KYMCO DINK 200i Manuel utilisateur

DINK 200i/125

By KWANG YANG Motor Co., Ltd.

First Edition, Jan 2007

unauthorized use without the written permission of

KWANG YANG Motor Co., Ltd.

is expressly prohibited.

T100SH4025

DINK 200i/125

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO DINK

200i/125.

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before any

operation is started.

Section 2 is the removal/installation

procedures for the frame covers which are

subject to higher removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules and

service information for each part, starting

from periodic maintenance.

Sections 6 through 14 give instructions

for disassembly, assembly and adjustment

of engine parts. Section 15 through 16 is

the removal/ installation of chassis.

Section 17 through 21 states the testing

and measuring 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.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

GENERAL INFORMATION 1

EXHAUST MUFFLER/FRAME COVERS 2

INSPECTION/ADJUSTMENT 3

LUBRICATION SYSTEM 4

ENGINE REMOVAL/INSTALLATION 5

CYLINDER HEAD/VALVES 6

CYLINDER/PISTON 7

DRIVE AND DRIVEN PULLEYS/KICK

STARTER

FINAL REDUCTION 9

A.C. GENERATOR/STARTER CLUTCH 10

CRANKCASE/CRANKSHAFT 11

COOLING SYSTEM 12

DINK 125:

FUEL SYSTEM/CARBURETOR/FUEL

PUMP FUEL TANK

DINK 200i:

FUEL SYSTEM (Auto Control Fuel

Injection System)

HANDLEBAR/FRONT WHEEL/FRONT

BRAKE/FRONT SHOCK

ABSORBER/STEERING STEM

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER`

BATTERY/CHARGING SYSTEM 17

IGNITION SYSTEM 18

STARTING SYSTEM 19

LIGHTS/METERS/SWITCHES 20

WIRING DIAGRAMS 21

ENGINE

The information and contents included in

this manual may be different from the

vehicle in case specifications are changed.

KYMCO reserves the right to make

changes at any time without notice and

without incurring any obligation.

CHASSIS

ELECTRICAL

UIPMENT

1. GENERAL INFORMATION

1-0

DINK 200i/125

_________________________________________________________________________________________

GENERAL INFORMATION

_________________________________________________________________________________________

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

SPECIFICATION (DINK 200i) -------------------------------------------- 1 - 2

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

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

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

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

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

CABLE & HARNESS ROUTING-------------------------------------------- 1-15

TROUBLESHOOTING (DINK 200i) -------------------------------------1-31

TROUBLESHOOTING (DINK 125) -------------------------------------- 1-42

1. GENERAL INFORMATION

1-1

DINK200i/125

SERIAL NUMBER

Location of Engine Serial Numbe

(1) Location of Frame Serial Numbe

1. GENERAL INFORMATION

1-2

DINK 200i/125

SPECIFICATIONS (DINK 200i)

Overall length 2030 mm (81.2 in)

Overall width 780 mm (31.2 in)

Overall height 1255 mm (50.2 in)

Wheel base 1390 mm (55.6 in)

Engine type Water cooled 4-stroke,

OHC engine

Displacement 174.5 cc (10.48 cu-in)

Fuel Used 92# nonleaded gasoline

Front wheel 58 kg (127.6 lb)

Rear wheel 82 kg (180.4 lb)

Dry weight

Total 140 (308 lb)

Front wheel 65 kg (143 lb)

Rear wheel 89 kg (195.8 lb)

Curb weight

Total 154 kg (338.8 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

Type Gasoline, 4-stroke

Cylinder arrangement Single cylinder

Combustion chamber

type Semi-sphere

Valve arrangement O.H.C.

Bore x stroke 62×57.8 mm

(2.48×2.312 in)

Compression ratio 11.2:1

Compression pressure 16 kgf/cm2(1600 kPa,

227.2 psi)

Open 12 (BTDC)

Intake Close 35 (ABDC)

Open 28 (BBDC)

Exhaust Close 8 (ATDC)

Intake 0.1 mm (0.004 in)Valve

clearance

(cold) Exhaust 0.1 mm (0.004 in)

Idle speed (rpm) 1660±100rpm

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 Programmed fuel

injection

Fuel System

Carburetion

Throttle bore !28 mm (!1.12 in)

Type ECU

Ignition timing ECU control

Spark plug NGK

DPR6EA-9

Ignition System

Spark plug gap 0.9 mm (0.036 in)

Electrical Equipment

Battery Capacity 12V10AH

Clutch type Dry multi-disc clutch

Type Non-stage transmission

Transmission

Gear

Operation Automatic centrifugal

Type

Type Two-stage reduction

1st 2.7~0.8

Power Drive System

Reduction

Gear

Reduction

ratio Final 8.48

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

1-3

DINK200i/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 Water cooled 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. !21.8 mm (!0.872 in)

Venturi dia. !24 mm (!0.96 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 200i/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

DINK200i/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 200i/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

DINK200i/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• •

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