KYMCO G-DINK 300i, Service Manual

Page 1: ...K 300i By KWANG YANG Motor Co Ltd 1st Edition Mar 2012 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T300 LHG7 A1 ...

Page 2: ...ing methods of electrical equipment 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 QUALITY TECHNOLOGY DEPT EDUCATION SECTION TABLE OF CONTENTS GENERAL INFORMATION 1 EXHAUST MUFFLER FRAME COVERS 2 INSPECTION ADJUSTMENT 3 LUBRICATION SYSTEM 4 ENGINE REMOVAL INSTALLAT...

Page 3: ..._________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION ________________________________________________________________________________ SERIAL NUMBER 1 1 SPECIFICATION 1 2 SERVICE PRECAUTIONS 1 5 TORQUE VALUES 1 9 SPECIAL TOOLS 1 11 LUBRICATION PO...

Page 4: ...1 GENERAL INFORMATION 1 1 G DINK 300i Identification Numbers Record ...

Page 5: ...ance Exhaust 0 10 Idle speed rpm 1600 100 rpm Cooling Type Liquid cooling Lubrication type Forced pressure wet sump Oil pump type Inner outer rotor Oil filter type Full flow filtration Oil capacity 1 1 liter Exchanging capacity 0 9 liter Fi injection system Air cleaner type No Paper element wet Fuel capacity 9 liters Brand Keihin Throttle Body Butterfly type Venturi diameter mm 32 Fuel pump pressu...

Page 6: ...embly Apply or add designated greases and lubricants to the specified lubrication points 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 instal...

Page 7: ... 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 t...

Page 8: ...crews Avoid the projected ends of bolts and screws Route harnesses so they are neither pulled tight nor have excessive slack Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner When rubber protector cover is used to protect the wire harnesses it shall be installed securely Do not break the sheath of wire If a wire or harness is with a broken sheath repai...

Page 9: ...r surrounding parts in all steering positions When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions Be careful not to drop any parts When rust is found on a terminal remove the rust with sand paper or equivalent before connecting Do you understand the instrument Remove Rust ...

Page 10: ...ent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Apply grease for lubrication Transmission Gear Oil 90 Use special tool Caution Warning Special Engine Oil Grease Gear Oil ...

Page 11: ...1 GENERAL INFORMATION 1 8 G DINK 300i TORQUE VALUES ...

Page 12: ...1 GENERAL INFORMATION 1 9 G DINK 300i TORQUE VALUES ...

Page 13: ...1 GENERAL INFORMATION 1 10 G DINK 300i TORQUE VALUES FRAME ...

Page 14: ...older Clutch spring compressor Thread protector Bearing puller 10 12 15 18mm E006 E012 E014 E021 E027 E029 E037 One way clutch removal Tapper adjustment Oil seal bearing install A C generator flywheel holding Clutch disassembly Protect the crankshaft s thread Bearing removal 9 3 7 9 10 11 4 10 9 10 10 Valve cotter installer E051 Valve cotter installation 7 Lock nut socket wrench F002 Steering stem...

Page 15: ...ion points for the frame Use grease for parts not listed Apply engine oil or grease to cables and movable parts not specified It will avoid abnormal noise and damage the durability of the motorcycle Grease Grease Front wheel axle nut Rear wheel axle nut Grease Side stand pivot Main stand pivot ...

Page 16: ...1 GENERAL INFORMATION 1 13 G DINK 300i CABLE HARNESS ROUTING Tilt Switch Speedometer Radiator Filler Cap Ignition Switch ECU Horn Coolant Reserve Tank ...

Page 17: ...1 GENERAL INFORMATION 1 14 G DINK 300i CABLE HARNESS ROUTING Fan Relay Hi Beam Relay Lo Beam Relay Fuel Pump Relay ECU Relay Start Relay Winker Relay ...

Page 18: ...1 GENERAL INFORMATION 1 15 G DINK 300i ISC Throttle Body TPS WTS Injector MAP Sensor O2 Sensor ...

Page 19: ...1 GENERAL INFORMATION 1 16 G DINK 300i Starter Relay Regulator Rectifier Crank Position Sensor Ignition Coil Hazard Control Unit R l R ifi ...

Page 20: ... ECU Good spark Broken or shorted spark plug wire Faulty ignition switch Faulty ignition pulse generator Loose or disconnected spark plug wire 5 Test cylinder compression Low compression Valve stuck open Worn cylinder and piston ring Damaged cylinder head gasket Compression normal Seized valve Improper valve timing 6 Starting following normal procedure Engine start Intake pipe leaking but stops Im...

Page 21: ...cleaner dirty not increase Restricted fuel flow Clogged muffler Engine speed increase Pinched fuel tank breather 4 Check ignition timing Incorrect Faulty ECU Faulty ignition pulse generator Correct 5 Test cylinder compression Incorrect Valve stuck open Worn cylinder and piston rings Leaking head gasket Normal Improper valve timing 6 Inspect fuel flow Abnormal Faulty pressure regulator Normal 7 Ins...

Page 22: ...rol orifice Valve train lubricated properly 11 Check for engine overheating Overheating Fan motor not working Excessive carbon build up in combustion chamber Use of poor quality fuel Not overheating Wrong type of fuel Drive and driven pulleys clutch slipping 12 Accelerate or run at high Engine knocks Worn piston and cylinder speed Worn type of fuel Excessive carbon build up in combustion chamber I...

Page 23: ...gulator Normal 3 Inspect the fuel injector Abnormal Faulty injector Normal 4 Check for leaks in the intake pipe Leaking Loose insulator clamp Damage insulator No leak 5 Perform spark test Weak or intermittent spark Faulty the spark plug Faulty carbon or wet fouled spark plug Faulty ECU Faulty ignition coil Faulty ignition pulse generator Faulty ignition switch Loose or disconnected spark plug wire...

Page 24: ...Camshaft not installed properly Correct 5 Check valve spring Weak Faulty valve spring Not weak POOR HANDLING Possible cause 1 If steering is heavy Steering stem adjusting nut too tight Damaged steering head bearings 2 If either wheel is wobbling Excessive wheel bearing play Bent rim Improper installed wheel hub Swing arm pivot bearing excessively worn Bent frame 3 If the motorcycle pulled to one s...

Page 25: ...______________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER FRAME COVERS __________________________________________________________________________________ SERVICE INFORMATION 2 1 TROUBLESHOOTING 2 1 FASTENER REMOVAL AND REINSTALLATION 2 2...

Page 26: ...ed Make sure to route cables and harnesses according to the Cable Harness Routing TORQUE VALUES Exhaust muffler pipe nuts 1 8 2 2 kgf m Exhaust muffler brake RR Frok 3 2 3 8 kgf m RR fork Engine case 2 4 3 0 kgf m TROUBLESHOOTING Noisy exhaust muffler Damaged exhaust muffler Exhaust muffler joint air leaks Lack of power Caved exhaust muffler Clogged exhaust muffler Exhaust muffler air leaks ...

Page 27: ...e Pull out the fastener INSTALLATION Let the center piece stick out toward the head so that the pawls close Insert the fastener into the installation hole Push in the head of center piece until it becomes flush with the fastener outside face To prevent the pawl from damage insert the fastener all the way into the installation hole ...

Page 28: ...gnition key Open the seat Remove 2 bolts 2 screws and 4 nuts on the luggage box SEAT Unlock the seat with the ignition key Open the seat Remove the two nuts and the seat Disconnect the luggage box light connector then remove the luggage box Installation is in the reverse order of removal Luggage Box Light Connector Nuts ...

Page 29: ...he center cover Installation is in the reverse order of removal REAR CARRIER Remove 4 bolts and rear carrier REAR CENTER COVER Remove two screws to remove the rear center cover Center Cover During removal do not pull the joint claws forcedly to avoid damage Screws Bolts Rear center cover Rear carrier ...

Page 30: ...XHAUST MUFFLER FRAME COVERS 2 5 G DINK 300i BODY COVER SET Remove the screws bolts nuts and connecter to remove the body cover set Screws Bolt Screw Nuts Screw Connector Dismantle Direction Body cover set ...

Page 31: ... 6 G DINK 300i FRONT SIDE MOLD Remove the fasteners to remove the right and left of front side molds Remove the mat leg shield UNDER COWL Remove the fasteners and under cowl Fastener Mat leg shield Fasteners Under cowl Front side mold ...

Page 32: ...2 EXHAUST MUFFLER FRAME COVERS 2 7 G DINK 300i SKIRT SET Remove the screws and fasteners to remove the right and left skirt sets Fasteners Screws Fasteners Screw Screws Screws Screws Skirt set ...

Page 33: ...2 EXHAUST MUFFLER FRAME COVERS 2 8 G DINK 300i PANEL FLOOR Remove the bolts and panel floor Bolts Panel floor ...

Page 34: ...AME COVERS 2 9 G DINK 300i HANDLE UP COVER Remove screws and bolts to remove the handle up cover HANDLE LOW COVER Remove throttle cables to remove the handle low cover Bolt Screw Screw Bolt Handle up cover Handle low cover ...

Page 35: ...2 EXHAUST MUFFLER FRAME COVERS 2 10 G DINK 300i WINDSHIELD Remove five bolts and windshield FRONT METER COVER SET Remove the front meter cover Handle up cover Front meter cover set ...

Page 36: ...XHAUST MUFFLER FRAME COVERS 2 11 G DINK 300i FRONT COVER SET Remove the screws nuts fasteners and connector to remove the front cover set Screws Fastener Nuts Connector Dismantle Direction Front cover set ...

Page 37: ...FFLER FRAME COVERS 2 12 G DINK 300i REAR METER COVER SET Remove the fasteners main switch lid bolts and connectors to remove the rear meter cover set Fasteners Main switch lid Connectors Bolts Rear meter cover set ...

Page 38: ...FLER FRAME COVERS 2 13 G DINK 300i LEG SHIELD SET Remove the screws bolt center clip connector and fuel filler cap to remove the leg shield Fuel filler cap Bolt Connector Screws Bolt Bolts Center clip Leg shield set ...

Page 39: ... COVERS 2 14 G DINK 300i FRONT INNER FENDER Remove the bolts fasteners to remove the front inner fender FRONT FENDER Remove the bolts to remove the front fender Bolts bolt Fasteners Bolt Bolt Bolts Leg shield set Front fender ...

Page 40: ...E COVERS 2 15 G DINK 300i EXHAUST MUFFLER REMOVAL Disconnect the connector with O2 heater O2 sensor Remove the bolts and nuts to remove the muffler Installation is in the reverse order of removal O2 sensor Muffler Nuts Bolts ...

Page 41: ..._________________________________________________ INSPECTION ADJUSTMENT ________________________________________________________________________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE 3 2 THROTTLE OPERATION 3 3 ENGINE OIL 3 4 RESERVE TANK 3 5 AIR CLEANER 3 6 SPARK PLUG 3 6 VALVE CLEARANCE 3 7 CYLINDER COMPRESSION 3 7 FINAL REDUCTION GEAR OIL 3 8 DRIVE BELT 3 8 BRAKE SYSTEM 3 9 CLUTCH...

Page 42: ...near the working area or fuel storage area SPECIFICATIONS ENGINE Throttle grip free play 2 6 mm Spark plug DPR6EA Spark plug gap 0 6 mm 0 7 mm Valve clearance IN 0 10 mm EX 0 10 mm Idle speed 1600 100 rpm Engine oil capacity Cylinder compression 16 2 kg cm At disassembly 1 1 Liter Ignition timing ECU At change 0 9 Liter Coolant type Water Cooling Gear oil capacity At disassembly 0 23 Liter At chan...

Page 43: ...3 INSPECTION ADJUSTMENT 3 2 G DINK 300i MAINTENANCE SCHEDULE ...

Page 44: ...or adjustment of the throttle grip free play is made with the adjusting nut at the throttle body side Adjust by loosening the lock nut and turning the adjusting nut Minor adjustment is made with the adjusting nut at the throttle grip side Slide the rubber cover 1 out and adjust by loosening the lock nut 3 and turning the adjusting nut 2 Lock Nut Adjusting Nut ...

Page 45: ...5 kg m Pour the recommended oil through the oil filler hole OIL CAPACITY Engine oil capacity 1 1 L Engine oil exchanging capacity 0 9 L Engine Oil Viscosity SAE 10W40 OIL FILTER SCREEN INSPECTION Drain the engine oil Remove the oil filter screen attaching the left under crankcase Clean the oil filter screen Install the oil filter screen and filter screen cap Fill the engine with recommended engine...

Page 46: ... 300i The spring will come out when the filter cap is removed Let the engine oil drain out Check that the O ring is in good condition Install a new oil filter Spring Make sure the rubber seal on the oil filter facing the left crankcase ...

Page 47: ...d spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug NGK CR7E Measure the spark plug gap Spark Plug Gap 0 6 0 7 mm Torque 17 2 N m The air cleaner element has a viscous type paper element Do not clean it with compressed air Be sure to install the air cleaner element and cover securely When installi...

Page 48: ...CYLINDER COMPRESSION Warm up the engine before compression test Remove the center cover and luggage box Remove the spark plug Insert a compression gauge Open the throttle fully and push the starter button to test the compression Max Compression 16 2 kg cm2 570 rpm If the compression is low check for the following Leaky valves Valve clearance too small Leaking cylinder head gasket Worn piston rings...

Page 49: ... capacity listed below Transmission fluid type SAE 90 Transmission fluid capacity 0 23 L Transmission fluid exchanging capacity 0 18 L Install the transmission filler bolt and tighten it to the specified torque DRIVE BELT Remove the left crankcase cover Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new one if necessary and in accordance with the Maintenance Sche...

Page 50: ...ervice limit Check if the brake pad wear exceeds the wear indicator line BRAKE FLUID Turn the steering handlebar upright and check if both brake fluid levels is at the upper limit If the brake fluid is insufficient fill to the upper limit Specified Brake Fluid DOT 4 Keep grease or oil off the brake disk to avoid brake failure The brake fluid level will decrease if the brake pads are worn ...

Page 51: ...em several times Check the entire shock absorber assembly for oil leaks looseness or damage REAR Each shock absorber 4 on your scooter has 5 spring preload adjustment positions for different load or riding conditions Use a pin spanner 5 to adjust the rear shock spring preload Position 1 is for light loads and smooth road conditions Position 3 to 5 increase spring preload for a stiffer rear suspens...

Page 52: ...5 kg cm Rear 2 0 kg cm 2 25 kg cm Tire Size Front 120 70 14 Rear 10 70 13 Check the front axle nut for looseness Check the rear axle nut for looseness If the axle nuts are loose tighten them to the specified torques Torque Front axle nut 2 kg m Rear axle nut 12 kg m STEERING HANDLEBAR Raise the front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves u...

Page 53: ...ride the scooter when the side stand is down Perform the following side stand inspection INTERLOCK FUNCTION CHECK Check the side stand ignition cut off system 1 Place the scooter on its center stand 2 Put the side stand up and start the engine 3 Lower the side stand The engine should stop as you put the side stand down If the side stand system does not operate as described see your KYMCO dealer fo...

Page 54: ...________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ LUBRICATION SYSTEM ________________________________________________________________________________ LUBRICATION SYSTEM 4 1 SERVICE INFORMATION 4 2 TROUBLESHOOTING 4 2 ENGINE OIL OIL...

Page 55: ...4 LUBRICATION SYSTEM 4 1 G DINK 300i LUBRICATION ...

Page 56: ... pump The oil pump must be replaced as a set when it reaches its service limit After the oil pump is installed check each part for oil leaks SPECIFICATIONS ENGINE OIL Engine Oil Capacity At disassembly 1 1 liter At change 0 9 liter Recommended Oil SAE5W50 API SJ TROUBLESHOOTING Oil level too low Poor lubrication pressure Natural oil consumption Oil level too low Oil leaks Clogged oil filter or oil...

Page 57: ...emove the oil filter screen cap Remove the oil filter screen and spring Check the oil filter screen for clogging or damage and replace if necessary Check the filter screen O ring for damage and replace if necessary Install the oil filter screen spring O ring and filter screen cap Recommended Oil SAE5W50 API SJ Oil Capacity At disassembly 1 1 liter At change 0 9 liter Start the engine and check for...

Page 58: ... filler cap attaching the right under crankcase cover The spring will come out when the filter cap is removed Let the engine oil drain out Check that the O ring is in good condition Install a new oil filter Make sure the rubber seal on the oil filter facing the left crankcase ...

Page 59: ...he attaching bolt and oil separator cover Remove snap ring Remove the oil pump driven gear then remove the oil pump drive chain Oil Separator Cover Bolts Drive Chain Driven Gear Snap Ring When removing and installing the oil pump use care not to allow dust or dirt to enter the engine ...

Page 60: ...l pump bolts to remove the oil pump DISASSEMBLY Remove the screw and oil pump cover Remove the dowel pin oil pump shaft oil pump outer rotor and inner rotor Bolts Oil Pump Screw Oil Pump Cover Outer Rotor Oil Pump Shaft Oil Pump Body Dowel Pin Inner Rotor ...

Page 61: ... into the oil pump body Measure the tip clearance Service limit 0 2 mm 0 008 in Measure the pump body clearance Service limit 0 25 mm 0 01 in Measure the side clearance with the straight edge and feeler gauge Service limit 0 12 mm 0 0048 in Measure at several points and use the largest reading to compare the service limit ...

Page 62: ...he dowel pin onto the oil pump body Install the oil pump cover onto the oil pump body by aligning the dowel pin Install and tighten the screw to the specified torque Torqur 3 N m 0 3kgf m 2 lbf ft INSTALLATION Install the oil pump and tighten the two bolts securely Dowel Pin Oil Pump Cover Screw Oil Pump Cover Bolts Oil Pump Arrow Mark Make sure the pump shaft rotates freely and arrow on the oil p...

Page 63: ...G DINK 300i Install the oil pump driven sprocket and drive chain Install the snap ring Install the oil separator cover properly and tighten two bolts securely as shown Snap Ring Drive Chain Driven Gear Oil Separator Cover Bolts ...

Page 64: ...________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION 5 1 ENGINE REMOVAL INSTALLATIO...

Page 65: ...ngine After the engine is installed fill the cooling system with coolant and be sure to bleed air from the water jacket Start the engine to check for coolant leaks Before removing the engine the rear brake caliper must be removed first Be careful not to bend or twist the brake fluid tube SPECIFICATIONS Engine oil capacity At disassembly 1 1 L At change 0 9 L TORQUE VALUES Engine hanger Engine side...

Page 66: ...le body TPS WTS MAP sensor and injector Disconnect the O2 sensor connector Disconnect the throttle cables Disconnect the Regulator Rectifier connector Disconnect the starter relay wire from starter motor Remove a bolt from fuel hose guide Disconnect the fuel hose from fuel injector Disconnect the input water hose Disconnect the air bleed hose Water hose ...

Page 67: ...ear axle nut Torque 12 0 kgf m 120 N m Remove bolts attaching to the rear brake caliper Torque 3 2 kgf m 32 N m Disconnect the alternator connector Disconnect the ignition pulse generator connector Release the rubber cap and remove the terminal screw to disconnect the start motor cable from the start motor Remove the bolt and engine ground cable Connector Nut Bolt ...

Page 68: ...NE REMOVAL INSTALLATION 5 4 G DINK 300i Remove the spark plug cap Disconnect the radiator hose Remove the right and left rear cushion lower mount bolts Torque 4 0 kgf m 40N m Spark Plug Cap Radiator Hose Bolt ...

Page 69: ...TALLATION Installation is in the reverse order of removal After installation inspect and adjust the following Throttle grip free play Fill the cooling system with coolant and start the engine to bleed air from the system API ABV Reset At removing the engine be careful not to catch your hand or finger between the engine hanger and crankcase Mount Nut ...

Page 70: ...unt nut and pull it out Remove the left right engine hanger mount bolt Remove the engine from frame INSTALLATION Installation is in the reverse order of removal Tighten the engine hanger mount bolts to the specified torque Torque 6 5 kgf m 65 N m Be careful to put the engine down Mount Nut ...

Page 71: ..._______________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD VALVES __________________________________________________________________________________ SCHEMATIC DRAWING 6 1 SERVICE INFORMATION 6 2 TROUBLESHOOTING 6 3 CYLINDER COMPRESSION TEST 6 4 CYLINDER H...

Page 72: ...6 CYLINDER HEAD VALVES 9 1 G Dink 300i 6 1 ...

Page 73: ... IN 0 1 mm 0 004 in Valve clearance cold EX 0 1 mm 0 004 in Cylinder head compression pressure 15 kg cm2 213 psi 1500 kPa Cylinder head warpage 0 05 0 002 IN 34 2987 1 371948 34 14 1 3656 Camshaft cam height EX 34 1721 1 366884 34 02 1 3608 IN 10 0 4 10 015 0 4006 10 1 0 404 Valve rocker arm I D EX 10 0 4 10 015 0 4006 10 1 0 404 Valve rocker arm shaft IN 9 972 0 399 9 987 0 3995 9 9 0 396 O D EX ...

Page 74: ...stem oil seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment Incorrect valve timing Sticking valve or broken valve spring Broken valve spring Damaged or worn camshaft Poor valve and seat contact Worn cam chain tensioner Leaking cylinder head gasket Worn camshaft and rocker arm Warped or cracked cylinder head Poorly...

Page 75: ...e with the starter motor until the gauge reading stops rising The maximum reading is usually reached 4 7 seconds Compression pressure 15 kg cm2 213 psi 1500 kPa Low compression can be caused by Blown cylinder head gasket Improper valve adjustment Valve leakage Worn piston ring or cylinder High compression can be caused by Carbon deposits in combustion chamber or on piston head Park Plug Cap To avo...

Page 76: ...i CYLINDER HEAD COVER DISASSEMBLY Remove the floorboard Disconnect the crankcase breather hose from the cylinder head cover Remove the four bolts and two nuts then remove cylinder head cover Remove the cylinder head cover O ring O ring 6 5 ...

Page 77: ...aft gear facing up and the location is the top dead center on the compression stroke Remove the cam chain tensioner lifter sealing bolt Turn the cam chain tensioner screw clockwise to pull the tensioner rod all the way in Remove the four cap nuts attaching the camshaft holder Cam Chain Tensioner Round Hole Camshaft Holder Cap Nuts Tensioner Screw Diagonally loosen the cylinder head cap nuts in 2 o...

Page 78: ...6 CYLINDER HEAD VALVES 9 7 G Dink 300i Remove the camshaft holder and dowel pins Remove the camshaft gear from the cam chain to remove the camshaft Camshaft Holder Dowel Pins Cam Chain Camshaft Gear 6 7 ...

Page 79: ... lobe for wear or damage Measure the cam lobe height Service Limits IN 34 14 mm 1 3656 in EX 34 02 mm 1 3608 in Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play Camshaft Bearings 6 8 ...

Page 80: ...on system Measure each rocker arm shaft O D Measure the I D of each rocker arm Measure arm to shaft clearance Replace as a set if out of specification Service limits 0 1 mm 0 004 in Inspect the rocker arm bore cam lobe contact surface and adjuster surface for wear pitting scratches blue discoloration If any defects are found replace the rocker arm shaft with a new one then inspect lubrication syst...

Page 81: ...Remove the two cylinder bolts Remove the bolt attaching the thermostat housing and the thermostat housing Remove the cylinder head Remove the dowel pins and cylinder head gasket Remove the cam chain guide Remove all gasket material from the cylinder head mating surface Bolt Cam Chain Tensioner Slipper Cylinder Cylinder Head Gasket Cylinder Bolts Be careful not to drop any gasket material into the ...

Page 82: ...otters retainers springs spring seats oil seals and valves using a valve spring compressor Special tool Valve Spring Compressor A120E00040 Be sure to compress the valve springs with a valve spring compressor Mark all disassembled parts to ensure correct reassembly Valve Spring Compressor 6 11 ...

Page 83: ...nding guide I D to obtain the stem to guide clearance Service limits IN 0 08 mm 0 0032 in EX 0 1 mm 0 004 in CYLINDER HEAD INPECTION Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge Service Limit 0 05 mm 0 002 in VALVE SPRING INSPECTION Measure the free length of the inner and outer valve springs Service Limit Inner 29 1...

Page 84: ...ASSEMBLY Install the valve spring seats and oil seal Lubricate each valve with engine oil and insert the valves into the valve guides Install the valve springs and retainers Compress the valve springs using the valve spring compressor then install the valve cotters Special tool Valve Spring Compressor A120E00040 Valve Spring Compressor Be sure to install new oil seal When assembling a valve spring...

Page 85: ...e and exhaust valve rocker arms then install the rocker arm shafts Gasket Cam Chain Guide Valve Rocker Arms Cam Chain Camshaft Holder Dowel Pins Install the exhaust valve rocker arm shaft on the EX side of the camshaft holder and the exhaust rocker arm shaft is shorter Clean the intake valve rocker arm shaft off any grease before installation Align the cutout on the exhaust valve rocker arm shaft ...

Page 86: ...lder washers and nuts on the cylinder head Tighten the four cylinder head cap nuts and two cylinder bolts to the specified torque Torque Cylinder head cap nut 25 N m 2 5 kgf m 18 lbf ft Apply engine oil to threads Cylinder bolt 10 N m 1 kgf m 7 lbf ft Dowel Pins Nut Washer Punch Marks Bolts Cam Chain Round Hole Camshaft Holder Dowel Pins EX Mark Install the camshaft holder with the EX mark face ex...

Page 87: ...m chain tension cap screw Adjust the valve clearance Install a new cylinder head cover O ring and install the cylinder head cover Install and tighten the cylinder head cover bolts Torque 10 N m 1 kgf m 7 lbf ft O ring Cylinder Head Cover Tensioner Screw Be sure to install the gasket into the groove properly Be sure to install the O ring into the groove properly 6 16 ...

Page 88: ..._________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER PISTON __________________________________________________________________________________ SCHEMATIC DRAWING 7 1 SERVICE INFORMATION 7 2 TROUBLESHOOTING 7 2 CYL...

Page 89: ...7 CYLINDER PISTON 10 1 G Dink 300i SCHEMATIC DRAWING 7 1 ...

Page 90: ...69 2 9076 72 6 2 904 Piston O D measuring position 9 mm from bottom of skirt Piston to cylinder clearance 0 01 0 0004 0 045 0 0018 0 1 0 004 Piston pin hole I D 17 002 0 68008 17 008 0 68032 17 04 0 6816 Piston pin O D 16 994 0 67976 17 0 68 16 96 0 6784 Piston to piston pin clearance 0 002 0 0001 0 014 0 0006 0 02 0 001 Connecting rod small end I D bore 17 016 0 68064 17 034 0 68136 17 06 0 6824 ...

Page 91: ...ve the cylinder Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface Remove the piston pin clip Press the piston pin out of the piston and remove the piston Water Hose Dowel Pins Gasket Gasket Shop Towel Piston Pin Piston Dowel Pins Cylinder Cam Chain Guide Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase...

Page 92: ...grooves without catching Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring to groove clearance Service Limits Top 0 08 mm 0 003 in 2nd 0 065 mm 0 0026 in Insert each piston ring into the bottom of the cylinder squarely Measure the piston ring end gap Service Limit Top 0 5 mm 0 02 in 2nd 0 65 mm 0 026 in Oil ring 1 mm 0 04 in Use the pisto...

Page 93: ... 2 904 in at A 9 mm Calculate the cylinder to piston clearance Measure the piston pin hole Take the maximum reading to determine the I D Service Limit 17 04 mm 0 6816 in Measure the piston pin O D at piston and connecting rod sliding areas Service Limit 16 96 mm 0 6784 in Measure the piston to piston pin clearance Service Limit 0 002 mm 0 0001 in 10 mm A 7 5 ...

Page 94: ... at three levels in an X and Y axis Take the maximum reading to determine the cylinder wear Service Limit 72 8 mm 2 912 in Calculate the piston to cylinder clearance Take a maximum reading to determine the clearance Service Limit 0 1 mm 0 004 in Calculate the taper and out of round at three levels in an X and Y axis Take the maximum reading to determine them Service Limit Taper 0 1 mm 0 004 in Out...

Page 95: ... in PISTON RING INSTALLATION Carefully install the piston rings into the piston ring grooves with the markings facing up Do not confuse the top and second rings To install the oil ring install the oil ring then install the side rails Stagger the piston ring end gaps 120 degrees apart from each other Stagger the side rail end gaps as shown Be careful not to damage the piston and rings 7 7 ...

Page 96: ...gine oil Carefully lower the cylinder over the piston by compressing the piston rings Be careful not to drop foreign matters into the crankcase Position the piston IN mark on the intake valve side Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Gasket Cylinder Dowel Pin Piston Piston Pin Clip Piston Pin IN Mark Be careful not to damage or break...

Page 97: ... G Dink 300i Install the cam chain guide Install the cylinder gasket and dowel pins Connect the water hose to the cylinder Insert the tab on the cam chain guide into the cylinder groove Gasket Dowel Pins Cam Chain Guide 7 9 ...

Page 98: ...____________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEY __________________________________________________________________________________ SERVICE INFORMATION 8 1 TROUBLESHOOTING 8 2 LEFT CRANKCASE COVER 8 3 DRIVE...

Page 99: ...riven face bushing I D 40 1 6 40 025 1 601 40 06 1 6024 Driven face collar O D 39 965 1 5986 39 985 1 5994 39 94 1 5976 Drive belt width 23 6 0 944 24 4 0 976 Clutch lining thickness 4 0 16 1 0 04 Clutch outer I D 153 6 12 153 2 6 128 153 5 6 14 Drive pulley collar O D 26 96 1 0784 26 974 1 07896 26 9 1 076 Weight roller O D 22 92 0 9168 23 08 0 9232 22 0 88 TORQUE VALUES Drive face nut 93 N m 9 3...

Page 100: ...but motorcycle won t move Lack of power Worn drive belt Worn drive belt Broken ramp plate Weak driven face spring Worn or damaged clutch lining Worn weight roller Broken driven face spring Faulty driven face Engine stalls or motorcycle creeps Broken clutch weight spring 8 2 ...

Page 101: ...IVE AND DRIVEN PULLEY 11 3 G Dink 300i LEFT CRANKCASE COVER REMOVAL Remove the left crankcase cover bolts and left crankcase covers Remove the seal gasket and dowel pins Left Crankcase Cover Bolts Gasket 8 3 ...

Page 102: ...he drive pulley face nut Special tool Universal holder A120E00017 Remove the nut washer and drive pulley face Hold the clutch outer with the special tool as shown Special tool Universal holder A120E00017 Remove the nut and clutch outer Remove the clutch driven pulley assembly and drive belt 8 4 Drive Pulley Face Universal Holder Movable Drive Face Drive Belt ...

Page 103: ...11 DRIVE AND DRIVEN PULLEY 11 5 G Dink 300i Remove the movable drive face assembly while holding the back of the face ramp plate 8 5 Drive Pulley Collar Movable Drive Face Assembly ...

Page 104: ...11 DRIVE AND DRIVEN PULLEY 11 6 G Dink 300i DISASSEMBLY Drive pulley Remove the ramp plate and slide pieces Remove the weight rollers 8 6 Ramp Plate Weight Roller ...

Page 105: ...e Check the drive face boss for wear or damage Measure the boss O D Service limit 26 9 mm 1 076 in Measure the face bushing I D Service limit 27 13 mm 1 058 in Weight Roller Check each roller for wear or damage Measure the weight roller O D Service limit 22 mm 0 888 in 8 7 ...

Page 106: ...llers Install the drive face boss into the movable drive face Install the weight rollers to the movable drive face Install the slide pieces to ramp plate Install the ramp plate to the movable drive face The direction of all weight rolls is the same The thin side is towards to clockwise 8 8 Weight Roller Ramp Plate ...

Page 107: ...que 54 N m 5 4 kgf m 36 lbf ft Install the drive pulley face and washer Apply oil to the drive pulley face nut threads and seating surface and install the nut Hold the drive face with the special tool and tighten the bolt to the specified torque Special tool Universal holder A120E00017 Torque 93 N m 9 3 kgf m 67 lbf ft 8 9 Driven Pulley Drive Pulley Collar Drive Belt Drive Pulley Universal Holder ...

Page 108: ...face nut Special tool Universal holder A120E00017 Remove the nut washer and drive pulley face Hold the clutch outer with the special tool as shown Special tool Universal holder A120E00017 Remove the nut and clutch outer Remove the clutch driven pulley assembly and drive belt 8 10 Drive Pulley Universal Holder Clutch Outer Universal Holder Driven Pulley Drive Pulley Collar Drive Belt ...

Page 109: ... compressor Special tool Clutch Spring Compressor A120E00034 Set the tool in a vise and remove the clutch drive plate nut Remove the spring compressor and disassemble the following Clutch assembly Driven face spring Driven pulley Be sure to use a clutch spring compressor to avoid spring damage Clutch spring compressor Lock Nut Wrench 8 11 ...

Page 110: ... face Driven Face Bearing Replacement Remove the driven face needle bearing Remove the snap ring then remove the ball bearing Apply grease to new ball bearing Install the ball bearing into the driven face Install the snap ring to groove in the driven face securely Ball Bearing Snap Ring Needle Bearing 8 12 Movable Driven Face Guide Roller Pin O ring Guide Roller Oil Seal ...

Page 111: ...le bearing Press the needle bearing into the driven INSPECTION Clutch Outer Check the clutch outer for wear or damage Measure the clutch outer I D Service limit 153 5 mm 6 14 in Clutch Shoe Lining Check the clutch shoe for wear or damage Measure the thickness of each shoe Service limit 1 mm 0 04 in Grease Needle Bearing 8 13 ...

Page 112: ...ce Check the driven face for scratches scoring or damage Measure the driven face boss O D Service limit XCITING 250 250 AFI 39 94 mm 1 5976 in Movable Driven Face Check the movable driven face for scratches scoring or damage Check the guide grooves for stepped wear or damage Measure the movable driven face I D Service limit 40 06 mm 1 6024 in 8 14 ...

Page 113: ...______________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING 9 1 SERVICE INFORMATION 9 2 TROUBLESHOOTING 9 2 FINAL REDUCTION DISASSEMBLY 9 3 FINAL ...

Page 114: ...9 FINAL REDUCTION 9 1 G DINK 300i SCHEMATIC DRAWING ...

Page 115: ...ATIONS Specified Oil SAE 90 Oil Capacity At disassembly 0 2 liter At change 0 18 liter TORQUE VALUES Transmission case cover bolt 17 7 21 6N m Oil check bolt 7 8 11 8N m SPECIAL TOOLS Bearing remover 12mm Bearing remover 15mm Pilot 12mm Pilot 15mm TROUBLESHOOTING Engine starts but motorcycle won t move Damaged transmission Seized or burnt transmission Abnormal noise Worn seized or chipped gears Wo...

Page 116: ...ankcase cover Remove the clutch driven pulleys Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket and dowel pins Remove the final gear and countershaft FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Final Shaft Dowel Pin Final Gear Countershaft Drive Shaft Co...

Page 117: ...he drive shaft and gear for wear or damage Check the transmission case covers bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Drive Shaft Bearing Final Shaft Bearing Countershaft Bearing Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and il l Drive Shaft Bearing Fin...

Page 118: ... the bearing remover Remove the final shaft oil seal Drive new bearings into the transmission case cover BEARING REPLACEMENT LEFT CRANKCASE COVER Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using the bearing remover Drive Shaft Bearing Bearing Remover 15mm Pilot 15mm Bearing Remover ...

Page 119: ...i Drive new bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Install the final gear and final shaft into the left crankcase Pilot Drive Shaft ...

Page 120: ...e resin washer onto the counter shaft Install the dowel pins and a new gasket Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley Install other removed parts in the reverse order of removal Countershaft Transmission Case Cover Bolts ...

Page 121: ...e 0 18 liter Install and tighten the oil check bolt Torque 7 8 11 8N m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper level if the oil level is low Place the motorcycle on its main stand on level ground Check the oil sealing washer for wear or damage Drain Bolt Oil Check Bolt Hole Oil Filler ...

Page 122: ...________________________________________________________________ __________________________________________________________________________________ A C GENERATOR STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING 10 1 SERVICE INFORMATION 10 2 TROUBLESHOOTING 10 2 RIGHT CRANKCASE COVER REMOVAL 10 3 STATOR REMOVAL 10 3 FLYWHEEL REMOVAL...

Page 123: ...10 A C GENERATOR STARTER CLUTCH 10 1 G Dink300i SCHEMATIC DRAWING ...

Page 124: ... clean container Drain the engine oil into a clean container before removing the right crankcase cover When the right crankcase cover is installed fill with the recommended engine oil and coolant Then bleed air from the water jacket SPECIAL TOOLS Flywheel puller Flywheel holder SPECIFICATIONS Item Standard mm Service Limit mm Starter driven gear I D 22 026 22 045 22 15mm Starter driven gear O D 42...

Page 125: ...ching screws and the pulser coil Remove the three A C generator stator bolts and the stator FLYWHEEL REMOVAL Hold the flywheel with a flywheel holder and remove the flywheel nut Remove the flywheel with a flywheel puller Water Outlet Hose Bolts Flywheel Nut Flywheel Holder When removing the pulser coil and stator be careful not to damage them to avoid shorted or broken wire Water Inlet Hose Screws...

Page 126: ... INSPECTION Inspect the starter driven gear for wear or damage Measure the starter driven gear I D and O D Service Limits I D 22 15mm replace if over O D 41 50mm replace if below Inspect the starter idle gear and shaft for wear or damage Starter Idle Gear Shaft Starter Driven Gear Starter Idle Gear Starter Driven Gear Starter Idle Gear Shaft ...

Page 127: ... and shaft FLYWHEEL INSTALLATION Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel Hold the flywheel with the flywheel holder and tighten the flywheel nut Torque 53 9 63 7N m Starter Idle Gear Shaft Groove Before installation check and make sure that the inside of the flywheel is not contaminated Starter Driven Gear Flywheel Key Flywheel...

Page 128: ...tall the two dowel pins and a new gasket Install the right crankcase cover over the crankcase aligning the water pump shaft groove with the oil pump shaft Tighten the nine right crankcase cover bolts Connect the water hoses to the right crankcase cover Add the recommended engine oil Fill the cooling system with the specified coolant Right Crankcase Cover Oil Pump Shaft Dowel Pins Be sure to route ...

Page 129: ..._____________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING 11 1 SERVICE INFORMATION 11 2 TROUBLESHOOTING 11 2 CRANKCASE SEPARATION 11...

Page 130: ...11 CRANKCASE CRANKSHAFT 11 1 G DINK 300i SCHEMATIC DRAWING ...

Page 131: ...ust be removed before separating the crankcase Cylinder head Cylinder piston Right crankcase cover drive and driven pulley A C generator starter clutch Rear wheel rear shock absorber Starter motor Oil pump SPECIFICATIONS Item Standard mm Service Limit mm Connecting rod big end side clearance 0 15 0 35 0 6 Crankshaft Connecting rod big end radial clearance 0 0 008 0 05 Runout 0 10 TORQUE VALUES Cra...

Page 132: ...ching bolts Remove the left crankcase Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase Remove the gasket and dowel pins Remove the crankshaft from the left crankcase Cam Chain Tensioner Slipper Cam Chain Bolt Never use a driver to pry the crankcase mating surfaces apart Left Crankcase Crankshaft Right Crankcase Left Crankcase Left Crankcase ...

Page 133: ... the oil seal from the 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 Oil Seal Left Crankcase ...

Page 134: ... crankshaft bearing play Service Limits Axial 0 20mm replace if over Radial 0 05mm replace if over CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces Install a new oil seal into the left crankcase Axial Play Play Radial Avoid damaging the crankcase mating surfaces Oil Seal Left Crankcase ...

Page 135: ... Place the right crankcase over the crankshaft and onto the left crankcase Install and tighten the right and left crankcase attaching bolts Torque 7 8 10 8N m Left Crankcase Gasket Right Crankcase Dowel Pins Bolts Install the right crankcase squarely and do not tap it with an iron or plastic hammer Avoid damaging the oil seal Apply grease to the lip of the oil seal ...

Page 136: ...ANKCASE CRANKSHAFT 11 7 G DINK 300i Install the cam chain Install the cam chain tensioner slipper Install and tighten the cam chain tensioner slipper bolt Torque 7 8 11 8N m Cam Chain Tensioner Slipper Bolt ...

Page 137: ..._____________________________ ________________________________________________________________________________ ________________________________________________________________________________ COOLING SYSTEM ________________________________________________________________________________ SCHEMATIC DRAWING 12 1 SERVICE INFORMATION 12 2 TROUBLESHOOTING 12 2 COOLING SYSTEM TESTING 12 3 RADIATOR 12 3 W...

Page 138: ...12 COOLING SYSTEM 12 1 G DINK 300i SCHEMATIC DRAWING ...

Page 139: ...h off any spilled coolant with fresh water as soon as possible After servicing the system check for leaks with a cooling system tester TORQUE VALUES Water pump impeller 1 0 1 4 kgf m 11 8 N m Water pump cover bolt 1 0 1 4 kgf m 11 8 N m TROUBLESHOOTING Engine temperature too high Coolant leaks Faulty temperature gauge or thermosensor Faulty pump mechanical water seal Faulty radiator cap Deteriorat...

Page 140: ...re 0 9 0 15 kg cm Install the radiator tester onto the radiator and apply specified pressure to it It must hold specified pressure for at least six seconds Check the water hoses and connectors for leaks RADIATOR RADIATOR INSPECTION Remove the front cover Apply water to the sealing cap surface before testing Radiator Cap Radiator Tester The test pressure should not exceed 1 05 kg cm Excessive press...

Page 141: ...traighten any bent fins RADIATOR REMOVAL Drain the coolant Disconnect the outlet tube of the reserve tank Remove the overflow tube clamp and disconnect the overflow tube Disconnect the air vent tube from the radiator filler Disconnect the fan motor wire coupler Loosen the hose band and disconnect the upper hose and lower hose from the radiator Disconnect the thermostatic switch wire coupler Thermo...

Page 142: ...2 COOLING SYSTEM 12 5 G DINK 300i Remove three bolts nuts on the radiator Remove the radiator RADIATOR DISASSEMBLY Remove bolts and then remove the fan rubber from the radiator Check fan motor by battery ...

Page 143: ...h hose bands Connect the thermostatic switch wire Connect the fan motor wire couplers Connect the overflow tube and secure with the tube clamp Fill the radiator with coolant Connect the vent tube to the radiator filler After installation check for coolant leaks Connect the outlet tube of the reservoir and secure with the tube clamp If you want to refill the coolant the following procedure must be ...

Page 144: ...e the right crankcase cover and replace the mechanical seal WATER PUMP IMPELLER REMOVAL Remove the coolant inlet hose and outlet hose Remove four bolts and the water pump cover gasket and 2 dowel pins Remove the water pump impeller Inspect the mechanical water seal and seal washer if wear or damage The impeller has left hand threads The mechanical seal and seal washer must be replace as a set ...

Page 145: ...ter pump shaft outer bearing MECHANICAL SEAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside WATER PUMP SHAFT INSTALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside Install the water pump shaft and shaft inner bearing into the waster pump assembly Install the snap ring to secure the inner bearing properly Apply seal...

Page 146: ...the mechanical seal is replaced a new seal washer must be installed to the impeller Install the impeller onto the water pump shaft Torque 1 0 1 4 kgf m 11 8 N m Install two dowel pins and a new gasket Install the water pump cover and tighten the 4 bolts Torque 1 0 1 4 kgf m 11 8 N m When installing the water pump assembly aligning the groove on the water pump shaft with the tab on the oil pump sha...

Page 147: ...r fender cover A Drain the coolant Disconnect the thermosensor wire Remove the thermosensor THERMOSENSOR INSPECTION Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up Temperature 50 80 100 120 Resistance Ω 154 52 27 16 Thermosensor Thermometer Thermosensor Thermosensor Wire ...

Page 148: ...s Remove the thermostat from the thermostat housing THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation Technical Data Begins to open 71 Full open 80 Valve lift 3 5 4 5mm THERMOSTAT INSTALLATION Fill the cooling system with the specified coolant Do not make the thermostat touch the pan as it will give a false...

Page 149: ...AM 13 3 PARTS LOCATION 13 4 TROUBLESHOOTING 13 8 SELF DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL 13 9 EFI SELF DIAGNOSIS CHECK ENGINE LAMP CELP FAILURE CODES 13 10 SELF DIAGNOSIS RESET PROCEDURE 13 11 CELP FAILURE CODES LIST 13 12 TPS ISC RESET 13 15 FUEL PUMP 13 16 FUEL CUT OFF RELAY 13 18 TILT SWITCH 13 19 ELECTRONIC CONTROL UNIT ECU 13 20 FUEL INJECTOR 13 22 WTS SENSOR 13 24 O2 SENSOR 13 25 ...

Page 150: ...ause throttle and idle valve synchronization failure Seal the cylinder head intake ports with tape or a clean towel to prevent dirt and debris from entering the intake ports after the throttle body has been removed Do not damage the throttle body It may cause incorrect throttle and idle valve synchronization Do not take the fuel pump on the ground downward Always replace the packing when the fuel ...

Page 151: ...L Hr 294 6 kPa 3 Bar At 20 C 4 F 18 8 KΩ At 40 C 104 F 1 136 KΩ Water temperature sensor resistance At 100 C 212 F 0 1553 KΩ Intake pressure sensor MAP pressure at 1 4 2 V 13 332 kPa 0 13332 kgf cm2 1 89 psi 119 99 kPa 1 1999 kgf cm2 17 04 psi Inductive ignition coil Primary 3 57 4 83Ω Secondary 10 42 14 49KΩ Throttle position sensor TPS resistance at 20 C 68 F 3500 6500Ω Crank position sensor vol...

Page 152: ...ch Angle detect sensor ROLL 03 Fuel pump Fuel level unit FP 04 Water temperature sensor WTS sensor 05 Crank position sensor Pulser CPS 06 Oxygen Oxygen heater sensor O2 O2 Heat sensor 08 Inductive ignition coil IG 09 Fuel injector Nozzle INJ 10 Intake pressure sensor MAP sensor 11 Idle air bypass valve ISC 12 Throttle position sensor TPS ...

Page 153: ...13 FUEL INJECTION SYSTEM 13 4 G DINK 300i PARTS LOCATION Tilt Switch Speedometer Radiator Filler Cap Ignition Switch ECU Horn Coolant Reserve Tank ...

Page 154: ...13 FUEL INJECTION SYSTEM 13 5 G DINK 300i CABLE HARNESS ROUTING Fan Relay Hi Beam Relay Lo Beam Relay Fuel Pump Relay ECU Relay Start Relay Winker Relay ...

Page 155: ...13 FUEL INJECTION SYSTEM 13 6 G DINK 300i ISC Throttle Body TPS WTS Injector MAP Sensor O2 Sensor ...

Page 156: ...13 FUEL INJECTION SYSTEM 13 7 G DINK 300i Starter Relay Regulator Rectifier Crank Position Sensor Ignition Coil Hazard Control Unit ...

Page 157: ...p Clogged fuel filter throttle body Sticking fuel injector needle Faulty fuel pump operating system Carbon deposit stayed on the fuel injector Spark plug dirty Fuel pressure incorrect Engine stall hard to start rough idling Poor performance drive ability and poor Intake air leak fuel economy Fuel contaminated deteriorated Pinched or clogged fuel hose Pinched or clogged fuel hose Faulty injector Id...

Page 158: ...ne has problem the CELP will blink to show the failure codes There re 11 failure codes for the KEHIN system If the vehicle gets more failure codes the CELP will be blinking from a lower number then show the higher number after three seconds All failure codes would be appeared repeatedly It can be performed without diagnostics program No matter when the CELP illuminated while riding condition shoul...

Page 159: ...is equal to ten For example one longer blink illumination and two shorter blinks 0 5 second x 2 of the indicator is equal to 12 blinks Follow code 12 If more than a damaged part has occurred the CELP begins blinking in order For example If the indicator blinks six times then shows one second illumination and two blinks so there are two failures have occurred Follow code 6 and 12 ...

Page 160: ...y open the throttle and wait for ten seconds 4 Release the throttle 5 The indicator will blink twice 0 5 second after five seconds quickly 6 Self diagnosis memory data is disappeared after the CELP lamp is off The self diagnosis can not be reset when has still problem inside the system Throttle closed KEY ON 10 s 10 s 5 s Indicator blinks twice continuously Throttle closed Throttle opened fully ...

Page 161: ...3 Ω Loose or poor connection on ECT Open or short circuit on ECT wire Faulty ECT Engine operates normally 15 P1630 Faulty Tilt switch Roll Faulty Tilt switch voltage range inclined angle 65 0 4 1 4 V Inclined angle 65 3 7 4 4 V Loose or poor connection on Tilt switch Open or short circuit in Tilt switch wire Faulty tilt switch Engine operates normally 17 P0130 Faulty O2 sensor Faulty O2 sensor vol...

Page 162: ...0 3Ω Loose or poor connection on fuel pump Open or short circuit on fuel pump wire Faulty fuel pump Engine fail to be operated 45 P0135 Faulty O2 sensor heater Faulty O2 sensor heater Ω range 6 7 Ω 9 5Ω Loose or poor connection on O2 sensor heater Open or short circuit on O2 sensor heater wire Faulty O2 sensor heater Engine starts normally but not smooth 49 P1505 Faulty ISC Loose or poor contacts ...

Page 163: ...INK 300i SPARK PLUG ANTI FLOOD When have not failure code occurs and pressing starter switch repeatedly can still not start the engine maybe the spark plug is wet by fuel perform the spark plug anti flood to purge the fuel in the engine ...

Page 164: ...en the ECU or the throttle body has been reinstalled It can cause engine stop hard to start engine or rough idling speed The throttle position sensor TPS and idle air bypass valve ISC have to be reset when throttle body MAP TPS ISC or ECU has been reinstalled TPS ISC RESET PROCEDURE 1 Put the side stand up and engine stop switch is at RUN 2 Turn the key to the OFF position 3 Fully open the throttl...

Page 165: ...nt battery voltage for a few seconds If there is still battery voltage replace the fuel pump If there is not any battery voltage inspect the following Fuse B 10 A Fuel cut off relay ECU Measure the resistance between the Red Black and Green terminals of the fuel pump side connector Standard at 20 C 68 F 1 9 0 3 Ω Fuel level sensor inspection Measure the resistance between the Yellow White and Gree...

Page 166: ...ire and ensure the connector rearward carefully Torque 0 35 kgf m 3 5 N m 2 5 lbf ft FUEL OUTPUT PRESSURE INSPECTIION Turn the key to the OFF position Use the fuel hose clamp Disconnect the fuel hose from the fuel injector Connect the fuel pressure gauge Turn the key to the ON position Check the fuel pressure Standard 3 0 Bar Hose band Connector Screw If the fuel output pressure is less than 3 0 b...

Page 167: ...ction Black Red Black Connect 12 V battery with the fuel pump relay connector Connection Blue Black Black There should be continuity only when 12 V battery connected If there is not continuity when the 12 V battery is connected replace a fuel pump relay REMOVAL Disconnect the fuel pump relay connector and remove it from frame Battery Fuel pump Relay Fuel pump Relay ...

Page 168: ...the tilt switch 65 10 degrees to the left or right with the ignition switch turned to ON Measure the voltage between the following terminals of the tilt switch connector with the connector connected Terminal Normal Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 3 7 4 4 V If repeat this test first turn the ignition switch to OFF then turn the ignition switch to ON REMOVAL INSTALLATION ...

Page 169: ...on is in the reverse order of the removal Do not disconnect or connect the ECU connector during the ignition switch ON it may cause the ECU damaged The throttle position sensor TPS and idle air bypass valve ISC have to be reset when throttle body MAP TPS ISC or ECU has been reinstalled Speedometer Radiator Filler Cap Ignition Switch ECU Horn Coolant Reserve Tank ...

Page 170: ...en pin 9 and 10 of the ECU side connector There should be continuity at all times Check for continuity between each pins 2 4 and 23 of the ECU side connector There should be continuity at all times Check for continuity between pin 24 and 10 of the ECU side connector There should be no continuity at all times ECU PIN FUNCTION ...

Page 171: ...connector from the fuel injector Remove the bolt of the fuel injector Take out of the fuel pipe and fuel injector from the Inlet pipe Remove the fuel injector from the fuel pipe Connector Bolt Ensure the fuel pipe without any pressure then remove the fuel injector STEP 1 Disconnect the fuel pump relay or fuel pump connector STEP 2 Turn the key to the ON position Starting the engine till the engine...

Page 172: ...ounting bolt FUEL INJECTOR CLEANING PROBLEM 1 Fuel Injector cannot output the fuel 2 The Injector injection time ms is shorter or longer Standard 1 6ms ANALYSIS Injector block With some carbons TROUBLESHOOTING 1 Use the specified injector cleaner 2 Pouring the liquid of carburetor cleaner until half container 3 Connect the battery as picture 4 The injector cleaner with the flash relay 5 Keeping th...

Page 173: ...move the WTS sensor and O ring Install a new O ring and WTS sensor Tighten the WTS sensor to the specified torque Torque 1 2 kgf m 12 N m 8 6 lbf ft Connect the WTS sensor connector Fill the cooling system with the recommended coolant INSPECTION Measure the resistance at the WTS sensor terminals STANDARD ºC 20 40 100 KΩ 18 8 1 136 0 1553 Always replace an O ring with a new one O ring WTS Sensor ...

Page 174: ...rols the fuel injector operation INSPECTION Disconnect the O2 sensor connector Measure the resistance between each White wire terminals of the O2 sensor side connector Standard 7 7 1 2 Ω at 20 C 68 F REMOVAL INSTALLATION Disconnect the O2 sensor connector and then remove it from exhaust muffler Installation is in the reverse order of removal Tighten the O2 sensor to specified torque Torque 2 5 kgf...

Page 175: ...MCO factory do not disassemble it by a wrong way Do not loosen or tighten the painted bolts and screws for the throttle body Loosen or tighten them can cause the throttle and idle valve to synchronization failure TPS and ISC have to be reset after the throttle body MAP TPS ISC or ECU has been reinstalled MAP INSPECTION Support the scooter on a level surface Put the side stand up and engine stop sw...

Page 176: ...nal Normal Violet Red Green Pink 5 V Throttle position sensor TPS resistance at 20 C 68 F 3500 6500Ω REMOVAL Loosen the throttle cables with the adjusting nuts Disconnect the throttle cable ends from throttle seat Disconnect the TPS ISC and MAP sensor connectors Loosen the air cleaner connecting hose band screw Loosen the intake manifold band screw Remove the throttle body MAP sensor TPS sensor an...

Page 177: ...e TPS onto the throttle body being careful not to damage the O ring Install and tighten the screw securely The throttle position sensor TPS and idle air bypass valve ISC have to be reset when the throttle body MAP TPS ISC or ECU has been reinstalled TPS Screw ISC Set Plate Screw Set Plate MAP Screw ISC TPS MAP The throttle position sensor TPS and idle air bypass valve ISC have to reset when the th...

Page 178: ... the throttle body being careful not to damage the O ring DIAGNOSTIC TOOL CONNECTOR INSPECTION Put the side stand up and engine stop switch is at RUN Turn the ignition switch to ON Measure the voltage between the following terminals of the diagnostic tool connector with PDA tester Terminal Normal Black Green Battery voltage White Yellow Green Battery voltage 1 V MAP O ring Always replace an O ring...

Page 179: ...13 FUELINJECTIONSYSTEM 30 13 28 G DINK 300i 13 30 FI DIAGNOSTIC TOOL OPERATION INSTRUCTIONS 3620A LEB2 E00 ...

Page 180: ... The power required of tool is connected with 12V battery z For connection please connect this tool with the connector of ECU It s available when turning on the ignition switch z The side stand must be upward when serving the diagnostic procedure z The function includes ECU version model name data analysis and reset ECU version includes model name ECU number identifications number and software ver...

Page 181: ... INSPECTION PROCEDURE Showing four functions on the screen when switching on power A ECU version Including of model name ECU number identifications number and software version Press the Enter button LHG7 is for G Dink 300i LHG7 is for G Dink 300i LHG7 LHG7 ...

Page 182: ...NJECTIONSYSTEM 31 13 31 G DINK 300i 13 33 B Press the Down button and then turn to the first page C Press the Enter button to check the DTC failure code LHG7 is for G Dink 300i LHG7 LHG7 is for G Dink 300i LHG7 ...

Page 183: ...13 FUELINJECTIONSYSTEM 30 13 32 G DINK 300i 13 34 D Press the Enter button E Press the Enter button F Display what s DTC number on this DTC List Press the Enter button and then turn to the previous page ...

Page 184: ...5 FUELINJECTION SYSTEM 5 33 G DINK 300i 13 35 13 G Press the UP button H Press the Enter button and then turn to the previous page with red color I Press the UP button ...

Page 185: ...5 FUELINJECTION SYSTEM 5 34 G DINK 300i 13 36 13 J Press the Enter button and then turn to the first page LHG7 is for G Dink 300i LHG7 is for G Dink 300i ...

Page 186: ...5 FUELINJECTION SYSTEM 5 35 G DINK 300i 13 37 13 3 DTC CLEAR PROCEDURE A Check the DTC B Press the Enter button C Choose Load DTC Press the Down button LHG7 is for G Dink 300i LHG7 is for G Dink 300i ...

Page 187: ...5 FUELINJECTION SYSTEM 5 36 G DINK 300i 13 38 13 D Press the Enter button and the indicator is lighting E Clearing DTC completed if the indicator is off ...

Page 188: ...EDURE A Press the Down twice B Choose Data Analyze Press the Enter button to enter page 01 C Down page 01 The measure figures including of Engine speed Battery voltage and DTC number Press the Down button to enter page 02 LHG7 is for G Dink 300i LHG7 is for G Dink 300i ...

Page 189: ...ture Press the Down button to enter page 03 E Down page 03 The measure figures including of Atmosphere pressure Fuel Injector interval and Ignition advance timing Press the Down button to enter page 04 F Down page 04 The measure figures including of Engine temperature O2 sensor voltage and O2 heater activation Press the Down button to enter page 05 ...

Page 190: ...luding of ISC target ISC step and ISC learn step Press the Down button to enter page 06 H Down page 06 The measure figures including of ISC motor state Press the Down button to enter page 07 I Down page 07 The measure figures including of Cut Out voltage J Press the UP to the previous page ...

Page 191: ...f Throttle Valve being changed or loose 5 Has the vehicle under regular service Is the gas station a good one 6 Is the spark plug the correct model of specified by the vehicle builder Vehicle can not be started Check for any Failure code Failure Lamp on How to tell the Failure code Turn on power to see if the engine inspection failure lamp off If it flashes continuously or light up for long time t...

Page 192: ...5 second x 2 of the indicator equals 12 blinks Refer to DTC 12 2 If more than one failure occurs the CELP shows the blinks in the occurred order For example if the indicator blinks 6 times then shows one second illumination and two blinks two failures have occurred Refer to DTC 6 and DTC 12 After excluding trouble how the DTC can be cleared Confirm the failure is excluded z Turn on power but maint...

Page 193: ..._____________ __________________________________________________________________________________ __________________________________________________________________________________ HANDLEBAR FRONTWHEEL FRONTBRAKE FRONTSHOCKABSORBER STEERINGSTEM __________________________________________________________________________________ SERVICE INFORMATION 14 1 TROUBLESHOOTING 14 2 HANDLEBAR 14 3 FRONT WHEEL ...

Page 194: ...g handlebar front shock absorber and front fork Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down During servicing keep oil or grease off the brake pads and brake disk TORQUE VALUES Handlebar post 6 0 7 0 kgf m Steering stem lock nut 6 0 6 5 kgf m Front axle 1 5 2 5 kgf m Brake caliper mounting bolt 3 4 kgf m Brake caliper bleed screw 0 4 0 7...

Page 195: ...ned axle nut Steers to one side or does not track straight Uneven front shock absorbers Soft front shock absorber Bent front fork Weak shock springs Bent front axle or uneven tire Insufficient damper oil Poor brake performance Front shock absorber noise Worn brake pads Slider bending Contaminated brake pad surface Loose fork fasteners Deformed brake disk Lack of lubrication Air in brake system Det...

Page 196: ...n remove the rear brake master cylinder Remove the two bolts and disconnect the brake light switch wire then remove the front brake master cylinder Remove the inner cover Remove the handlebar lock nut and take out the bolt Remove the handlebar INSTALLATION Install the handlebar onto the steering stem and install the handlebar lock nut and bolt Tighten the bolt to the specified torque Torque 4 5 kg...

Page 197: ...14 4 G DINK 300i Install the front and rear master cylinders and connect the brake light switch wires DISASSEMBLY Remove two screws attaching to the right handlebar switch Disconnect the throttle cable from the throttle grip Remove the right handlebar switch Throttle cable ...

Page 198: ...ebar switch Install and tighten the two screws securely Install the right handlebar switch Lubricate the throttle grip front end with grease and then connect the throttle cable to the throttle grip Install and tighten the two screws Align the pin on the left handlebar switch with the hole on the handlebar Align the pin on the right handlebar switch with the hole on the handlebar ...

Page 199: ...nt wheel off the ground Remove the bolt and then pull out the axle Remove the front wheel and collar AXLE RUNOUT INSPECTION Set the axle in V blocks and measure the runout using a dial gauge The actual runout is 1 2 of the total indicator reading Service Limit 0 2 mm 0 008 in WHEEL RIM INSPECTION Check the wheel rim runout Axle ...

Page 200: ...BLY Remove the side collar and dust seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub Remove the front wheel bearing Remove the distance collar from wheel Collar Dust Seal Bearing ...

Page 201: ...wo screws Remove the reservoir cover diaphragm plate and diaphragm Connect a bleed hose to the bleed valve A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent Do not allow foreign material to enter the system when filling the reservoir Avoid spilling brake fluid on painted plastic or rubber parts...

Page 202: ... front caliper bleed valve Check the fluid level often while bleeding the brake to prevent air from being pumped into the system Pump the brake bleeder and loosen the front caliper bleed valve Add fluid when the fluid level in the master cylinder is low to prevent drawing air into the system Repeat the above procedures until no air bubbles appear in the plastic hose Close the front caliper bleedin...

Page 203: ...ds and close the bleed valve 2 Release the brake lever slowly until the bleed valve has been closed Add fluid when the fluid level in the master cylinder is low to prevent drawing air into the system 3 Repeat the steps 1 2 until there are no air bubbles in the bleed hose After bleeding air completely tighten the bleed valve to the specified torque Torque 6 N m 0 6 kgf m 4 3 lbf ft Fill the reservo...

Page 204: ... SHOCK ABSORBER STEERING STEM 14 11 G DINK 300i FRONT BRAKE PAD BRAKE PAD REPLACEMENT Remove the caliper mounting bolts then remove the caliper Remove the brake pads Always replace the brake pads in pairs to ensure even disc pressure Brake Pads ...

Page 205: ... their ends rest on the pad retainer on the brake properly Install the front caliper onto the fork leg and then install and tighten the new two caliper mounting bolts to the specified torque Torque 35 N m 3 5 kgf m Tighten the pad pins to the specified torque Torque 18 N m 1 8 kgf m 13 lbf ft BRAKE DISC INSPECTION ...

Page 206: ...e guide from right front shock absorber Remove two mounting bolts and then remove the right left front shock absorber INSTALLATION Installation is in the reverse order of removal INSPECTION Inspect the following items and replace if necessary Front shock absorber tube bending damage or wear Weak front shock absorber spring Damper and damper rod bending Oil seal damage or wear Tighten the shock abs...

Page 207: ... the steering handlebar Remove the front brake hose and speed wheel sensor connector from the guide Hold the steering stem top cone race and remove the steering stem lock nut by using the special tool Special tool Lock nut wrench F00002 Remove the top cone race and washer Remove the steering stem Lock Nut Wrench Right ...

Page 208: ... balls for wear or damage Replace if necessary Remove the top balls Remove the upper ball race by using a chisel if necessary Remove the bottom balls Remove the bottom ball race Remove the bottom cone race by using a chisel if necessary Install with reverse operation Ball Top Ball Cone Race Be careful not to damage the steering stem ...

Page 209: ...______________________________________ ________________________________________________________________________________ ________________________________________________________________________________ REARBRAKE REARFORK REARWHEEL REARSHOCKABSORBER _________________________________________________________________________________________ SCHEMATIC DRAWING 15 1 SERVICE INFORMATION 15 2 TROUBLESHOOTIN...

Page 210: ...15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 1 G DINK 300i SCHEMATIC DRAWING ...

Page 211: ...ss 4 0 Rear brake disk runout TORQUE VALUES Exhaust muffler pipe nuts 1 8 2 2 kgf m Exhaust muffler brake RR Frok 3 2 3 8 kgf m RR fork Engine case 2 4 3 0 kgf m TROUBLESHOOTING Rear wheel wobbling Poor brake performance Bent rim Air in brake system Faulty tire Deteriorated brake fluid Axle not tightened properly Contaminated brake pad surface Worn brake pads Soft rear shock absorber Clogged brake...

Page 212: ...hing the rear brake caliper Remove the rear brake caliper INSPECTION Inspect the brake pads and brake disk Measure the brake disk thickness Visually check the brake pad thickness DISASSEMBLY Remove two brake pads dowel pins and three bolts from the brake caliper Remove the brake pads When removing the brake fluid tube use shop towels to cover plastic parts and coated surfaces to avoid damage Bolt ...

Page 213: ... the brake fluid inlet opening and place a towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if necessary Check the caliper cylinder for scratches or wear and measure the cylinder bore ASSEMBLY Install the two spring plates onto the groove of the caliper Compressed Air 15 4 ...

Page 214: ... to the brake caliper and install fluid tube bolt copper washers and tighten the fluid tube bolt Fill the brake reservoir with the specified brake fluid and bleed air from the brake system Make sure the spring plate next to the brake pad dowel pin orientation Brake Pads When installing the brake fluid tube be sure to install the two copper sealing washers 15 5 Bolt Bolts Brake Caliper ...

Page 215: ... Remove the exhaust muffler Remove the rear brake caliper Remove the right rear shock absorber lower mount bolt Remove the rear axle nut and remove the collar Remove the rear fork The installation sequence is the reverse of removal Bear Axle Nut Bear Axle Collar Bolt 15 6 ...

Page 216: ...wer mount bolt 40 N m 4 kgf m Rear axle nut 120 N m 12 kgf m REAR SHOCK ABSORBER REMOVAL Remove the met in box and carrier Remove the body cover center cover and rear fender A together Remove the right left rear shock absorber upper and lower mount bolts Remove the right and left rear shock absorbers INSTALLATION Install the rear suspension in the reverse order of removal Torque Upper Mount Bolt 4...

Page 217: ...15 REAR WHEEL REAR BRAKE REAR SUSPENSION G DINK 300i 15 8 ...

Page 218: ...____________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT 16 1 CHARGING CIRCUIT 16 1 SERVICE INFORMATION 16 2 TROUBLESHOOTING 16 3 BA...

Page 219: ...16 BATTERY CHARGING SYSTEM 16 1 G DINK 300i CHARGING SYSTEM LAYOUT ACG BATTERY REGULATOR RECTIFIER ...

Page 220: ...ould be recharged when the capacity is insufficient Recharging a new battery will prolong its service life Inspect the charging system according to the sequence specified in the Troubleshooting Do not disconnect and soon reconnect the power of any electrical equipment because the electronic parts in the regulator rectifier will be damaged Turn off the ignition switch before operation It is not nec...

Page 221: ...ttery cable Loose charging system connection Fuse burned out Loose connection or short circuit in Faulty ignition switch ignition system Low power Charging system failure Weak battery Loose broken or shorted wire or connector Loose battery connection Faulty regulator rectifier Charging system failure Faulty A C generator Faulty regulator rectifier ...

Page 222: ... the battery first then disconnect the positive terminal lead 6 Remove the battery from the battery box BATTERY INSTALLATION Install in the reverse order of the removal VOLTAGE INSPECTION Remove the battery cover Measure the battery voltage by using a commercially available digital multimeter Voltage 20ºC 68ºF Fully charged 13 0 13 2 V Insufficient charged 12 3 V When install the battery first con...

Page 223: ...orming this test Start the engine and warm it up to the operating temperature stop the engine Connect the multimeter between the positive and negative terminals of the battery To prevent short make absolutely certain which are the positive and negative terminals or cable With the headlight on and turned to the high beam position restart the engine Measure the voltage on the multimeter when the eng...

Page 224: ...tifier connectors Check the connectors for loose contacts of corroded terminals BATTERY WIRE Measure the voltage between the Red White wire terminal and ground There should be battery voltage at all times GROUND WIRE Check the continuity between the Green wire terminal and ground There should be continuity at all times Regulator Rectifier ...

Page 225: ... regulator rectifier connector Check for continuity between each Yellow wire terminal regulator rectifier side and ground There should be no continuity REMOVAL INSTALLATION Remove the side body cover Disconnect the regulator rectifier connectors Remove the two bolts regulator rectifier Installation is in the reverse order of removal Connectors Regulator Rectifier ...

Page 226: ..._____________________ ________________________________________________________________________________ ________________________________________________________________________________ IGNITION SYSTEM ________________________________________________________________________________ IGNITION SYSTEM LAYOUT 17 1 SERVICE INFORMATION 17 2 TROUBLESHOOTING 17 2 SPARK PLUG 17 3 IGNITION COIL INSPECTION 17 3...

Page 227: ...17 IGNITION SYSTEM 17 1 G DINK 300i IGNITION SYSTEM LAYOUT IGNITION CIRCUIT Crank Position Sensor Ignition Switch Ignition Coil ECU A C Generator Tilt switch ...

Page 228: ...engine cranking speed as well as no spark at the spark plug Use a spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine SPECIFICATIONS Item Standard Spark plug Standard type DPR6EA Spark plug gap 0 6 0 7 mm Primary coil 3 57 4 83Ω Inductive Ignition Coil Secondary coil without plug cap 10 42 14 49 KΩ Throttle Position Sensor 3500 6500Ω Fuel Pump 1...

Page 229: ...TY TEST Inspect the continuity of the ignition coil primary coil and secondary coil Measure the ignition coil resistances at 20 Primary coil 3 57 4 83Ω Secondary coil with plug cap 15 19 KΩ Secondary coil without plug cap 10 14 KΩ This is a general test Accurate ignition coil test must be performed with an ignition unit tester Ignition Coil Primary Coil Secondary Coil with plug cap Secondary Coil ...

Page 230: ...rtical as shown at the ignition switch ON Measure the voltage as below Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 0 4 1 4 V less Incline the tilt switch 65 10 degrees to the left or right at the ignition switch ON Measure the voltage as below Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 3 7 4 4 V If repeat this test first turn the...

Page 231: ...AL INSTALLATION Disconnect the connector and remove two screws then remove tilt switch Installation is in the reverse order of removal Tighten the mounting screws securely Install the tilt switch with its up mark facing up Tilt Switch UP Mark ...

Page 232: ..._________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ STARTING SYSTEM ________________________________________________________________________________ STARTING SYSTEM LAYOUT 18 1 SERVICE INFORMATION 18 2 TROUBLESHOOTING 18 2 STARTER MOTOR 18 ...

Page 233: ...18 STARTING SYSTEM 18 1 G DINK 300i STARTING SYSTEM LAYOUT STARTING CIRCUIT Starter Relay Relay R Ignition Switch ...

Page 234: ... motor brush length 12 5mm 8 5mm SPECIAL TOOLS Flywheel holder E021 Flywheel puller E003 TROUBLESHOOTING Starter motor won t turn Lack of power Fuse burned out Weak battery Weak battery Loosed wire or connection Faulty ignition switch Foreign matter stuck in starter motor Faulty starter clutch or gear Faulty front or rear stop switch Faulty starter relay Starter motor rotates but engine does Poorl...

Page 235: ... goes to the starter relay and relax cable band to disconnect the starter motor cable Remove two start motor mounting bolts and the motor Before removing the starter motor turn the ignition switch OFF and remove the battery ground Then turn on the ignition switch and push the starter button to make sure the starter motor can t operate securely Nut Starter Motor Cable Bolts ...

Page 236: ...ow wire There should be continuity when the starter button is depressed If there is no continuity check the starter button for continuity and inspect the wire OPERATION TEST Connect the electric meter to the starter relay terminals that connect to the battery positive cable and the starter motor cable Connect a fully charged battery across the starter relay yellow red and green yellow wire termina...

Page 237: ..._______________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS METERS SWITCHES __________________________________________________________________________________ SERVICE INFORMATION 19 1 BULB REPLACEMENT 19 2 BRAKE LIGHT SWITCH 19 6 IGNITION SWITCH 19 6 HANDLEBAR SW...

Page 238: ...n the scooter Route the wires and cables properly after servicing each component TROUBLESHOOTING Lights do not come on when ignition Temperature gauge does not register switch is ON correctly Burned bulb Faulty temperature gauge Faulty switch Faulty thermosensor Poorly connected broken or shorted wire Broken or shorted wire between the temperature gauge and thermosensor Fuel gauge does not work or...

Page 239: ... SWITCHES FUEL PUMP 19 2 G DINK 300i BULB REPLACEMENT LICENECE LIGHT Remove the seat assembly and luggage box Remove the body covers Disconnect the license bulb socket Remove the bulb and replace with a new one ...

Page 240: ...headlight connector from the headlight bulb Install a new bulb into the headlight case Install the headlight and connect the headlight connector A halogen headlight bulb becomes hot while the headlight is ON and remains for a while after it is turned OFF Be sure to let it cool down before servicing Connector Headlight Bulb ...

Page 241: ... the bulb socket then remove the front turn signal light Push and turn the bulb counterclockwise to remove it then replace with a new one Installation is in the reverse order of removal TAILLIGHT BRAKE LIGHT REAR TURN SIGNAL LIGHT Remove the seat and met in then remove the taillight bulb socket ...

Page 242: ...ITCHES 19 5 G DINK 300i REAR TURN SIGNAL LIGHT Push and turn the bulb counterclockwise to remove it then replace with a new one Installation is in the reverse order of removal Rear Turn Signal Light Taillight Brake Light ...

Page 243: ...ontinuity with the front or rear brake lever squeezed and there should be no continuity with the front or rear brake lever is released IGNITION SWITCH INSPECTION Remove the front cover Disconnect the ignition switch connector and check the ignition switch for continuity at the switch side connector terminals Continuity should exist between the color code wires as follows Front Brake Light Switch R...

Page 244: ...WITCH INSPECTION Remove the front cover Disconnect the right handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wires as follows Engine Stop Switch Lighting Switch Starter Switch ...

Page 245: ...ows LUGGAGE BOX LIGHT SWITCH INSPECTION Remove the luggage box Disconnect the luggage box light switch connector and check the luggage box light switch for continuity between the switch terminals There should be no continuity with the luggage box light switch pushed and there should be continuity with the luggage box light switch is released Dimmer Switch Horn Switch Turn Signal light Switch Passi...

Page 246: ...luggage box Side stand switch is located on side stand Disconnect the side stand switch connector There should be continuity between the Yellow Green and Green with the side stand is up There should be continuity between the Yellow Black and Green with the side stand is down Connector ...

Page 247: ...G DINK 300i HORN INSPECTION Remove the front cover Disconnect the horn connectors from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the 12 V battery is connected across the horn terminals ...