2007 Kymco Grand Dink 250

11. CRANKCASE/CRANKSHAFT

GRAND DINK 250

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CRANKCASE/CRANKSHAFT __________________________________________________________________________________

SCHEMATIC DRAWING ------------------------------------------------- 11-1 SERVICE INFORMATION------------------------------------------------ 11-2 TROUBLESHOOTING----------------------------------------------------- 11-2 CRANKCASE SEPARATION -------------------------------------------- 11-3 CRANKSHAFT INSPECTION-------------------------------------------- 11-4 CRANKCASE ASSEMBLY ----------------------------------------------- 11-5

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11. CRANKCASE/CRANKSHAFT SCHEMATIC DRAWING

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GRAND DINK 250

11. CRANKCASE/CRANKSHAFT

GRAND DINK 250

SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces. • When installing the crankcase, do not use an iron hammer to tap it. • The following parts must be removed before separating the crankcase. Cylinder head (Ö6-4) Cylinder/piston (Ö7-3) Right crankcase cover/drive and driven pulley (Ö8-3) A.C. generator/starter clutch (Ö10-3) Rear wheel/rear shock absorber (Ö15-4) Starter motor (Ö19-3) Oil pump (Ö4-4) SPECIFICATIONS Item Connecting rod big end side clearance Crankshaft Connecting rod big end radial clearance Runout TORQUE VALUES Crankcase bolt Cam chain tensioner slipper bolt

Standard (mm) 0.15～0.35 0.～0.008 ⎯

Service Limit (mm) 0.6 0.05 0.10

7.8～10.8N-m 7.8～11.8N-m

SPECIAL TOOL Gear remover

TROUBLESHOOTING Excessive engine noise • Excessive bearing play • Excessive crankpin bearing play • Worn piston pin and piston pin hole

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11. CRANKCASE/CRANKSHAFT

GRAND DINK 250 Cam Chain Tensioner Slipper

CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt. Remove the cam chain tensioner slipper and cam chain. Remove the three right crankcase attaching bolts.

Bolt

Cam Chain

Remove the left crankcase.

Left Crankcase

Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase.

Right Crankcase

＊ • Never use a driver to pry the crankcase mating surfaces apart. Remove the gasket and dowel pins.

Left Crankcase

Remove the crankshaft from the left crankcase.

Crankshaft

Left Crankcase

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11. CRANKCASE/CRANKSHAFT

GRAND DINK 250 Oil Seal

Remove the oil seal from the left crankcase.

Left Crankcase

CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.6mm replace if over

Measure the connecting rod small end I.D. Service Limit: 17.06mm replace if over

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11. CRANKCASE/CRANKSHAFT

GRAND DINK 250

Measure the crankshaft runout. Service Limit: 0.10mm replace if over

Measure the crankshaft bearing play. Service Limits: Axial : 0.20mm replace if over Radial: 0.05mm replace if over

Play Play

Axial

Radial

CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces.

＊ • Avoid damaging the crankcase mating surfaces.

Install a new oil seal into the left crankcase.

Oil Seal

Left Crankcase

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11. CRANKCASE/CRANKSHAFT

GRAND DINK 250

Place the left crankcase down and install the crankshaft into the left crankcase.

＊ • Avoid damaging the oil seal.

• Apply grease to the lip of the oil seal.

Gasket

Install the two dowel pins and a new gasket.

Dowel Pins Right Crankcase

Place the right crankcase over the crankshaft and onto the left crankcase.

＊ • Install the right crankcase squarely and do not tap it with an iron or plastic hammer.

Left