER BRACKET INSPECTION Inspect the stopper rubbers and bushings for damage and replace with new ones if necessary. Bushings Stopper Rubbers ENGINE INSTALLATION Install the engine in the reverse order of removal.
Page 61: Cylinder Head/Cylinder/Piston
. CYLINDER HEAD/CYLINDER/PISTON GRAND DINK 50 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER HEAD/CYLINDER/PISTON ________________________________________________________________________________ SERVICE INFORMATION ..................6-2 TROUBLESHOOTING..................6-2 CYLINDER HEAD....................6-3 CYLINDER/PISTON ..................... 6-6...
Page 62 GRAND DINK 50 . CYLINDER HEAD/CYLINDER/PISTON Torque: 1.1 1.7kg-m (cold) Torque: 1.5 1.7kg-m...
Page 63 . CYLINDER HEAD/CYLINDER/PISTON GRAND DINK 50 SERVICE INFORMATION GENERAL INSTRUCTIONS x The cylinder head, cylinder and piston can be serviced with the engine installed in the frame. x Before disassembly, clean the engine to prevent dust from entering the engine.
Page 64 GRAND DINK 50 . CYLINDER HEAD/CYLINDER/PISTON Spark Plug Cap CYLINDER HEAD REMOVAL Remove the rear carrier. Remove the frame body cover. ( Ö 12-5) Remove the spark plug cap. Fan Cover/Engine Hood Remove the three bolts attaching the fan cover to remove the fan cover.
Page 65 . CYLINDER HEAD/CYLINDER/PISTON GRAND DINK 50 Combustion Chamber COMBUSTION CHAMBER DECABONIZING Remove the carbon deposits from the combustion chamber Avoid damaging the combustion cham- ber wall and cylinder mating surface. Mating Surface CYLINDER HEAD INSPECTION Check the cylinder head for warpage with a straight edge and feeler gauge.
Page 66 GRAND DINK 50 . CYLINDER HEAD/CYLINDER/PISTON Cylinder head Bolts Cylinder Head Bolts Installation Install and tighten the cylinder head bolts diagonally in 2 or 3 times. Torque: 1.5 1.7kg-m Install the spark plug. Torque: 1.1 1.7kg-m Spark Plug Cylinder Head...
Page 67 . CYLINDER HEAD/CYLINDER/PISTON GRAND DINK 50 Cylinder CYLINDER/PISTON CYLINDER REMOVAL Remove the met-in box and seat. Remove the frame body cover. Remove the cylinder head. Remove the two exhaust muffler joint lock nuts and two exhaust muffler lock bolts. Remove the exhaust muffler.
Page 68 GRAND DINK 50 . CYLINDER HEAD/CYLINDER/PISTON CYLINDER/PISTON INSPECTION Check the cylinder and piston for wear or damage. Clean carbon deposits from the exhaust port area. Be careful not to damage the cylinder inside wall. Measure the cylinder bore at three levels of A, B and C in both X and Y directions.
Page 69 . CYLINDER HEAD/CYLINDER/PISTON GRAND DINK 50 A Mark The cylinder has an ‘A’ mark or no mark on it. When replacing the cylinder with a new one, use a cylinder having the same mark as the old one. Measure the piston O.D. at a point 5mm from the bottom of the piston skirt.
Page 70 GRAND DINK 50 . CYLINDER HEAD/CYLINDER/PISTON PISTON RING INSPECTION Measure each piston ring end gap. Service Limits: Top/Second 0.40mm replace if over Set each piston ring squarely into the cylinder using the piston and measure the end gap. <Small End I.D. Measurement>...
Page 71 . CYLINDER HEAD/CYLINDER/PISTON GRAND DINK 50 Cylinder Gasket Install a new cylinder gasket on the mating surface between the cylinder and crankcase. Ring Pins Make sure that the ring end gaps are aligned with the piston ring pins in the ring grooves.
Page 72: A.c. Generator
. A.C. GENERATOR GRAND DINK 50 ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ A.C. GENERATOR ________________________________________________________________________________ SERVICE INFORMATION ..................7-2 A.C. GENERATOR REMOVAL................7-3 A.C. GENERATOR INSTALLATION..............7-4...
Page 73 GRAND DINK 50 . A.C. GENERATOR Torque: 0.8 1.2kg-m Torque: 3.5 4.0kg-m Torque: 0.6 1.0kg-m Torque: 0.8 1.2kg-m...
Page 74 . A.C. GENERATOR GRAND DINK 50 SERVICE INFORMATION GENERAL INSTRUCTIONS x All A.C. generator maintenance and inspection can be made with the engine installed. x Refer to Section 15 for A.C. generator inspection. TORQUE VALUE Flywheel nut : 3.5 4.0kg-m...
Page 75 GRAND DINK 50 . A.C. GENERATOR Fan Cover A.C. GENERATOR REMOVAL Remove the three bolts attaching the fan cover to remove the fan cover. Bolts Bolts Remove the cooling fan by removing the four bolts. Cooling Fan Hold the flywheel with an universal holder and then remove the 10mm flywheel nut.
Page 76 . A.C. GENERATOR GRAND DINK 50 Lock Nut Wrench Remove the A.C. generator flywheel using the flywheel puller. Flywheel Puller A.C. Generator Wire Connector Remove the A.C. generator wire connector. Stator Pulser Coil Remove the two pulser coil bolts and pulser coil from the right crankcase.
Page 77 GRAND DINK 50 . A.C. GENERATOR A.C. Generator Wire Install the A.C. generator and pulser coil bolts. Connect the A.C. generator wire connector. Woodruff Key Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft keyway.
Page 78 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ KICK STARTER/DRIVE PULLEY/ CLUTCH/DRIVEN PULLEY ________________________________________________________________________________ SERVICE INFORMATION ..................8- 3 TROUBLESHOOTING..................8- 3 KICK STARTER....................8- 4 DRIVE BELT......................8- 8 DRIVE PULLEY ....................8-10 STARTER ONE-WAY CLUTCH DRIVE GEAR ............
Page 79 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Torque: 5.0 6.0kg-m Torque: 3.5 4.5kg-m Torque: 3.5 4.0kg-m...
Page 80 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY SERVICE INFORMATION GENERAL INSTRUCTIONS x Avoid getting grease and oil on the drive belt and pulley faces. SPECIFICATIONS GRAND DINK 50 Standard (mm) Service Limit (mm) Item 20.01 20.025 24.24 Drive pulley collar O.D.
Page 81 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Bolt KICK STARTER LEFT CRANKCASE COVER REMOVAL Remove the drive belt cooling air tube connector circlip. Remove the nine left crankcase cover bolts, left crankcase cover and dowel pins. Inspect the left crankcase cover seal rubber for damage or deterioration.
Page 82 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Return Spring Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushing. Kick Starter Spindle Spindle Return Spring KICK STARTER SPINDLE INSPECTION Inspect the kick starter spindle and gear for wear or damage.
Page 83 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Kick Starter Spindle Forcing Part Inspect the kick starter spindle and driven gear forcing parts for wear or damage. Kick Starter Driven Gear Forcing Part Friction Spring KICK STARTER INSTALLATION Install the kick starter spindle bushing and return spring onto the left crankcase cover.
Page 84 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY First install the washer and then the circlip onto the kick starter spindle. Install the kick lever. Circlip Washer Dowel Pins LEFT CRANKCASE COVER INSTALLATION First install the dowel pins and then the seal rubber.
Page 85 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY DRIVE BELT Remove the left crankcase cover. INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: 16.5mm replace if below Use specified genuine parts for replace-ment.
Page 86 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Clutch/Driven Pulley Remove the drive belt from the clutch/ driven pulley. Drive Belt Drive Belt DRIVE BELT INSTALLATION Turn the driven pulley clockwise and lift it up to expand the drive belt groove and then install a new drive belt.
Page 87 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Drive Pulley Face Starting Ratchet DRIVE PULLEY REMOVAL Hold the drive pulley with the holder and remove the 12mm drive face nut. Remove the starting ratchet, 12mm washer and drive pulley face.
Page 88 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Weight Roller MOVABLE DRIVE FACE INSPECTION Remove the weight rollers. Check each weight roller for wear or damage. Measure each roller O.D. Service Limit: 12.4mm replace if below Measure the movable drive face bushing assembly I.D.
Page 89 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Drive Pulley Face Install the drive belt on the crankshaft. Install the drive face, starting ratchet and washer, then tighten the 12mm drive face nut. Torque: 3.5 4.0kg-m Keep grease or oil off the drive belt and drive pulley faces.
Page 90 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Universal Holder Clutch Outer CLUTCH/DRIVEN PULLEY CLUTCH/DRIVEN PULLEY REMOVAL Remove the drive pulley. ( Ö 8-8) Hold the clutch outer with the universal holder and remove the 10mm clutch outer nut.
Page 91 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Remove the seal collar. Seal Collar Driven Pulley Oil Seal Pull out the guide roller pins from the driven pulley and then remove the O-rings and oil seal from the driven pulley.
Page 92 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Measure the driven face spring free length. Service Limit: 82.6mm replace if below Check the driven face assembly for wear or damage.
Page 93 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Inner Bearing DRIVEN PULLEY FACE BEARING REPLACEMENT Check the needle bearings in the driven face and replace them if they have excessive play, damage or abnormal noise. Drive the inner bearing out of the driven pulley face.
Page 94 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Bearing Driver Pilot Drive in a new needle bearing into the driven face with the mark facing up. Outer Driver, 24x26mm Driven Pulley Oil Seal CLUTCH/DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face.
Page 95 . KICK STARTER/DRIVE PULLEY/ GRAND DINK 50 CLUTCH/DRIVEN PULLEY Set the driven pulley, driven face spring and clutch assembly onto the clutch spring compressor. Compress the tool and install the 28mm drive plate nut. Tighten the 28mm nut to the specified torque.
Page 96: Final Reduction
GRAND DINK 50 . FINAL REDUCTION ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ FINAL REDUCTION ________________________________________________________________________________ SERVICE INFORMATION ..................9-2 TROUBLESHOOTING..................9-2 FINAL REDUCTION DISASSEMBLY ..............9-3 FINAL REDUCTION INSPECTION ..............9-3 FINAL REDUCTION ASSEMBLY ................. 9-6...
Page 97 . FINAL REDUCTION GRAND DINK 50...
Page 98 GRAND DINK 50 . FINAL REDUCTION SERVICE INFORMATION Specified Oil: SAE90# At disassembly: 0.12 liter At change: 0.1 liter SPECIAL TOOLS Bearing remover set, 12mm Bearing remover set, 15mm Crankcase assembly collar Crankcase assembly shaft Bearing outer driver, 37x40mm Bearing outer driver, 32x35mm...
Page 99 . FINAL REDUCTION GRAND DINK 50 Bolts FINAL REDUCTION DISAS-SEMBLY Remove the rear wheel. ( Ö 14-3) Remove the left crankcase cover. ( Ö 8-4) Remove the clutch/driven pulley. ( Ö 8-15) Drain the transmission gear oil into a clean container.
Page 100 GRAND DINK 50 . FINAL REDUCTION Inspect the final gear and final shaft for wear, damage or seizure. Drive Shaft Bearing Countershaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage.
Page 101 . FINAL REDUCTION GRAND DINK 50 Drive Shaft Bearing BEARING REPLACEMENT (Transmission Case Cover) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Bearing Remover Set Bearing Outer Driver Handle Drive new bearings into the transmission case cover.
Page 102 GRAND DINK 50 . FINAL REDUCTION Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Bearing Outer Driver FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Drive Shaft Install the final gear and final shaft into the left crankcase.
Page 103 . FINAL REDUCTION GRAND DINK 50 Dowel Pins Install the countershaft and gear into the left crankcase. Install the resin washer onto the counter- shaft. Install the dowel pins and a new gasket. Resin Washer Countershaft Install the transmission case cover.
Page 104 GRAND DINK 50 . FINAL REDUCTION Oil Check Bolt Hole/Filler After installation, fill the transmission case with the specified oil. x Place the motorcycle on its main stand on level ground. x Check the sealing washer for wear or damage.
Page 105: Crankcase/Crankshaft
GRAND DINK 50 . CRANKCASE/CRANKSHAFT CRANKCASE/CRANKSHAFT SERVICE INFORMATION ..................10-2 TROUBLESHOOTING..................10-2 CRANKCASE SEPARATION ................10-3 CRANKSHAFT REMOVAL ................... 10-3 CRANKSHAFT INSPECTION................10-4 CRANKSHAFT INSTALLATION ................10-5 CRANKCASE ASSEMBLY ................... 10-7 10-0...
Page 106 GRAND DINK 50 . CRANKCASE/CRANKSHAFT Torque: 0.8 1.2kg-m 10-1...
Page 107: Carburetor
GRAND DINK 50 . CRANKCASE/CRANKSHAFT SERVICE INFORMATION GENERAL INSTRUCTIONS x This section covers crankcase separation to service the crankshaft. x The following parts must be removed before separating the crankcase. Engine ( Ö Section 5) Driven pulley ( Ö Section 9) Carburetor ( Ö...
Page 108 GRAND DINK 50 . CRANKCASE/CRANKSHAFT CRANKCASE SEPARATION Remove the crankcase attaching bolts. Bolts Attach the crankcase puller on the right crankcase and remove the right crankcase from the left crankcase. Crankcase Puller Crankcase Puller CRANKSHAFT REMOVAL Attach the crankcase puller on the left crankcase and remove the crankshaft from the left crankcase.
Page 109 GRAND DINK 50 . CRANKCASE/CRANKSHAFT Remove the remaining bearing on the crankshaft side using the universal bearing puller. When separating the crankcase, the oil seals must be removed. Replace the oil seals with new ones. Universal Bearing Puller CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance.
Page 110 GRAND DINK 50 . CRANKCASE/CRANKSHAFT Measure the crankshaft runout. Service Limit 0.150mm 0.100mm replace if over replace if over Check the crankshaft bearings for Play excessive play. The bearings must be replaced if they are noisy or have excessive play.
Page 111 Bearing Outer Driver, 42x47mm Pilot, 20mm Crankcase Assembly Tool Install the crankshaft into the left crankcase. x Apply KYMCO ULTRA motor oil or molybdenum disulfide to the crank- shaft bearings and connecting rod big end. x Apply grease to the lip of the oil seal and then install it.
Page 112 GRAND DINK 50 . CRANKCASE/CRANKSHAFT Dowel Pins CRANKCASE ASSEMBLY Install the dowel pins and a new gasket to the crankcase mating surface. Crankcase Assembly Tool Assemble the crankcase halves. Crankcase Assembly Collar The distance between the right crankcase Oil Seal oil seal and crankcase surface is about 12.5r0.5 mm.
Page 113 GRAND DINK 50 . CRANKCASE/CRANKSHAFT The distance between the left crankcase oil seal and crankcase surface is about 1.0mm. Oil Seal 1.0mm Install and tighten the crankcase attaching bolts. After assembly, check the crankshaft for smooth operation. 10-8...
Page 114 GRAND DINK 50 . CARBURETOR CARBURETOR SERVICE INFORMATION ..................11- 2 TROUBLESHOOTING..................11- 2 THROTTLE VALVE DISASSEMBLY ..............11- 3 THROTTLE VALVE INSTALLATION..............11- 4 CARBURETOR REMOVAL .................. 11- 5 AUTO BYSTARTER ..................... 11- 6 FLOAT CHAMBER ....................11- 8 FLOAT LEVEL INSPECTION ................
Page 115 GRAND DINK 50 CARBURETOR 11-1...
Page 116 GRAND DINK 50 . CARBURETOR 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. • All cables, fuel lines and wires must be routed and secured at correct locations.
Page 117 GRAND DINK 50 CARBURETOR THROTTLE VALVE DIS-ASSEMBLY Remove the rear carrier. ( Ö 12-5) Remove the met-in box. ( Ö 12-4) Remove the rubber cover. Loosen carburetor cap and the throttle valve. Rubber Cover Throttle Valve Disconnect the throttle cable from the throttle valve.
Page 118 GRAND DINK 50 . CARBURETOR Remove the jet needle by removing the needle clip. Needle Clip Check the jet needle and throttle valve for wear or damage. Jet Needle Throttle Valve Rubber Seal Carburetor Cap THROTTLE VALVE INSTALLA-TION Install the jet needle on the throttle valve and secure with the needle clip.
Page 119 GRAND DINK 50 CARBURETOR Groove Install the throttle valve by aligning the groove in the throttle valve with the throttle stop screw. Throttle Stop Screw Carburetor Cap Tighten the carburetor cap. After installation, perform the following adjustments and inspections. x Throttle cable free play ( Ö 3-12) x Idle speed adjustment ( Ö...
Page 120 GRAND DINK 50 . CARBURETOR Remove the carburetor. AUTO BYSTARTER AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 5: (10 minutes minimum after stopping the engine) If the resistance exceeds 5:, replace the auto bystarter with a new one.
Page 121 GRAND DINK 50 CARBURETOR Connect the auto bystarter yellow wire to the battery positive (+) terminal and green/ black wire to the battery negative (-) terminal and wait 5 minutes. Connect a hose to the fuel enriching circuit and blow the hose with mouth.
Page 122 GRAND DINK 50 . CARBURETOR Auto Bystarter Screws AUTO BYSTARTER INSTALLATION Install the auto bystarter into the carburetor body until it bottoms.. Install the set plate and then tighten the two screws. Set Plate FLOAT CHAMBER Screws Remove the two float chamber screws and the float chamber.
Page 123 GRAND DINK 50 CARBURETOR Float Valve FLOAT/FLOAT VALVE INSPECTION Inspect the float for damage or fuel inside the float. Check the float valve seat for wear or damage. Float Seat Main Jet JETS/SCREWS REMOVAL Before removing the throttle stop screw or air screw, record the number of rotations until it seats lightly.
Page 124 GRAND DINK 50 . CARBURETOR Needle Jet holder Main Jet FLOAT CHAMBER ASSEMBLY Install the main jet and needle jet holder. Install the air screw and throttle stop screw according to the rotations recorded. If the air screw must be replaced, be sure to perform the air screw adjustment again.
Page 125 GRAND DINK 50 CARBURETOR O-rings CARBURETOR INSTALLATION When installation, do not allow foreign particles to enter the carburetor. Check the carburetor insulator and O-ring for wear or damage. Install the carburetor and insulator onto the intake manifold and tighten the two lock nuts.
Page 126 GRAND DINK 50 . CARBURETOR Bolts REED VALVE REMOVAL Remove the rear carrier. Remove the frame body cover. Remove the four intake manifold bolts and gasket. Remove the reed valve and gasket. Intake Manifold Reeds Reed Stopper INSPECTION Check the reed valve for damaged or weak reeds.
Page 127 GRAND DINK 50 CARBURETOR Fuel Pump Bolts FUEL TANK FUEL PUMP REMOVAL Remove the met-in box. ( Ö 12-4) Remove the frame body cover. ( Ö 12-5) Remove the rear carrier. ( Ö 12-5) Disconnect the fuel pump inlet, outlet and vacuum tubes.
Page 128 GRAND DINK 50 . CARBURETOR Tube To Fuel Filler Fuel Unit 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.
Page 129: Frame Covers
GRAND DINK 50 . FRAME COVERS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ FRAME COVERS ________________________________________________________________________________ SERVICE INFORMATION ..................12-2 FRAME COVERS REMOVAL/INSTALLATION ............ 12-3 12-0...
Page 130 GRAND DINK 50 . FRAME COVERS ASSEMBLY DRAWING 12-1...
Page 131 GRAND DINK 50 . FRAME COVERS SERVICE INFORMATION x When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. Items Related for Removal x Handlebar front cover Headlight wire x Front cover...
Page 132 . FRAME COVERS GRAND DINK 50 Bolt Nuts FRAME COVERS REMOVAL REAR CARRIER & 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. Bolts Bolts Remove the hand rail right and left lock hex bolts.
Page 133 GRAND DINK 50 . FRAME COVERS Remove the three bolts on the back fender. Remove the back fender. Bolts Screws Remove the two screws on the molding covers. Remove the molding covers. Molding Cover Bolt Remove the two nuts and one bolt on the back taillight.
Page 134 . FRAME COVERS GRAND DINK 50 Remove the left and right sides screws on the Screws frame body cover. Remove the frame body cover. Body Cover FLOOR BOARD REMOVAL Remove the blot on the front right and left side covers.
Page 135 GRAND DINK 50 . FRAME COVERS Remove the four bolts on the floor board. Remove the floor board. Bolts FRONT UPPER COVER REMOVAL Remove the two screws on the front upper cover. Remove the front upper cover. Screws Bolts Remove the four bolts on the front windshield.
Page 136 . FRAME COVERS GRAND DINK 50 Bolts FRONT COVER REMOVAL First remove the front upper cover. Remove the two bolts attaching the front headlight. Remove the six screws on the back of the front cover. Disconnect the right/left turn signal light wire connectors.
Page 137 GRAND DINK 50 . FRAME COVERS Fuel Cap Molding Key Molding 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. Bolt Screws Remove the three screws attaching fuel tank inlet tube join.
Page 138 . FRAME COVERS GRAND DINK 50 FRONT FENDER REMOVAL Blots Remove the four bolts attaching the fender. Remove the front fender cover. The installation sequence is the reverse of removal. Blots EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts.
Page 139 GRAND DINK 50 . FRAME COVERS Screws Remove the screw from the handlebar upper cover. Handlebar Upper Cover Remove the screw from the bottom of handlebar upper cover. Remove the handlebar upper cover. Screws 12-10...
Page 140 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ________________________________________________________________________________ SERVICE INFORMATION ..................13- 2 TROUBLESHOOTING..................13- 2 STEERING HANDLEBAR..................13- 3 FRONT WHEEL....................13- 5 FRONT BRAKE (DRUM BRAKE) .................
Page 141 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 3.3kg-m 2.7kg-m 6.0kg-m 13-1...
Page 142 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION SPECIFICATIONS Item Standard (mm) Service Limit (mm) Axle shaft runout Radial Front wheel rim runout Axial Front shock absorber spring free length 182.8 Brake disk thickness 35 3.8 Brake disk runout 0.30...
Page 143 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolts Brake Master Cylinder STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. ( Ö 12-3) Remove two bolts attaching the left brake lever holder. Remove two bolts attaching the brake master cylinder (disk brake) to the right brake lever.
Page 144 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSTALLATION Install the handlebar, aligning the tabs of the handlebar with the grooves in the steering stem. Install and tighten the handlebar lock nut. Torque: 4.5 5.0kg-m Groove Throttle Cable Lubricate the throttle pipe front end with grease.
Page 145 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Speedometer Cable FRONT WHEEL REMOVAL (DISK BRAKE) Jack the motorcycle front wheel off the ground. Remove the speedometer cable set screw and disconnect the speedometer cable. Remove the front axle nut and pull out the axle.
Page 146 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Turn the wheel bearings and replace them Play if they have excessive play or noise. Play Axial Radial Dust Seal DISASSEMBLY Remove the dust seal. Bearing Puller Remove the wheel bearings and distance collar.
Page 147 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ASSEMBLY Grease Greas Pack all bearing cavities with grease. Drive in the left bearing . Install the distance collar. Drive in the right bearing. Drive the bearing squarely with the...
Page 148 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT WHEEL INSTALLATION (Disk Brake) Install the front wheel, aligning the speedometer gear tab with the front fork groove. Connect the speedometer cable. Torque: 5.0 7.0kg-m HYDRAULIC BRAKE (FRONT BRAKE) Brake Fluid Replacement/Air Bleeding Check the brake fluid level on level ground.
Page 149 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Blots Brake Pad/Disk Replacement The brake pads must be replaced as a set to ensure the balance of the brake disk. Remove the two bolts attaching the brake caliper.
Page 150 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Master Cylinder BRAKE MASTER CYLINDER Removal First drain the brake fluid from the hydraulic brake system. x When servicing the brake system, use shop towels to cover rubber and...
Page 151 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Inspection Measure the brake master cylinder I.D. Service Limit: 12.75mm Inspect the master cylinder for scratch or crack. Measure the brake master cylinder piston O.D. Service Limit: 12.64mm Before assembly, inspect the lst and 2nd rubber cups for wear.
Page 152 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Place the brake master cylinder on the handlebar and install the holder with “up” mark facing up. Be sure to align the punch mark with the holder joint. First tighten the upper bolt and then tighten the lower bolt.
Page 153 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Disassembly Remove the brake caliper seat from the brake caliper. Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake...
Page 154 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Check the piston for scratch or wear. Measure the piston O.D. with a micrometer. Service Limit: 25.30mm Check the caliper cylinder for scratch or wear and measure the cylinder bore.
Page 155 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Installation Install the brake caliper and tighten the two bolts. Torque: 2.9 3.5kg-m Bolts Bolt Connect the brake fluid pipe to the brake caliper and tighten the fluid pipe bolt.
Page 156 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Mount Bolt FRONT SHOCK ABSORBER REMOVAL Remove the front wheel. ( Ö 13-5) Remove the front fender. ( Ö 12-6) Remove the front shock absorber upper mount bolts. Loosen the lower mount bolts to remove the front shock absorbers.
Page 157 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Use a vise to hold the front shock absorber tube and remove the damper from the shock absorber tube. When holding the shock absorber tube, place a shop towel under it and do not apply too much force.
Page 158 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Install the damping spring to the damper and then install them into the front shock absorber tube. Install the front shock absorber spring and tighten the damper nut. Install the front shock absorber spring with the loosely wound coils facing up.
Page 159 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Mount Bolts INSTALLATION Install the front shock absorbers onto the steering stem. Install and tighten the front shock absorber upper mount bolts. Tighten the lower mount bolts. Install the front fender.
Page 160 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK BOTTOM CONE RACE REPLACEMENT Remove the bottom cone race using a chisel. Drive a new bottom cone race into place with a proper driver. Be careful not to damage the steering stem and front fork.
Page 161 . STEERING HANDLEBAR/FRONT WHEEL/FRONT GRAND DINK 50 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSTALLATION Apply grease to top and bottom ball races and install 26 steel balls on the top ball race and 29 steel balls on the bottom ball race. Apply grease to the ball races again and then install the front fork.
Page 162: Rear Wheel/Rear Brake/Rear Shock Absorber
. REAR WHEEL/REAR BRAKE/REAR GRAND DINK 50 SHOCK ABSORBER ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER ________________________________________________________________________________ SERVICE INFORMATION ..................14-2 TROUBLESHOOTING..................14-2 REAR WHEEL ...................... 14-3 REAR BRAKE....................... 14-4 REAR SHOCK ABSORBER ................. 14-7 14-0...
Page 163 . REAR WHEEL/REAR BRAKE/REAR GRAND DINK 50 SHOCK ABSORBER 4.0kg-m 2.7kg-m 1.2kg-m 0.6kg-m 11.0kg-m 14-1...
Page 164 . REAR WHEEL/REAR BRAKE/REAR GRAND DINK 50 SHOCK ABSORBER SERVICE INFORMATION SPECIFICATIONS Standard (mm) Service Limit (mm) Item Rear wheel rim runout Rear brake drum I.D. Rear brake lining thickness 235.7 218.7 Rear shock absorber spring free length TORQUE VALUES Rear axle nut 11.0 13.0kg-m...
Page 165: Shock Absorber
. REAR WHEEL/REAR BRAKE/REAR GRAND DINK 50 SHOCK ABSORBER Rear Axle Nut REAR WHEEL REMOVAL Remove the two exhaust muffler joint lock nuts. Remove the two exhaust muffler lock bolts. Remove the exhaust muffler. Remove the rear axle nut to remove the rear wheel.
Page 166 . REAR WHEEL/REAR BRAKE/REAR GRAND DINK 50 SHOCK ABSORBER REAR BRAKE Remove the rear wheel. ( Ö 14-3) Inspect the rear brake drum. Measure the rear brake drum I.D. Service Limit: 95.5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness.
Page 167 . REAR WHEEL/REAR BRAKE/REAR GRAND DINK 50 SHOCK ABSORBER Remove the brake cam bolt to remove the brake arm, wear indicator plate and felt seal. Remove the. brake arm. Brake Cam Brake Arm REAR BRAKE ASSEMBLY Apply grease to the anchor pin and brake shoe moving parts.
Page 168 . REAR WHEEL/REAR BRAKE/REAR GRAND DINK 50 SHOCK ABSORBER Brake Cable Brake Arm Pin Install the brake arm pin. Connect the brake cable and install the adjusting nut. Install the rear wheel. ( Ö 14-3) Adjust the rear brake lever free play.
Page 169 GRAND DINK 50 . ELECTRICAL EQUIPMENT ELECTRICAL EQUIPMENT SERVICE INFORMATION ..................15- 1 TROUBLESHOOTING..................15- 1 CHARGING SYSTEM................... 15- 3 BATTERY ......................15- 4 IGNITION SYSTEM ....................15- 7 STARTING SYSTEM .................... 15- 11 15-0...
Page 170: Electrical Equipment
. ELECTRICAL EQUIPMENT GRAND DINK 50 SERVICE INFORMATION GENERAL INSTRUCTIONS x It is not necessary to check the battery electrolyte or fill with distilled water. x Remove the battery from the motorcycle for charging. Do not remove the electrolyte cap..
Page 171 GRAND DINK 50 . ELECTRICAL EQUIPMENT IGNITION SYSTEM No spark at plug Engine starts but turns poorly x Faulty spark plug x Ignition primary circuit x Poorly connected, broken or shorted wire —Faulty ignition coil —Between A.C. generator and CDI unit —Poorly connected wire or connector...
Page 172 . ELECTRICAL EQUIPMENT GRAND DINK 50 CHARGING SYSTEM Dimmer Switch Headlight Switch Resistor Ignition Switch A.C. Generator 15-3...
Page 173 GRAND DINK 50 . ELECTRICAL EQUIPMENT BATTERY BATTERY REMOVAL Remove the battery cover. Disconnect the battery cables . First disconnect the battery negative (-) cable and then the positive (+) cable. Remove the battery. The installation sequence is the reverse of removal.
Page 174 . ELECTRICAL EQUIPMENT GRAND DINK 50 PERFORMANCE TEST Warm up the engine. Remove the floor mat and front tool box cover. Use a fully charged battery to check the charging system output. Stop the engine and open the fuse box.
Page 175 GRAND DINK 50 . ELECTRICAL EQUIPMENT Bolt RESISTOR INSPECTION Remove the frame front cover. ( Ö 12-3) Measure the resistance between the resistor B pink wire and ground. Measure the resistance between the resistor A green/black wire and ground. Resistances: Resistor A: 9.9 12.0:...
Page 176 . ELECTRICAL EQUIPMENT GRAND DINK 50 Ignition Coil A.C. Generator (Exciter Coil) Ignition Switch Spark Plug 15-7...
Page 177 GRAND DINK 50 . ELECTRICAL EQUIPMENT IGNITION COIL INSPECTION Continuity Test This test is to inspect the continuity of ignition coil. Remove the met-in box. ( Ö 12-4) Measure the resistance between the ignition coil primary coil terminals. Resistance (20 ): 0.153 0.187:...
Page 178 . ELECTRICAL EQUIPMENT GRAND DINK 50 Performance Test Remove the ignition coil. Ignition Coil Inspect the ignition coil with an ignition coil tester. Follow the ignition coil tester manufac- turer‘s instructions. 1. Turn the changeover switch to 12V and connect the ignition coil to the tester.
Page 179 GRAND DINK 50 . ELECTRICAL EQUIPMENT Coupler CDI UNIT INSPECTION Remove the battery cover. Disconnect the CDI coupler and remove the CDI unit. CDI Unit CDI CIRCUIT INSPECTION Measure the resistance between the terminals. Black/ Yellow Green Replace the CDI unit if the readings are not within the specifications in the table below.
Page 180 . ELECTRICAL EQUIPMENT GRAND DINK 50 Starter Button Starter Relay Ignition Switch Starter Motor 15-11...
Page 181 GRAND DINK 50 . ELECTRICAL EQUIPMENT Starter Relay STARTER RELAY INSPECTION Remove the front cover. Disconnect the starter relay coupler and then remove the starter relay. Yellow/Red Connect the starter relay green/yellow terminal to the 12V battery positive (+) terminal and the relay yellow/red terminal to the battery negative (-) terminal.
Page 182 . ELECTRICAL EQUIPMENT GRAND DINK 50 STARTER MOTOR INSPECTION Connect a battery across the starter motor Starter Motor and check for its operation. Battery (+) Terminal 1. Do not turn the starter motor for a long time. 2. This inspection should be done with a fully charged battery.
Page 183: Instrument/Switches/Lights
. INSTRUMENT/SWITCHES/LIGHTS GRAND DINK 50 INSTRUMENT/SWITCHES/LIGHTS SERVICE INFORMATION ..................16-1 TROUBLESHOOTING..................16-1 FUEL UNIT ......................16-2 OIL METER ......................16-3 SWITCHES......................16-5 STOP SWITCH INSPECTION/HORN ..............16-6 BULB REPLACEMENT..................16-7 INSTRUMENT/HEADLIGHT................. 16-8 16-0...
Page 184 . INSTRUMENT/SWITCHES/LIGHTS GRAND DINK 50 SERVICE INFORMATION GENERAL INSTRUCTIONS x Wires should be connected to other wires of the same color. Couplers must be connected to other couplers of the same color. x All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
Page 185 . INSTRUMENT/SWITCHES/LIGHTS GRAND DINK 50 Fuel Unit FUEL UNIT No Smoking! REMOVAL Remove the floor board. (2-4) Remove the leg shield. (2-5) Disconnect the fuel unit wire connectors. Do not damage the fuel unit wire. Remove the fuel unit. Fuel Unit Wire Be careful not to bend or damage the fuel unit float arm.
Page 186 . INSTRUMENT/SWITCHES/LIGHTS GRAND DINK 50 Groove INSTALLATION The installation sequence is the reverse of removal. x Align the groove on the fuel unit with the flange on the fuel tank. Flange OIL METER INSPECTION Oil Meter Remove the met-in box. ( Ö 12-4) Remove the frame body cover.
Page 187 . INSTRUMENT/SWITCHES/LIGHTS GRAND DINK 50 Move the oil meter float up and down to see if the oil indicator light will go out and come If the oil indicator light does not light, check for burned bulb, loose wire or connector.
Page 188 . INSTRUMENT/SWITCHES/LIGHTS GRAND DINK 50 HEADLIGHT SWITCH INSPECTION Remove the handlebar front cover. ( Ö 12-3) Disconnect the headlight switch wire coupler and check for continuity between wire terminals. Color BR/W Symbol Headlight Switch Passing Switch DIMMER SWITCH INSPECTION Check for continuity between wire terminals.
Page 189 . INSTRUMENT/SWITCHES/LIGHTS GRAND DINK 50 STARTER SWITCH INSPECTION Check for continuity between wire terminals. Push the starter button when measuring. Color Symbol FREE PUSH Starter Switch HORN SWITCH INSPECTION Check for continuity between wire terminals. Push the horn button when measuring.
Page 190 . INSTRUMENT/SWITCHES/LIGHTS GRAND DINK 50 Horn Terminal HORN INSPECTION Remove the frame front cover. ( Ö 12-3) Disconnect the horn wire couplers. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals.
Page 191 . INSTRUMENT/SWITCHES/LIGHTS GRAND DINK 50 INSTRUMENT Instrument Bulbs Replacement Remove the front upper cover. Disconnect the instrument wire couplers and connectors. Disconnect the speedometer cable. Remove four screws in the instrument cover and leg shield. Remove the instrument. Instrument SPEEDOMETER REMOVAL Disconnect the speedometer cable.
Page 192: Exhaust Emission Control System
. EXHAUST EMISSION CONTROL GRAND DINK 50 SYSTEM ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ EXHAUST EMISSION CONTROL SYSTEM ________________________________________________________________________________ SCHEMATIC DRAWING ..................17-1 EXHAUST EMISSION CONTROL SYSTEM FUNCTION ........17-1 TROUBLESHOOTING .................... 17-2 SERVICE INFORMATION..................17-2 SECONDARY AIR CLEANER ................. 17-3 AIR INJECTION CUT-OFF VALVE (A.I.C.V.)............
Page 193 . EXHAUST EMISSION CONTROL GRAND DINK 50 SYSTEM SCHEMATIC DRAWING EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted in this model utilizes the reed valve to draw secondary air into the exhaust system for re-combustion by means of exhaust pulsation so as to minimize the exhaust emission.
Page 194: Exhaust Emission Control
. EXHAUST EMISSION CONTROL GRAND DINK 50 SYSTEM TROUBLESHOOTING High CO at idle speed 1. Damaged or clogged reed valve 2. Damaged or clogged air injection cut-off valve 3. Clogged air cleaner Backfiring at sudden deceleration 1. Damaged reed valve (malfunction) 2.
Page 195 . EXHAUST EMISSION CONTROL GRAND DINK 50 SYSTEM Secondary Air Cleaner / A.I.C.V. SECONDARY AIR CLEANER / AIR INJECTION CONTROL VALVE (A.I.C.V.) REMOVAL Remove the seat. ( Ö 2-4) Remove the body cover. Disconnect the secondary air cleaner /(A.I.C.V) connecting tube.
Page 196 . EXHAUST EMISSION CONTROL GRAND DINK 50 SYSTEM Reed Valve Cover Bolt REED VALVE REMOVAL Disconnect the secondary air inlet tube connector. Remove the reed valve cover three bolts. Secondary Air Inlet Tube Bolt Remove the three bolts attaching the reed valve cover and the reed valve.

KYMCO GRAND DINK 50 Service Manual

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