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3. INSPECTION/ADJUSTMENT

3-0

GRA ND DINK 125/150

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INSPECTION/ADJUSTMENT

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SERVICE INFORMATION -------------------------------------------- 3- 1

MAINTENANCE SCHEDULE ---------------------------------------- 3- 2

FUEL LINE/FUEL FILTER ------------------------------------------- 3- 3

THROTTLE OPERATION --------------------------------------------- 3- 3

ENGINE OIL ------------------------------------------------------------ 3- 4

AIR CLEANER ---------------------------------------------------------- 3- 5

SPARK PLUG ----------------------------------------------------------- 3- 5

VALVE CLEARANCE ------------------------------------------------- 3- 6

CARBURETOR IDLE SPEED ----------------------------------------- 3- 6

IGNITION TIMING----------------------------------------------------- 3- 7

CYLINDER COMPRESSION ------------------------------------------ 3- 7

FINAL REDUCTION GEAR OIL ------------------------------------- 3- 8

DRIVE BELT ------------------------------------------------------------ 3- 8

HEADLIGHT AIM ------------------------------------------------------ 3- 9

CLUTCH SHOE WEAR ------------------------------------------------ 3- 9

COOLING SYSTEM ---------------------------------------------------- 3- 9

BRAKE SYSTEM ------------------------------------------------------- 3-10

NUTS/BOLTS/FASTENERS------------------------------------------- 3-11

WHEELS/TIRES -------------------------------------------------------- 3-11

STEERING HANDLEBAR--------------------------------------------- 3-11

SUSPENSION ----------------------------------------------------------- 3-11

Summary of content (12 pages)

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3.
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3. INSPECTION/ADJUSTMENT GRAND DINK 125/150 SERVICE INFORMATION GENERAL ð 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 carbon monoxide gas which may cause death to people. •Gasoline is extremely flammable and is explosive under some conditions. The working area must be well-ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area.
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. INSPECTION/ADJUSTMENT GRAND DINK 125/150 MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period. I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary.
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3. INSPECTION/ADJUSTMENT GRAND DINK 125/150 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. ＊ • Do not smoke or allow flames or sparks in your working area. Fuel Filter Fuel Line THROTTLE OPERATION Check the throttle grip for smooth movement. Measure the throttle grip free play.
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3. INSPECTION/ADJUSTMENT GRAND DINK 125/150 Oil Dipstick ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the motorcycle upright on level ground. Wait for 2_ 3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when making this check. OIL CHANGE ＊ • Drain the oil while the engine is warm. Remove the oil drain bolt to drain the engine oil. Install the aluminum washer and tighten the oil drain bolt. Torque: 14.
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3. INSPECTION/ADJUSTMENT GRAND DINK 125/150 Screws AIR CLEANER Remove the seven air cleaner case cover screws and the cover. Air Cleaner Case Cover Remove the air cleaner element. Check the element and replace it if it is excessively dirty or damaged. Air Cleaner Element CHANGE INTERVAL More frequent replacement is required when riding in unusually dusty or rainy areas. ＊• The air cleaner element has a viscous type paper element. Do not clean it with compressed air.
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3. INSPECTION/ADJUSTMENT GRAND DINK 125/150 Bolts VALVE CLEARANCE ＊ • Inspect and adjust valve clearance while the engine is cold (below 35℃ ). Remove the cylinder head cover. Cylinder Head Cover Turn the A.C. generator flywheel to the top dead center (TDC) on the compression stroke so that the “T” mark on the flywheel aligns with the index mark on the left crankcase cover. “T” Mark Top Dead Center Inspect and adjust valve clearance. Valve Clearance: IN: 0.1mm EX: 0.
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3. INSPECTION/ADJUSTMENT GRAND DINK 125/150 Timing Hole Cap IGNITION TIMING ＊ • The CDI unit is not adjustable. • If the ignition timing is incorrect, check the ignition system, Remove the timing hole cap. Check the ignition timing with a timing light. When the engine is running at the specified idle speed, the ignition timing is correct if the “F” mark on the flywheel aligns with the index mark on the crankcase cover. Also use a timing light to check the advance. Raise the engine speed to 4,000rpm.
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3. INSPECTION/ADJUSTMENT GRAND DINK 125/150 Oil Check Bolt Hole/Oil Filler FINAL REDUCTION GEAR OIL ＊ • Place the motorcycle on its main stand on level ground. 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 recommended oil SAE90# to the proper level. Install the oil check bolt. ＊ • Make sure that the sealing washer is in good condition. OIL CHANGE Remove the oil check bolt.
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3. INSPECTION/ADJUSTMENT GRAND DINK 125/150 HEADLIGHT AIM Turn the ignition switch ON. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting bolt. Headlight Aim Adjusting Bolt CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually. If the motorcycle tends to creep, or the engine stalls, check the clutch shoes for wear and replace if necessary.
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3. INSPECTION/ADJUSTMENT GRAND DINK 125/150 Coolant capacity : 1400±20cc Radiator capacity : 1000±20cc Reserve tank capacity : 400±20cc Start the engine and check if there is no bubbles in the coolant and the coolant level is stable. Reinstall the radiator cap. If there are bubbles in the coolant, bleed air from the system. Fill the reserve tank with the recommended coolant up to the upper line. Drain Bolt BRAKE SYSTEM BRAKE LEVER Measure the front and rear brake lever free plays.
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3. INSPECTION/ADJUSTMENT GRAND DINK 125/150 NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages. Check the tire pressure. ＊ • Tire pressure should be checked when tires are cold. Tire Pressure 1 Rider 2 Riders Front 1.75kg/cm_ 1.75kg/cm_ Rear 2.00kg/cm_ 2.