KYMCO DINK 200i Service Manual
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KYMCO DINK 200i Service Manual

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Table of Contents

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DINK 200i/125
By KWANG YANG Motor Co., Ltd.
First Edition, Jan 2007
All rights reserved. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T100SH4025

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Summary of Contents for KYMCO DINK 200i

  • Page 1 DINK 200i/125 By KWANG YANG Motor Co., Ltd. First Edition, Jan 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T100SH4025...

  • Page 2: Table Of Contents

    REAR BRAKE/REAR FORK/REAR this manual may be different from the vehicle in case specifications are changed. WHEEL/REAR SHOCK ABSORBER` KYMCO reserves the right to make BATTERY/CHARGING SYSTEM changes at any time without notice and without incurring any obligation. IGNITION SYSTEM STARTING SYSTEM KWANG YANG MOTOR CO., LTD.

  • Page 3: General Information

    _________________________________________________________________________________________ _________________________________________________________________________________________ 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 &...

  • Page 4: General Information

    1. GENERAL INFORMATION DINK200i/125 SERIAL NUMBER (1) Location of Frame Serial Number Location of Engine Serial Number...

  • Page 5: Specification (Dink 200I)

    1. GENERAL INFORMATION DINK 200i/125 SPECIFICATIONS (DINK 200i) Air cleaner type Paper element, wet Overall length 2030 mm (81.2 in) 11 L (2.31 lmp gal, Overall width 780 mm (31.2 in) Fuel capacity 2.86 US gal) Overall height 1255 mm (50.2 in) Wheel base 1390 mm (55.6 in)

  • Page 6: Specification (Dink 125)

    1. GENERAL INFORMATION DINK200i/125 SPECIFICATIONS (DINK 125) Air cleaner type Paper element, wet Overall length 2030 mm (81.2 in) 11 L (2.31 lmp gal, Overall width 760 mm (30.4 in) Fuel capacity 2.86 US gal) Overall height 1255 mm (50.2 in) Type LEA5 Wheel base...
  • Page 7 1. GENERAL INFORMATION DINK 200i/125 SERVICE PRECAUTIONS „ Apply or add designated greases and lubricants to the specified lubrication „ Make sure to install new gaskets, O-rings, points. circlips, cotter pins, etc. when reassembling. „ After reassembly, check all parts for proper tightening and operation.
  • Page 8 1. GENERAL INFORMATION DINK200i/125 „ If the fuse is burned out, find the cause and „ The connector shall be inserted repair it. Replace it with a new one completely. according to the specified capacity. „ If the double connector has a lock, lock it at the correct position.
  • Page 9 1. GENERAL INFORMATION DINK 200i/125 „ After clamping, check each wire to make „ Route harnesses so they are neither sure it is secure. pulled tight nor have excessive slack. Do not pull too tight• • „ Do not squeeze wires against the weld or its clamp.
  • Page 10 1. GENERAL INFORMATION DINK200i/125 „ After routing, check that the wire harnesses „ Symbols: are not twisted or kinked. The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the „ Wire harnesses routed along with specified points.

  • Page 11: Torque Values

    Water pump impeller 1.2 (12, 9) Left hand threads CYLINDER HEAD: Cylinder head cover 1.2 (12, 8.6) Cylinder head nut (DINK 200i) 2.3 (23, 16.6) Apply oil Cylinder head nut (DINK 125) 2 (20, 14) Apply oil Tensioner sealing bolt 0.6 (6, 4)
  • Page 12 CYLINDER: Cylinder bolt 1 (10, 7.2) DRIVE/DRIVEN PULLEY: L crankcase cover 1.2 (12, 8.6) Drive pulley nut (DINK 200i) 5.8 (58, 42) Drive pulley nut (DINK 125) 5.5 (55, 40) Clutch outer nut 5.5 (55, 40) Driven pulley assembly plate nut 5.5 (55, 40)
  • Page 13 1. GENERAL INFORMATION DINK 200i/125 Thread dia. Torque Item Q‘ty Remarks (mm) kgf-m (N-m, lbf-ft) SUSPENSION: Rear shock absorber upper mount bolt 4 (40, 29) Rear shock absorber lower mount bolt 2.7 (27, 19) Rear fork 2.7 (27, 19) BRAKE: Front caliper 2.7 (27, 19)

  • Page 14: Special Tools

    1. GENERAL INFORMATION DINK200i/125 SPECIAL TOOLS Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Flywheel puller (Refer to the “STARTER A120E00003 CLUTCH” section in the chapter 10.) Oil seal and bearing A120E00014 installer...
  • Page 15 1. GENERAL INFORMATION DINK 200i/125 Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Bearing puller A120E00037 Valve spring compressor (Refer to the “CYLINDER A120E00040 HEAD” section in the chapter 6.) AFI diagnostic tool pda (Refer to the “SELF-...

  • Page 16: Lubrication Points

    DINK200i/125 LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part xGenuine KYMCO Engine Oil (SAE 10W- Camshaft protruding surface Valve rocker arm friction surface xAPI SG Egnine Oil Camshaft drive chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...
  • Page 17 1. GENERAL INFORMATION DINK 200i/125 FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.

  • Page 18: Cable & Harness Routing

    1. GENERAL INFORMATION DINK200i/125 CABLE & HARNESS ROUTING (1) Brake light switch (Front brake) (2) Front brake hose (3) Throttle cable (Note) (4) Left handlebar switch (5) Brake light switch (Rear brake) (6) Rear brake hose (7) Right handlebar switch (A) Pass the front brake hose, rear brake hose, throttle cable, right handlebar switch and left handlebar switch through the guide.
  • Page 19 (5) Fuel fill cap ground wire connector (6) Fuel cap lock cable (7) Radiator bleed hose (8) Flashing relay (9) Coolant fill hose (10) Radiator bleed hose (11) Siphon hose (12) Angle detect sensor (DINK 200i) (A) Pass the radiator bleed hose through the guide. 1-16...
  • Page 20 1. GENERAL INFORMATION DINK200i/125 (1) Low beam relay (2) Speedometer cable (3) Resistor (4) Fuel tank breather hose (5) Right handlebar switch (6) Left handlebar switch (7) Harness wire (8) Fuel fill hose (9) Throttle cable (10) Seat lock cable (11) Siphon hose (12) Left turn signal light connector (13) Headlight connector...

  • Page 21: General Information Dink

    1. GENERAL INFORMATION DINK 200i/125 (1) Throttle cable (2) Harness wire (3) Seat lock cable (4) Speedometer cable (A) Pass the harness wire and throttle cable through the guide. (B) Pass the seat lock cable through the guide pipe. 1-18...
  • Page 22 1. GENERAL INFORMATION DINK200i/125 (1) Throttle cable (2) Harness wire (3) Seat lock cable (4) Siphon hose (5) Fuel tank breather hose (6) Fuel fill hose (A) Pass the harness wire through the guide. (B) Pass the harness wire and throttle cable through the guide. (C) Pass the seat lock cable through the guide pipe.
  • Page 23 1. GENERAL INFORMATION DINK 200i/125 • • Refer to the page 1-30 to understand the fuel system wire routing of DINK 200i. (1) Throttle cable (2) AICV air inlet hose (3) Harness wire (4) Seat lock cable (5) Side stand switch wire (A) Pass the seat lock cable through the guide.
  • Page 24 1. GENERAL INFORMATION DINK200i/125 • • Refer to the page 1-30 to understand the fuel system wire routing of DINK 200i. (1) Rear brake hose (2) Bleed hose (3) AICV Vacuum hose (4) Fuel pump vacuum hose (DINK 125) (5) Carburetor heater connector (DINK 125)
  • Page 25 1. GENERAL INFORMATION DINK 200i/125 • • Refer to the page 1-30 to understand the fuel system wire routing of DINK 200i. (1) Heater control connector (DINK 125) (2) Auto choke connector (DINK 125) (3) Heater connector (DINK 125) (4) Fuse box...
  • Page 26 1. GENERAL INFORMATION DINK200i/125 • • Refer to the page 1-30 to understand the fuel system wire routing of DINK 200i. (1) Battery negative terminal (2) Luggage box light connector (3) Battery positive terminal (4) A.C.G/Regulator/Rectifier/Starter relay connectors (5) Combination light connector...
  • Page 27 1. GENERAL INFORMATION DINK 200i/125 (1) Rear brake hose (2) Siphon hose (3) Radiator cap (4) Bleed hoses (5) Fan motor switch (6) Upper radiator hose (7) Right turn signal light wire (8) Lower radiator hose (9) Front brake hose...
  • Page 28 DINK200i/125 • • Refer to the page 1-30 to understand the fuel system of DINK 200i. (1) DINK 125: Fuel hose (between the fuel pump and fuel filter) (2) DINK 125: Fuel hose (between the fuel filter and fuel tank)
  • Page 29 (D) Pass the rear brake hose through the guide. (E) DINK 200i: Pass the O2 sensor wire through the guide (F) DINK 200i: Pass the O2 sensor wire, harness wire, starter motor cable and A.C.G. wire through the guide 1-26...
  • Page 30 (15) Regulator/Rectifier (DINK 200i) (16) Harness wire (DINK 200i) (17) ECU (DINK 200i) (18) Fuel pump relay (DINK 200i) (A) Pass the starter motor cable and A.C.G. wire through the guide. (B) Pass the rear brake hose through the guide.
  • Page 31 1. GENERAL INFORMATION DINK 200i/125 • • Refer to the page 1-30 to understand the fuel system of DINK 200i. (1) Coolant temperature sensor wire (2) Ground cable (3) Throttle cable (4) Ignition coil (5) Crankcase breather hose (6) Thermostat...
  • Page 32 1. GENERAL INFORMATION DINK200i/125 (1) AICV vacuum hose (2) Air inlet hose (3) AICV control solenoid valve (4) Air supply hose (5) Air inlet pipe (6) AICV (A) Pass the AICV vacuum hose through the guide. 1-29...
  • Page 33 (4) T-MAP sensor (DINK 200i) (5) Fuel vacuum hose (DINK 200i) (6) AICV vacuum hose (7) Fuel injector (DINK 200i) (8) WTS sensor (DINK 200i) (9) Fuel pump connector (DINK 200i) (10) Fuel pump (DINK 200i) (11) Fuel hose (DINK 200i) (12) Harness wire (DINK 200i) (12) TPS sensor (DINK 200i) (A) Pass the AICV vacuum hose and fuel vacuum hose through the plastic band.

  • Page 34: Inspection/Adjustment

    1. GENERAL INFORMATION DINK200i/125 TROUBLESHOOTING (DINK 200i) ENGINE WILL NOT START OR IS HARD TO START Symptom Inspection/Adjustment Probable Cause Connect the diagnostic c Empty fuel tank tool (PDA), then check DTC and correct d Clogged fuel hose Fuel reaches Fuel does not problems.
  • Page 35 1. GENERAL INFORMATION DINK 200i/125 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and accelerate lightly for observation c Clogged air cleaner Engine speed does Engine speed d Faulty fuel pressure regulator not increase increases e Clogged exhaust muffler...
  • Page 36 1. GENERAL INFORMATION DINK200i/125 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Connect the diagnostic tool, then check DTC and correct problems. c Damaged insulator rubber d Throttle body not securely Air leaks No air leak tightened e Faulty intake manifold gasket Remove spark plug and...
  • Page 37 1. GENERAL INFORMATION DINK 200i/125 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Connect the diagnostic tool, then check DTC and correct problems. Check ignition timing c Improperly installed camshaft Correct timing Incorrect timing d Faulty A.C. generator Check valve clearance...
  • Page 38 1. GENERAL INFORMATION DINK200i/125 ENGINE NOISE Symptom Probable Cause c Valve clearance too large Valve noise d Worn camshaft lobe c Worn piston rings d Worn piston pin and connecting rod small Piston noise e Excessive carbon build-up in combustion chamber c Damaged cam chain tensioner d Worn cam gear teeth...
  • Page 39 1. GENERAL INFORMATION DINK 200i/125 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause c Worn or slipping drive belt d Broken ramp plate Engine starts but motor- e Broken drive face spring cycle does not move f Separated clutch lining...
  • Page 40 1. GENERAL INFORMATION DINK200i/125 STARTER MOTOR 1. Starter motor won’t turn Symptom Inspection/Adjustment Probable Cause Check operation of c Burned out fuse brake light switch by d Weak or dead battery applying brake e Faulty brake light switch Stoplight does not Stoplight comes on connectors f Loose or disconnected...
  • Page 41 1. GENERAL INFORMATION DINK 200i/125 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Connect the diagnostic tool, then check DTC and correct problems. Replace with a new spark plug and inspect again. Faulty spark plug Good spark Weak or no spark...
  • Page 42 1. GENERAL INFORMATION DINK200i/125 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals c Faulty A.C. generator Voltage does not Normal voltage d Faulty regulator/rectifier increase e Faulty battery Measure resistance between AC generator coil terminals...
  • Page 43 1. GENERAL INFORMATION DINK 200i/125 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals c Burned out fuse d Weak or dead battery Signals operate Signals dim, remain...
  • Page 44 1. GENERAL INFORMATION DINK200i/125 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Probable Cause Symptom (Front and rear tire pressures are mormal) c Steering stem nut too tight Steering is heavy d Broken steering steel balls c Excessive wheel bearing play Front or rear wheel is d Bent rim wobbling e Loose axle nut...

  • Page 45: Troubleshooting (Dink 125)

    1. GENERAL INFORMATION DINK 200i/125 TROUBLESHOOTING (DINK 125) ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw cEmpty fuel tank dClogged carburetor fuel inlet tube, vacuum tube or fuel tube...
  • Page 46 1. GENERAL INFORMATION DINK200i/125 ENGINE LACKS POWER Inspection/Adjustment Probable Cause Symptom Start engine and cClogged air cleaner accelerate lightly for dRestricted fuel flow observation eClogged fuel line between fuel tank and carburetor Engine speed does Engine speed fClogged exhaust muffler not increase increases gFaulty auto bystarter...
  • Page 47 1. GENERAL INFORMATION DINK 200i/125 POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing cFaulty ignition unit Incorrect timing Correct timing dFaulty A.C. generator Check carburetor pilot screw adjustment cMixture too rich (turn screw out)
  • Page 48 1. GENERAL INFORMATION DINK200i/125 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing cFaulty ignition unit Correct timing Incorrect timing dFaulty A.C. generator Check valve clearance cImproperly adjusted valve Correctly adjusted Incorrectly adjusted clearance dWorn valve seat Check fuel pump for fuel supply cEmpty fuel tank...
  • Page 49 1. GENERAL INFORMATION DINK 200i/125 ENGINE NOISE Symptom Probable Cause cValve clearance too large Valve noise dWorn camshaft lobe cWorn piston rings dWorn piston pin and connecting rod small end Piston noise eExcessive carbon build-up in combustion chamber cDamaged cam chain tensioner...
  • Page 50 1. GENERAL INFORMATION DINK200i/125 CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause cWorn or slipping drive belt dBroken ramp plate eBroken drive face spring Engine starts but motor- fSeparated clutch lining cycle does not move gDamaged driven pulley shaft splines hDamaged final gear iSeized final gear cBroken shoe spring...
  • Page 51 1. GENERAL INFORMATION DINK 200i/125 STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of brake light switch by cBurned out fuse applying brake dWeak or dead battery Stoplight does not Stoplight comes on eFaulty stop switch...
  • Page 52 1. GENERAL INFORMATION DINK200i/125 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark cFaulty spark plug Check spark plug cap and high-tension wire for looseness Not loose Loose cFaulty spark plug...
  • Page 53 1. GENERAL INFORMATION DINK 200i/125 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals cFaulty AC generator Voltage does not Normal voltage dFaulty regulator/rectifier increase eFaulty battery Measure resistance...
  • Page 54 1. GENERAL INFORMATION DINK200i/125 FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn signals cBurned out fuse dWeak or dead battery Signals operate Signals dim, remain eFaulty ignition switch properly on or don‘t operate fLoose or disconnected...
  • Page 55 1. GENERAL INFORMATION DINK 200i/125 STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) cSteering stem nut too tight Steering is heavy dBroken steering steel balls cExcessive wheel bearing play Front or rear wheel is...
  • Page 56 . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 2- 1 SERVICE INFORMATION------------------------------------------------ 2- 2 TROUBLESHOOTING----------------------------------------------------- 2- 2 FASTENER REMOVAL AND REINSTALLATION------------------ 2- 3 FRAME COVERS REMOVAL/INSTALLATION --------------------- 2- 4 EXHAUST MUFFLER ----------------------------------------------------- 2-15...

  • Page 57: Schematic Drawing

    . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 SCHEMATIC DRAWING...

  • Page 58: Service Information

    . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS x When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged. x Make sure to route cables and harnesses according to the Cable & Harness Routing.

  • Page 59: Fastener Removal And Reinstallation

    . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 FASTENER REMOVAL AND REINSTALLATION REMOVAL Depress the head of fastener center piece {. 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.

  • Page 60: Frame Covers Removal/Installation

    . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 FRAME COVERS REMOVAL/ INSTALLATION SEAT Unlock the seat with the ignition key. Open the seat. Remove the two nuts and the seat. Installation is in the reverse order of removal. LUGGAGE BOX Unlock the seat with the ignition key.
  • Page 61 . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 Center Cover CENTER COVER Remove the luggage box (see page 2-4). Remove the center cover. • • During removal, do not pull the joint claws forcedly to avoid damage. Installation is in the reverse order of removal.
  • Page 62 Disconnect the throttle cable (DINK 125: refer to the “CARBURETOR” section in the chapter 13. DINK 200i: refer to the “THROTTLE BODY /TPS” section in the chapter 14), then pull the throttle cable out from the lower cover.
  • Page 63 . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 WINDSHIELD/WINDSHIELD GARNISH Remove the three bolts and windshield garnish. Remove the two screws. Remove the two screws from the inner cover, then remove the windshield. Installation is in the reverse order of removal.
  • Page 64 . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 FRONT METER VISOR Remove the windshield (see page 2-7). Remove the three fasteners and two screws, then remove the front meter visor. Installation is in the reverse order of removal. FRONT COVER Remove the front meter visor (see page 2-8).
  • Page 65 . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 Disconnect the headlight/position light connect and right/left turn signal light connectors. Installation is in the reverse order of removal. FRONT FENDER Remove the four screws and front fender. Installation is in the reverse order of removal.
  • Page 66 . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 FRONT LOWER COVER Remove the front cover (see page 2-8). Remove the foot skirt (see page 2-9). Remove the six screws and front lower cover. Installation is in the reverse order of removal. REAR FENDER Remove the two bolts and two nuts, then remove the rear fender.
  • Page 67 . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 Rear Combination Light Connector Disconnect the rear combination light connector. Installation is in the reverse order of removal. REAR COMBINATION LIGHT UNDER COVER Remove body cover (see page 2-10). Remove the two bolts and rear combination light under cover.
  • Page 68 . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 Remove the four bolts, then remove the floorboard. Air Inlet Hose Disconnect the air inlet hose of the air cleaner. Installation is in the reverse order of removal. UNDER COVER Remove the four bolts and side stand stop rubber.
  • Page 69 . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 Air Solenoid Valve Cut the rubber band off, then remove the solenoid valve. Installation is in the reverse order of removal. Speedometer Cable METER PANEL Disconnect the speedometer cable. Disconnect the meter connectors. Remove the two screws.
  • Page 70 . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 INNER COVER Remove the front cover (see page 2-8). Remove the front lower cover (see page 2- 10). Remove the floorboard (see page 2-11). Turn the fuel fill cap garnish counterclockwise and remove it.

  • Page 71: Exhaust Muffler

    . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 EXHAUST MUFFLER REMOVAL DINK 200i only: Disconnect the O2 heater/O2 sensor (2) connector (1). Remove the two exhaust pipe joint nuts Remove three muffler mount bolts and muffler and gasket. 2-15...
  • Page 72 . EXHAUST MUFFLER/FRAME COVERS DINK 200i/125 INSTALLATION Replace the gasket with new ones. Install the exhaust muffler and three mounting bolt but do not tighten them. Install and tighten the two exhaust pipe joint nuts to the specified torque Torque: 20 N•m (2 kgf•m, 14 lbf•ft)
  • Page 73 . INSPECTION/ADJUSTMENT DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 3- 1 MAINTENANCE SCHEDULE-------------------------------------------- 3- 2 FUEL LINE/FUEL FILTER------------------------------------------------ 3- 4 THROTTLE OPERATION------------------------------------------------- 3- 4 ENGINE OIL ----------------------------------------------------------------- 3- 6 TRANSMISSION OIL ------------------------------------------------------ 3-12 AIR CLEANER -------------------------------------------------------------- 3-13...

  • Page 74: Service Information

    : DINK 125: 1700 rpm : DINK 200i: 1660 rpm Cylinder compression : DINK 125: 15 kgf/cm²(1500 kPa, 213 psi) : DINK 200i: 16 kgf/cm²(1600 kPa, 227.2 psi) Engine oil capacity: At disassembly : 1.1 L (0.968 lmp qt, 1.166 US qt) At change : 0.9 L (0.792 lmp qt, 0.954 US qt)

  • Page 75: Maintenance Schedule

    KYMCO by properly trained and equipped technicians. Your KYMCO dealer meets all of these requirements. Should be serviced by your KYMCO dealer, unless the owner has the proper tools and service data and is mechanically qualified. In the interest of safety, we recommend these items be serviced only by your KYMCO dealer.
  • Page 76 . INSPECTION/ADJUSTMENT DINK 200i125 MAINTENANCE SCHEDULE...

  • Page 77: Fuel Line/Fuel Filter

    . INSPECTION/ADJUSTMENT DINK 200i/125 FUEL LINE/FUEL FILTER DINK 125: Check the fuel lines (2) and replace any parts which show signs of deterioration, damage or leakage. Check for dirty or clogged fuel filter (1) and replace with a new one if it is clogged.
  • Page 78 DINK 125 carburetor side. Adjust by loosening the lock nut (1) and turning the adjusting nut. DINK 200i 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).

  • Page 79: Engine Oil

    . INSPECTION/ADJUSTMENT DINK 200i/125 ENGINE OIL Engine oil recommendation Use a premium quality 4-stroke motor oil to ensure longer service life of your scooter. Use only oils which are rated, SG under the API service classification. The recommended viscosity is SAE 10W-30. If a SAE 10W-30 motor oil is not available, select an alternative according to the right chart.
  • Page 80 . INSPECTION/ADJUSTMENT DINK 200i125 Engine oil replacement Engine oil quality is the chief factor affecting engine service life. Change the engine oil as specified in the maintenance schedule. When running in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule.
  • Page 81 . INSPECTION/ADJUSTMENT DINK 200i/125 1. Remove the oil filler cap/dipstick (1) from the right crankcase cover. 2. Place a container under the left crankcase. 3. Remove the oil drain plug (2) to drain the oil. 4. Reinstall the drain plug and tighten the drain plug to specification.
  • Page 82 . INSPECTION/ADJUSTMENT DINK 200i125 Oil strainer screen clean Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. Let the engine and exhaust system cool before working in those areas. 1.
  • Page 83 . INSPECTION/ADJUSTMENT DINK 200i/125 Oil filter replacement Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. Let the engine and exhaust system cool before working in those areas.
  • Page 84 . INSPECTION/ADJUSTMENT DINK 200i125 5. Install the new oil filter. Make sure the rubber seal on the oil filter facing the left crankcase. 6. Install the spring, O-ring and cap. Cap bolt torque: 12 N-m (1.2 kgf-m, 8.6 lbf-ft) 7. Fill the crankcase with the recommended grade oil and install the oil filler cap.

  • Page 85: Transmission Oil

    . INSPECTION/ADJUSTMENT DINK 200i/125 TRANSMISSION OIL Oil change 1. Place the scooter in its center stand. 2. Place a drain pan under the drain bolt (1). 3. Remove the transmission oil drain bolt. 4. Remove the transmission oil filler bolt (2), slowly turn the rear wheel and drain the oil.

  • Page 86: Air Cleaner

    Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model. Using the wrong KYMCO air cleaner element or a non-KYMCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems.

  • Page 87: Secondary Air Supply System

    . INSPECTION/ADJUSTMENT DINK 200i/125 SECONDARY AIR SUPPLY SYSTEM Check the AICV (air injection control valve) This model is equipped with a built-in hoses between the AICV control solenoid valve secondary air supply system. The pulse and cylinder head for deterioration, damage or secondary air supply system is located on the loose connections.

  • Page 88: Spark Plug

    Clean any fouling deposits with a spark plug cleaner or a wire brush. Specified Spark Plug: DINK 125: NGK: DP7EA9 DINK 200i: NGK: DPR6EA9 Cracks Damage Measure the spark plug gap. Deformation Spark Plug Gap: 0.9 mm (0.036 in)

  • Page 89: Valve Clearance

    . INSPECTION/ADJUSTMENT DINK 200i/125 VALVE CLEARANCE x Inspect and adjust valve clearance while the engine is cold (below 35 ). Remove the two nuts (1) and four bolts (2), then remove cylinder head cover. Remove the timing hole cap and O-ring (4).

  • Page 90: Idle Speed

    The engine must be warm for accurate idle speed inspection and adjustment. It is not necessary to adjust idle speed for DINK 200i. The throttle body is factory pre-set, do not loosen or tighten the painted bolts and screws of throttle body.

  • Page 91: Cylinder Compression

    Open the throttle valve fully and push the starter button to test the compression. Compression: DINK 125:15 kgf/cm² (1500 kPa, 213 psi) DINK 200i:16 kgf/cm² (1600 kPa, 227.2 psi) If the compression is low, check for the following: Leaky valves...

  • Page 92: Clutch Shoe Wear

    . INSPECTION/ADJUSTMENT DINK 200i125 CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually. If the scooter tends to creep, or the engine stalls, check the clutch shoes for wear and replace if necessary (refer to the “DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY”...

  • Page 93: Coolant

    If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your KYMCO dealer for repair. Coolant recommendation The owner must properly maintain the coolant to prevent freezing, overheating, and...
  • Page 94 . INSPECTION/ADJUSTMENT DINK 200i125 check the cooling system frequently and add higher concentrations of antifreeze (up to a maximum of 60% antifreeze) if required. 3-21...

  • Page 95: Brake Fluid

    Front brake Check the cutout in each pad. If either pad is worn to the cutout, replace both pads as a set. See your KYMCO dealer for this service. Rear brake Check the cutout in each pad.

  • Page 96: Nuts/Bolts/Fasteners

    . INSPECTION/ADJUSTMENT DINK 200i125 NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Tire pressure Insufficient air pressure in the tires not only hastens tire wear but also seriously affects the stability of the scooter.

  • Page 97: Steering Handlebar

    . INSPECTION/ADJUSTMENT DINK 200i/125 STEERING HANDLEBAR Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing. SUSPENSION Check the action of the front/rear shock absorbers by compressing them several times.

  • Page 98: Side 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 for service. 3-25...

  • Page 99: Lubrication System

    . LUBRICATION SYSTEM DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM ---------------------------------- 4-1 SERVICE INFORMATION------------------------------------------------ 4-2 TROUBLESHOOTING----------------------------------------------------- 4-2 OIL PUMP ------------------------------------------------------------------- 4-3...

  • Page 100: Lubrication System

    . LUBRICATION SYSTEM DINK 200i/125 LUBRICATION SYSTEM DIAGRAM Rocker Arm Shaft Crankshaft Oil Strainer Screen Oil Pump Oil Filter Screen...

  • Page 101: Service Information

    . LUBRICATION SYSTEM DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS x The maintenance of lubrication system can be performed with the engine installed in the frame. x Drain the coolant before starting any operations. x Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.

  • Page 102: Oil Pump

    . LUBRICATION SYSTEM DINK 200i/125 OIL PUMP Bolts REMOVAL Remove the flywheel and driven gear (refer to the “STARTER CLUTCH” section in the chapter 10). Remove the bolt and then oil separator cover. When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine.
  • Page 103 . LUBRICATION SYSTEM DINK 200i/125 Arrow Mark INSTALLATION Install the oil pump and oil separator and tighten the two bolts. Make sure the pump shaft rotates freely and arrow on the oil pump is upside. Bolts Oil Separator Pump Drive Chain...
  • Page 104 . LUBRICATION SYSTEM DINK 200i/125 DISASSEMBLY Remove the screw and disassemble the oil pump as shown. Pump Cover Outer Rotor Inner Rotor Pump Body Screw Dowel Pin Pump Shaft INSPECTION Pump Body Outer Rotor Measure the pump body-to-outer rotor clearance.
  • Page 105 . LUBRICATION SYSTEM DINK 200i/125 Outer Rotor Inner Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.2 mm (0.008 in) Measure the rotor end-to-pump body clearance. Service Limit: 0.12 mm (0.0048 in) Pump Body Rotor End ASSEMBLY Pump Body...

  • Page 106: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION DINK200i/DINK 125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 5-1 ENGINE REMOVAL/INSTALLATION--------------------------------- 5-2 ENGINE HANGER --------------------------------------------------------- 5-9...
  • Page 107 5. ENGINE REMOVAL/INSTALLATION DINK 200i/DINK 125 SERVICE INFORMATION GENERAL INSTRUCTIONS x A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the scooter body, cables and wires during engine removal.
  • Page 108 13). Remove the carburetor (refer to the “CARBURETOR” section in the chapter 13). • • DINK 200i only: Remove the air cleaner (refer to the “AIR CLEANER” section in the chapter 14) Remove the two bolts from the intake manifold.
  • Page 109 5. ENGINE REMOVAL/INSTALLATION DINK 200i/DINK 125 Loosen the rear axle nut. Support the scooter securely on its main stand. Remove the three bolts (1) from rear brake hose clamps. Remove the two bolts (2), then remove the rear brake caliper.
  • Page 110 . ENGINE REMOVAL/INSTALLATION DINK200i/DINK 125 Remove the bolt (6) and engine ground cable. DINK 125 only: Remove the two nuts (7), then remove the intake manifold from cylinder head. Remove the bolt (8), then remove the thermostat from cylinder head. Remove the spark plug cap (9).
  • Page 111 5. ENGINE REMOVAL/INSTALLATION DINK 200i/DINK 125 Disconnect the air supply hose (10) from cylinder head cover. Disconnect the lower radiator hose (11) from lower radiator pipe. Remove the right and left rear shock absorber lower mount bolts (12).
  • Page 112 . ENGINE REMOVAL/INSTALLATION DINK200i/DINK 125 Remove the engine mount nut (13). Pull out the engine mount bolt. Remove the engine from the frame. • • At removing the engine, be careful not to catch your hand or finger between the engine hanger and crankcase.
  • Page 113 5. ENGINE REMOVAL/INSTALLATION DINK 200i/DINK 125 INSTALLATION Installation is in the reverse order of removal. Tighten the engine mounting bolt/nut to the specified torque. Torque: 5 kgf-m (50 N-m, 36 lbf-ft) Tighten the right and left rear shock absorber lower mount bolts to the specified torque.
  • Page 114 . ENGINE REMOVAL/INSTALLATION DINK200i/DINK 125 INSPECTION Inspect the engine mount bolt: Band/Damage Replace • • Do not attempt to straighten a bent engine mount bolt.
  • Page 115 5. ENGINE REMOVAL/INSTALLATION DINK 200i/DINK 125 ENGINE HANGER REMOVAL Remove the engine mount nut (1). Pull the engine mount bolt (2) out. • • Be careful to put the engine down. Remove the left engine hanger mount bolt (3). Remove the right engine hanger mount bolt and collar (4).

  • Page 116: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 6- 1 SERVICE INFORMATION------------------------------------------------ 6- 2 TROUBLESHOOTING----------------------------------------------------- 6- 3 CYLINDER HEAD COVER----------------------------------------------- 6- 4 CAMSHAFT HOLDER----------------------------------------------------- 6- 5 CAMSHAFT ----------------------------------------------------------------- 6- 8 CYLINDER HEAD---------------------------------------------------------- 6-12...

  • Page 117: Cylinder Head/Valves

    . CYLINDER HEAD/VALVES DINK 200i/125 SCHEMATIC DRAWING...

  • Page 118: Service Information

    Tensioner mounting bolt 0.9 kgf-m (9 N-m, 6.5 lbf-ft) Tensioner sealing bolt 0.9 kgf-m (9 N-m, 6.5 lbf-ft) Cylinder head cap nut (DINK 200i) 2.3 kgf-m (23 N-m, 16.6 lbf-ft) Apply engine oil to threads Cylinder head cap nut (DINK 125) 2 kgf-m (20 N-m, 14.4 lbf-ft)

  • Page 119: Troubleshooting

    . CYLINDER HEAD/VALVES DINK 200i/125 SPECIAL TOOLS Valve spring compressor A120E00040 TROUBLESHOOTING x The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler...

  • Page 120: Cylinder Head Cover

    . CYLINDER HEAD/VALVES DINK 200i/125 CYLINDER HEAD COVER REMOVAL Remove the two nuts (1) and four bolts (2), then remove the cylinder head cover. INSTALLATION Install a new cylinder head cover O-ring and install the cylinder head cover. Be sure to install the O-ring into the groove properly.

  • Page 121: Camshaft Holder

    Tighten the four cylinder head nuts to the specified torque. Torque: DINK 200i: 2.3 kgf-m (23 N-m, 16.6 lbf-ft) DINK 125: 2 kgf-m (20 N-m, 14.4 lbf-ft) x Install the camshaft holder with the “EX” mark face exhaust valve side.
  • Page 122 . CYLINDER HEAD/VALVES DINK 200i/125 Valve Rocker Arms DISASSEMBLY Take out the valve rocker arm shafts using a 6mm bolt. Remove the valve rocker arms. Rocker Arm Shafts 6mm Bolt INSPECTION Camshaft Holder Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage.
  • Page 123 . CYLINDER HEAD/VALVES DINK 200i/125 Measure the I.D. of each valve rocker arm. Service Limits: IN: 10.1 mm (0.404 in) EX: 10.1 mm (0.404 in) Measure each rocker arm shaft O.D. Service Limits: IN: 9.9 mm (0.396 in) EX: 9.9 mm (0.396 in) Measure arm to shaft clearance.

  • Page 124: Camshaft

    . CYLINDER HEAD/VALVES DINK 200i/125 CAMSHAFT REMOVAL Turn the A.C. generator flywheel so that the Tensioner Sealing Bolt/Spring “T” mark on the flywheel aligns with the index mark on the crankcase. Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke.
  • Page 125 Inspect camshaft lobes for pitting/scratches/blue discoloration. Measure the cam lobe height. Service Limits: DINK 200i: IN : 31.1 mm (1.244 in) EX: 30.75 mm (1.23 in) DINK 125: IN : 30.75 mm (1.23 in) EX: 30.26 mm (1.2104 in) Camshaft Bearings...
  • Page 126 . CYLINDER HEAD/VALVES DINK 200i/125 Punch Marks INSTALLATION Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear facing up and align the punch marks on the...
  • Page 127 . CYLINDER HEAD/VALVES DINK 200i/125 Release the timing chain tensioner one-way cam and push the tensioner rod all the way in. Install a new cam chain tensioner gasket. Gasket Sealing Bolt Cam Chain Tensioner Install the cam chain tensioner and tighten the two bolts to the specified torque.

  • Page 128: Cylinder Head

    . CYLINDER HEAD/VALVES DINK 200i/125 CYLINDER HEAD REMOVAL First drain the coolant from the radiator and water jacket (refer to the “COOLING SYSTEM” section in the chapter 3). Remove the camshaft (refer to the “CAMSHAFT REMOVAL” section in this chapter).
  • Page 129 . CYLINDER HEAD/VALVES DINK 200i/125 Dowel Pins Cylinder Head Gasket INSTALLATION Install the cam chain tensioner slipper. Install two dowel pins. Install the new gasket. Cam Chain Tensioner Slipper Intake Manifold Install the cylinder head. Install the intake manifold and tighten the two mounting nuts securely.
  • Page 130 . CYLINDER HEAD/VALVES DINK 200i/125 Valve Spring Compressor DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor. x Be sure to compress the valve springs with a valve spring compressor.
  • Page 131 . CYLINDER HEAD/VALVES DINK 200i/125 INSPECTION Combustion Chamber Remove carbon deposits from the exhaust port and combustion chamber. Be careful not to damage the cylinder head mating surface. Exhaust Port Valve /Valve guide Inspect each valve for bending, burning, scratches or abnormal stem wear.
  • Page 132 . CYLINDER HEAD/VALVES DINK 200i/125 Cylinder head 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 Compressor ASSEMBLY Install the valve spring seats and oil seal.

  • Page 133: Cylinder/Piston

    . CYLINDER/PISTON DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 7-1 SERVICE INFORMATION------------------------------------------------ 7-2 TROUBLESHOOTING----------------------------------------------------- 7-3 CYLINDER AND PISTON ------------------------------------------------ 7-4...

  • Page 134: Cylinder/Piston

    . CYLINDER/PISTON DINK 200i/125 SCHEMATIC DRAWING...

  • Page 135: Service Information

    . CYLINDER/PISTON DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS x The cylinder and piston can be serviced with the engine installed in the frame. x When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.

  • Page 136: Troubleshooting

    . CYLINDER/PISTON DINK 200i/125 TROUBLESHOOTING x When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken. Compression too low or uneven...

  • Page 137: Cylinder And Piston

    . CYLINDER/PISTON DINK 200i/125 CYLINDER AND PISTON REMOVAL Remove the cylinder head (refer to “CYLINDER HEAD” section in the chapter Remove the water hose (1) from the cylinder. Remove the two cylinder bolts/washers (2). Remove the cylinder. Remove the cylinder gasket (4) and dowel pins (3).
  • Page 138 . CYLINDER/PISTON DINK 200i/125 Spread each piston ring and remove it by lifting up at a point opposite the gap Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston ring grooves.
  • Page 139 . CYLINDER/PISTON DINK 200i/125 Piston/Piston pin Measure the piston O.D. at the point (A) from 10 mm the bottom and 90° to the piston pin hole. Service Limit: DINK 200i: 61.9 mm (2.476 in) at (A): 5 mm (0.2 in) DINK 125: 52.3 mm (2.092 in) at (A): 9 mm (0.36 in)
  • Page 140 X and Y axis. Take the maximum reading to determine the cylinder wear. MIDDLE Service Limit: DINK 200i: 62.1 mm (2.484 in) BOTTOM DINK 125: 52.5 mm (2.1 in) Calculate the piston-to-cylinder clearance. Take a maximum reading to determine the clearance.
  • Page 141 . CYLINDER/PISTON DINK 200i/125 Intake Side Guide Inspect the exhaust side and intake side chain guides. Wear/Damage Replace. Exhaust Side Guide INSTALLATION Piston ring Carefully install the piston rings into the piston ring grooves with the markings facing Be careful not to damage the piston and rings.
  • Page 142 . CYLINDER/PISTON DINK 200i/125 Cylinder/Piston Clean any gasket material from the cylinder mating surfaces of the crankcase and oil passage. Apply engine oil to the piston pin. Apply engine oil to the connecting rod small end and piston pin hole.
  • Page 143 . CYLINDER/PISTON DINK 200i/125 Apply engine oil to the cylinder wall, piston and piston ring outer surfaces. Pass the cam chain through the cylinder and install the cylinder over the piston. Be careful not to damage the piston rings and cylinder walls.

  • Page 144: Drive And Driven Pulleys/Kick Starter

    . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS/ KICK STARTER __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 8- 1 SERVICE INFORMATION------------------------------------------------ 8- 2 TROUBLESHOOTING----------------------------------------------------- 8- 3 LEFT CRANKCASE COVER --------------------------------------------- 8- 4 DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY ---------- 8- 8...

  • Page 145: Drive And Driven Pulleys/ Kick Starter

    . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER SCHEMATIC DRAWING...

  • Page 146: Service Information

    19.8 (0.792) Weight roller O.D. TORQUE VALUES Left crankcase cover 1.2 kgf-m (12 N-m, 8.6 lbf-ft) Drive pulley nut (DINK 200i) 5.8 kgf-m (58 N-m, 42 lbf-ft) Drive pulley nut (DINK 125) 5.5 kgf-m (55 N-m, 40 lbf-ft) Clutch outer nut 5.5 kgf-m (55 N-m, 40 lbf-ft)

  • Page 147: Troubleshooting

    . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER TROUBLESHOOTING Engine starts but motorcycle won‘t move Lack of power x Worn drive belt x Worn drive belt x Broken ramp plate x Weak driven face spring x Worn or damaged clutch lining...

  • Page 148: Left Crankcase Cover

    . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER LEFT CRANKCASE COVER REMOVAL Remove the eight left crankcase cover bolts and then remove the left crankcase cover. Remove the gasket and dowel pins. Dowel Pins INSTALLATION Install the dowel pins and new gasket.
  • Page 149 . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER DISASSEMBLY (DINK 125 only) Bolt Kick Lever Remove the bolt from the kick lever, then remove the kick lever. Remove the snap ring and washer from the kick starter spindle. Friction Spring...
  • Page 150 . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER Return Spring Plastic Bushing Remove the kick starter spindle and return spring from the left crankcase cover. Remove the plastic bushing and kick starter spindle bushing. Bushing Kick Starter Spindle Plastic Bushing...
  • Page 151 . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER Kick Starter Spindle Forcing Part Inspect the kick starter spindle and starter driven gear forcing parts for wear or damage. Starter Driven Gear Shaft Forcing Part ASSEMBLY (DINK 125 only) Return Spring Plastic Bushing Apply grease to the spindle gear shaft.

  • Page 152: Drive Pulley, Drive Belt And Driven Pulley

    . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY REMOVAL Remove the left crankcase cover (refer to the “LEFT CRANKCASE COVER” section in this Nut/Ratchet chapter). Use the special tool to hold the drive pulley, then remove the nut and ratchet.
  • Page 153 Check the drive belt for cracks, separation or abnormal or excessive wear. Measure the drive belt width. Service Limit: DINK 200i: 17.5 mm (0.7 in) DINK 125: 17.3 mm (0.692 in) Use specified genuine parts for replacement. Clutch out inspection Inspect the clutch outer for wear or damage.
  • Page 154 . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER Boss INSTALLATION Apply lubricant to the drive face boss inner surface, then install the movable drive face assembly. Movable Drive Face Assembly Clutch Outer/Driven Pulley Assembly Install the clutch outer onto the driven pulley assembly.
  • Page 155 Install the drive pulley face and ratchet. Use the special tool to hold drive pulley face, then tighten the nut to the specified torque. Torque: DINK 200i: 5.8 kgf-m (58 N-m, 42 lbf-ft) DINK 125: 5.5 kgf-m (55 N-m, 40 lbf-ft) Special tool: Universal holder...
  • Page 156 . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER DRIVE PULLEY DISASSEMBLY Remove the drive face boss. Boss Ramp Plate Remove the ramp plate and four slide pieces. Slide Pieces Remove the six weight rollers. Weight Roller 8-12...
  • Page 157 . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER DRIVE PULLEY INSPECTION Weight rollers Check each roller for wear or damage. Measure outside diameter. Service limit: 19.8 mm (0.792 in) Movable drive face/Slide pieces/Drive pulley face Ramp Plate Check the slide pieces and movable drive face splines for wear, cracks or damage.
  • Page 158 . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER DRIVE PULLEY ASSEMBLY Clean the movable drive face, drive pulley face, weight rollers, slide pieces, ramp plate and drive face boss. Remove any excess grease. Install the weight rollers. The direction of all weight rollers is the same.
  • Page 159 . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER Install the drive face boss. Boss 8-15...
  • Page 160 . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER DRIVEN PULLEY DISASSEMBLY Hold the clutch/driven pulley assembly with the clutch spring compressor. Be sure to use a clutch spring compressor to avoid spring damage. Special tool: Lock Nut Wrench Clutch Spring Compressor...
  • Page 161 . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER Remove the spring. Remove the spring collar on the movable driven face. Remove the three guide pins/rollers, then remove the movable driven face. Remove the needle bearing from driven face. Remove the snap ring, then remove the bearing from driven face.
  • Page 162 Check the spring for damage. Measure the spring free length. Service limit: DINK 200i: 130 mm (5.2 in) DINK 125: 82 mm (3.28 in) Check the clutch shoe for heat damage. Measure the clutch shoe thickness.
  • Page 163 . DRIVE AND DRIVEN PULLEYS/ DINK 200i/125 KICK STARTER DRIVEN PULLEY ASSEMBLY Clean any oil from the drive belt sliding surfaces on the driven face. Apply grease Filling 12 g of grease to driven face inner side. Apply grease to lips of the new dust seals and install into the movable driven face.

  • Page 164: Final Reduction

    . FINAL REDUCTION DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 9-1 SERVICE INFORMATION------------------------------------------------ 9-2 TROUBLESHOOTING----------------------------------------------------- 9-2 FINAL REDUCTION ------------------------------------------------------- 9-3 BEARING REPLACEMENT ---------------------------------------------- 9-7...

  • Page 165: Final Reduction

    . FINAL REDUCTION DINK 200i125 SCHEMATIC DRAWING...

  • Page 166: Service Information

    . FINAL REDUCTION DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS x The servicing operations of this section can be made with the engine installed. x When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation.
  • Page 167 . FINAL REDUCTION DINK 200i125 FINAL REDUCTION REMOVAL Drain the transmission gear oil into a clean container (refer to the “TRANSMISSION OIL” section in the chapter 3). Remove the driven pulley (refer to the “DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY” section in the chapter Remove the nine bolts from the transmission case cover, then remove the transmission case cover.
  • Page 168 . FINAL REDUCTION DINK 200i/125 Driveshaft Remove the final gear shaft and final gear. Press the driveshaft out from the drive belt compartment. Final Gear Shaft/Final Gear Washers INSPECTION Inspect the countershaft and gear for wear or damage. Countershaft Inspect the final gear and final gear shaft...
  • Page 169 . FINAL REDUCTION DINK 200i125 Drive Shaft Bearing Drive Shaft Bearing Check the driveshaft for wear or damage. Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Countershaft Bearing Final Shaft Bearing Oil Seal/Final Gear Shaft Bearing Check the transmission case cover bearings for excessive play and inspect the final...
  • Page 170 . FINAL REDUCTION DINK 200i/125 Countershaft/Inner Washer Outer Washer Install the inner washer, countershaft and outer washer. Install new gasket. Install the two dowel pins. Dowel Pins Gasket Install the transmission case cover. Install and tighten the nine bolts to the specified torque in a crisscross pattern in 2 or 3 steps.

  • Page 171: Bearing Replacement

    . FINAL REDUCTION DINK 200i125 BEARING REPLACEMENT TRANSMISSION CASE COVER Remove the transmission case cover (refer to the “FINAL REDUCTION” section in this chapter). Remove the transmission case cover bearings by using the special tool. Special tool: Bearing puller A120E00037 Install the new bearings or new oil seal into the transmission case cover by using the special tool.
  • Page 172 . FINAL REDUCTION DINK 200i/125 Install the new bearings or new oil seal into the transmission case by using the special tool. Special tool: Oil seal and bearing installer A120E00014 Driveshaft Bearing DRIVESHAFT BEARING Remove the driveshaft (refer to the “FINAL REDUCTION”section in this chapter).

  • Page 173: Generator/Starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 10-1 SERVICE INFORMATION------------------------------------------------ 10-2 TROUBLESHOOTING----------------------------------------------------- 10-2 ALTERNATOR STATOR-------------------------------------------------- 10-3 STARTER CLUTCH-------------------------------------------------------- 10-6 10-0...

  • Page 174: Generator/Starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH DINK 200i125 SCHEMATIC DRAWING 10-1...

  • Page 175: Service Information

    . A.C. GENERATOR/STARTER CLUTCH DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS x All servicing operations and inspections in this section can be made with the engine installed. x Drain the coolant before removing the right crankcase cover. x Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.)

  • Page 176: Alternator Stator

    . A.C. GENERATOR/STARTER CLUTCH DINK 200i125 ALTERNATOR STATOR REMOVAL Drain the engine oil (refer to the “ENGINE OIL” section in the chapter 3). Disconnect the alternator stator connectors (refer to the chapter 17). Remove the nine bolts from the right crankcase cover and then remove the cover.
  • Page 177 . A.C. GENERATOR/STARTER CLUTCH DINK 200i/125 INSPECTION Check the stator and pulse coil for damage. Grommet Stator INSTALLATION Install the stator and tighten the stator mount bolts to the specified torque. Torque: 1 kgf-m (10 N-m, 7.2 lbf-ft) Apply sealant to the grommet seating surface and install it to the cover groove properly.
  • Page 178 . A.C. GENERATOR/STARTER CLUTCH DINK 200i125 Install the dowel pins and gasket. Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 or 3 steps. 10-5...

  • Page 179: Starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH DINK 200i/125 STARTER CLUTCH REMVOAL Remove the right crankcase cover (refer to the “ALTERNATOR STATOR” section in this chapter). Hold the flywheel with a special tool and remove the flywheel nut. Special tool: Flywheel holder A120E00021...
  • Page 180 . A.C. GENERATOR/STARTER CLUTCH DINK 200i125 Starter Driven Gear Remove the starter driven gear. INSPECTION Install the driven gear into the flywheel. Check the operation of the sprag clutch by turning the driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should not turn counterclockwise.
  • Page 181 . A.C. GENERATOR/STARTER CLUTCH DINK 200i/125 INSTALLATION Starter Driven Gear Install the starter driven gear onto the crankshaft. Shaft Reduction Gear Apply oil to the starter reduction gear shaft. Install the starter reduction gear and shaft to the right crankcase.
  • Page 182 . A.C. GENERATOR/STARTER CLUTCH DINK 200i125 Hold the flywheel with the special tool and tighten the flywheel nut. Torque: 5.5 kgf-m (55 N-m, 40 lbf-ft) Special tool: Flywheel holder A120E00021 Flywheel Flywheel Holder 10-9...

  • Page 183: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 11-1 SERVICE INFORMATION------------------------------------------------ 11-2 TROUBLESHOOTING----------------------------------------------------- 11-2 CRANKCASE SEPARATION -------------------------------------------- 11-3 CRANKSHAFT INSPECTION-------------------------------------------- 11-4 CRANKCASE ASSEMBLY ----------------------------------------------- 11-5 11-0...

  • Page 184: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT DINK 200i/125 SCHEMATIC DRAWING 11-1...

  • Page 185: Service Information

    . CRANKCASE/CRANKSHAFT DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS x This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. x When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces.

  • Page 186: Crankcase Separation

    . CRANKCASE/CRANKSHAFT DINK 200i/125 Cam Chain Tensioner Slipper CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt. Remove the cam chain tensioner slipper and cam chain. Remove the two right crankcase attaching bolts. Bolt Cam Chain Bolts Remove the five left crankcase bolts.

  • Page 187: Crankshaft Inspection

    . CRANKCASE/CRANKSHAFT DINK 200i/125 Oil Seal Remove the oil seal from the left crankcase. Left Crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.6 mm (0.024 in) Measure the connecting rod small end I.D. Service Limit: 15.06 mm (0.6024 in)

  • Page 188: Crankcase Assembly

    . CRANKCASE/CRANKSHAFT DINK 200i/125 Measure the crankshaft runout. Service Limit: 0.1 mm (0.004 in) Measure the crankshaft bearing play. Play Play Service Limits: Axial : 0.2 mm (0.008 in) Radial: 0.05 mm (0.002 in) Axial Radial CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces.
  • Page 189 . CRANKCASE/CRANKSHAFT DINK 200i/125 Place the left crankcase down and install the crankshaft into the left crankcase. x Avoid damaging the oil seal. x Apply grease to the lip of the oil seal. Gasket Dowel Pins Install the two dowel pins and a new gasket.
  • Page 190 . CRANKCASE/CRANKSHAFT DINK 200i/125 Cam Chain Tensioner Slipper Install the cam chain. Install the cam chain tensioner slipper. Install and tighten the cam chain tensioner slipper bolt. Torque: 1.2 kgf-m (12 N-m, 8.6 lbf-ft) Bolt 11-7...

  • Page 191: Cooling System

    . COOLING SYSTEM DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 12- 1 SERVICE INFORMATION------------------------------------------------ 12- 2 TROUBLESHOOTING----------------------------------------------------- 12- 2 COOLING SYSTEM TESTING------------------------------------------- 12- 4 COOLANT REPLACEMENT --------------------------------------------- 12- 5 RADIATOR ------------------------------------------------------------------ 12- 8 FAN MOTOR ---------------------------------------------------------------- 12-10...

  • Page 192: Cooling System

    . COOLING SYSTEM DINK 200i/125 SCHEMATIC DRAWING 12-1...

  • Page 193: Service Information

    . COOLING SYSTEM DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS x The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame. x The engine must be cool before servicing the cooling system.
  • Page 194 -37• • -44.5• • Cautions for Using Coolant: x Use coolant of specified mixing rate. (The mixing rate of 425cc KYMCO SIGMA coolant concentrate + 975cc distilled water is 30%.) x Do not mix coolant concentrate of different brands. x Do not drink the coolant which is poisonous.

  • Page 195: Cooling System Testing

    . COOLING SYSTEM DINK 200i/125 COOLING SYSTEM TESTING RADIATOR CAP INSPECTION • • Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap.

  • Page 196: Coolant Replacement

    . COOLING SYSTEM DINK 200i/125 COOLANT REPLACEMENT PREPARATION The effectiveness of coolant decreases with the accumulation of rest or if there is a change in the mixing proportion during usage. Therefore, for best performance change the coolant regularly as specified in he maintenance schedule.
  • Page 197 . COOLING SYSTEM DINK 200i/125 Remove the screw (3) and reserve tank lid (4). Remove the reserve tank cap (5) and drain the coolant from the reserve tank. Reinstall and tighten the drain bolt securely. Place the scooter on its center stand on a flat, level surface.
  • Page 198 . COOLING SYSTEM DINK 200i/125 Fill the system with the recommended coolant through the filler opening up to the filler neck (1). Bleed air from the system as follow: 1. Start the engine and let it idle for 23 minutes.

  • Page 199: Radiator

    . COOLING SYSTEM DINK 200i/125 RADIATOR REMOVAL Drain the coolant (see page 12-5). Disconnect the siphon hose (1) and air bleed hose (2). Remove the bolt (3). Loosen the hose bands, then disconnect the upper radiator hose (4) and lower radiator hose (5) from the radiator.
  • Page 200 . COOLING SYSTEM DINK 200i/125 Remove the three nuts (10) and then remove the radiator from frame. INSTALLATION Installation is in the reverse order of removal. Refill the coolant (refer to the “COOLANT REPLACEMENT” section in this chapter). 12-9...

  • Page 201: Fan Motor

    . COOLING SYSTEM DINK 200i/125 FAN MOTOR REMOVAL Remove the radiator (refer to the “RADIATOR” section in this chapter) Remove the three mounting bolts (1) and then remove the fan motor (2) INSPECTION Battery Check the fan motor to operate using an available battery.

  • Page 202: Fan Motor Switch

    . COOLING SYSTEM DINK 200i/125 FAN MOTOR SWITCH REMOVAL Disconnect the fan motor switch connectors (refer to the “RADIATOR” section in this chapter). Remove the fan motor switch (1). INSPECTION Place the fan motor switch in oil contained in a pan as shown and raise the oil...

  • Page 203: Water Pump

    . COOLING SYSTEM DINK 200i/125 Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.
  • Page 204 . COOLING SYSTEM DINK 200i/125 Water Pump Cover Bolts Remove the four bolts and the water pump cover, gasket and 2 dowel pins. Impeller (Left Hand Threads) Remove the water pump impeller. • • The impeller has left hand threads.
  • Page 205 . COOLING SYSTEM DINK 200i/125 Bolts WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove the 3 bolts attaching the water pump assembly. Remove the water pump assembly, gasket and dowel pins. Water Pump Assembly...
  • Page 206 . COOLING SYSTEM DINK 200i/125 Water Pump Assembly MECHANICAL SEAL REPLACEMENT Drive the mechanical seal out of the water pump assembly from the inside. Mechanical Seal (Water Seal) Mechanical Seal Driver Drive in a new mechanical seal using a mechanical seal driver.
  • Page 207 . COOLING SYSTEM DINK 200i/125 Snap Ring Water Pump Shaft Install the water pump shaft and shaft inner bearing into the waster pump assembly. Install the snap ring to secure the inner bearing properly. Inner Bearing Water Pump Assembly Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover.
  • Page 208 . COOLING SYSTEM DINK 200i/125 Impeller (Left Hand Threads) Install the impeller onto the water pump shaft. Torque: 1.2 kgf-m (12 N-m, 9 lbf-ft) • • The impeller has left hand threads. Dowel Pins Install the two dowel pins and a new gasket.

  • Page 209: Water Temperature Sensor

    . COOLING SYSTEM DINK 200i/125 WATER TEMPERATURE SENSOR REMOVAL Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Drain the coolant (refer to the “COOLANT REPLACEMENT” section in this chapter). Disconnect the water temperature sensor connectors (1).
  • Page 210 . COOLING SYSTEM DINK 200i/125 INSTALLATION With thread lock applied to the threaded part, tighten the water temperature sensor. Torque: 0.8 kgf-m (8 N-m, 5.8 lbf-ft) Connect the sensor connectors. After the water temperature sensor has been installed, fill coolant and perform air bleeding (refer to the “COOLANT...

  • Page 211: Thermostat

    . COOLING SYSTEM DINK 200i/125 THERMOSTAT THERMOSTAT REMOVAL REMOVAL Drain the coolant (refer to the “COOLANT REPLACEMENT” section in this chapter). Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the water temperature sensor connectors (1).
  • Page 212 . COOLING SYSTEM DINK 200i/125 Bolts DISASSEMBLY Remove the two bolts and separate the thermostat housing halves. Thermostat Thermostat Remove the thermostat from the thermostat housing. 12-21...
  • Page 213 . COOLING SYSTEM DINK 200i/125 INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water Thermostat temperature to check its operation. Thermometer Technical Data 80 - 82°C (176 - Begins to open 180°F) Full-open 90°C (198°F)
  • Page 214 . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/FUEL TANK __________________________________________________________________________________ FUEL SYSTEM-------------------------------------------------------------- 13- 1 SCHEMATIC DRAWING ------------------------------------------------- 13- 2 SERVICE INFORMATION------------------------------------------------ 13- 3 FUEL PUMP CONSTRUCTION------------------------------------------ 13- 4...

  • Page 215: Fuel System

    . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 FUEL SYSTEM 13-1...

  • Page 216: Schematic Drawing

    . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 SCHEMATIC DRAWING 13-2...

  • Page 217: Service Information

    . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area.

  • Page 218: Fuel Pump Construction

    . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 FUEL PUMP CONSTRUCTION The fuel pump adopted for this model is a vacuum-type fuel pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve.

  • Page 219: Troubleshooting

    . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 TROUBLESHOOTING Engine does not start Engine idles roughly, stalls or runs poorly x No fuel in tank x Incorrect idle speed x Restricted fuel line x Rich mixture x Too much fuel getting to cylinder x Lean mixture x Clogged air cleaner x Clogged air cleaner...

  • Page 220: Carburetor

    . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 CARBURETOR REMOVAL/INSTALLATION Remove the luggage box and center cover (refer to the “FRAME COVERS REMOVAL” section in the chapter 2). Disconnect the auto choke connector (1). Disconnect the vacuum hose (2).
  • Page 221 . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 Remove the carburetor. Disconnect the fuel hose from the carburetor. Installation is in the reverse order of removal. Adjust the throttle grip free play (refer to the “THROTTLE OPERATION” section in the chapter 3) after the carburetor has reinstalled.
  • Page 222 . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 DISASSEMBLY Loosen the drain screw to drain the gasoline from the float chamber. x Keep sparks and flames away from the work area. x Drain gasoline into a clean container.
  • Page 223 . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 Piston Valve Remove the spring and piston valve. Spring Spring Retainer Remove the spring retainer, jet needle. Jet Needle Float Chamber Remove the four screws and float chamber. 13-9...
  • Page 224 . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 Float Pull float pin outs, then remove the float and float valve. Float Valve Float Pin Slow Jet Remove the slow jet. Remove main jet. Remove the needle jet holder and needle jet.
  • Page 225 . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 Casting Enrichment Valve Cover Remove the two screws and casting enrichment valve cover and then take out the spring. Remove the casting enrichment valve. Spring/Casting Enrichment Valve Remove the two screws and auto choke seat. Auto Choke Seat Then remove the O-ring.
  • Page 226 . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 INSPECTION Carburetor body/jets cleaning Check carburetor body and each jet for wear or damage. Clean all jets with a spray-type carburetor cleaner and dry them using compressed air. Clean all circuits of the carburetor thoroughly-not just the perceived problem area.
  • Page 227 . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 Float Check the float and float tang for deformation or damage. Float Valve Float Pin Check the float valve and valve seat for foreign substance, clogging or damage. Check the tip of the float valve, where it contacts the valve seat, for stepped wear or contamination.
  • Page 228 . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 Check top cap and spring for cracks and damage. Top Cap Spring Check the diaphragm (1) of the coasting enrichment valve for tears. Check the spring (2) and cover (3) of the coasting enrichment for damage.
  • Page 229 . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 Insert the piston valve into the carburetor body, and check for free movement. If stick is found, replace the part with a new one. Check throttle valve for free movement. If stick is found, replace the part with a new carburetor.
  • Page 230 . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 ASSEMBLY Carburetor reassembly can be performed in the reverse order of disassembly. When reassembling, carefully observe the following instructions. Assemble the parts taking consideration of their function. Before assembling, wash all of the parts in a clean petroleum based solvent.

  • Page 231: Auto Choke

    . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 AUTO CHOKE REMOVAL Remove the cap. Remove the two screws, then remove the auto choke and set plate. Auto Choke/Set Plate INSPECTION Check the auto chake valve and needle for nicks, wear or damage.
  • Page 232 . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 Measure the resistance between the auto choke wire terminals. Resistance: 10 Ÿ below (10 minutes minimum after stopping the engine) If the reading is not within the limit, replace the auto auto choke with a new one.
  • Page 233 . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 Install the cap. 13-19...

  • Page 234: Carburetor Heater

    . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 Heater Connectors CARBURETOR HEATER INSPECTION/REPLACEMNER Check the heater with battery. If the heater is getting hot, means the heater without problem, otherwise the heater has to be changed. Remove the carburetor (refer to the “CARBURETOR”...

  • Page 235: Fuel Pump

    . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 FUEL PUMP REMOVAL/INSTALLATION When removing the fuel pump, do not allow flames or sparks near the working area and drain the residual gasoline into a container. Remove the body cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION”...
  • Page 236 . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 Screws DISASSEMBLY Remove the four fuel pump body screws. Disassemble the fuel pump. Diaphragm INSPECTION Inspect the fuel pump diaphragms A and B for damage. Inspect each gasket for damage.
  • Page 237 . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 Relief Valve Suction Valve Inspect the suction valve, outlet valve and relief valve in the fuel pump body for damage, cracks or foreign matters. Spring Spring Outlet Valve ASSEMBLY Lower Cover Assemble the fuel pump in the reverse order of disassembly.

  • Page 238: Fuel Strainer

    . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 FUEL STRAINER REMOVAL/INSTALLATION When removing the fuel strainer, do not allow flames or sparks near the working area and drain the residual gasoline into a container. Remove the center cover (refer to the “FRAME COVERS...

  • Page 239: Fuel Tank

    . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 FUEL TANK REMOVAL/INSTALLATION When removing the fuel tank, do not allow flames or sparks near the working area and drain the residual gasoline into a container. Remove the inner cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION”...
  • Page 240 . DINK 125:FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 200i/125 Remove the two nuts (7) from right fuel tank plate and remove a bolt (8) from radiator pipe. Remove the right fuel tank plate (9). Remove the two nuts (10) and then remove the left fuel tank plate (11).

  • Page 241: Air Cleaner

    . DINK 125: FUEL SYSTEM/CARBURETOR/ FUEL PUMP/ FUEL TANK DINK 2000i/125 AIR CLEANER REMOVAL/INSTALLATION Remove the body cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Loosen the air cleaner clamp screw (1). Disconnect the crankcase breather hose (2) from the air cleaner.
  • Page 242 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) SYSTEM DIAGRAM ................14-1 SYSTEM LOCATION................. 14-2 SERVICE INFORMATION ............... 14-6 TROUBLESHOOTING............... 14-5 CHECK ENGINE LAMP (CELP) ............. 14-7 SELF-DIAGNOSIS PROCEDURES WITHOUT DIGNOSTIC TOOL ................
  • Page 243 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) SYSTEM DIAGRAM (1) Engine Control Unit (ECU) (11) Engine temperature Sensor (WTS) (2) Check Engine Lamp (CELP) (12) Crankshaft position Sensor (Pulser) (3) Temperature/Manifold Absolute Pressure Sensor (13) Angle Detect Sensor...

  • Page 244: Dink 200 I: Fuel System (Auto Control Fuel Injection System)

    14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) SYSTEM LOCATION Air Cleaner Throttle Body Air Temperature/Manifold Absolute Pressure Sensor Injector Intake Manifold Fuel and Air Fuel Pump Fuel Tank 14-2...
  • Page 245 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) 14-3...
  • Page 246 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) 14-4...

  • Page 247: Service Information

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area.

  • Page 248: Troubleshooting

    14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) Standard Item Crank position sensor (Pulser) resistance 100~130 (20°C/68°F) Fuel injection resistance (20°C/68°F) 11.3±10% Normal: 3.5~4.7V Angle detect sensor voltage (diagnostics) ±60° angle position: 0.3~1.4V Idle speed 1660±100 rpm TROUBLESHOOTING Engine won’t start Backfiring or misfiring during acceleration...

  • Page 249: Check Engine Lamp (Celp)

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) CHECK ENGINE LAMP (CELP) To test check engine lamp operation, the lamp shall light for a period of 2 seconds upon “key-on”. This lamp test shall indicate to the operator that the lamp is functional and capable of signaling faults should they occur.

  • Page 250: Self-Diagnosis Procedures Without Dignostic Tool

    14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) SELF-DIAGNOSTIC PROCEDURES WITHOUT DIAGNOSTIC TOOL SELF-DIAGNOSTIC PROCEDURES CELP (Check Engine Lamp) Make sure the throttle position sensor connector has connected and it is good. Place the scooter on its main stand. Turn the ignition switch ON the CELP will light for two second then off.
  • Page 251 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) (3) Close the throttle fully when the CELP comes on again. (4) When the CELP begins to blink that the CELP denotes the failure codes (the number of blinks from 1 to 24 but there are not number 20 and 23).
  • Page 252 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) SELF-DIAGNOSIS RESET (CLEAR FAILURE CODES) PROCEDURE (1) Turn ignition switch to OFF, open and hold the throttle fully. (2) Turn ignition switch to ON while the CELP comes on, after 2 seconds the CELP will be off.

  • Page 253: Celp Failure Codes Chart

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) CELP FAILURE CODES CHART Failure Blinks Fault description Priority Fault management Codes 1. Park the car and Be immediately carry on maintaining a check immediately. 2.The confirmation has the engine temperature...
  • Page 254 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) Failure Blinks Fault description Priority Fault management Codes 1.Does confirming the TPS deal with contact, connect line and haven't moved and short circuit? 2.If still appear an abnormality, P1121 TPI range fault depend on to change whether the new article process confirmation reduce expenses a valve body TPS...
  • Page 255 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) Failure Blinks Fault description Priority Fault management Codes 1.Confirm Dai soon the air side whether valve electric resistance break the road or short circuit or not? 2.Does confirming the sensor know...
  • Page 256 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) Failure Blinks Fault description Priority Fault management Codes 1.The confirmation light the front line turn electric resistance whether in the specification? 2.Does the confirmation light the front line turn and deal with contact, connect line and haven't moved and break road?(the ECU pin 12)
  • Page 257 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) Failure Blinks Fault description Priority Fault management Codes 1.When the engine start turns soon over the 3250 rpms, in order to avoid hurtling suddenly and violently, the ECU will reduce engine to turn to even turn off soon.
  • Page 258 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) Failure Blinks Fault description Priority Fault management Codes 1.Confirm whether the output voltage of the sensor is within specification? 2.Check whether the output pin position of the sensor is correct or open circuit occurs? (the ECU pin P0105 Manifold pressure fault 3.Replace with a new sensor...

  • Page 259: Diagnostic Tool (Pda)

    You have to use a PDA and download Diagnostic Cable diagnostics program (KYDTool-5.0.E or latest version of diagnostics program) into the SD card at KYMCO web site. We recommended the diagnostics program be installed in the SD card. Because the diagnostics program will lose when the PDA no power if the diagnostics program be installed in PDA.
  • Page 260 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) “OK” “Language” 5. Perform the diagnostics program, wait a moment then select “OK”. 6. Select “SET”. 7. Select “Language”, then to select language (English). “SET” “English” “Find ECU” 7. Select the “Find ECU”, then the ECU will be find automatically.
  • Page 261 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) “OK” Select the “Ding” mark, then select ok to leave SELF-DIAGNOSTIC program. “Ding” mark “Load DTC” “Clear DTC” CLEAR DTC 1. Select “Load DTC”, select “All DTC”, “Active”, “Occurred” or “history” by select option block then to select option.
  • Page 262 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) RECIVE SIGNAL MENU (USING DIAGNOSTIC TOOL) There are 7 page in this section to displays the scooter’s condition. They are not trouble indicators for AFI system and some data no definite range but you can compare normal with abnormal condition from current data.
  • Page 263 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) SIGNAL DATA CONTENTS Page01: Air Temp. (°C) Air Temp. sensor volt (V) Engine Temp. (°C) Engine Temp. sensor volt (V) Atm. Press. (kPa) Page 02 Engine speed (rpm) Throttle Position (%)
  • Page 264 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) Page 03 Engine speed (rpm) Battery Volt (V) Transducer power supply volt (V) Standard: 5±0.1V Idle speed setpoint (rpm) Standard: 1660±100 rpm Page 04 ABVOnTimeOfs (ms) Standard: 0 AirflowAdap Ofs (g/s) Standard: 0 Manual TPI initialisation Cut Out switch volt (V)
  • Page 265 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) Page 06 Engine speed (rpm) Secondary TPI initial adaptation ISCAdapMean (° ABVAngDurMech (° Page 07 Accumulated eng. run time Fuel pump state Primary TPI AdapInit (V) O2 sensor voltage (mV)

  • Page 266: Maintenance Menu (Using Diagnostic Tool)

    14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) MAINTENANCE MENU (USING DIAGNOSTIC TOOL) 1. Follow step 1 to 7 under “SELF- DIAGNOSTIC PROCEDURES USING DIAGNOSTIC TOOL (PDA)” 2. Select “ mark” to enter Maintenance menu. Reset TPI “Reset TPI”...
  • Page 267 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) “Load” APC Valve learning Reset Select “LOAD”. Select “Reset” to reset the “AirflowAdapOfs (g/s)” value. • • To reset the APC when the cylinder/piston is replaced. To adapt the APC plus or minus 0.01 unit at a time, select the options.

  • Page 268: Throttle Position Sensor Initial Procedure

    14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) THROTTLE POSITION SENSOR INITIAL PROCEDURE • • To reset the throttle position sensor when the throttle body is replaced. 14-26...

  • Page 269: Reset The Air By Pass Valve

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) RESET THE AIR BY PASS VALVE (ABV) To reset the ABV when the throttle body, air by pass valve, cylinder head or cylinder is replaced. 14-27...

  • Page 270: Adapt Air Flow Per Cycle (Apc)

    14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) ADAPT AIR FLOW PER CYCLE (APC) • • To reset the APC Adapt Offset Value when throttle body is cleaned up. 14-28...

  • Page 271: Apc Adaption Procedure

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) APC ADAPTION PROCEDURE • • When the vehicle ride on the road, the ECU will automatic adapt the APC, if the condition has been meet. 14-29...

  • Page 272: Spark Plug Anti-Flood

    14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) SPARK PLUG ANTI-FLOOD When no failure code occurs and pressing starter switch repeatedly still can not start the engine, maybe the spark plug is flood by fuel, perform the spark plug anti-flood to purge the fuel in the engine.

  • Page 273: Engine Control Unit (Ecu)

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) ENGINE CONTROL UNIT (ECU) REMOVAL/INSTALLATION Do not disconnect or connect the ECU connector during the ignition switch “ON”; it may cause the ECU damage. Connect the battery terminals topsy- turvy may cause ECU damage.
  • Page 274 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) Check for continuity Disconnect and remove the ECU from the frame. Check for continuity between wire terminal 1 and 16 of the ECU side connector There should be continuity at all times. ECU PIN FUNCTION PIN NO.

  • Page 275: Temperature/Manifold Absolute

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) TEMPERATURE/MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP) REMOVAL Disconnect T-MAP sensor connector and remove two screws, then remove T-MAP sensor. INSTALLATION Installation is in the reverse order of the removal. Coat O-ring with clean engine oil.
  • Page 276 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) Resistance Measure the resistance between the air pressure signal (V/R) and manifold temperature sensor (Br/B) terminals. Standard: 14260 16022 : (-20°C) 2353 2544 : (20°C) 568.9 597.4 : (60°C) (Using diagnostic tool) Enter RECIVE SIGNAL MENU (refer to the “RECIVE SIGNAL MENU (USING...

  • Page 277: Throttle Body/Throttle Position Sensor

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) THROTTLE BODY/THROTTLE POSITION SENSOR (TPS)/IDLE AIR BY PASS VALVE (ABV) Turn ignition switch off and set up center stand when do the replacement. Check and confirm the battery voltage above 12V by a voltmeter after replacement.
  • Page 278 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) TPS INSPECTION (Using a commercially available multimeter) Input voltage Turn ignition switch to ON with the engine stop switch in the run position and put the side stand up. Disconnect throttle position sensor connector.
  • Page 279 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) (Using diagnostic tool) Enter RECIVE SIGNAL MENU (refer to the “RECIVE SIGNAL MENU (USING DIAGNOSTIC TOOL)” section in this chapter). Read page 02 Throttle position (%) Standard: 0% (close throttle fully)
  • Page 280 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) ABV INSPECTION (Using a commercially available multimeter) Input voltage Put the side stand up and the engine stop switch is “RUN”. Disconnect the air by pass valve connector. Connect the multimeter (+) probe to the red wire terminal and the multimeter (-) probe to the green/black wire terminal.
  • Page 281 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) Check that the air should flow (A) to (B), only when the 12-V battery is connected to the idle air bypass valve terminals. (Using diagnostic tool) Enter RECIVE SIGNAL MENU (refer to the “RECIVE SIGNAL MENU (USING...
  • Page 282 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) THROTTLE BODY INSPECTION Check throttle valve for free movement. If stick is found, replace the part with a new throttle body. 14-40...

  • Page 283: Water Temperature Sensor (Wts)

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) WATER TEMPERATURE SENSOR (WTS) REMOMAL Disconnect the WTS connector, then remove WTS. INSTALLATION Replace a new washer. Install and tighten the WTS to the specified torque. Torque: 2 kgf-m (20 N-m, 14 lbf-ft) Connect the WTS connector.

  • Page 284: Fuel Injector

    14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) (Using diagnostic tool) Enter RECIVE SIGNAL MENU and then read data in page 01 (refer to the “RECIVE SIGNAL MENU (USING DIAGNOSTIC TOOL)” section in this chapter). Read the data: Engine Temp.
  • Page 285 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) INSTALLATION O-ring Coat O-rings with clean engine oil. Replace the new O-rings if it has damaged. O-ring Install fuel hose joint onto the fuel injection. Install the spring clip into the groove on the fuel injection.
  • Page 286 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) Install the fuel injection assembly into the intake manifold. Install and tighten the bolt securely. Connect the connector. INSPECTION Terminals (Using a commercially available multimeter) Measure the fuel injection resistance. Standard: 11.3±10% Ÿ...

  • Page 287: Fuel Tank

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) FUEL TANK REMOVAL/INSTALLATION When removing the fuel tank, do not allow flames or sparks near the working area and drain the residual gasoline into a container. Remove the floorboard (refer to the “FRAME COVERS...

  • Page 288: Fuel Pump Relay

    14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) FUEL PUMP REMOVAL When removing the fuel tank, do not allow flames or sparks near the working area and drain the residual gasoline into a container. Remove the floorboard (refer to the “FRAME COVERS REMOVAL/INSTALLATION”...
  • Page 289 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) INSTALLATION Install the fuel pump being careful not to damage the fuel pump wire and make sure the fuel hose joint on fuel pump facing rear. Tighten the bolts using crisscross pattern.
  • Page 290 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) (Using a commercially available multimeter) Input voltage Put the side stand up and the engine stop switch is at “RUN” Disconnect the fuel pump connector. Connect the multi-meter (+) probe to the Red/Black terminal and the multi-meter (-) probe to the Green terminal.
  • Page 291 14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) INSPECTION (Using diagnostic tool) Enter RECIVE SIGNAL MENU and then read data in page 07 (refer to the “RECIVE SIGNAL MENU (USING DIAGNOSTIC TOOL)” section in this chapter). Read the data: Fuel pump state When the engine is stopping, check the “Fuel...
  • Page 292 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) FUEL PUMP RELAY REMOVAL/INSTALLATION Disconnect the fuel pump relay connector, then remove the fuel pump relay. Installation is in the reverse order of the removal. Battery INSPECTION Remove the fuel pump relay. Connect the ohmmeter to the fuel pump relay connector terminals.

  • Page 293: O2/O2 Ht Sensor

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) O2/O2 HT SENSOR REMOVAL/INSTALLATION Disconnect the O2/O2 HT sensor connector, then remove it from exhaust muffler. Installation is in the reverse order of removal. Apply anti-seize compound on circumference of thread area before O2/O2 HT sensor installation.
  • Page 294 14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) (Using diagnostic tool) Enter RECIVE SIGNAL MENU and then read data in page 07 (refer to the “RECIVE SIGNAL MENU (USING DIAGNOSTIC TOOL)” section in this chapter). Read the data: O2 sensor voltage (mV) O2 sensor heater activation 14-52...

  • Page 295: Angle Detect Sensor

    14. DINK 200i: FUEL SYSTEM (Auto Control Fuel Injection System) ANGLE DETECT SENSOR REMOVAL/INSTALLATION Support the scooter level surface. Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the angle detect sensor connector.

  • Page 296: Air Cleaner

    14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System) AIR CLEANER HOUSING REMOVAL/INSTALLATION Refer to the “AIR CLEANER” section in the chapter 13. 14-54...

  • Page 297: Handlebar/Front Wheel/Front Brake/Front Shock

    15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 15- 1 SERVICE INFORMATION------------------------------------------------ 15- 2 TROUBLESHOOTING----------------------------------------------------- 15- 3 HANDLEBAR --------------------------------------------------------------- 15- 4 FRONT WHEEL------------------------------------------------------------- 15- 8...
  • Page 298 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM SCHEMATIC DRAWING 15-1...
  • Page 299 15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM SERVICE INFORMATION GENERAL INSTRUCTIONS x Remove the motorcycle frame covers before removing the front wheel, steering 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.

  • Page 300: Troubleshooting

    15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling x Excessively tightened steering stem top x Bent rim cone race x Loose front axle x Broken steering balls x Bent spoke plate x Insufficient tire pressure x Faulty tire Steers to one side or does not track straight x Improperly tightened axle nut...

  • Page 301: Handlebar

    15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM HANDLEBAR REMOVAL Remove the lower handlebar cover and front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Remove the two bolts (1) and disconnect the brake light switch wire (2), then remove the rear brake master cylinder.
  • Page 302 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM INSTALLATION Install the handlebar onto the steering stem and install the handlebar collar, lock nut and bolt. Tighten the bolt to the specified torque. Torque: 4.5 kgf-m (45 N-m, 32 lbf-ft) Connect the right and left handlebar switch connectors.
  • Page 303 15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM DISASSEMBLY Remove the two screws (1) from right handlebar switch. Disconnect the throttle cable (2) from the throttle grip. Remove the right handlebar switch. Remove the two screws (3) and then remove the left handlebar switch.
  • Page 304 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM ASSEMBLY Install the left handlebar switch. Align the pin on the left handlebar switch with the hole on the handlebar. Install and tighten the two screws securely. Install the right handlebar switch. Align the pin on the right handlebar switch with the hole on the handlebar.

  • Page 305: Front Wheel

    15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM FRONT WHEEL REMOVAL Jack the scooter front wheel off the ground. Remove the nut (1), then pull out the axle (2). Remove the front wheel and collar. Axle runoutn inspection Set the axle in V blocks and measure the runout using a dial gauge.
  • Page 306 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM INSTALLATION Apply grease to the collar (1), then install the collar onto the wheel. Apply grease to the speedometer gear unit (2). Install the speedometer gear unit by aligning its retaining pawl with the hub cutout. If not aligned, the retaining pawl will be deformed when the axle nut is tightened.
  • Page 307 15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM DISASSEMBLY Remove the side collar (1) and dust seal (2). 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.
  • Page 308 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM Remove the front wheel bearing (5) by using the special tool. Special tool: Bearing puller A120E00037 ASSEMBLY Install the front wheel bearing (5) by using the special tool. Special tool: Bearing installer A120E00014 Install the distance collar.

  • Page 309: Front Brake Fluid

    15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM FRONT BRAKE FLUID Check Brake fluid: Brake hose: Cracks/wear/damage Replace. Apply the brake lever several times. Fluid leakage Replace. Brake hose clamp: Loosen Tighten FLUID REPLACEMENT/AIR BLEEDING A contaminated brake disc or pad reduces stopping power.
  • Page 310 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM Brake fluid draining Make sure that the master cylinder parallel to the ground, before removing the reservoir cover. Remove the two screws (1). Remove the reservoir cover (2), diaphragm plate (3) and diaphragm (4). Connect a bleed hose (5) to the bleed valve (6).
  • Page 311 15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM Loosen the bleed valve and pump the brake lever. Stop operating the brake when no more fluid flows out of the bleed valve. Brake fluid filling/Air bleeding Do not mix different types of fluid since they are not compatible.
  • Page 312 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM If the brake bleeder is not available, perform the following procedure. Pump up the system pressure with the brake lever until these are not air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt.

  • Page 313: Front Brake Pad

    15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM FRONT BRAKE PAD BRAKE PAD REPLACEMENT Remove the two pad pins (1). Remove the two caliper mounting bolts (2), then remove the caliper. Remove the brake pads. Always replace the brake pads in pairs to ensure even disc pressure.
  • Page 314 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM Install new pads so that their ends rest on the pad retainer on the brake properly. Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper.

  • Page 315: Brake Disc Inspection

    15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks. Measure the brake disc thickness. Service limits: 3 mm (0.12 in) Replace the brake disc if the smallest measurement is less than the service limit.

  • Page 316: Brake Master Cylinder

    15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM BRAKE MASTER CYLINDER REMOVAL When removing the brake hose bolt, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out. Remove the upper handlebar cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION”...
  • Page 317 15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM Remove the screw (6) and brake light switch. INSTALLATION Install the brake light switch and tighten the screw to the specified torque. Torque: 1 N•m (0.1 kgf•m, 0.7 lbf•ft) Align the pin on the master cylinder holder with the hole on the handlebar.
  • Page 318 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM Rest the brake hose eyelet against the stopper. Install the brake hose eyelet with the oil bolt and new sealing washers. Tighten the oil bolt to the specified torque. Torque: 35 N•m (3.5 kgf•m, 25 lbf•ft) Apply silicone grease to the master piston tip.
  • Page 319 15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM Snap Ring DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder. Snap Ring Pliers (Close) Remove the washer, main piston and spring Spring Master Cylinder Main Piston from the brake master cylinder.
  • Page 320 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75 mm (0.5 in) Measure the brake master cylinder piston O.D. Service Limit: 12.64 mm (0.5056 in) Before assembly, inspect the lst and 2nd rubber cups for wear.

  • Page 321: Front Brake Caliper

    15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM FRONT BRAKE CALIPER DISASSEMBLY Drain the front brake hydraulic system (refer to the “FRONT BRAKE FLUID” section in this chapter). Remove the oil bolt (1), sealing washers and brake hose from the brake caliper.
  • Page 322 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM Remove pad spring (3) from the caliper body. Do not remove the retainer from the bracket unless replacement. Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the...
  • Page 323 15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM ASSEMBLY Clean all removed parts. Apply silicon grease to the piston and new oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the new oil seals. Install the brake caliper piston with grooved side facing out.
  • Page 324 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM INSPECTION Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge. Service Limit: 25.3 mm (1.012 in) Check the caliper cylinder for scratches or wear and measure the cylinder bore. Service Limit: 25.45 mm (1.018 in) 15-27...

  • Page 325: Front Shock Absorber

    15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM FRONT SHOCK ABSORBER REMOVAL Remove the front cover and front fender. ( refer to the “FRAME CVOERS REMOVAL/INSTALLATION” section in the chapter 2 ). Remove the front brake caliper ( refer to the “...

  • Page 326: Steering Stem

    15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM STEERING STEM REMOVAL Remove the steering handlebar ( refer to the “HANDLEBAR” section in this chapter ). Remove the front shock absorber ( refer to the “FRONT SHOCK ABSORBER” section in this chapter ).
  • Page 327 15.HANDLEBAR/FRONT WHEEL/FRONTBRAKE/ DINK 200i/125 FRONT SHOCK ABSORBER/STEERING STEM Ball Inspect the ball races, cone races and steel balls for wear or damage. Replace if necessary. Remove the top balls. Remove the upper ball race by using a chisel if necessary.
  • Page 328 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ DINK 200i125 FRONT SHOCK ABSORBER/STEERING STEM INSTALLATION Install the new bottom cone race onto the steering stem. Install the new upper and bottom ball races into the frame. Apply grease to the top and bottom ball races and install new 26 steel balls on the top ball race and 19 new steel balls on the bottom ball race.

  • Page 329: Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 16- 1 SERVICE INFORMATION------------------------------------------------ 16- 2 TROUBLESHOOTING----------------------------------------------------- 16- 3 REAR BRAKE FLUID ----------------------------------------------------- 16- 4...

  • Page 330: Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 SCHEMATIC DRAWING 16-1...

  • Page 331: Service Information

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS x When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding. x During servicing, keep oil or grease off the brake pads and brake disk.

  • Page 332: Troubleshooting

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 TROUBLESHOOTING Rear wheel wobbling Poor brake performance x Bent rim x Air in brake system x Faulty tire x Deteriorated brake fluid x Axle not tightened properly x Contaminated brake pad surface...

  • Page 333: Rear Brake Fluid

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 REAR BRAKE FLUID Check Brake fluid: Brake hose: Cracks/wear/damage Replace. Apply the brake lever several times. Fluid leakage Replace. Brake hose clamp: Loosen Tighten FLUID REPLACEMENT/AIR BLEEDING A contaminated brake disc or pad reduces stopping power.
  • Page 334 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 Brake fluid draining Make sure that the master cylinder parallel to the ground, before removing the reservoir cover. Remove the two screws (1). Remove the reservoir cover (2), diaphragm plate (3) and diaphragm (4).
  • Page 335 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 Loosen the bleed valve and pump the brake lever. Stop operating the brake when no more fluid flows out of the bleed valve. Brake fluid filling/Air bleeding Do not mix different types of fluid since they are not compatible.
  • Page 336 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 If the brake bleeder is not available, perform the following procedure. Pump up the system pressure with the brake lever until these are not air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt.

  • Page 337: Rear Brake Pad

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 REAR BRAKE PAD BRAKE PAD REPLACEMENT Remove the two pad pins (1). Remove the two caliper mounting bolts (2), then remove the caliper. Remove the brake pads. Always replace the brake pads in pairs to ensure even disc pressure.
  • Page 338 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 Install new pads so that their ends rest on the pad retainer on the brake properly. Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper.

  • Page 339: Brake Disc Inspection

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks. Measure the brake disc thickness. Service limits: 3 mm (0.12 in) Replace the brake disc if the smallest measurement is less than the service limit.

  • Page 340: Brake Master Cylinder

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 BRAKE MASTER CYLINDER REMOVAL When removing the brake hose bolt, cover the end of the hose to prevent contamination. Secure the hose to prevent fluid from leaking out. Remove the upper handlebar cover (refer to the “FRAME COVERS...
  • Page 341 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 Remove the screw (6) and brake light switch. INSTALLATION Install the brake light switch and tighten the screw to the specified torque. Torque: 1 N•m (0.1 kgf•m, 0.7 lbf•ft) Align the pin on the master cylinder holder with the hole on the handlebar.
  • Page 342 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 Rest the brake hose eyelet against the stopper. Install the brake hose eyelet with the oil bolt and new sealing washers. Tighten the oil bolt to the specified torque. Torque: 35 N•m (3.5 kgf•m, 25 lbf•ft) Apply silicone grease to the master piston tip.
  • Page 343 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 Snap Ring DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder. Snap Ring Pliers (Close) Spring Master Cylinder Main Piston Remove the washer, main piston and spring from the brake master cylinder.
  • Page 344 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75 mm (0.5 in) Measure the brake master cylinder piston O.D. Service Limit: 12.64 mm (0.5056 in) Before assembly, inspect the lst and 2nd rubber cups for wear.

  • Page 345: Rear Brake Caliper

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 REAR BRAKE CALIPER DISASSEMBLY Drain the rear brake hydraulic system (refer to the “REAR BRAKE FLUID” section in this chapter). Remove the oil bolt (1), sealing washers and brake hose from the brake caliper.
  • Page 346 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 Remove pad spring (3) from the caliper body. Do not remove the retainer from the bracket unless replacement. Remove the piston from the brake caliper. If necessary, use compressed air to squeeze...
  • Page 347 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 ASSEMBLY Clean all removed parts. Apply silicon grease to the piston and new oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the new oil seals. Install the brake caliper piston with grooved side facing out.
  • Page 348 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 INSPECTION Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge. Service Limit: 25.3 mm (1.012 in) Check the caliper cylinder for scratches or wear and measure the cylinder bore.

  • Page 349: Rear Wheel/Rear Fork

    . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 REAR WHEEL/REAR FORK REMOVAL Remove the muffler (refer to the “EXHAUST MUFFLER” section in the chapter 2). Loosen the rear axle nut (1). Support the scooter securely on its main stand.
  • Page 350 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 Remove the rear wheel. INSTECTION Wheel Check the wheel rim runout using dial indicator. Actual urnout is 1/2 the total indicator reading. Service Limits: Radial: 2 mm (0.08 in) Axial: 2 mm (0.08 in)
  • Page 351 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 Remove the dust seal (2) from the rear fork. Remove the snap ring (3). Turn the inner race of the bearing with your finger. The bearing should turn smoothly and quietly.
  • Page 352 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 Drive in a new bearing squarely until it is fully seated, using the special tools. Special tool: Bearing installer A120E00014 Install the snap ring to the groove of the rear fork securely.
  • Page 353 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 Install the rear wheel onto the final gear shaft, aligning the spline. Install the inner side collar. Install the rear fork. Install the rear fork and tighten the two bolts (5) to the specified torque.
  • Page 354 . REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER DINK 200i/125 REAR SHOCK ABSORBER REMOVAL Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Remove the rear shock absorber lower mount bolt (1). Remove the rear shock absorber upper mount bolt (2) and shock absorber.

  • Page 355: Battery/Charging System

    . BATTERY/CHARGING SYSTEM DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT ---------------------------------------- 17-1 CHARGING CIRCUIT ----------------------------------------------------- 17-1 SERVICE INFORMATION------------------------------------------------ 17-2 TROUBLESHOOTING----------------------------------------------------- 17-3 BATTERY -------------------------------------------------------------------- 17-4 CHARGING SYSTEM ----------------------------------------------------- 17-6 ALTERNATOR CHARGING COIL-------------------------------------- 17-8 REGULATOR/RECTIFIER ----------------------------------------------- 17-9...
  • Page 356 . BATTERY/CHARGING SYSTEM DINK 200i/125 CHARGING SYSTEM LAYOUT CHARGING CIRCUIT 17-1...
  • Page 357 . BATTERY/CHARGING SYSTEM DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention x The battery can be charged and discharged repeatedly.

  • Page 358: Troubleshooting

    . BATTERY/CHARGING SYSTEM DINK 200i/125 TROUBLESHOOTING No power Intermittent power x Dead battery x Loose battery cable connection x Disconnected battery cable x Loose charging system connection x Fuse burned out x Loose connection or short circuit in ignition system...

  • Page 359: Battery

    . BATTERY/CHARGING SYSTEM DINK 200i/125 BATTERY REMOVAL/INSTALLATION The battery is in the battery box below seat. 1. Open the seat. 2. Remove the two screws and battery cover (1). 3. Remove the four screws and then remove the battery retainer (2).
  • Page 360 . BATTERY/CHARGING SYSTEM DINK 200i/125 VOLTAGE INSPECTION Remove the battery cover (last page). Measure the battery voltage using a commercially available digital multimeter. Voltage (20ºC/68ºC): Fully charged: 13 13.2 V Under charged: below 12.3 V BATTERY CHARGING Remove the battery (page 17-4).

  • Page 361: Charging System

    . BATTERY/CHARGING SYSTEM DINK 200i/125 CHARGING SYSTEM INSPECTION Remove the battery cover (see page 17-4). CURRENT LEAKAGE TEST Turn the ignition switch OFF, disconnect the negative (-) cable from the battery. Connect the ammeter (+) probe to the negative (-) cable and the ammeter (-) probe to the battery (-) terminal.
  • Page 362 . BATTERY/CHARGING SYSTEM DINK 200i/125 CHARGING VOLTAGE INSPECTION Be sure that the battery is in good condition before performing this test. Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch. Failure to follow this precaution can damage the tester or electrical components.

  • Page 363: Alternator Charging Coil

    . BATTERY/CHARGING SYSTEM DINK 200i/125 ALTERNATOR CHARGING COIL INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the alternator connector (1). Measure the resistance between each Yellow wire terminals. Standard: 0.4 0.6 : (20ºC/68ºF)

  • Page 364: Regulator/Rectifier

    2). Disconnect the regulator/rectifier connectors (1). Check the connectors for loose contacts of corroded terminals. Regulator/Rectifier (DINK 200i type) Battery line Measure the voltage between the Red/White wire terminal and ground. There should be battery voltage at all times.
  • Page 365 . BATTERY/CHARGING SYSTEM DINK 200i/125 Ground line Check the continuity between the Green wire terminal and ground. There should be continuity at all times. Charging coil line Measure the resistance between each Yellow wire terminals. Standard: 0.4 0.6 : (20ºC/68ºF) Disconnect the regulator/rectifier connector.
  • Page 366 . BATTERY/CHARGING SYSTEM DINK 200i/125 REMOVAL/INSTALLATION Remove the side body cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the regulator/rectifier connectors (1). Remove the two bolts (2), regulator/rectifier (3). Installation is in the reverse order of removal.

  • Page 367: Ignition System

    __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT (DINK 200i) -------------------------- 18-1 IGNITION CIRCUIT (DINK 200i) --------------------------------------- 18-1 IGNITION SYSTEM LAYOUT (DINK 125) --------------------------- 18-2 IGNITION CIRCUIT (DINK 125) ---------------------------------------- 18-2 SERVICE INFORMATION------------------------------------------------ 18-3 TROUBLESHOOTING----------------------------------------------------- 18-4 IGNITION COIL INSPECTION ------------------------------------------ 18-5...
  • Page 368 . IGNITION SYSTEM DINK 200i/125 IGNITION SYSTEM LAYOUT (DINK 200i) IGNITION CIRCUIT (DINK 200i) 18-1...
  • Page 369 . IGNITION SYSTEM DINK 200i/125 IGNITION SYSTEM LAYOUT (DINK 125) IGNITION CIRCUIT (DINK 125) FUSE LOCATION 18-2...
  • Page 370 . IGNITION SYSTEM DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS (DINK 200i) Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. When servicing the ignition system, always follow the steps in the troubleshooting.
  • Page 371 . IGNITION SYSTEM DINK 200i/125 TROUBLESHOOTING DINK 200i LOW PEAK VOLTAGE Cranking speed is too low (battery is undercharged). Poorly connected connectors or an open circuit in the ignition system. Faulty ignition-coil. Faulty ignition control module. NO PEAK VOLTAGE Short circuit in engine stop switch or ignition switch wire.
  • Page 372 . IGNITION SYSTEM DINK 200i/125 IGNITION COIL INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the center cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Check cylinder compression and check that the spark plug (1) is installed correctly in the cylinder.
  • Page 373 Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the ignition pulse generator connector (1). Measure the ignition pulse generator resistance between the Green/White wire and Blue/Yellow wire. Standard: DINK 200i: 16.4: (20ºC/68ºF) DINK 125: 106: (20ºC/68ºF) 18-6...
  • Page 374 . IGNITION SYSTEM DINK 200i/125 IGNITION COIL REMOVAL/INSTALLATION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the spark plug cap from the spark plug (1). DINK 200i: Disconnect the ignition coil primary connector (2).
  • Page 375 . IGNITION SYSTEM DINK 200i/125 CDI (DINK 125) REMOVAL/INSTALLATION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the CDI connectors (1) and remove the CDI (2). RESISTANCE INSPECTION Measure the resistance between the terminals.
  • Page 376 . IGNITION SYSTEM DINK 200i/125 Unit: : 0.27M 0.32M 0.27M 0.27M 0.27M 0.27M 0.58M 7.74M 7.74M 7.74M 7.74M 0.27M 0.32M 0.27M 0.32M 0.27M 4.94K 0.32M 0.32M 0.6M 0.32M 0.32M 0.32M 18-9...

  • Page 377: Starting System

    . STARTING SYSTEM DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT ----------------------------------------- 19-1 STARTING CIRCUIT ------------------------------------------------------ 19-1 SERVICE INFORMATION------------------------------------------------ 19-2 TROUBLESHOOTING----------------------------------------------------- 19-2 STARTER MOTOR --------------------------------------------------------- 19-3 STARTER RELAY INSPECTION---------------------------------------- 19-5 19-0...
  • Page 378 . STARTING SYSTEM DINK 200i/125 STARTING SYSTEM LAYOUT STARTING CIRCUIT 19-1...
  • Page 379 . STARTING SYSTEM DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS x The removal of starter motor can be accomplished with the engine installed. x For the starter clutch removal, refer to the chapter 10. x After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
  • Page 380 . STARTING SYSTEM DINK 200i/125 START MOTOR INSPECTION Disconnect the start motor cable ( 2) from the start MAG (1). Connect the start motor cable directly to the battery positive terminal (3). If the start motor does not turn, the starter motor is faulty.
  • Page 381 . STARTING SYSTEM DINK 200i/125 INSTALLATION Coat a new O-ring (1) with engine oil and install it into the start motor groove. Install the starter motor into the crankcase. Install the two mounting bolts and engine ground cable, then tighten the bolts securely.
  • Page 382 . STARTING SYSTEM DINK 200i/125 START RELAY INSPECTION Release the rubber cap (1) and remove the nut (2), then disconnect the start motor cable. Turn the ignition switch to “ON”. Squeeze and hold the brake lever fully then push the starter switch.

  • Page 383: 20. Lights/Meters/Switches

    20. LIGHTS/METERS/SWITCHES DINK 200i/125 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/METERS/SWITCHES __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 20- 1 BULB REPLACEMENT --------------------------------------------------- 20- 2 BRAKE LIGHT SWITCH-------------------------------------------------- 20- 6 IGNITION SWITCH -------------------------------------------------------- 20- 6 HANDLEBAR SWITCH --------------------------------------------------- 20- 7 LUGGAGE BOX LIGHT SWITCH -------------------------------------- 20- 9...
  • Page 384 DINK 200i/125 20. LIGHTS/METERS/SWITCHES SERVICE INFORMATION GENERAL • • A halogen head light bulb becomes very hot while the head light is on, and remains for a while after it is turned off. Be sure to let it cool down before servicing.
  • Page 385 20. LIGHTS/METERS/SWITCHES DINK 200i/125 BULB REPLACEMENT POSITION LIGHT Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Remove the bulb socket (1). Remove the bulb (2) and replace with a new one. Installation is in the reverse order of removal.
  • Page 386 DINK 200i/125 20. LIGHTS/METERS/SWITCHES HEADLIGHT • • A halogen headlight bulb becomes very hot while the headlight is ON, and remain for a while after it is turned OFF. Be sure to let it cool down before servicing. Remove the front cover (refer to the “FRAME COVERS...
  • Page 387 20. LIGHTS/METERS/SWITCHES DINK 200i/125 Cover FRONT TURN SIGNAL LIGHT Remove the two screws, then remove the front turn signal light cover. Push and turn the bulb counterclockwise to remove it, then replace with a new one.. Installation is in the reverse order of removal.
  • Page 388 DINK 200i/125 20. LIGHTS/METERS/SWITCHES Bulb Rear turn signal light Remove the screw and then remove the bulb cover. Push and turn the bulb counterclockwise to remove it, then replace with a new one. Installation is in the reverse order of removal.
  • Page 389 20. LIGHTS/METERS/SWITCHES DINK 200i/125 BRAKE LIGHT SWITCH Remove the upper handlebar cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect front or rear light switch connectors and check for continuity between the switch terminals (1). There should be continuity with the front or...
  • Page 390 DINK 200i/125 20. LIGHTS/METERS/SWITCHES HANDLEBAR SWITCH INSPECTION Engine Stop Switch Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Right handlebar switch Disconnect the right handlebar switch connector and check for continuity at switch side connector terminals.
  • Page 391 20. LIGHTS/METERS/SWITCHES DINK 200i/125 Dimmer Switch Left handlebar switch Disconnect the left handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows: Turn Signal light Switc Horn Switch...
  • Page 392 DINK 200i/125 20. LIGHTS/METERS/SWITCHES LUGGAGE BOX LIGHT SWITCH INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the luggage box light switch connector (2) and check the luggage box light switch (1) for continuity between the switch terminals.
  • Page 393 20. LIGHTS/METERS/SWITCHES DINK 200i/125 FUEL UNIT REMOVAL Remove the floorboard (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Remove the four nuts (1) and then remove the bridge plate (2). Disconnect the fuel unit connectors (3). Turn the fuel unit retainer (4) counterclockwise and remove it.
  • Page 394 DINK 200i/125 20. LIGHTS/METERS/SWITCHES Remove the fuel unit (5). • • Be careful not to bend or damage the fuel unit float arm. INSPECTION Connect the fuel unit wire connectors and turn the ignition switch “ON”. • • Before performing the following test, operate the turn signals to determine that the battery circuit is normal.
  • Page 395 20. LIGHTS/METERS/SWITCHES DINK 200i/125 INSTALLATION Install the O-ring (1) and fuel unit (2). • • Align the groove on the fuel unit with the flange on the fuel tank. Install the fuel unit retainer. • • Align the arrow mark on the fuel unit retainer with the arrow mark on the fuel tank.
  • Page 396 DINK 200i/125 20. LIGHTS/METERS/SWITCHES SIDE STAND SWITCH INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Side stand switch (1) is located on side stand Disconnect the side stand switch connector (2). There should be continuity between the Yellow/Green and Green with the side stand retracted.
  • Page 397 20. LIGHTS/METERS/SWITCHES DINK 200i/125 HORN INSPECTION Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2) Disconnect the horn connectors (1) 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.
  • Page 398 DINK 200i/125 20. LIGHTS/METERS/SWITCHES HEATER CONTROLLER UNIT (DINK 125) INSPECTION Heater control unit inspection 1.Open ignition switch to check if the brown /blue wire of it is enough voltage. 2.Put the heater controller unit in refrigerator. Start engine after keeping the temperature under 10 ±...

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Dink 125

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