1. GENERAL INFORMATION

1-0

GRAND DINK 250

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GENERAL INFORMATION__________________________________________________________________________________

ENGINE SERIAL NUMBER--------------------------------------------- 1-1

SPECIFICATION---------------------------------------------------------- 1-2

SERVICE PRECAUTIONS----------------------------------------------- 1-3

TORQUE VALUES ------------------------------------------------------- 1-7

TOOLS --------------------------------------------------------------------- 1-8

LUBRICATION POINTS------------------------------------------------- 1-9

CABLE & HARNESS ROUTING-----------------------------------------1-11

WIRING DIAGRAM-------------------------------------------------------------------1-16

TROUBLESHOOTING --------------------------------------------------1-17

1

1. GENERAL INFORMATION

1-1

GRAND DINK 250

SERIAL NUMBER

Location of Engine Serial NumberLocation of Frame Serial Number

Vehicle Identification Serial Number

1. GENERAL INFORMATION

1-2

GRAND DINK 250

SPECIFICATIONS

Name & Model No. SH50DAMotorcycle Name & Type GRAND DINK 250Overall length 2060mmOverall width 770mmOverall height 1360mmWheel base 1435mm

Engine type Water cooled 4-stroke,OHC engine

Displacement 249ccFuel Used 92# nonleaded gasoline

Front wheel 58Net weight (kg) Rear wheel 92

Total 150Front wheel 63.5

Gross weight(kg) Rear wheel 99.5Total 163

Front wheel 120/70-12Rear wheel 140/70-12

Ground clearance 140mmPerform-

Braking distance (m) 7.0m/30km/hr

ance Min. turning radius 2350mm

Starting system Starting motor

Type Gasoline, 4-strokeCylinder arrangement Single cylinderCombustion chamber type Semi-sphereValve arrangement O.H.C.Bore x stroke (mm) 72.7 x 60Compression ratio 10.3:1Compression pressure(kg/cm_) 15±2

Max. output (kw/rpm) 13.4/7000Max. torque (N.m/rpm) 19.6/5500

BTDC 8°Port

IntakeABDC 42°

t iming

BBDC 33°Exhaust

ATDC 1°

Valve Intake 0.1clearance (cold) Exhaust 0.1Idle speed (rpm) 1700±100rpm

Lubrication type Forced pressure &wet sump

Oil pump type Inner/outer rotortype

Oil filter type Full-flow filtrationOil capacity 1.1 liters

Cooling Type Water cooling

Air cleaner type & No Paper element, wetFuel capacity 9.1 liters

Type CVKPiston dia. 30Venturi dia. 30 equivalentThrottle type Butterfly typeType CDIIgnition timing repeatedlyContact breaker Non-contact point

type

Spark plug NGKDPR7EA-9

Spark plug gap 0.9mmBattery Capacity 12V10AHClutch Type Dry multi-disc clutch

Type Non-stage transmission

Operation Automaticcentrifugal

Type

Type Two-stage reduction

Reduction 1st 0.83~2.2ratio 2nd 6.98

Front Caster angle 27°Axle Connecting rod

Front 2.00Tire pressure(kg/cm_) Rear 2.25

Turning Left 45°angle Right 45°

Front Disk brakeBrake systemtype Rear Disk brake

Suspension Front Telescopetype Rear Double swing

Shock absorber Front Telescopetype Rear Double swing

Frame type Under bone

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power D

rive System

Transm

is-sion G

earR

eductionG

ear

Moving D

eviceD

amping

Device

1. GENERAL INFORMATION

1-3

GRAND DINK 250

SERVICE PRECAUTIONS

nMake sure to install new gaskets, O-rings,circlips, cotter pins, etc. whenreassembling.

nWhen tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torquediagonally.

n Use genuine parts and lubricants.

nWhen servicing the motorcycle, be sure touse special tools for removal andinstallation.

n After disassembly, clean removed parts.Lubricate sliding surfaces with engine oilbefore reassembly.

n Apply or add designated greases andlubricants to the specified lubricationpoints.

n After reassembly, check all parts forproper tightening and operation.

nWhen two persons work together, payattention to the mutual working safety.

n Disconnect the battery negative (-) terminalbefore operation.nWhen using a spanner or other tools, make

sure not to damage the motorcycle surface.

n After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.nWhen connecting the battery, the positive

(+) terminal must be connected first.n After connection, apply grease to the

battery terminals.n Terminal caps shall be installed securely.

1. GENERAL INFORMATION

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GRAND DINK 250

n If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.

n After operation, terminal caps shall beinstalled securely.

nWhen taking out the connector, the lock onthe connector shall be released beforeoperation.

n Hold the connector body when connectingor disconnecting it.n Do not pull the connector wire.

n Check if any connector terminal is bending,protruding or loose.

n The connector shall be insertedcompletely.n If the double connector has a lock, lock

it at the correct position.n Check if there is any loose wire.

n Before connecting a terminal, check fordamaged terminal cover or loose negativeterminal.

n Check the double connector cover forproper coverage and installation.

n Insert the terminal completely.n Check the terminal cover for proper

coverage.n Do not make the terminal cover opening

face up.

n Secure wire harnesses to the frame withtheir respective wire bands at thedesignated locations.Tighten the bands so that only theinsulated surfaces contact the wireharnesses.

ConfirmCapacity

1. GENERAL INFORMATION

1-5

GRAND DINK 250

n After clamping, check each wire to makesure it is secure.

n Do not squeeze wires against the weld orits clamp.

n After clamping, check each harness to makesure that it is not interfering with anymoving or sliding parts.

nWhen fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.

n Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends ofbolts and screws.n Route wire harnesses passing through the

side of bolts and screws. Avoid theprojected ends of bolts and screws.

n Route harnesses so they are neitherpulled tight nor have excessive slack.

n Protect wires and harnesses with electricaltape or tube if they contact a sharp edge orcorner.

nWhen rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled securely.

n Do not break the sheath of wire.n If a wire or harness is with a broken sheath,

repair by wrapping it with protective tapeor replace it.

nWhen installing other parts, do not press orsqueeze the wires.

Do not pulltoo tight

No Contact

Do not pressor squeeze thewire

1. GENERAL INFORMATION

1-6

GRAND DINK 250

n After routing, check that the wire harnessesare not twisted or kinked.

nWire harnesses routed along with handlebarshould not be pulled tight, have excessiveslack or interfere with adjacent orsurrounding parts in all steering positions.

nWhen a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.

n Be careful not to drop any parts.

nWhen rust is found on a terminal, removethe rust with sand paper or equivalentbefore connecting.

n Symbols:The following symbols represent theservicing methods and cautions included inthis service manual.

: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

Special

Engine Oil

Grease

Gear Oil

＊Do youunderstand theinstrument？

RemoveRust

1. GENERAL INFORMATION

1-7

GRAND DINK 250

TORQUE VALUES

STANDARD TORQUE VALUES

Item Torque (N-m) Item Torque (N-m)

5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut

4.99.821.634.353.9

5mm screw6mm screw, SH bolt6mm flange bolt, nut8mm flange bolt, nut10mm flange bolt, nut

3.98.811.826.539.2

Torque specifications listed below are for important fasteners.

ENGINE

Item Q‘ty Thread dia.(mm) Torque (N-m) Remarks

Cylinder head bolt ACylinder head bolt BOil filter screen capExhaust muffler joint lock nutCylinder head cap nutValve adjusting lock nutCam chain tensioner slipper boltOil boltClutch outer nutClutch drive plate nutFlywheel nutOil pump boltCylinder head cover boltSpark plugCam chain tensioner boltWater pump impeller

2212421111124111

8830885612121214561068

8.9

8.914.78.824.58.88.812.753.953.958.83.911.817.211.811.8

Double end boltDouble end boltApply oil tothreads

Left hand threads

FRAME

Item Q‘ty Thread dia.(mm) Torque (N-m) Remarks

Steering stem lock nutFront axle nutRear axle nutRear shock absorber upper boltRear shock absorber lower boltFront shock absorber lock boltEngine hanger bolt

1112241

1012141081012

44.168.6127.429.429.424.553.9

U-nutU-nutU-nut

1. GENERAL INFORMATION

1-8

GRAND DINK 250

SPECIAL TOOLS

Tool Name Tool No. Remarks Ref. Page

Valve guide driver Valve guide removal/installationValve guide reamer Valve guide grindingValve spring compressor Valve removalLock nut wrench, 39mm E027 Clutch disassemblyBearing driver Bearing removalBearing remover,10,12,15,18mm

E037 Bearing removal

Clutch spring compressor E027 Clutch disassemblyBall race remover extension Ball race removalBall race remover Ball race removalSpring compressor E038 Spring removal

Mechanical seal driver E014 Water pump mechanical sealremoval/installation

Kick starter spring remover Kick starter spring removalGear remover Starter gear removalValve adjuster E012 Tapper adjustmentFloat level gauge Carburetor fuel level checkValve seat cutter 45° Valve seat refacingValve seat cutter 32° Valve seat refacingValve seat cutter 60° Valve seat refacingCutter clip, 5mmUniversal holder E017 Holding clutch for removalBearing driver (32x35mm) E014 Bearing installationPilot, 12mm E014 Bearing installationPilot, 15mm E014 Bearing installationPilot, 17mm E014 Bearing installationFlywheel puller E003 A.C. generator flywheel removalRear shock absorber compressor F004 Rear shock absorber disassemblySteering head bearing remover F005 Steering head bearing removalFlywheel holder E021 A.C. generator flywheel holdingReamer clipFuel unit wrench Fuel unit removal

1. GENERAL INFORMATION

1-9

GRAND DINK 250

LUBRICATION POINTS

ENGINE

Lubrication Points Lubricant

Valve guide/valve stem movable part

Camshaft protruding surface

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

•Genuine KYMCO Engine Oil (SAE15W-40)

•API SE, SF or SG Egnine Oil

Starter idle gear

Friction spring movable part/shaft movable part

Shaft movable grooved part

Starter spindle movable part

High-temperature resistant grease

Starter one-way clutch threads Thread locking agent

A.C. generator connector

Transmission case breather tubee Adhesive

1. GENERAL INFORMATION

1-10

GRAND DINK 250

FRAMEThe following is the lubrication points for the frame.Use general purpose grease for parts not listed.Apply clean engine oil or grease to cables and movable parts not specified. This will avoidabnormal noise and rise the durability of the motorcycle.

Seat Lock

Rear Wheel Bearing

GreaseSpeedometer CableThrottle Cable

Speedometer Gear/Front Wheel Bearing

Engine Oil

Grease

GreaseGrease

Front Brake Lever Pivot

1. GENERAL INFORMATION

1-11

GRAND DINK 250

CABLE & HARNESS ROUTING

Front Stop Brake

Rear Stop Brake

Throttle Cable

Radiator

Front Brake Fluid Tube Front / Rear BrakeMaster Cylinder

Speedometer Cable

Horn

Pressure TypeRadiator Cap

Radiator AirVentilated Tube

1. GENERAL INFORMATION

1-12

GRAND DINK 250

Front Brake Fluid Tube

Fuel TankInlet Tube

Water Hose

Ignition Switch

Fuel Filler

Water Hoses

Fuel TankBreather Tube

Left Brake Fluid Tube

Ventilated Hose

Reserve Tank

1. GENERAL INFORMATION

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GRAND DINK 250

Throttle Cable

Speedometer Cable

Radiator AirVentilated Tube

Rear Brake FluidTube

Fuel Tank InletTube

Water Hose

Fuel Filler

Fuel TankBreather Tube

Throttle Cable

Wire Harness

Fuel Tank

Rear-view MirrorControl Relay

1. GENERAL INFORMATION

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GRAND DINK 250

Starter Relay

Fuel Tube

Battery (-) Cable

Battery (+) Cable

Ignition Coil

Thermosensor WireThermostat

Carburetor

Regulator/Rectifier

CDI Unit

Fuse Box

Starter Motor

Oil VaporRecovery Tube

1. GENERAL INFORMATION

1-15

GRAND DINK 250

Fuel Tube

Ignition Coil

Thermostat

Carburetor

Fuel Tube

Auto Bystarter

Spark Plug Cap

FuelPump

Wire Harness

Spark Plug Cap

Throttle Cable

Fuel Pump Vacuum Tube

Oil VaporRecovery Tube

Fuel Pump Vacuum Tube

Ignition Coil

Starter RelayT.P.S

Oil VaporRecovery Tube

1. GENERAL INFORMATION

1-16

GRAND DINK 250

WIRING DIAGRAM

1. GENERAL INFORMATION

1-17

GRAND DINK 250

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

ÅEmpty fuel tankÇClogged carburetor fuel inlet

tube, vacuum tube or fuel tubeÉClogged auto fuel valveÑClogged float oil passageÖClogged fuel tank cap

breather holeÜClogged fuel straineráClogged fuel filteràFaulty fuel pump

ÅFaulty spark plugÇFouled spark plugÉFaulty CDI unitÑFaulty A.C. generatorÖBroken or shorted ignition coilÜBroken or shorted exciter

coiláFaulty ignition switch

ÅStarter motor idles butcrankshaft does not rotateÇValve clearance too smallÉImproper valve and seat

contactÑWorn cylinder and piston ringsÖBlown cylinder head gasketÜFlaws in cylinder headáSeized valveàImproper valve timing

ÅFaulty auto bystarterÇAir leaking through intake

pipeÉIncorrect ignition timingÑIncorrectly adjusted pilot

screw

ÅFlooded carburetorÇFaulty auto bystarterÉThrottle valve excessively

open

Check if fuel reachescarburetor byloosening drain screw

Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground

Inspection/Adjustment Probable Cause

Spark jumps

Normal compression

Engine does not fire

Weak or no spark

Low or no compression

Engine fires but does not start

Test cylindercompression

Start engine by follow-ing normal startingprocedure

Remove spark plug andinspect again

Symptom

Fuel reaches carburetor

Fuel does not reach carburetor

Wet spark plugDry spark plug

1. GENERAL INFORMATION

1-18

GRAND DINK 250

ENGINE LACKS POWER

ÅClogged air cleanerÇRestricted fuel flowÉClogged fuel line between fuel

tank and carburetorÑClogged exhaust mufflerÖFaulty auto bystarterÜSplit carburetor vacuum piston

diaphragm

ÅFaulty CDI unitÇFaulty A.C. generator

ÅImproper valve clearanceadjustmentÇWorn valve seat (valve stem too

protruding

ÅImproper valve and seat contactÇWorn cylinder and piston ringsÉBlown cylinder head gasketÑFlaws in cylinder headÖImproper valve timing

ÅClogged carburetor jets

ÅFouled spark plugÇIncorrect heat range plug

ÅOil level too highÇOil level too lowÉOil not changed

ÅClogged oil pipeÇFaulty oil pump

ÅInsufficient coolantÇFaulty thermostatÉWorn cylinder and piston ringsÑMixture too leanÖPoor quality fuelÜExcessive carbon buildup in

combustion chamberáIgnition timing too earlyàAir in cooling system

ÅExcessive carbon build-up incombustion chamberÇPoor quality fuelÉClutch slippingÑMixture too leanÖ Ignition timing too early

Start engine and acceleratelightly for observation

Inspection/Adjustment Symptom Probable Cause

Engine speed increases

Correct timing

Engine speed does not increase sufficiently

Incorrect timing

Check ignition timing(using a timing light)

Test cylinder compression

Check carburetor forclogging

Rapidly accelerate or runat high speed

Remove spark plug andinspect

Check if engine overheats

Check valve clearance

Correct Incorrect

Normal compression

Abnormal compression

Not Clogged Clogged

Remove oil dipstick andcheck oil level and condition

Remove cylinder head oilpipe bolt and inspect

Engine overheats Engine does not overheats

Plug not fouled or discolored

Plug fouled or discolored

Correct and not contaminated

Incorrect or contaminated

Valve train lubricatedproperly

Valve train notlubricated properly

Engine does not knock Engine knocks

1. GENERAL INFORMATION

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GRAND DINK 250

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

ÅFaulty CDI unitÇFaulty A.C. generator

ÅMixture too rich (turn screwout)ÇMixture too lean (turn screw

in)

ÅDamaged insulator rubberÇCarburetor not securely

tightenedÉFaulty intake manifold

gasketÑDeformed carburetor O-ring

ÅFaulty or fouled spark plugÇFaulty CDI unitÉFaulty A.C. generatorÑFaulty ignition coilÖBroken or shorted high

tension wireÜFaulty ignition switch

ÅDamaged air cut-off valvediaphragmÇDamaged air cut-off valve

spring

Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

Check carburetor aircut-off valve

Check carburetorgasket for air leaks

Check carburetor pilotscrew adjustment

Correct timing Incorrect timing

Correctly adjusted

No air leak Air leaks

Good spark Weak or inter- mittent spark

Good Faulty

Incorrectly adjusted

1. GENERAL INFORMATION

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GRAND DINK 250

POOR PERFORMANCE (AT HIGH SPEED)

ÅFaulty CDI unitÇFaulty A.C. generator

ÅImproperly adjusted valveclearanceÇWorn valve seat

ÅEmpty fuel tankÇClogged fuel tube or filterÉFaulty fuel pumpÑCracked fuel pump vacuum

tube

ÅClean and unclog

ÅCam timing gear aligningmarks not aligned

ÅFaulty spring

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

Check carburetor jetsfor clogging

Check fuel pump forfuel supply

Correct timing Incorrect timing

Check valve springtension

Check valve clearance

Fuel flows freely Fuel flow restricted

Correct Incorrect

Not clogged Clogged

Correctly adjusted Incorrectly adjusted

Not weakened Weak spring

Check valve timing

1. GENERAL INFORMATION

1-21

GRAND DINK 250

ENGINE NOISE

ÅValve clearance too large

ÇWorn camshaft lobe

ÅWorn piston rings

ÇWorn piston pin and connecting rodsmall endÉExcessive carbon build-up in combustion

chamber

ÅDamaged cam chain tensionerÇWorn cam gear teethÉWorn or damaged cam chainÑExtended cam chain

ÅFaulty crankshaft bearing

ÇWorn crank pin bearing

ÅWorn or damaged final reduction gears

ÇWorn final reduction gear shaft splines

Valve noise

Symptom Probable Cause

Crankshaft noise

Gear noise

Piston noise

Cam chain noise

1. GENERAL INFORMATION

1-22

GRAND DINK 250

CLUTCH, DRIVE AND DRIVEN PULLEYS

ÅWorn or slipping drive beltÇBroken ramp plateÉBroken drive face springÑSeparated clutch liningÖDamaged driven pulley shaft splinesÜDamaged final gearáSeized final gear

ÅBroken shoe spring

ÇClutch outer and clutch weight stuck

ÉSeized pivot

ÅWorn or slipping drive beltÇWorn weight rollersÉSeized drive pulley bearingsÑWeak driven face springÖWorn or seized driven pulley bearings

ÅWorn or slipping drive beltÇWorn weight rollersÉWorn or seized driven pulley bearings

ÅOil or grease fouled drive beltÇWorn drive beltÉWeak driven face springÑWorn or seized driven pulley bearings

Engine starts butmotor-cycle does notmove

Engine lacks power atstart of a grade(poorslope performance)

Symptom Probable Cause

Engine lacks power athigh speed

There is abnormalnoiseor smell while running

Motorcycle creeps orengine starts but soonstops or seems to rushout (Rear wheelrotates when engineidles)

1. GENERAL INFORMATION

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GRAND DINK 250

STARTER MOTOR1. Starter motor won‘t turn

ÅBurned out fuseÇWeak or dead batteryÉFaulty stop switchÑLoose or disconnected

connectorsÖBroken or shorted ignition

switch wire

ÅFaulty or weak battery

ÅPoor starter buttonconnectionÇOpen or shorted starter relayÉLoose or disconnected

connectors

ÅWorn brushesÇOpen or shorted wires or

rotorÉOpen starter motor cableÑLoose connectors

ÅOpen wire harness2. Starter motor turns slowly or idles

ÅWeak or dead battery

ÅLoose connector or terminalÇPoor contact in starter relayÉFaulty starter clutch

ÅSeized cylinder

ÅBroken or shorted startermotor cable

3. Starter motor does not stop turning

ÅFaulty starter pinion

ÅStarter relay shorted or stuck

Inspection/Adjustment

Inspection/Adjustment

Inspection/Adjustment

Symptom

Symptom

Symptom

Check operation ofstop switch byapplying brake

Stoplight does notcome on

Stoplight comesonCheck battery

circuit by operatingturn signals

Check batterycircuit by operatingturn signals

Turn ignitionswitchOFF

Probable Cause

Probable Cause

Probable Cause

Signals operate properly

Signals dim, remainon or don‘toperateCheck operation of

starter relay bydepressing starterbutton

Connect startermotor directly tobattery

Connect startermotor directly tobattery

Starter motor turns slowly

Starter motor turns normally

Signals operate properly

Signals dim, remainon or don‘t operate

Not stopped Stopped

Rotate crankshaft

Starter motorturns

Starter does notturn

Relay operates properly

Relay does not operate

Turns easily Hard to turn

1. GENERAL INFORMATION

1-24

GRAND DINK 250closed

NO SPARK AT SPARK PLUG

ÅFaulty spark plug

ÅFaulty spark plug

ÅPoorly connected coupler

ÅFaulty ignition switchÇFaulty exciter coilÉFaulty pulser coilÑFaulty ignition coil

ÅBroken wire harnessÇPoorly connected coupler

ÅFaulty CDI unit

ÅFaulty ignition coil

Replace with a newspark plug and inspectagain

Check CDI unitcoupler for looseness

Inspection/Adjustment Symptom Probable Cause

Normal

Abnormal

Normal

Abnormal

Normal Abnormal

Abnormal

Measure resistancebetween terminals ofCDI unit coupler

Check related parts

Check ignition coilwith a CDI unit tester

Weak or no spark

Not loose

Good spark

Loose

Good Good

Check spark plug capand high-tension wirefor looseness

Check CDI unit with aCDI unit tester

1. GENERAL INFORMATION

1-25

GRAND DINK 250

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging

ÅFaulty AC generatorÇFaulty regulator/rectifierÉFaulty battery

ÅShorted AC generator coilÇOpen circuit between AC

generator 3 yellow wires

ÅFaulty regulator/rectifierÇFaulty AC generatorÉLoose regulator/rectifier

couplerÑLimit voltage too high

Overcharging

ÅFaulty batteryÇFaulty regulator/rectifierÉBroken or poorly

connectedregulator/rectifier black wire

ÅLimit voltage too high

Start engine and testlimit voltage ofbattery terminals

Measure battery limitvoltage with anelectric tester

Test output voltage ofregulator/rectifiercoupler red wire

Inspection/Adjustment

Inspection/Adjustment

Symptom

Symptom

Probable Cause

Probable Cause

Normal voltage

Normal

Normal

Voltage does not increase

Abnormal

Resistance toolow

Normal voltage No voltage

Measure resistancebetween AC generatorcoil terminals

Check resistancebetween regulator/rectifier terminals

Normal Abnormal

1. GENERAL INFORMATION

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GRAND DINK 250

FUEL GAUGE1. Pointer does not register correctly (Ignition switch ON)

ÅBurned out fuseÇWeak or dead batteryÉFaulty ignition switchÑLoose or disconnected

connectorsÖBroken wire harness

ÅFaulty float

ÅBroken or shorted fuelunit wire

ÅDisconnected connectorÇIncorrectly connected

connectorÉBroken or shorted wire in

fuel gauge2. Pointer fluctuates or swings (Ignition switch ON)

ÅBurned out fuseÇWeak or dead batteryÉFaulty ignition switchÑLoose or disconnected

connectorÖBroken wire harness

ÅPoor contact in fuel unit

ÅInsufficient damping oil infuel gauge

ÅLoose or disconnectedconnectorÅBroken or shorted wire in

fuel gauge

Inspection/Adjustment

Inspection/Adjustment

Symptom

Symptom

Remove fuel unit andcheck operation ofpointer by movingfloat up and down

Remove fuel unit andcheck operation ofpointer by movingfloat up and down

Signals operate properly

Signals dim, remainon or don‘toperate

Signals operate properly

Signals dim,remainon or don‘toperate

Check battery circuitby operating turnsignals

Check battery circuitby operating turnsignals and horn

Probable Cause

Probable Cause

Pointer does not move Pointer moves

Pointer movesPointer does notmove

Check operation ofpointer by opening andshorting fuel unitterminal on wireharness side

Move float up anddown rapidly (1 round/sec.) to check theoperation of pointer

Pointer does not movePointer moves

Pointer does notmove in accord-ance with float

Pointer moves inaccordance withfloat

Good Faulty

Check connectors forproper connection

Check connectors forproper connection.

Good Faulty

Float up: FullFloat down: Empty

1. GENERAL INFORMATION

1-27

GRAND DINK 250

STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

(Front and rear tire pressures are normal)

ÅSteering stem nut too tightÇBroken steering steel balls

ÅExcessive wheel bearing playÇBent rimÉLoose axle nut

ÅMisaligned front and rear wheelsÇBent front fork

POOR SUSPENSION PERFORMANCE

(Front and rear tire pressures are normal)ÅWeak shock springÇExcessive loadÉShock damper oil leaking

ÅBent fork tube or shock rod

ÅFork tube and slider bindingÇFork spring and slider bindingÉDamaged shock stopper rubberÑLoose steering stem nut

POOR BRAKE PERFORMANCE

ÅWorn brake liningsÇForeign matter on brake liningsÉRough brake drum contacting area

ÅWorn brake liningsÇForeign matter on brake liningsÉRough brake drum contacting area

ÅWorn brake liningsÇWorn brake cam contacting area on

ÅWorn brake liningsÇForeign matter on brake linings

ÅSluggish or elongated brake cablesÇBrake shoes improperly contactÉWater and mud in brake systemÑOil or grease on brake linings

Steering is heavy

Suspension is too soft

Soft brake lever

Hard brake lever

Poor brakeperformance

Front or rear wheel iswobbling

Symptom

Symptom

Symptom

Probable Cause

Probable Cause

Probable Cause

Steering handlebar pullsto one side

Suspension is too hard

Suspension is noisy

Brake squeaks

Hard to brake