KYMCO 125 DINK - Manuel utilisateur

1. GENERAL INFORMATION

1-0

DINK 50/125

_________________________________________________________________________________________

GENERAL INFORMATION

_________________________________________________________________________________________

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

SPECIFICATION (DINK 50)-----------------------------------------------1 - 2

SPECIFICATION (DINK 125) ---------------------------------------------1 - 3

SERVICE PRECAUTIONS-------------------------------------------------1 - 4

TORQUE VALUES ----------------------------------------------------------1 - 8

SPECIAL TOOLS ------------------------------------------------------------1-11

LUBRICATION POINTS ---------------------------------------------------1-13

CABLE&HARNESSROUTING (DINK 125) ----------------------------1-15

CABLE&HARNESSROUTING (DINK 50)------------------------------1-30

TROUBLESHOOTING------------------------------------------------------1-35

1. GENERAL INFORMATION

1-1

DINK50/125

SERIAL NUMBER

Location of Engine Serial Numbe

(1) Location of Frame Serial Numbe

DINK 50 DINK 125

1. GENERAL INFORMATION

1-2

DINK 50/125

SPECIFICATIONS(DINK 50)

Overall length 2030 mm (81.2 in)

Overall width 780 mm (31.2in)

Overall height 1255 mm (50.2 in)

Wheel base 1390 mm (55.6 in)

Engine type Air cooled 4-stroke,

OHC engine

Displacement 49.5cc (2.97 cu-in)

Fuel Used 92↑nonleaded

gasoline

Front wheel 47 kg (103.4 lb)

Rear wheel 64 kg (140.8 lb)

Dry weight

Total 111 (244.2 lb)

Front wheel 52 kg (114.4lb)

Rear wheel 69 kg (151.8lb)

Curb weight

Total 121 kg (266.2 lb)

Front wheel 120/70-13

Tire Rear wheel 130/70-12

Ground clearance 140 mm (308 in)

Braking distance 7 m/30 km/hr

Min. turning radius 2350 mm (94 in)

Starting system Starting motor/Kick

starter

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Triple-sphere

Valve arrangement O.H.C.

Bore x stroke 39.0×41.6 mm

(1.56×1.66 in)

Compression ratio 11:1

Compression pressure 18 kgf/cm2(1800

kPa, 256 psi)-Max

Open 3°(BTDC)

Intake Close 11°(ABDC)

Open -9°(BBDC)

Exhaust Close 19°(ATDC)

Intake 0.05 mm (0.002 in)Valve

clearance

(cold) Exhaust 0.05 mm (0.02 in)

Idle speed (rpm) 2000~2200rpm

Lubrication type Forced pressure &

Wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Oil capacity 0.85 L (0.748 lmp qt,

0.901 US qt))

Lubrication System

Oil exchanging

capacity 0.7L (0.616 lmp qt,

0.742 US qt)

ENGINE

Cooling Type Air cooling

Air cleaner type & No Paper element, wet

Fuel capacity 7 L (1.47 lmp gal,

1.82 US gal)

Type LFA1

Main jet No. #100(speed limited:#90)

Venturi dia. φ17mm (φ0.68 in)

Fuel System

Carburetor

Throttle type piston

Type CDI

Ignition timing 13°/2100 rpm

28°/4000r

Spark plug NGK

CR7HSA

Ignition System

Spark plug gap 0.7 mm (0.028 in)

Electrical Equipment

Battery Capacity 12V4AH

Clutch type C.V.T

Type Non-stage transmission

Transmission

Gear

Operation Automatic centrifugal

Type

Type C.V.T

1st 0.75~2.47

Power Drive System

Reduction

Gear

Reduction

ratio Final 13.67

Front 1.75 kgf/cm2(175 kPa,

24.85 psi)

Tire pressure

(1 person)

Rear 2 kgf/cm2(200 kPa,

28.4 psi)

Turning Left 42.5°

Moving Device

angle Right 42.5°

Fron

Disk brake

Brake system

type Rear Drum brake

Sus

ension Fron

Telescope

type Rear Double swing

Shock absorbe

Front Telescope

Damping

Device

type Rear Double swing

Frame type Under bone

1. GENERAL INFORMATION

1-3

DINK50/125

SPECIFICATIONS (DINK 125)

Overall length 2030 mm (81.2 in)

Overall width 760 mm (30.4 in)

Overall height 1255 mm (50.2 in)

Wheel base 1390 mm (55.6 in)

Engine type Watercooled 4-stroke,

OHC engine

Displacement 124.6 cc (7.6 cu-in)

Fuel Used 92# nonleaded

gasoline

Front wheel 53 kg (116.6 lb)

Rear wheel 85 kg (187 lb)

Dry weight

Total 138 (303.6 lb)

Front wheel 60 kg (132 lb)

Rear wheel 92 kg (202.4 lb)

Curb weight

Total 152 kg (334.4 lb)

Front wheel 120/70-13

Tire Rear wheel 140/70-12

Ground clearance 140 mm (308 in)

Min. turning radius 2350 mm (94 in)

Starting system Starting motor/Kick

starter

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C.

Bore x stroke 52.4×57.8 mm

(2.096×2.312 in)

Compression ratio 10:1

Compression pressure 15 kgf/cm2(1500

kPa, 213 psi)

Open 12°(BTDC)

Intake Close 35°(ABDC)

Open 28°(BBDC)

Exhaust Close 0°(ATDC)

Intake 0.1 mm (0.004 in)Valve

clearance

(cold) Exhaust 0.1 mm (0.004 in)

Idle speed (rpm) 1700±150rpm

Lubrication type Forced pressure &

Wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Oil capacity 1.1 L (0.968 lmp qt,

1.166 US qt))

Lubrication System

Oil exchanging

capacity 0.9 L (0.792 lmp qt,

0.954 US qt)

ENGINE

Cooling Type Liquid cooled

Air cleaner type Paper element, wet

Fuel capacity 11 L (2.31 lmp gal,

2.86 US gal)

Type LEA5

Piston dia. φ21.8 mm (φ0.872 in)

Venturi dia. φ24 mm (φ0.96 in)

Fuel System

Carburetor

Throttle type Butterfly type

Type CDI

Ignition timing 10°±1.5°/1000 rpm

Spark plug NGK

DPR7EA-9

Ignition System

Spark plug gap 0.9 mm (0.036 in)

Electrical Equipment

Battery Capacity 12V8AH

Clutch type Dry multi-disc clutch

Type Non-stage transmission

Transmission

Gear

Operation Automatic centrifugal

Type

Type Two-stage reduction

1st 2.8~1

Power Drive System

Reduction

Gear

Reduction

ratio Final 8.82

Front 1.75 kgf/cm2(175 kPa,

24.85 psi)

Tire pressure

Rear 2 kgf/cm2(200 kPa,

28.4 psi)

Turning Left 42.5°

Moving Device

angle Right 42.5°

Fron

Disk brake

Brake system

type Rear Disk brake

Sus

ension Fron

Telescope

type Rear Double swing

Shock absorbe

Front Telescope

Damping

Device

type Rear Double swing

Frame type Under bone

1. GENERAL INFORMATION

1-4

DINK 50/125

SERVICE PRECAUTIONS

Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when

reassembling.

When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

Use genuine parts and lubricants.

When servicing the motorcycle, be sure to

use special tools for removal and

installation.

After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

Apply or add designated greases and

lubricants to the specified lubrication

points.

After reassembly, check all parts for proper

tightening and operation.

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 installation.

When connecting the battery, the positive

(+) terminal must be connected first.

After connection, apply grease to the

battery terminals.

Terminal caps shall be installed securely.

1. GENERAL INFORMATION

1-5

DINK50/125

If the fuse is burned out, find the cause and

repair it. Replace it with a new one

according to the specified capacity.

After operation, terminal caps shall be

installed securely.

When taking out the connector, the lock on

the connector shall be released before

operation.

Hold the connector body when connecting

or disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is bending,

protruding or loose.

The connector shall be inserted

completely.

If the double connector 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

their respective wire bands at the

designated locations.

Tighten the bands so that only the insulated

surfaces contact the wire harnesses.

Confir

Capacity

1. GENERAL INFORMATION

1-6

DINK 50/125

After clamping, check each wire to make

sure it is secure.

Do not squeeze wires against the weld or

its clamp.

After clamping, check each harness to

make sure that it is not interfering with any

moving or sliding parts.

When fixing the wire harnesses, do not

make it contact the parts which will

generate high heat.

Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of

bolts and screws.

Route wire harnesses passing through the

side of bolts and screws. 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 protecting 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,

repair by wrapping it with protective tape

or replace it.

When installing other parts, do not press or

squeeze the wires.

Do not pull

too tight！

o Contac

Do not press or

squeeze the wire

1. GENERAL INFORMATION

1-7

DINK50/125

After routing, check that the wire harnesses

are not twisted or kinked.

Wire harnesses routed along with

handlebar should not be pulled tight, have

excessive slack or interfere with adjacent

or 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.

Symbols:

The following symbols represent 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#)

: Caution

: Warning

Engine Oil

Grease

Gear Oil

＊

Remove Rust！

Do you understand

the instrument？

1. GENERAL INFORMATION

1-8

DINK 50/125

TORQUE VALUES

STANDARD TORQUE VALUES

Item Torque

kgf-m (N-m, lbf-ft) Item Torque

kgf-m (N-m, lbf-ft)

5mm bolt and nut

6mm bolt and nut

8mm bolt and nut

10mm bolt and nut

12mm bolt and nut

14mm bolt and nut

0.5 (5, 3.6)

1 (10, 7.2)

2.2 (22, 16)

3.5 (35, 25)

5.5 (55, 40)

7 (70, 50)

4mm screw

5mm screw

6mm screw, SH bolt

6mm flange bolt and nut

8mm flange bolt and nut

10mm flange bolt and nut

0.3 (3, 2.2)

0.4 (4, 2.9)

0.9 (9, 6.5)

1.2 (12, 9)

2.7 (27, 20)

4 (40, 29)

Torque specifications listed below are for important fasteners.

ENGINE

Item Q‘ty Thread dia.

(mm)

Torque

(

N-m,

lbf-ft) Remarks

MAINTENANCE:

Spark plug

Tappet ADJ nut

Engine oil strainer screen cap

Engine oil filter cap bolt

Engine oil drain plug

Transmission gear oil drain bolt

Transmission gear oil fill bolt

LUBRICATION SYSTEM:

Oil pump screw

COOLING SYSTEM:

Fan motor bolt

Fan motor switch

Water pump impeller

CYLINDER HEAD:

Cylinder head cover

Cylinder head nut (DINK 50)

Cylinder head nut (DINK 125)

Tensioner sealing bolt

Cam chain tensioner mounting bolt

Cylinder head bolt

1.2 (12, 8.6)

0.9 (9, 6.5)

1.5 (15, 11)

1.2 (12, 8.6)

2.5 (25, 18)

1.3 (13, 9)

0.2 (2, 1.5)

0.53 (5, 2.8)

1.8 (17, 13)

1.2 (12, 9)

1.2 (12, 8.6)

0.7-1.1(10, 7.2)

2 (20, 14)

0.6 (6, 4)

1.2 (12, 8.6)

1 (10, 7.2)

Apply oil

Left hand threads

Apply oil

(Cont’d)

1. GENERAL INFORMATION

1-9

DINK50/125

Item Q‘ty Thread dia.

(mm) Torque

kgf-m (N-m, lbf-ft) Remarks

CYLINDER:

Cylinder bolt

DRIVE/DRIVEN PULLEY:

L crankcase cover

Drive pulley nut (DINK 50)

Drive pulley nut (DINK 125)

Clutch outer nut

Driven pulley assembly plate nut

STARTER SYSTEM:

Flywheel nut

TRANSMISSION:

Transmission case cover bolt

1 (10, 7.2)

1.2 (12, 8.6)

5.5 (55, 40)

1.2 (12, 8.6)

FRAME

Item Q‘ty Thread dia.

(mm) Torque

(

N-m, lbf-ft

)

Remarks

EXHAUST MUFFLER:

Exhaust muffler mounting bolt

Exhaust pipe mounting nut

ENGINE ASSEMBLY:

Engine hanger mounting bolt

Engine mounting bolt/nut

STEERING SYSTEM:

Steering stem lock nut

Handlebar lock nut

Steering stem pinch bolt

WHEEL:

Front wheel axle nut

Rear wheel axle nut

3.3 (33, 24)

2 (20, 14)

5 (50, 36)

8 (80, 58)

4.5 (45, 32)

3.2 (32, 23)

6 (60, 43)

12 (120, 86)

(Cont’d)

Autres manuels pour 125 DINK -

Ce manuel convient aux modèles suivants

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