3. INSPECTION/ADJUSTMENT

3-0

GRAND DINK 125/150

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SERVICE INFORMATION -------------------------------------------- 3- 1MAINTENANCE SCHEDULE ---------------------------------------- 3- 2FUEL LINE/FUEL FILTER ------------------------------------------- 3- 3THROTTLE OPERATION --------------------------------------------- 3- 3ENGINE OIL ------------------------------------------------------------ 3- 4AIR CLEANER ---------------------------------------------------------- 3- 5SPARK PLUG ----------------------------------------------------------- 3- 5VALVE CLEARANCE ------------------------------------------------- 3- 6CARBURETOR IDLE SPEED ----------------------------------------- 3- 6IGNITION TIMING----------------------------------------------------- 3- 7CYLINDER COMPRESSION ------------------------------------------ 3- 7FINAL REDUCTION GEAR OIL ------------------------------------- 3- 8DRIVE BELT ------------------------------------------------------------ 3- 8HEADLIGHT AIM ------------------------------------------------------ 3- 9CLUTCH SHOE WEAR ------------------------------------------------ 3- 9COOLING SYSTEM ---------------------------------------------------- 3- 9BRAKE SYSTEM ------------------------------------------------------- 3-10NUTS/BOLTS/FASTENERS------------------------------------------- 3-11WHEELS/TIRES -------------------------------------------------------- 3-11STEERING HANDLEBAR--------------------------------------------- 3-11SUSPENSION ----------------------------------------------------------- 3-11

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3. INSPECTION/ADJUSTMENT

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GRAND DINK 125/150

SERVICE INFORMATION

GENERAL

WARNING

•Before running the engine, make sure that the working area is well-ventilated.Never run the engine in a closed area. The exhaust contains poisonous carbonmonoxide gas which may cause death to people.

•Gasoline is extremely flammable and is explosive under some conditions. Theworking area must be well-ventilated and do not smoke or allow flames orsparks near the working area or fuel storage area.

SPECIFICATIONS

ENGINEThrottle grip free play : 2_ 6mmSpark plug : NGK: DPR7EA9Spark plug gap : 0.9mmValve clearance : IN: 0.1mm EX: 0.1mmIdle 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±20ccGear oil capacity : Radiator capacity : 1000±20cc At disassembly : 0.20 liter Reserve tank capacity : 400±20cc At change : 0.18 liter

CHASSISFront/rear brake free play: 20_ 30mm

TIRE

1 Rider 2 Riders

Front 1.75kg/cm_ 1.75kg/cm_

Rear 2.00kg/cm_ 2.25kg/cm_

TIRE SPECIFICATION: Front : 120/70-12 56J Rear : 140/70-12 59J

TORQUE VALUES Front axle nut : 14.8_ 68.6N-m Rear axle nut : 107.8_ 127.4N-m

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GRAND DINK 125/150

MAINTENANCE SCHEDULEPerform the periodic maintenance at each scheduled maintenance period.I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary.A: Adjust C: Clean R: Replace T : Tighten

Regular Service Mileage (km)Frequency

Item

comesfirst ! Ú

1000 2000 4000 6000 8000 10000

Engine oil R Newmotorcycle

300kmR R R R R

Engine oil filter screen Replace at every 6000 km(R)

Fuel filter screen R

Gear oil Note 3 R Newmotorcycle

300kmR R

Valve clearance A A A

Carburetor I I

Air Cleaner Note 2,3 I R R

Spark plug Clean at every 3000km and replace if necessary

Brake system I I I I I I

Drive belt I

Suspension I I

Nut, bolt, fastener I

Tire I I

Steering head bearing I I I

Brake fluid Perform pre-ride inspection daily

Radiator coolant Replace every year or at every 10000km (R)

Radiator core I I

Radiator cap I I

Brake lever I I

Brake shoe wear I I

Shock absorber I I

• In the interest of safety, we recommend these items be serviced only by an authorizedKYMCO 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.

Whichever

3. INSPECTION/ADJUSTMENT

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GRAND DINK 125/150

FUEL LINE/FUEL FILTERRemove the center cover.Check the fuel lines and replace any partswhich show signs of deterioration, damage orleakage.Check for dirty or clogged fuel filter andreplace with a new one if it is clogged.

THROTTLE OPERATIONCheck the throttle grip for smooth movement.Measure the throttle grip free play.Free Play: 2_ 6mm

Major adjustment of the throttle grip freeplay is made with the adjusting nut at thecarburetor side. Adjust by loosening the locknut and turning the adjusting nut.

Minor adjustment is made with the adjustingnut at the throttle grip side.Slide the rubber cover out and adjust byloosening the lock nut and turning theadjusting nut.

Lock Nut

Adjusting Nut

Fuel Filter

• Do not smoke or allow flames orsparks in your working area.

＊

Fuel Line

Lock Nut

Adjusting Nut

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GRAND DINK 125/150

ENGINE OILOIL LEVEL INSPECTIONStop the engine and support the motorcycleupright on level ground.Wait for 2_ 3 minutes and check the oillevel with the dipstick. Do not screw in thedipstick when making this check.

OIL CHANGE

Remove the oil drain bolt to drain the engineoil.Install the aluminum washer and tighten theoil drain bolt.Torque: 14.7N-m

Pour the recommended oil through the oilfiller hole.Oil Capacity: At disassembly: 1.1 liter At change: 0.9 literRecommended Oil: SAE: 15W40# API: SJStart the engine and check for oil leaks.Stop the engine and recheck the oil level.

OIL FILTER SCREEN INSPECTIONDrain the engine oil.Remove the oil filter screen cap.Clean the oil filter screen.Install the oil filter screen, and filter screencap.Fill the engine with recommended engine oil.

• Drain the oil while the engine is warm.＊

• Replace the aluminum washer with anew one if it is deformed or damaged.

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Oil Dipstick

Oil Filter Screen Cap

Oil Filter Screen

Oil Filter Screen Cap

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GRAND DINK 125/150

AIR CLEANERRemove the seven air cleaner case coverscrews and the cover.

Remove the air cleaner element.Check the element and replace it if it isexcessively dirty or damaged.

CHANGE INTERVALMore frequent replacement is required whenriding in unusually dusty or rainy areas.

SPARK PLUGRemove the frame center cover.Remove the spark plug cap and spark plug.Check the spark plug for wear and foulingdeposits.Clean any fouling deposits with a spark plugcleaner or a wire brush.

Specified Spark Plug: NGK: DP7EA9Measure the spark plug gap.Spark Plug Gap: 0.9mm

Torque: 7.8_ 9.8N-m ｝GapWearFoulingDeposits

Spark Plug

CracksDamage

• The air cleaner element has aviscous type paper element. Do notclean it with compressed air.

• Be sure to install the air cleanerelement and cover securely.

＊

• When installing, first screw in the sparkplug by hand and then tighten it with aspark plug wrench.

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Screws

Air Cleaner Case Cover

Air Cleaner Element

Deformation

0.9mm

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GRAND DINK 125/150

VALVE CLEARANCE

Remove the cylinder head cover.

Turn the A.C. generator flywheel to the topdead center (TDC) on the compression strokeso that the “T” mark on the flywheel alignswith the index mark on the left crankcasecover.

Inspect and adjust valve clearance.Valve Clearance: IN: 0.1mm

EX: 0.1mmLoosen the lock nut and adjust by turning theadjusting nut

Valve Wrench

CARBURETOR IDLE SPEED

Lift up the seat and remove the inspectioncover.Warm up the engine before this operation.Start the engine and connect a tachometer.Turn the throttle stop screw to obtain thespecified idle speed.Idle Speed: 1700rpmWhen the engine misses or run erratic, adjustthe pilot screw.

Throttle Stop Screw Pilot Screw

Feeler Gauge

• Inspect and adjust valve clearance whilethe engine is cold (below 35℃ ).

＊

• Check the valve clearance again afterthe lock nut is tightened.

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• The engine must be warm for accurateidle speed inspection and adjustment.

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Cylinder Head Cover

Bolts

“T” Mark

Top Dead Center

Valve Wrench

Special

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GRAND DINK 125/150

IGNITION TIMING

Remove the timing hole cap.

Check the ignition timing with a timing light.When the engine is running at the specifiedidle speed, the ignition timing is correct if the“F” mark on the flywheel aligns with theindex 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 theadvance marks.

CYLINDER COMPRESSIONWarm up the engine before compression test.Remove the center cover and spark plug cap.Remove the spark plug .Insert a compression gauge.Open the throttle valve fully and push thestarter button to test the compression.Compression: 15±2kg/cm_If the compression is low, check for thefollowing:_Leaky valves_Valve clearance to small_Leaking cylinder head gasket_Worn pistons_Worn piston/cylinderIf the compression is high, it indicates thatcarbon deposits have accumulated on thecombustion chamber and the piston head.

Compression Gauge

Timing Light

• The CDI unit is not adjustable.• If the ignition timing is incorrect, check

the ignition system,

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Timing Hole Cap

“F” Mark

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GRAND DINK 125/150

FINAL REDUCTION GEAR OIL

Stop the engine and remove the oil check bolt.The oil level shall be at the oil check bolt hole.If the oil level is low, add the recommendedoil SAE90# to the proper level.

Install the oil check bolt.

OIL CHANGERemove the oil check bolt.Remove the oil drain bolt and drain the oilthoroughly.Install the oil drain bolt.Torque: 9.8N-m

Fill the final reduction with the recommendedoil SAE90#.Gear Oil Capacity: At disassembly : 200cc At change : 180ccReinstall the oil check bolt and check for oilleaks.

DRIVE BELTRemove the left crankcase cover.Inspect the drive belt for cracks or excessivewear.Replace the drive belt with a new one ifnecessary and in accordance with theMaintenance Schedule.

Drive Belt

Oil Check Bolt Hole/Oil Filler

• Place the motorcycle on its main standon level ground.

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Oil Drain Bolt/Sealing Washer

• Make sure that the sealing washer is ingood condition.

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• Make sure that the sealing washer is ingood condition.

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GRAND DINK 125/150

HEADLIGHT AIMTurn the ignition switch ON.Turn on the headlight switch.Adjust the headlight aim by turning theheadlight aim adjusting bolt.

CLUTCH SHOE WEARStart the engine and check the clutchoperation by increasing the engine speedgradually.If the motorcycle tends to creep, or the enginestalls, check the clutch shoes for wear andreplace if necessary.

COOLING SYSTEMCOOLANT LEVEL INSPECTIONPlace the motorcycle on its main stand onlevel ground.Check the coolant level of the reserve tankand the level should be between the upperand lower level lines.If necessary, fill the reserve tank withrecommended coolant to the “F” level line.Recommended Coolant: SIGMA Coolant (Standard Concentration 30%)

COOLANT REPLACEMENT

Remove the front cover.Remove the radiator cap.Remove the drain bolt to drain the coolantand tilt the motorcycle to the right and thecoolant will drain more easily.Drain the coolant in the reserve tank.Reinstall the drain bolt.Fill the radiator with the specified coolant.

Lower Line

Headlight Aim Adjusting Bolt

Upper Line

Radiator Cap

• The coolant level does not change nomatter the engine is warm or cold. Fillto the “F” (upper) line.

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• The coolant freezing point should be5℃ lower than the temperature ofthe riding area.

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• Perform this operation when the engineis cold.

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Reserve Tank

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GRAND DINK 125/150

Coolant capacity : 1400±20ccRadiator capacity : 1000±20ccReserve tank capacity : 400±20ccStart the engine and check if there is nobubbles in the coolant and the coolant level isstable. Reinstall the radiator cap.If there are bubbles in the coolant, bleed airfrom the system.Fill the reserve tank with the recommendedcoolant up to the upper line.

BRAKE SYSTEMBRAKE LEVERMeasure the front and rear brake lever freeplays.

BRAKE FLUIDTurn the steering handlebar upright and checkif the front/rear brake fluid level is at theupper limit. If the brake fluid is insufficient,fill to the upper limit.Specified Brake Fluid: DOT-4

BRAKE DISK/BRAKE PADCheck the brake disk surface for scratches,unevenness or abnormal wear.Check if the brake disk runout is within thespecified service limit.Check if the brake pad wear exceeds the wearindicator line.

Wear Indicator Line

Drain Bolt

Rear Brake Reservoir

Brake Disk

• The brake fluid level will decrease if thebrake pads are worn.

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• Keep grease or oil off the brake disk toavoid brake failure.

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Front Brake Reservoir

3. INSPECTION/ADJUSTMENT

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GRAND DINK 125/150

NUTS/BOLTS/FASTENERSCheck all important chassis nuts and bolts forlooseness.Tighten them to their specified torque valuesif any looseness is found.

WHEELS/TIRESCheck the tires for cuts, imbedded nails orother damages.Check the tire pressure.

Tire Pressure

1 Rider 2 Riders

Front 1.75kg/cm_ 1.75kg/cm_

Rear 2.00kg/cm_ 2.25kg/cm_

STEERING HANDLEBARRaise the front wheel off the ground andcheck that the steering handlebar rotatesfreely.If the handlebar moves unevenly, binds, orhas vertical movement, adjust the steeringhead bearing.

SUSPENSIONCheck the action of the front/rear shockabsorbers by compressing them several times.Check the entire shock absorber assembly foroil leaks, looseness or damage.Jack the rear wheel off the ground and movethe rear wheel sideways with force to see ifthe engine hanger bushings are worn.Replace the engine hanger bushings if there isany looseness.

• Tire pressure should be checked whentires are cold.

＊ Pressure Gauge