KYMCO Dink 50 Manual de usuario

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. 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.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

OCTOBER 2004

The information, specifications, and

illustrations included in this manual

may be different from the motorcycle

in case specifications are changed.

• •

1.SPECIFICATIONS

1-0

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.................................................................................12

STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/

FRONT SHOCK ABSORBER/FRONT FORK .....................................13

REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER ..............14

ELECTRICAL EQUIPMENT................................................................. 15

INSTRUMENT/SWITCHES/LIGHTS ....................................................16

EXHAUST EMISSION CONTROL SYSTEM //////////////////////////17

1.SPECIFICATIONS

1-1

GRAND DINK 50

SPECIFICATIONS

Name & Model SF10JA(LDA5)

Overall length (mm) 2045

Overall width (mm) 760

Overall height (mm) 1360

Wheel base (mm) 1435

Engine type Air cooled 2-stroke

Fuel Used 92# nonleaded gasoline

Displacement (cc) 49.4 cc

Front wheel 50

Net weight (kg) Rear wheel 70

Total 120

Front wheel 91

Gross weight(kg) Rear wheel 173

Total 264

Front wheel 120/70-12

Tires Rear wheel 130/70-12

Ground clearance (mm) 140

Braking distance (m)

(Initial speed Km/h) 4.4m (30km/h)

Min. turning radius (mm)R/L 2250/2200

Starting system Starting motor &

kick starter

Fuel type Gasoline, 2-stroke

motor oil

Cylinder arrangement Single cylinder, flat

Combustion chamber type Semi-sphere

Valve arrangement Reed valve & piston

Bore x stroke (mm) 39 x 41.4

Compression ratio 7.2:1 0.2

Compression pressure

(kg/cm²rpm) 11.8kg/cm²2

Max. output (ps/r/min)

Speed limit/No limit

3.5/7000

4.0/7000

Max. torque (kg m/rpm) 0.4/6000 kg m/rpm

Open Automatic controlled

Intake Close Automatic controlled

Port Open !

timing Exhaust Close !

Open !

Scaveng

eClose !

Idle speed (rpm) 1850 100

Lubrication type Separate type

Oil pump type Plunger type

Oil filter type Full-flow filtration

Lubrication oil capacity (liter) 1.3

Air cleaner type & No. Wet, single

Fuel capacity (liter) 9.5

Type Plunger type

Carburetor Piston dia. (mm) !

Venturi dia. (mm) 14

Ignition system type CDI electromagnetic

Ignition

Ignition timing F mark 13.5" 1"BTDC/2000

rpm

Spark

plug NGK BR8HSA

Spark plug gap (mm) 0.6Д0.7

Battery capacity 12V3AH

Power to transmission gear Power-transmission

gear-clutch

Reduction ratio of power to

transmission !

Clutch type Dry multi-disc clutch

Transmission gear operation

type Automatic centrifugal

type

Transmission ratio 1 speed !

Reduction Type Two-stage reduction

gear 1st reduction ratio 3.1~1.4

2nd reduction ratio 12.48

Transmission gear type Non-stage

Tire

ressure Front wheel 1.75 kg/cm²

(kg/cm²)Rear wheel 2.0 kg/cm²

Turning angle Right & left 45"

Brake s

stem Front wheel hydraulic

type Rear wheel Expanding

Sus

ension Front wheel Telescope

type Rear wheel Unit swing

Shock absorber Front wheel Telescope

type Rear wheel Unit swing

Frame type Pipe under bone

2. GENERAL INFORMATION

2-0

GRAND DINK 50

________________________________________________________________________________

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 ....................................................................................... 2- 15

WIRING DIAGRAM............................................................................................... 2- 16

CABLE & HARNESS ROUTING........................................................................... 2- 18

TROUBLESHOOTING.......................................................................................... 2- 22

2. GENERAL INFORMATION

2-1

GRAND DINK 50

ENGINE SERIAL NUMBER/IDENTIFICATION

Location of Engine Serial Numbe

2. GENERAL INFORMATION

2-2

GRAND DINK 50

SERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when reassembling.

When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

Use genuine parts and lubricants.

When servicing the motorcycle, be sure to

use special tools for removal and

installation.

After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

2. GENERAL INFORMATION

2-3

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.

Disconnect the battery negative (-) terminal

before operation.

When using a spanner or other tools, make

sure not to damage the motorcycle surface.

After operation, check all connecting points,

fasteners, and lines for proper connection

and installation.

When connecting the battery, the positive

(+) terminal must be connected first.

After connection, apply grease to the

battery terminals.

Terminal caps shall be installed securely.

2. GENERAL INFORMATION

2-4

GRAND DINK 50

If the fuse is burned out, find the cause and

repair it. Replace it with a new one

according to the specified capacity.

After operation, terminal caps shall be

installed securely.

When taking out the connector, the lock on

the connector shall be released before

operation.

Hold the connector body when connecting

or disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is bending,

protruding or loose.

Confirm

Capacity

2. GENERAL INFORMATION

2-5

GRAND DINK 50

The connector shall be inserted

completely.

If the double connector has a lock, lock

it at the correct position.

Check if there is any loose wire.

Before connecting a terminal, check for

damaged terminal cover or loose

negative terminal.

Check the double connector cover for

proper coverage and installation.

Insert the terminal completely.

Check the terminal cover for proper

coverage.

Do not make the terminal cover opening

face up.

Secure wire harnesses to the frame with

their respective wire bands at the

designated locations.

Tighten the bands so that only the

insulated surfaces contact the wire

harnesses.

Snapping!

2. GENERAL INFORMATION

2-6

GRAND DINK 50

After clamping, check each wire to make

sure it is secure.

Do not squeeze wires against the weld or

its clamp.

After clamping, check each harness to

make sure that it is not interfering with any

moving or sliding parts.

When fixing the wire harnesses, do not

make it contact the parts which will

generate high heat.

Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of

bolts and screws.

Route wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

No Contact !

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