User Guide

ManualsBrandsKymco ManualsOtherMO GD125 150

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-0

GRA ND DINK 125/ 150

__________________________________________________________________________________

DRIVE AND DRIVEN PULLEYS/

KICK STARTER

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 8- 1

SERVICE INFORMATION -------------------------------------------- 8- 2

TROUBLESHOOTING ------------------------------------------------- 8- 2

LEFT CRANKCASE COVER------------------------------------------ 8- 3

DRIVE PULLEY -------------------------------------------------------- 8- 4

CLUTCH/DRIVEN PULLEY ------------------------------------------ 8- 8

KICK STARTER -------------------------------------------------------- 8-15

Summary of content (18 pages)

PAGE 1
8.
PAGE 2
8.
PAGE 3
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER GRAND DINK 125/150 SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. • Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley. SPECIFICATIONS Item Movable drive face bushing I.D. Drive face collar O.D. Drive belt width Clutch lining thickness Clutch outer I.D.
PAGE 4
8. DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Air Tube Band LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw. Remove the left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins. Bolts Kick Lever INSTALLATION Install the dowel pins and the gasket. Left Crankcase Cover Dowel Pins Gasket Install the left crankcase cover. ＊ • Do not pull out the kick starter spindle.
PAGE 5
8. DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Install the drive belt air tube and tighten the tube band screw. Tube Band Screw Universal Holder DRIVE PULLEY REMOVAL Remove the left crankcase cover. Hold the drive pulley using an universal holder and remove the drive face nut and washer. Remove the drive pulley face. Special Universal Holder Drive Pulley Face Remove the drive belt from the movable drive face.
PAGE 6
8. DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Remove the movable drive face assembly. Remove the drive pulley collar. Drive Pulley Collar Movable Drive Face Assembly DISASSEMBLY Remove the ramp plate. Ramp Plate Remove the weight rollers. Weight Roller INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 16.
PAGE 7
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER GRAND DINK 125/150 Measure the movable drive face bushing assemblyy I.D. Service Limit: 27.20mm replace if over Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface. Service Limit: 26.90mm replace if below ASSEMBLY Install the weight rollers into the movable drive face.
PAGE 8
. DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Ramp Plate Install the ramp plate. Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly Lay the drive belt on the driven pulley. Set the drive belt on the drive pulley collar.
PAGE 9
8. DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Install the drive pulley face, washer and drive face nut. Drive Pulley Face Washer Hold the drive pulley with the universal holder and tighten the drive face nut. Torque: 49.0_ 58.5N-m Drive Face Nut Universal Holder Special Universal Holder ＊• Do not get oil or grease on the drive belt or drive pulley faces. Drive Pulley CLUTCH/DRIVEN PULLEY Clutch Outer Remove the left crankcase cover.
PAGE 10
8. DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY DISASSEMBLY Hold the clutch/driven pulley assembly with the clutch spring compressor. ＊• Clutch Spring Compressor Be sure to use a clutch spring compressor to avoid spring damage. Special Clutch Spring Compressor Set the tool in a vise and remove the clutch drive plate nut.
PAGE 11
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. GRAND DINK 125/150 Guide Roller Pin Movable Driven Face Remove the oil seal from the movable driven face. Guide Roller O-ring Oil Seal INSPECTION Measure the driven face spring free length. Service Limit: 83.2mm replace if below Check the driven face assembly for wear or damage. Measure the driven face O.D. Service Limit: 33.
PAGE 12
8. DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play. Drive the inner needle bearing out of the driven pulley face. ＊• Discard the removed bearing and replace with a new one.
PAGE 13
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER GRAND DINK 125/150 Press a new needle bearing into the driven face. Special Bearing Driver Circlips CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. ＊• Keep grease off the clutch linings.
PAGE 14
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER GRAND DINK 125/150 CLUTCH ASS EMBLY Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips. Circlips Drive Plate Movable Driven Face CLUTCH/DRIVEN PULLEY AS SEMBLY Clean the pulley faces and remove any grease from them. Apply grease to the O-rings and install them onto the moveable driven face.
PAGE 15
8. DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face. Guide Roller Pin Guide Roller Driven Face Install the seal collar. Remove any excessive grease. ＊• Movable Driven Face Seal Collar Be sure to clean the driven face off any grease.
PAGE 16
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER GRAND DINK 125/150 Clutch Outer Install the clutch outer. Hold the clutch outer with the universal holder. Install and tighten the clutch outer nut. Torque: 49.0_ 58.8kg-m Special Universal Holder Install the drive belt. (!8-7) Install the left crankcase cover. (!8-3) Kick Lever KICK STARTER REMOVAL Remove the left crankcase cover. (!8-3) Remove the seal rubber and dowel pins. Remove the kick lever. Remove the circlip and washer from the kick starter spindle.
PAGE 17
8. DRIVE AND DRIVEN PULLEYS/ GRAND DINK 125/150 KICK STARTER INSPECTION Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushings for wear or damage. Plastic Bushing Spindle Return Spring Spindle Bushing Starter Driven Gear Inspect the starter driven gear for wear or damage. Inspect the friction spring for wear or damage.
PAGE 18
8. DRIVE AND DRIVEN PULLEYS/ KICK STARTER GRAND DINK 125/150 Install the kick lever. Install the left crankcase cover and tighten the cover bolts diagonally. Connect the drive belt air tube and tighten the band screw. Left Crankcase Cover LEFT CRANKCASE COVER BEARING INSPECTION Inspect the bearing into the left crankcase cove for loose, wear or damage. If any abnormal problem is found, replace the bearing with a new one.