KYMCO G-Dink 125i Manual

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1. External Components

External Components

This chapter covers the location and servicing of the

external components for the KYMCO G-Dink 125i.

• Front Cover

G- Dink 125i

2-12

13-15

16-18

19-31

32-43

44-48

49-56

57-61

62-64

65-68

69-74

75-80

81-84

Chapters

Table of Contents

Summary of Contents for KYMCO G-Dink 125i

Page 1: Table Of Contents
1. External Components G- Dink 125i External Components This chapter covers the location and servicing of the external components for the KYMCO G-Dink 125i. • Exhaust System 2-12 • Seat 13-15 • Luggage Box 16-18 • Body Cover 19-31 • Front Cover 32-43 •...
Page 2: Exhaust System
G- Dink 125i 1. External components > Exhaust System Exhaust System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. General Instructions • When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged.
Page 3 G- Dink 125i 1. External components > Exhaust System Remove the two exhaust pipe joint nuts with a 12 mm deep well socket. Unplug the O sensor connector. Remove the three muffler mounting bolts with a 14 mm socket.
Page 4 G- Dink 125i 1. External components > Exhaust System Remove the exhaust system. Remove the exhaust pipe gasket and discard it.
Page 5 G- Dink 125i 1. External components > Exhaust System Sensor Removal Remove the O sensor with a 17 mm wrench. Use care not to pinch the wires. The O sensor issues signal to ECU when the temperature is over 350° C while the engine is running.
Page 6 G- Dink 125i 1. External components > Exhaust System Measure the resistance between the white wire terminals of the O sensor connector. Replace the O sensor if the reading is out of specification. ITEM SPECIFICATIONS 6.7 - 9.5 $ (engine warming condition) heater sensor resistance (at 20°C/68°F) Heat Shields...
Page 7 G- Dink 125i 1. External components > Exhaust System Remove the four muffler heat shield bolts with a #2 screwdriver if needed. Remove the heat shield.
Page 8 G- Dink 125i 1. External components > Exhaust System To remove the heat shield on the exhaust pipe remove the two bolts with an 8 mm socket. To remove the four bolts to free the heat shield on the muffler. Remove the two bolts to remove the heat shield on the head pipe.
Page 9 G- Dink 125i 1. External components > Exhaust System Installation Heat Shields Install the heat shields and tighten the bolts securely. Sensor Apply anti-seize compound to the threads of the O sensor. Install the sensor and tighten it to specification with a 17 mm wrench. Use care not to pinch the wires.
Page 10 G- Dink 125i 1. External components > Exhaust System Exhaust System Insert a new exhaust pipe gasket into the exhaust port. Fit the exhaust system into place...
Page 11 G- Dink 125i 1. External components > Exhaust System Install the two exhaust pipe joint nuts with a 12 mm deep well socket. Do not tighten. Install the three muffler mounting bolts and tighten to specification with a socket. Torque Item kgf-m Muffler Mounting Bolts...
Page 12 G- Dink 125i 1. External components > Exhaust System If the exhaust pipe and muffler were separated tighten the muffler clamp securely. Plug in the O sensor. Install the luggage box. See the Luggage Box topic for more information. Install the seat. See the Seat topic for more information.
Page 13: Seat
G-Dink 125i 1. External Components > Seat Seat SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Insert the key and turn it counterclockwise . Remove the two luggage box hinge nuts with a 10 mm socket.
Page 14 G-Dink 125i 1. External Components > Seat Remove the two seat hinge nuts with a 10 mm socket. Remove the seat with the piston pivot. Seat Latch Cable The seat latch cable runs from the ignition switch to the seat latches.
Page 15 G-Dink 125i 1. External Components > Seat Installation Install the seat with the piston pivot onto the hinge. Install the two seat hinge nuts and tighten securely with a 10 mm socket. Install the two luggage box hinge nuts and tighten securely with a 10 mm socket.
Page 16: Luggage Box
G-Dink 125i 1. External Components > Luggage Box Luggage Box SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the seat. See the Seat topic for more information. Remove the two luggage nuts with a 10 mm socket.
Page 17 G-Dink 125i 1. External Components > Luggage Box Remove the PDA panel located at the rear of the luggage box and free the PDA plug. Lift up the luggage box to unplug the luggage box light connector. Remove the luggage box.
Page 18 G-Dink 125i 1. External Components > Luggage Box Mount the PDA plug and install the panel located at the rear of the luggage box. Install the two luggage nuts and tighten securely with a 10 mm socket. Install the seat. See the Seat topic for more information.
Page 19: Body Cover
G-Dink 125i 1. External Components > Body Cover Body Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the seat. See the Seat topic for more information. Remove the luggage box. See the Luggage Box topic for more information.
Page 20 G-Dink 125i 1. External Components > Body Cover Remove the rear center cover. Remove the upper body cover bolt with a 10 mm socket.
Page 21 G-Dink 125i 1. External Components > Body Cover Remove the two lower body cover nuts with a 10 mm socket. Unplug the taillight connector.
Page 22 G-Dink 125i 1. External Components > Body Cover Remove the two screws from the front of the body cover. Remove the two bolts on both sides of the body cover. Carefully unhook the tabs on both sides of the body cover.
Page 23 G-Dink 125i 1. External Components > Body Cover Remove the body cover. Disassembly Taillight Assembly...
Page 24 G-Dink 125i 1. External Components > Body Cover Remove the six taillight assembly screws with a #2 Phillips. Unhook the taillight section and separate from the body cover.
Page 25 G-Dink 125i 1. External Components > Body Cover Remove the two mud flap screws with a #2 Phillips. Separate the mud flap from the taillight assembly.
Page 26 G-Dink 125i 1. External Components > Body Cover License Light Remove the two license light assembly screws with a screwdriver. Remove the license light assembly.
Page 27 G-Dink 125i 1. External Components > Body Cover Mud Flap Installation Fit the body cover into place.
Page 28 G-Dink 125i 1. External Components > Body Cover Install the two screws on both sides of the body cover. Carefully push the hooks into the corresponding tabs on both sides of the body cover. Install the two screws into body cover and tighten them securely with a...
Page 29 G-Dink 125i 1. External Components > Body Cover Plug in the taillight connector. Install the two lower body cover nuts and tighten securely with a 10 mm socket.
Page 30 G-Dink 125i 1. External Components > Body Cover Install the upper body cover bolts and tighten securely with a 10 mm socket. Carefully install the rear center cover.
Page 31 G-Dink 125i 1. External Components > Body Cover Install the two rear center cover screws and tighten securely with a #2 Phillips. Install the rear carrier. See the RearCarrier topic for more information. Install the luggage box. See the Luggage Box topic for more information.
Page 32: Front Cover
G-Dink 125i 1. External Components > Front Cover Front Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the windshield. See the Windshield topic for more information. Open the hidden bolt cover. Remove the hidden bolt with a 10mm socket.
Page 33 G-Dink 125i 1. External Components > Front Cover Remove the four windshield bolts with a 6mm Allen. There are two bolts on each side. Remove the windshield.
Page 34 G-Dink 125i 1. External Components > Front Cover Remove the four front cover mounting screws with a #2 Phillips. There are two screws on each side. Remove the push pin. Depress the head of the fastener center piece. Pull out the fastener.
Page 35 G-Dink 125i 1. External Components > Front Cover Remove the two front cover mounting nuts with a 10 mm socket. Carefully pull out off the front cover with a screwdriver. Gently pull the cover forward and free the tabs.
Page 36 G-Dink 125i 1. External Components > Front Cover Unplug the headlight and turn signal leads. Remove the front cover. Disassembly Lower Fairing Remove the four lower fairing push pins on each side. Remove the six upper fairing push pins on the upper.
Page 37 G-Dink 125i 1. External Components > Front Cover Light Assembly Remove the eight light assembly mounting screws with a #2 Phillips. Remove the light assembly from the front cover.
Page 38 G-Dink 125i 1. External Components > Front Cover Side Piece Remove the eighteen side piece screws with a #2 Phillips. Remove the side piece.
Page 39 G-Dink 125i 1. External Components > Front Cover Assembly Side Piece Install the side piece on the front cover. Install the eighteen side piece screws and tighten securely with a #2 Phillips.
Page 40 G-Dink 125i 1. External Components > Front Cover Light Assembly Install the light assembly on the front cover. Install the eight light assembly mounting screws and tighten securely with a #2 Phillips.
Page 41 G-Dink 125i 1. External Components > Front Cover Lower Fairing Install the lower fairing. Install the four lower fairing push pins on each side. Install the six upper fairing push pins on the upper side. Installation Plug in the headlight and turn signal leads.
Page 42 G-Dink 125i 1. External Components > Front Cover Align front cover tabs. Install the front cover. Install the four front cover mounting screws and tighten securely with a #2 Phillips. There are two screws on each side.
Page 43 G-Dink 125i 1. External Components > Front Cover Install the two front cover mounting nuts and tighten securely with a 10 mm socket. Align the two posts with the grommets. Carefully push on the small black cover. Install the small black cover push pin.
Page 44: Front Lower Cover
G-Dink 125i 1. External Components > Front Lower Cover Front Lower Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. The process for removing and installing the front lower covers are the same for both sides. Remove the screw from the bottom of the cover.
Page 45 G-Dink 125i 1. External Components > Front Lower Cover Pull up the front skirt rubber covers. Remove the two upper screws under the lower rubber cover with a #2 Phillips on each side. Remove the screw under the rubber cover with a #2 Phillips.
Page 46 G-Dink 125i 1. External Components > Front Lower Cover Remove the screw mounting on the front lower cover with a #2 Phillips on each side. Gently separate the front lower cover from the front cover. Remove the front lower cover.
Page 47 G-Dink 125i 1. External Components > Front Lower Cover Install the two screws under the rubber cover with a #2 Phillips. Tighten them securely. Install the screw under the rubber cover with a #2 Phillips. Install the lower screws mounting on the body frame with a #2 Phillips on each side.
Page 48 G-Dink 125i 1. External Components > Front Lower Cover Install the screw.
Page 49: Inner Cover
G-Dink 125i 1. External Components > Inner Cover Inner Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove front cover. See the Front Cover topic for more information. Remove front center cover. See the Front Center Cover topic for more information.
Page 50 G-Dink 125i 1. External Components > Inner Cover Remove the fuel cap with the key. Remove the two push pins below the handlebar. Depress the head of the fastener center piece. Pull out the fastener. There are six mounting bolts on the floorboard.
Page 51 G-Dink 125i 1. External Components > Inner Cover Remove the six mounting bolts on both sides with a 10 mm socket. Lift off the inner cover. Remove the mounting bolt on the water reserve box.
Page 52 G-Dink 125i 1. External Components > Inner Cover Remove the two mounting bolts on the body frame. Remove the gas cap overflow pad. Remove the connector output voltage device.
Page 53 G-Dink 125i 1. External Components > Inner Cover Remove the inner cover. Inspect the gas panel.
Page 54 G-Dink 125i 1. External Components > Inner Cover Installation Install the inner cover and align the bolt holes. Install the gas cap overflow pad. Install the two front mounting bolts on both sides and tighten them securely with a 10 mm socket.
Page 55 G-Dink 125i 1. External Components > Inner Cover Install the bolt attaching to the water reserve box and tighten securely with a #10 socket. Install the floorboard. Install the six mounting bolts and tighten them securely on both sides with a 10 mm socket.
Page 56 G-Dink 125i 1. External Components > Inner Cover Install the two side push pins. Push in the head of the center piece until it becomes flush with the fastener outside face. Note: To prevent the pawl from damage, insert the fastener all the way into the installation hole.
Page 57: Front Fender
G-Dink 125i 1. External Components > Front Fender Front Fender SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal The front fender is held in place with four bolts, two on each side. Remove the left forward front fender bolt with a 6 mm Allen.
Page 58 G-Dink 125i 1. External Components > Front Fender Remove the left rear fender bolt with a 10 mm socket. Remove the right forward front fender bolt with a 6 mm Allen. Remove the right rear fender bolt with a 10 mm socket.
Page 59 G-Dink 125i 1. External Components > Front Fender Remove the front fender from the forks. Installation Guide the fender between the forks.
Page 60 G-Dink 125i 1. External Components > Front Fender Install the left forward front fender bolt and tighten securely with a 6 mm Allen. Install the left rear fender bolt and tighten securely with a 10 mm socket.
Page 61 G-Dink 125i 1. External Components > Front Fender Install the right forward front fender bolt and tighten securely with a 6 mm Allen. Install the right rear fender bolt and tighten securely with a 10 mm socket.
Page 62: Rear Carrier
G-Dink 125i 1. External Components > Rear Carrier Rear Carrier Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Page 63 G-Dink 125i 1. External Components > Rear Carrier Remove the four carrier bolts with a 6 mm Allen. Remove the carrier. Installation...
Page 64 G-Dink 125i 1. External Components > Rear Carrier Install the carrier. Install the two upper carrier bolts with a 6 mm Allen. Install the two carrier bolts on each side with a 6 mm Allen.
Page 65: Rear Fender
G-Dink 125i 1. External Components > Rear Fender Rear Fender SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the airbox. See the Airbox topic for more information.
Page 66 G-Dink 125i 1. External Components > Rear Fender Remove the two fender mounting bolts with a 8 mm socket on the right side. Remove the airbox . Remove the left fender mounting bolts with a 10 mm socket on the back side.
Page 67 G-Dink 125i 1. External Components > Rear Fender Remove the rear fender. Installation Install the rear fender.
Page 68 G-Dink 125i 1. External Components > Rear Fender Install the left fender mounting bolts with a 10 mm socket on the back side. Install the left fender mounting bolts with a 8 mm socket on the front side. Install the two right fender mounting bolts and tighten securely with a 8 mm socket on the right side.
Page 69: Stands
G-Dink 125i 1. External Components > Stands Stands SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Side stand Removal Remove the luggage box. See the Luggage Box topic for more information. Remove the foot skirt. See the Foot Skirt topic for more information.
Page 70 G-Dink 125i 1. External Components > Stands Remove the side stand spring with a spring puller. Remove the side stand bolt, switch, and side stand. Installation...
Page 71 G-Dink 125i 1. External Components > Stands Install the side stand, switch, and bolt. Make sure to fit the switch into place correctly. Tighten the bot securely. Install the side stand spring with a spring puller.
Page 72 G-Dink 125i 1. External Components > Stands Plug in the side stand switch connector. Install the foot skirt. See the Foot Skirt topic for more information. Install the luggage box. See the Luggage Box topic for more information. Center Stand Removal Remove the center stand spring with a spring puller.
Page 73 G-Dink 125i 1. External Components > Stands Remove the two center stand nuts and bolts. Remove the center stand. Installation Install the nuts and bolts. Tighten them securely.
Page 74 G-Dink 125i 1. External Components > Stands Install the center stand spring with a spring puller.
Page 75: Handlebar Cover
G-Dink 125i 1. External Components > Handlebar Cover Handlebar Covers SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Upper Cover Remove the four cover screws with a #2 Phillips.
Page 76 G-Dink 125i 1. External Components > Handlebar Cover Carefully free the tabs and remove the upper handlebar cover. Lower Cover Remove the luggage box. See the Luggage Box topic for more information. Remove the throttle cables from the throttle body. See the Throttle Body...
Page 77 G-Dink 125i 1. External Components > Handlebar Cover Route the throttle cables out of the handlebar cover.
Page 78 G-Dink 125i 1. External Components > Handlebar Cover Remove the lower cover. Installation...
Page 79 G-Dink 125i 1. External Components > Handlebar Cover Place the lower cover onto the handlebar.
Page 80 G-Dink 125i 1. External Components > Handlebar Cover Route the throttle cables into the handlebar cover. See the Throttle Cable topic for more information.
Page 81: Under Cover
G-Dink 125i 1. External Components > Under Cover Under Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the right and left foot skirts. See the Foot Skirt topic for more information. Remove the two under cover bolts on the right side with a 10 mm...
Page 82 G-Dink 125i 1. External Components > Under Cover Remove the two under cover bolts on the left side with a 10 mm socket. Remove the under cover.
Page 83 G-Dink 125i 1. External Components > Under Cover Installation Install the under cover.
Page 84 G-Dink 125i 1. External Components > Under Cover Install the two under cover bolts on the left side and tighten securely with a 10 mm socket. Install the two under cover bolts on the right side and tighten securely with a 10 mm socket.
Page 85 2. Engine G-Dink 125i Engine This chapter covers the location and servicing of the engine components for the KYMCO G-Dink 125i. • Generator Removal & Installation 4-23 • Crankshaft 24-26 • Crankcase Splitting & Assembly 27-36 • Cylinder Head Cover 37-41 •...
Page 86 2. Engine G-Dink 125i Poor lubrication pressure 1. Oil level too low 2. Clogged filter or oil passages 3. No use the specified oil Cylinder Head, Camshaft, and Valves • The cylinder head can be serviced with the engine installed in the frame.
Page 87 2. Engine G-Dink 125i Compression too high • Excessive carbon build-up in combustion chamber Abnormal noise • Incorrect valve clearance adjustment • Sticking valve or broken valve spring • Damaged or worn camshaft • Worn cam chain tensioner • Worn camshaft and rocker arm White smoke from exhaust muffler •...
Page 88 2. Engine > Generator G-Dink 125i A.C. Generator and Starter clutch SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Generator Cover Remove the following components - # Seat # Luggage Box # Center Cover # Rear Carrier...
Page 89 G-Dink 125i 2. Engine > Generator Loosen the water pump hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the water pump. Allow any remaining coolant to drain into a suitable container.
Page 90 G-Dink 125i 2. Engine > Generator Remove the 9 generator cover bolts with an 8 mm socket. Note the upper most bolt holds a wire stay. Utilize the pry points and remove the generator cover.
Page 91 G-Dink 125i 2. Engine > Generator Remove the generator cover gasket. Remove the two dowel pins.
Page 92 G-Dink 125i 2. Engine > Generator Stator and Pulsar Coil/Crank Position Sensor Free the rubber wire grommet from the right crankcase cover. Remove the three stator mounting bolts and the two crank position sensor bolts with an 8 mm socket. Remove the stator and the crank position sensor together.
Page 93 G-Dink 125i 2. Engine > Generator To remove the fly wheel two special tools are needed. ITEM TOOL NO. UNIVERSAL HOLDER A120E00021 ITEM TOOL NO. FLYWHEEL PULLER A120E00003...
Page 94 G-Dink 125i 2. Engine > Generator Hold the flywheel with the universal holder and loosen the nut with a 19 mm socket. Remove the flywheel nut and washer.
Page 95 2. Engine > Generator G-Dink 125i Apply grease to the threads of the flywheel puller tool before using it. Thread the puller onto the flywheel. Hold the tool with a large wrench and turn in the bolt until the pressure separates the flywheel from the crankshaft.
Page 96 2. Engine > Generator G-Dink 125i Slide the starter driven gear off of the crankshaft. Remove the woodruff key from the crankshaft. Starter Clutch...
Page 97 G-Dink 125i 2. Engine > Generator Remove the starter idle gear and shaft from the crankcase. Inspect the starter idle gear and shaft for wear and damage. Replace the idle gear and shaft as needed. Inspect the starter driven gear for wear and damage. Measure the inside and outside diameter of the starter driven gear and replace it as needed.
Page 98 2. Engine > Generator G-Dink 125i Fit the boss of the starter driven gear into the starter clutch. The starter clutch should only allow the driven gear to turn in one direction. If the starter clutch allows turning both ways or will not let the driven gear rotate smoothly in one direction the starter clutch must be replaced.
Page 99 G-Dink 125i 2. Engine > Generator Tighten the starter clutch mounting bolts to specification with a 6 mm Allen socket. Torque Thread Item size (mm) kgf-m lb-ft Oneway clutch bolt 1.8-2.2 13.02-15.91 Lubricate the starter idle gear shaft with fresh engine oil. Install the starter idle gear and shaft into the crankcase.
Page 100 G-Dink 125i 2. Engine > Generator Install the woodruff key into its slot on the end of the crankshaft. Lubricate the inside of the starter driven gear with fresh engine oil. Slide the starter driven gear onto the flywheel as shown.
Page 101 G-Dink 125i 2. Engine > Generator Line up the groove in the flywheel with the key and fit the flywheel onto the crankshaft. Guide the starter driven gear into the starter clutch on the back of the flywheel. Install the washer and flywheel nut.
Page 102 G-Dink 125i 2. Engine > Generator Hold the flywheel with the universal holder and torque the flywheel nut to specification with a 19 mm socket. Torque Thread Item size (mm) kgf-m lb-ft ACG flywheel nut 5.0 - 6.0 36.0 – 43.2 ITEM TOOL NO.
Page 103 G-Dink 125i 2. Engine > Generator Fit the stator and the crankshaft position sensor into the generator cover together as shown. Insert the two crank position sensor mounting bolts and the three stator mounting bolts. Tighten the bolts securely with an 8 mm socket.
Page 104 G-Dink 125i 2. Engine > Generator Fit the generator cover into place. Make sure the water pump shaft engages correctly with the oil pump shaft.
Page 105 2. Engine > Generator G-Dink 125i Insert the 12 generator cover bolts. Note the upper most bolt holds a wire stay. Tighten the bolts securely in a with an 8 mm socket. Fit the coolant hose to the right crankcase cover pipe. Secure the hose with the clamp and tighten the coolant hose clamp securely with a #2 Phillips screwdriver.
Page 106 2. Engine > Generator G-Dink 125i Connect the coolant hose to the water pump. Move the clamp into place and tighten it securely with a #2 Phillips screwdriver. Plug in the regulator/rectifier 3-pin connector.
Page 107 G-Dink 125i 2. Engine > Generator Plug in the crank position sensor wire coupler on the right side of the frame. Fill the engine oil. See the Engine Oil topic for more information. Install the exhaust system. See the Exhaust System topic for more information.
Page 108: Crankshaft
2. Engine > Crankshaft G-Dink 125i Crankshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Split the crankcases. See the Crankcase topic for more information. Lift the crankshaft out of the left crankcase half.
Page 109 G-Dink 125i 2. Engine > Crankshaft Crankshaft Inspection Check the side clearance of the big end of the connecting rod with a feeler gauge. Item Standard (mm) Service Limit (mm) Connecting rod big Crankshaft 0.15 - 0.35 end side clearance Grip the small end of the connecting rod and try and push the rod down towards the crank weights.
Page 110 G-Dink 125i 2. Engine > Crankshaft Crankshaft Bearings Installation Lubricate the connecting rod big end and crankshaft shaft bearings with fresh engine oil. Fit the crankshaft into the left crankcase bearing. Take care to avoid damaging the new oil seal.
Page 111 G-Dink 125i 2. Engine > Crankcase Crankcase SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Splitting Drain the engine oil and remove the strainer screen. See the Engine Oil topic for more information. Remove the engine. See the Engine Removal topic for more information.
Page 112 G-Dink 125i 2. Engine > Crankcase Remove the upper cam chain guide. Inspect the cam chain guides for damage and excessive wear. Replace the guides as needed.
Page 113 G-Dink 125i 2. Engine > Crankcase Remove the cam chain from the crankshaft and crankcase. Inspect the cam chain for wear and damage. Replace the cam chain as needed. Remove the oil filter cover with an 8 mm socket. Remove the oil filter. It should be replaced a new one per 2000km.
Page 114 G-Dink 125i 2. Engine > Crankcase There are 4 crankcase bolts attaching the left side. There are 2 crankcase bolts attaching the right side. Loosen the 6 crankcase bolts in a crisscross pattern with an 8 mm socket. Remove the crankcase bolts from the left side of the engine.
Page 115 G-Dink 125i 2. Engine > Crankcase Set the crankcases on the right side. Separate the halves of the crankcase. If needed gently tap the reinforced areas of the right crankcase half with a rubber mallet. Lift the right crankcase off of the left.
Page 116 G-Dink 125i 2. Engine > Crankcase To remove the crankshaft see the Crankshaft topic. Replace the left crankshaft seal if the crankcases are separated. Remove the seal with a seal pick.
Page 117 G-Dink 125i 2. Engine > Crankcase Drive the new seal into the left crankcase from the outside with a suitable driver. The driver should have the same outside diameter as the seal. Lubricate the new crankshaft seal lips with fresh engine oil.
Page 118 G-Dink 125i 2. Engine > Crankcase Set the right case half down on top of the left. Install the engine mount spacer. Insert the 5 crankcase bolts onto the left crankcase. Insert the 2 crankcase bolts onto the right crankcase. Tighten the bolts...
Page 119 G-Dink 125i 2. Engine > Crankcase Install the cam chain around the timing sprocket teeth on the crankshaft. Fit the upper cam chain guide into place. Insert the upper cam chain guide mounting bolt and tighten it to specification with an 10 mm Allen socket.
Page 120 G-Dink 125i 2. Engine > Crankcase Torque Thread Item size (mm) kgf-m lb-ft Cam chain tensioner pivot 1.2-1.6 8.64 – 11.52 Install the oil pump. See the Oil Pump topic for more information. Install the starter idle gear, driven gear, flywheel, and the generator cover.
Page 121: Cylinder Head Cover
2. Engine > Cylinder Head Cover G-Dink 125i Cylinder Head Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the seat. See the Seat topic for more information. Remove the luggage box. See the Luggage Box topic for more information.
Page 122 2. Engine > Cylinder Head Cover G-Dink 125i Loosen the fuel hose stay bolt with an 10 mm socket. Free the fuel hose stay from the cylinder head cover. Loosen the four cylinder head cover bolts with a 10 mm socket. Remove the cylinder head cover bolts.
Page 123 2. Engine > Cylinder Head Cover G-Dink 125i Installation Fit the cylinder head cover gasket onto the cylinder head. Make sure the projection fits into the groove. Install the cylinder head cover over the gasket. Make sure the ridge on the gasket fits into the groove on the cylinder head cover correctly.
Page 124 2. Engine > Cylinder Head Cover G-Dink 125i Insert the cylinder head cover bolts. Tighten the cylinder head cover bolts securely in two steps and in a crisscross pattern with an 10 mm socket.
Page 125 G-Dink 125i 2. Engine > Cylinder Head Cover Fit the fuel stay into place. Tighten the stay bolt securely with an 10 mm socket. Install the breather hose to the cylinder head cover. Secure the hose with the clamp. Install the spark plug. See the Spark Plug topic for more information.
Page 126: Camshaft
G-Dink 125i 2. Engine > Camshaft Camshaft SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the seat. See the Seat topic for more information. Remove the luggage box. See the Luggage Box topic for more information.
Page 127 G-Dink 125i 2. Engine > Camshaft The crankshaft must be rotate (clockwise) until the piston is at top dead center (TDC) on the compression stroke. Turn crankshaft clockwise until the "T" mark aligns with the index notch in the timing inspection hole.
Page 128 G-Dink 125i 2. Engine > Camshaft The piston should now be at TDC on the compression stroke. You can make sure that it is on the compression stroke by checking that there is some slack in the rocker arms. If the rocker arms are rigid, rotate the crankshaft 360°...
Page 129 G-Dink 125i 2. Engine > Camshaft Remove the cam chain tensioner cap bolt with a 10 mm socket. Loosen the cam chain tensioner mounting bolts evenly with an 8 mm socket. Lift the cam chain tensioner out of the cylinder. Remove the cam chain...
Page 130 G-Dink 125i 2. Engine > Camshaft Remove four cam chain holder bolts with a 12 mm socket Remove the cam chain holder Remove the camshaft sprocket as shown. Support the chain so it does not fall into the cylinder head.
Page 131 G-Dink 125i 2. Engine > Camshaft Remove the rocker arm shafts and pull the shafts out with a large flat blade screwdriver. Lift out the rocker arms as the shafts are removed. Remove the camshaft from the cylinder head.
Page 132 G-Dink 125i 2. Engine > Camshaft Inspection Inspect the camshaft cam heights for the intake and exhaust lobes. Inspect the camshaft bearings for excessive play or roughness. Replace the entire camshaft assembly if the bearings are rough or have excessive play.
Page 133 G-Dink 125i 2. Engine > Camshaft Inspect the rocker arm inner diameter for the intake and exhaust valves. Inspect the camshaft bearing journals for scoring or scratches.
Page 134 G-Dink 125i 2. Engine > Camshaft Inspect the camshaft sprocket for worn teeth or other signs of wear or damage. Camshaft Installation Clear out the cylinder head oil passages with compressed air. Make sure all cylinder head oil passages are free of clogs.
Page 135 G-Dink 125i 2. Engine > Camshaft Put the camshaft into the cylinder head with the lobes facing down. Lubricate the inside diameter of the rocker arms and the roller with fresh engine oil. Position the rocker arms to accept the rocker arm shafts.
Page 136 G-Dink 125i 2. Engine > Camshaft Install the camshaft sprocket onto the camshaft so the camshaft sprocket boss fits into the appropriate hole on the camshaft sprocket. Make sure the camshaft sprocket boss is facing up so it is visible above the edge of the cylinder head as shown.
Page 137 G-Dink 125i 2. Engine > Camshaft Install the camchain tensioner with a new gasket. Insert the mounting bolts and tighten them evenly to specification with an 8 mm socket. Torque Thread Item size (mm) kgf-m lb-ft Cam chain tensioner bolt 1.0-1.4...
Page 138 G-Dink 125i 2. Engine > Camshaft Make sure the cam chain tensioner cap bolt washer is in good condition. Install the cam chain tensioner cap bolt. Tighten the bolt to securely with a 10 mm socket. Check the valve clearance. See the Valve Clearance topic for more information.
Page 139: Valves
G-Dink 125i 2. Engine > Valves Valves SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the camshaft. See the Camshaft topic for more information. Remove the cylinder head. See the Cylinder Head topic for more information.
Page 140 G-Dink 125i 2. Engine > Valves Remove the spring retainer. Remove the valve springs.
Page 141 G-Dink 125i 2. Engine > Valves Push the valve stem down and remove the valve from the combustion chamber side of the cylinder head. Rotate the valve as it is removed. Remove the valve seal from the valve guide. The valve seals should be replaced if they are removed or you are going to install new valves.
Page 142 G-Dink 125i 2. Engine > Valves Inspect the valve springs for fatigue and damage. Replace the valve springs as needed or if the valve is also to be replaced.
Page 143 G-Dink 125i 2. Engine > Valves Inspect the valves for damage and burning. Measure the valve stem diameter in several places where the valve makes contact with the guide. If the measurement is below specification replace the valve. Item Standard (mm) 4.975 ─...
Page 144 G-Dink 125i 2. Engine > Valves Installation Clean the cylinder head components thoroughly with a high flash-point solvent and compressed air. Return the components to their original locations. NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.
Page 145 G-Dink 125i 2. Engine > Valves Coat the valve stem in fresh engine oil and insert the valve into the valve guide and through the seal. Turn the valve slowly as it is inserted. If you are installing a new valve you must ream the valve guide first. Make sure the valve will move smoothly in the valve guide without wobble.
Page 146 G-Dink 125i 2. Engine > Valves Place the spring retainer on top of the spring. Push down the valve springs with a valve spring compressor to allow enough room to install the split keepers. The valve cotter installer tool can also be used to install the split keepers.
Page 147 G-Dink 125i 2. Engine > Valves Apply grease to the inside of the split keepers. Apply a dab of grease to the end of a flat blade screwdriver. Set the keeper in the grease on the screwdriver and insert it onto the valve stem. Repeat this with the other keeper.
Page 148: Cylinder And Piston
G-Dink 125i 2. Engine > Cylinders and Pistons Cylinders and Pistons SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Cylinder Block Removal Remove the engine from the frame. See the Engine Removal topic for more information. Remove the cylinder head cover. See the CylinderHead Cover topic for more information.
Page 149 2. Engine > Cylinders and Pistons G-Dink 125i Remove the two right side cylinder bolts with an 8 mm socket. Loosen the cylinder coolant hose clamp with a #2 Phillips screwdriver. Free the coolant hose from the cylinder.
Page 150 2. Engine > Cylinders and Pistons G-Dink 125i Slide the cylinder off of the studs and piston. Guide the cam chain through its opening and do not allow if to fall into the crankcase. Remove the cylinder. Remove the two cylinder dowel pins from the left studs.
Page 151 2. Engine > Cylinders and Pistons G-Dink 125i Remove the piston pin and the piston. Clean off the cylinder mating surface, but take care to keep debris from falling into the crankcase. Spread the piston rings and lift them off opposite the gap. Spread the rings the minimum amount during removal.
Page 152 2. Engine > Cylinders and Pistons G-Dink 125i The two upper rings are each a single piece of metal. The oil ring consists of an expander ring and two side rails. Clean the carbon build up off of the piston with a stiff bristled plastic...
Page 153 2. Engine > Cylinders and Pistons G-Dink 125i Also clean out the ring grooves. You can use an old ring to scrape out any carbon build up in the grooves. Inspection Inspect the cylinder bore for damage and abnormal wear...
Page 154 2. Engine > Cylinders and Pistons G-Dink 125i Measure the cylinder diameter as described below with a telescoping gauge. Inspect the cylinder front to back and side to side at three different height levels with a dial bore gauge. Item...
Page 155 2. Engine > Cylinders and Pistons G-Dink 125i Measure the outside diameter of the piston at 9 mm up from the bottom of the skirt at a 90° angle to the piston pin. Measure the piston with vernier calipers or a micrometer. Check the piston for wear, damage, and extreme discoloration.
Page 156 2. Engine > Cylinders and Pistons G-Dink 125i Measure the inside diameter of the small end of the connecting rod with vernier calipers. Item Standard (mm) Connecting rod small end I.D. Bore 15.016 - 15.034 Measure the ring groove width and the ring-to-groove clearance with feeler gauges.
Page 157 2. Engine > Cylinders and Pistons G-Dink 125i Insert the top ring into the cylinder. Push the top ring in the cylinder about an inch. Use the piston to push in the ring to keep it square with the cylinder.
Page 158 2. Engine > Cylinders and Pistons G-Dink 125i Check the oil way for clogs. Assembly Clean the piston ring grooves and apply fresh engine oil to the piston rings. Spread the rings the minimum amount possible to install them. Do...
Page 159 2. Engine > Cylinders and Pistons G-Dink 125i Install the top and second rings with their markings facing up. Install the rings to the piston as shown above so that no ring end gaps line up with the piston pin or perpendicular to the piston pin. The rings should turn easily on the piston without sticking or roughness.
Page 160 2. Engine > Cylinders and Pistons G-Dink 125i The "IN" mark should face the intake side (rear) of the engine. Place the piston over the connecting rod. Insert the piston pin into the piston and rod. Install new piston pin clips securely into their grooves. Turn the gap in...
Page 161 2. Engine > Cylinders and Pistons G-Dink 125i Make sure the cylinder head mating surface is clean. Install the two dowel pins as shown. Install the new base gasket onto the crankcase. Coat the inside of the cylinder, piston rings, and piston in fresh engine oil.
Page 162 2. Engine > Cylinders and Pistons G-Dink 125i Thread in the two cylinder bolts on the right side of the engine. Fit the coolant hose to the cylinder. Tighten the cylinder coolant hose clamp to securely with a #2 Phillips screwdriver.
Page 163: Oil Pump
G-Dink 125i 2. Engine > Oil Pump Oil Pump SAFETY FIRST: Protective gloves and eyewear are recommended at this point. GENERAL INSTRUCTIONS The maintenance of lubrication system can be performed with the engine installed in the frame. Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 164 G-Dink 125i 2. Engine > Oil Pump The oil pump is driven by a chain off of the crankshaft. Loosen the oil pump cover bolt with an 8 mm socket. Remove the oil pump cover bolt and the oil pump cover.
Page 165 G-Dink 125i 2. Engine > Oil Pump Remove the snap ring on the oil pump shaft with snap ring pliers. Remove the oil pump drive chain and driven sprocket. Inspect the oil pump drive chain and sprocket for signs of wear and...
Page 166 G-Dink 125i 2. Engine > Oil Pump Remove the two oil pump screws with an 10 mm socket. Remove the oil pump.
Page 167 G-Dink 125i 2. Engine > Oil Pump Turn the oil pump shaft by hand and make sure it turns smoothly. If the oil pump shaft will not rotate smoothly the oil pump should be replaced with a new unit. Oil Pump Installation Fit the oil pump into place so that the arrow is pointing up.
Page 168 G-Dink 125i 2. Engine > Oil Pump Fit the oil pump driven sprocket into the drive chain. Install the gear onto the oil pump shaft and fit the chain onto its teeth on the crankshaft. Install a new snap ring into its groove with snap ring pliers.
Page 169 G-Dink 125i 2. Engine > Oil Pump Tighten the oil pump cover bolt securely with an 8 mm socket. Install the starter driven gear, flywheel, and the generator cover. See the Generator topic. Fill the engine oil. See the Engine Oil topic for more information.
Page 170: Engine Removal
2. Engine > Engine Removal G-Dink 125i Engine Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. • 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 171 2. Engine > Engine Removal G-Dink 125i The regulator/rectifier is located on the left side of the vehicle. Disconnect the generator 3-pin connector. Disconnect the crank position sensor wire coupler. Unplug the water temperature sensor.
Page 172 2. Engine > Engine Removal G-Dink 125i Unplug the thermosensor unit and thermo unit ground connectors. Pull back the rubber starter motor lead cover. Remove the starter motor lead nut with a #2 Phillips screwdriver. Free the cable lead from the starter motor. Thread the screw back on to keep track...
Page 173 2. Engine > Engine Removal G-Dink 125i Loosen the fuel hose stay bolt with an 10 mm socket. Free the fuel hose stay from the cylinder head cover. Loosen the water pump hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the water pump.
Page 174 2. Engine > Engine Removal G-Dink 125i Loosen the main engine ground bolt with an 8 mm socket. Remove the bolt and free the engine ground from the right side of the engine. Free the starter motor lead from the stay.
Page 175 2. Engine > Engine Removal G-Dink 125i Loosen the engine mounting bracket damper nut with a 17 mm socket. Remove the nut and washer. Hold the engine mounting bolts with a 14 mm wrench and loosen the nuts with a 19 mm socket.
Page 176 2. Engine > Engine Removal G-Dink 125i Remove the engine mounting bracket damper bolt and nut. Remove the engine mounting bracket. Remove the engine mounting bracket damper assembly. Carefully move the engine back and separate it from the chassis. To install the engine see the Engine Installation topic.
Page 177: Engine Installation
2. Engine > Engine Installation G-Dink 125i Engine Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Before the engine is returned to the install the rear wheel. See the Rear Wheel topic for more information. Set the chassis on its center stand. Use a jack to support the engine.
Page 178 2. Engine > Engine Installation G-Dink 125i Install the two engine mounting bracket to frame mounting bolts and nuts. Insert the bolts from the outside of the frame. Insert the engine mounting bracket and damper bolt from the right side.
Page 179 G-Dink 125i 2. Engine > Engine Installation Hold the engine mounting bolts with a 14 mm wrench and torque the nuts to specification with a 17 mm socket. Torque Thread Item Remarks size (mm) kgf-m lb-ft Engine hanger: Frame side 6.0-7.0...
Page 180 2. Engine > Engine Installation G-Dink 125i Tighten the damper nut securely with a 14 mm socket. Install the rear shock absorbers. See the Shock Absorbers topic for more information. Route the starter motor lead to the starter motor and secure it in the stay.
Page 181 2. Engine > Engine Installation G-Dink 125i Fit the rubber starter motor lead cover into place. Install the main engine ground to the right side of the engine. Tighten the main engine ground bolt securely with an 8 mm socket.
Page 182 G-Dink 125i 2. Engine > Engine Installation Connect the coolant hose to the thermostat. Move the clamp into place and tighten it securely with a #2 Phillips screwdriver. Connect the coolant hose to the water pump. Move the clamp into place and tighten it securely with a #2 Phillips screwdriver.
Page 183 G-Dink 125i 2. Engine > Engine Installation Plug in the water temperature sensor connector. Connect the generator 3-pin connector for regulator/rectifier .
Page 184 G-Dink 125i 2. Quick Reference > Specifications KYMCO G-Dink 125i Specifications General Information Engine Head Item Standard (mm) Valve clearance (cold) 0.10 0.10 Cylinder head compression pressure 15 kg/cm , 214.5 psi Camshaft cam height 30.8763 30.4081 10 ─ 10.018 Valve rocker arm I.D.
Page 185 G-Dink 125i 2. Quick Reference > Specifications Crankshaft Standard (mm) Item 0.15 ─ 0.35 Connecting rod big end side clearance 0 ─ 0.008 Connecting rod big end radial clearance Standard (mm) Item 33 ─ 33.025 Movable drive face bushing I.D.
Page 186 G-Dink 125i 2. Quick Reference > Specifications COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Mixing Coolant Distilled Point Rate Concentrate Water -9°C 260 cc 1040 cc -15°C 390 cc 910 cc -25'°C 520 cc 780 cc -37°C 650 cc 650 cc -44.5°C...
Page 187 3. CVT Continuously Variable Transmission G-Dink 125i CVT Continuously Variable Transmission This chapter covers the location and servicing of the CVT components for the KYMCO Downtown 300i. • Belt Case • CVT Removal 8-23 • CVT Installation GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed.
Page 188 3. CVT Transmission > Belt Case G-Dink 125i Belt Case SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the following components - ◦ Seat ◦ Luggage Box ◦ Center Cover ◦ Rear Carrier ◦ Body Cover ◦...
Page 189 3. CVT Transmission > Belt Case G-Dink 125i Remove the belt case plastic cover bolts with an 8 mm socket. Remove the belt case cover bolts with an 8 mm socket. Use the pry points to free the belt case cover.
Page 190 3. CVT Transmission > Belt Case G-Dink 125i Remove the belt case cover and gasket. Remove the two dowel pins. Inspection Inspect the drive belt for cracks or excessive wear.
Page 191 3. CVT Transmission > Belt Case G-Dink 125i Installation Install the two dowel pins into the belt case. Install a new gasket with the belt case cover.
Page 192 3. CVT Transmission > Belt Case G-Dink 125i Install the belt case cover bolts and tighten them securely with an 8 mm socket. Insert the plastic cover bolts and tighten them securely with an 8 mm socket.
Page 193 3. CVT Transmission > Belt Case G-Dink 125i Fit the drain hose to the plastic belt case cover as shown. Install the following components - ◦ Foot Skirt ◦ Front Lower Cover ◦ Front Cover ◦ Body Cover ◦ Rear Carrier ◦...
Page 194 3. CVT Transmission > CVT Removal G-Dink 125i CVT Removal SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the belt case. See the Belt Case topic for more information. Pulleys and Belt Hold the drive pulley with a universal holder tool and loosen the nut with a 17 mm socket.
Page 195 3. CVT Transmission > CVT Removal G-Dink 125i Remove the left face of the drive pulley. Loosen the driven pulley nut with a 17 mm socket. Remove the driven pulley nut.
Page 196 3. CVT Transmission > CVT Removal G-Dink 125i Slide the driven pulley off of the shaft. Remove the belt from the driven pulley.
Page 197 3. CVT Transmission > CVT Removal G-Dink 125i Inspect the drive belt for cracks or excessive wear. Remove the right (movable) face of the drive pulley from the crankshaft. Slide the bushing out of the movable drive face. Drive Pulley Disassembly Inspect the faces of the drive pulley.
Page 198 3. CVT Transmission > CVT Removal G-Dink 125i Lift the ramp plate out of the back of the left drive pulley face. Remove the rubber damper pieces from the ramp. There are six weight rollers in the back of the right face of the drive...
Page 199 3. CVT Transmission > CVT Removal G-Dink 125i Remove the rollers and check them for excessive or uneven wear. Measure the outside diameter of the rollers. Replace the weight rollers as needed. Item Standard (mm) Service Limit (mm) Weight roller O.D (Drive Pulley) 15.9 ±...
Page 200 3. CVT Transmission > CVT Removal G-Dink 125i Inspect the inside of the clutch outer for excessive wear and damage. Measure the inside diameter of the clutch outer and replace the part as needed. Item Standard (mm) Service Limit (mm) Clutch outer I.D.
Page 201 3. CVT Transmission > CVT Removal G-Dink 125i Fit the clutch and fitting tool into the clutch spring compressor tool. Use the clutch spring compressor tool to compress the spring in the driven pulley assembly. Loosen the clutch drive plate nut with the special socket that comes with the fitting tool.
Page 202 3. CVT Transmission > CVT Removal G-Dink 125i Inspect the left side bearing by turning it with a finger. If the bearing is rough turning or noisy it should be replaced. Remove the clutch spring compressor tool. Lift off the centrifugal clutch.
Page 203 3. CVT Transmission > CVT Removal G-Dink 125i Measure the free length of the clutch spring. Replace the spring if the measurement fails to meet the service limit. Remove the three circlips from the clutch pivot pins with a small flat...
Page 204 3. CVT Transmission > CVT Removal G-Dink 125i Lift off the plate. Slide the clutch shoes off of the pivots on the drive plate. Inspect the clutch shoe bumpers and replace them as needed.
Page 205 3. CVT Transmission > CVT Removal G-Dink 125i Driven Pulley Disassembly Remove the clutch as shown above. Remove the four guide rollers with guide roller pins. Separate the left and right faces of the driven pulley.
Page 206 3. CVT Transmission > CVT Removal G-Dink 125i Inspect the faces of the driven pulley. Clean away any grease from the faces where the belt rides. Remove the seals from the left face of the driven pulley. Drive in the new seals with a suitable driver with the same outside...
Page 207 3. CVT Transmission > CVT Removal G-Dink 125i Remove the O-rings on the left face. Clean the left face and roller pins with a high flash point solvent and compressed air. NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else.
Page 208 3. CVT Transmission > CVT Removal G-Dink 125i Remove the needle bearing with a suitable puller. Remove the collar, snap ring, and bearing from the right face of the driven pulley. Clean the right face with a high flash point solvent and compressed air.
Page 209 3. CVT Transmission > CVT Removal G-Dink 125i Drive in the new baring so the sealed side face out towards the clutch. Install the snap ring into the groove. Install the collar and drive in the new needle bearing so that its markings face out. Drive in the bearings with a suitable driver with the same outside diameter as the bearing.
Page 210 3. CVT Transmission > CVT Installation G-Dink 125i CVT Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Driven Pulley Lubricate the bearings in the right face of the driven pulley with grease. Drive in the new seals with a suitable driver with the same outside...
Page 211 4. Cooling System G-Dink 125i Cooling System This chapter covers the location and servicing of the cooling system components for the KYMCO G-Dink 125i. • Coolant • Radiator 9-22 • Radiator cover 23-24 • Thermostat 25-33 • Water Pump 34-42 GENERAL INSTRUCTIONS •...
Page 212 4. Cooling System > Coolant G-Dink 125i Coolant SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Allow the engine sufficient time to cool before handling or working on the cooling system components. To check the coolant level see the Coolant Level Check topic for more information.
Page 213 4. Cooling System > Coolant G-Dink 125i Remove the radiator cap in two stages. Allow any built up pressure to vent and then open the cap all the way and remove it. The water pump is located on the right side of the engine. Ready a drain pan under the water pump drain bolt.
Page 214 4. Cooling System > Coolant G-Dink 125i Remove the drain bolt and sealing washer and allow the coolant to drain into a suitable container. The coolant reserve tank is under the legshield. Remove the engine coolant lid screw with a #2 Phillips.
Page 215 4. Cooling System > Coolant G-Dink 125i Tighten the drain bolt securely with an 8 mm socket. Filling Radiator: 1000±50 cc Coolant capacity Total 1300 cc Reserve tank: 300 cc • Use coolant of specified mixing rate. (The mixing rate of 520cc coolant concentrate is 40% + 780cc distilled water is 60%.)
Page 216 4. Cooling System > Coolant G-Dink 125i Fill the cooling system with a mix of distilled water and Coolant Concentrate. Continue filling until the coolant until it reaches the bottom of the filler neck as shown. Add coolant to the reserve tank until it reaches the upper level mark.
Page 217 4. Cooling System > Coolant G-Dink 125i When the air bubbles stop coming up turn off the engine and recheck the coolant level, add coolant if necessary. Check the reserve tank and add coolant if needed. Wet the seal of the radiator cap and install.
Page 218 4. Cooling System > Coolant G-Dink 125i Install the radiator cap access panel. Install the radiator coolant panel screws and tighten securely with a #2 Phillips screwdriver. Install the windshield. See the Windshield topic for more information.
Page 219 4. Cooling System > Radiator G-Dink 125i Radiator SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: Allow the engine sufficient time to cool before handling or working on the cooling system components. Pressure Testing Remove the windshield. See the Windshield topic for more information.
Page 220 4. Cooling System > Radiator G-Dink 125i Remove the radiator cap in two stages. Allow any built up pressure to vent and then open the cap all the way and remove it. When checking the cooling system for leaks you will need a pressure tester.
Page 221 4. Cooling System > Radiator G-Dink 125i Removal Remove the front cover. See the Front Cover topic for information. Remove the right and left front lower covers. See the Front Lower Cover topic for information. Remove the radiator cover. See the Radiator Cover topic for more information.
Page 222 4. Cooling System > Radiator G-Dink 125i Loosen the coolant hose clamps with a #2 Phillips screwdriver. Free the filler neck coolant hose from the stay and remove it from the radiator. Remove the water pump and thermostat hoses in the same manner.
Page 223 4. Cooling System > Radiator G-Dink 125i Remove the two radiator mounting bolts with a 10 mm socket. Slide the radiator to the left and free the grommet from the post above the right side of the radiator.
Page 224 4. Cooling System > Radiator G-Dink 125i Remove the radiator from the frame. Coolant Reserve Tank The coolant reserve tank is mounting to the frame with a bolt. There are two hoses that connect to the reserve tank. The top hose is a dump hose that hangs over the other side.
Page 225 4. Cooling System > Radiator G-Dink 125i Position a suitable container below the reserve tank. Pull back the clamp and free the overflow hose from the bottom of the reserve tank. Allow the coolant in the reserve tank to drain into the container.
Page 226 4. Cooling System > Radiator G-Dink 125i Remove the reserve tank from the frame. Inspection Inspect the radiator fins for damage and clogging. To remove the fan take out the three mounting bolts with a 10 mm socket. Clean out the fins with low pressure compressed air and water.
Page 227 4. Cooling System > Radiator G-Dink 125i NOTE: Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else. Check the radiator for any bent or damaged fins. Use a small flat blade screwdriver to straighten them out, but be careful not to puncture the radiator.
Page 228 4. Cooling System > Radiator G-Dink 125i If the thermostatic switch needs to be removed use a 22 mm wrench. The thermostatic switch should be off below 85°C (185°F) and on above 90°C (194°F). Installation Coolant Reserve Tank Fit the reserve tank onto the frame.
Page 229 4. Cooling System > Radiator G-Dink 125i Insert the reserve tank mounting bolt and tighten them securely with a 10 mm socket. Connect the dump hose to the top of the reserve tank and the overflow hose to the bottom. Secure the hoses with the clamps.
Page 230 4. Cooling System > Radiator G-Dink 125i Fit the radiator into place so that the post on the frame fits into the rubber grommet on the right side of the radiator. Install the two radiator mounting bolts and tighten them securely with a...
Page 231 4. Cooling System > Radiator G-Dink 125i Route the filler neck coolant hose through the guide to the top right of the radiator. Connect the coolant hose from the thermostat on the cylinder head to the top left of the radiator. Connect the coolant hose from the water pump to the bottom right of the radiator.
Page 232 4. Cooling System > Radiator G-Dink 125i Plug in the cooling fan motor connector. Plug in the thermostatic switch connectors. Fill and bleed the coolant. See the Coolant topic for more information. Install the radiator cover. See the RadiatorCovertopic for more information.
Page 233 4. Cooling system > Radiator Cover G-Dink 125i Radiator Cover SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the right and left front lower covers. See the Front Lower Cover topic for information. Remove the four bolts from the bottom of the radiator cover.
Page 234 4. Cooling system > Radiator Cover G-Dink 125i Installation Install the radiator cover. Install the four bolts. Install the right and left front lower covers. See the Front Lower Cover topic for information.
Page 235 4. Cooling System > Thermostat G-Dink 125i Thermostat and Thermosensor SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Drain the coolant. See the Coolant topic for more information. Remove the seat. See the Seat topic for more information.
Page 236 4. Cooling System > Thermostat G-Dink 125i Remove the thermosensor unit with a 12 mm deep well socket Water Temperature Sensor (WTS) Unplug the water temperature sensor. Use a 17 mm wrench to remove the water temperature sensor.
Page 237 4. Cooling System > Thermostat G-Dink 125i Discard the WTS O-ring and replace it with a new item. Thermostat Loosen the thermostat hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the thermostat.
Page 238 4. Cooling System > Thermostat G-Dink 125i Remove the two thermostat mounting bolts with an impact #3 Phillips screwdriver. Lift off the thermostat cover. Lift out the thermostat. Remove the thermostat O-ring and discard it.
Page 239 4. Cooling System > Thermostat G-Dink 125i Inspection Thermosensor Set a digital multimeter to read ohms of resistance Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up. Do not allow the thermosensor or the thermometer to contact the sides of the pan.
Page 240 4. Cooling System > Thermostat G-Dink 125i Suspend the thermostat and a thermometer in a pot of water with string. Make sure the thermostat and the thermometer are not touching the pot. Bring the temperature up to the specification slowly and check the operation of the thermostat.
Page 241 4. Cooling System > Thermostat G-Dink 125i Plug in the thermosensor unit and ground connectors. Water Temperature Sensor Install the WTS with a new O-ring. Tighten the WTS to specification with a 17 mm wrench. Plug in the water temperature sensor connector.
Page 242 4. Cooling System > Thermostat G-Dink 125i Thermostat Make sure the thermostat seal is in good condition. Replace the thermostat if needed. Apply a light coat of waterproof grease to the thermostat seal. Insert the thermostat into its cavity in the cylinder head.
Page 243 4. Cooling System > Thermostat G-Dink 125i Insert the two thermostat bolts and tighten them securely with an impact #3 Phillips screwdriver. Install air bleed hose and secure it with the clamp. Connect the coolant hose to the thermostat. Move the clamp into place and tighten it securely with a #2 Phillips screwdriver.
Page 244 4. Cooling System > Water Pump G-Dink 125i Water Pump SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Mechanical Seal Inspection Inspect the telltale hole in the generator cover below the water pump for signs of coolant leaking. If there is coolant coming from this hole the mechanical seal is compromised and must be replaced.
Page 245 4. Cooling System > Water Pump G-Dink 125i Drain the coolant. See the Coolant topic for more information. Loosen the water pump hose clamp with a #2 Phillips screwdriver. Slide up the clamp and free the coolant hose from the water pump. Allow any remaining coolant to drain into a suitable container.
Page 246 4. Cooling System > Water Pump G-Dink 125i Remove the two dowel pins and the water pump cover gasket. Impeller and Shaft Remove the generator cover. See the Generator topic for more information. Hold the water pump shaft and loosen the impeller with a 12 mm socket.
Page 247 4. Cooling System > Water Pump G-Dink 125i Remove the seal washer from the back of the impeller. Inspect the impeller blades and seal. Replace the seal washer if the mechanical seal is to be replaced. Remove the water pump shaft from the generator cover.
Page 248 4. Cooling System > Water Pump G-Dink 125i Assembly Seals, Shaft, and Impeller Coat the lips of the new oil seal in fresh engine oil and drive it in with a suitable drive that is the same outside diameter as the oil seal.
Page 249 4. Cooling System > Water Pump G-Dink 125i Place the washer and thrust washer on the water pump shaft. Install a new snap ring onto the water pump shaft if the snap ring was removed. Lubricate the water pump shaft with fresh engine oil where it will ride in the case.
Page 250 4. Cooling System > Water Pump G-Dink 125i Install the impeller to the water pump shaft. Note: Left hand threads. Hold the water pump shaft and tighten the impeller to specification with a 12 mm socket. Remember the impeller has left hand threads.
Page 251 4. Cooling System > Water Pump G-Dink 125i Install the water pump cover and insert the four bolts. Tighten the water pump cover bolts to specification with an 8 mm socket. Connect the coolant hose to the water pump. Move the clamp into place and tighten it securely with a #2 Phillips screwdriver.
Page 252 4. Cooling System > Water Pump G-Dink 125i Fill the coolant and bleed the coolant. See the Coolant topic for more information. Foot Skirt Front LowerCover Front Cover Body Cover RearCarrier CenterCover Luggage Box Seat...
Page 253 5. Final Drive G-Dink 125i Final Drive This chapter covers the location and servicing of the final drive components for the KYMCO G-Dink 125i. • Final Reduction • Final Drive Oil GENERAL INSTRUCTIONS • The servicing operations of this section can be made with the engine installed.
Page 254 5. Final Drive > Transmission Oil G-Dink 125i Final Drive Oil SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Place the scooter on level ground and up on its center stand. The oil drain bolt and oil filler bolt are located on the transmission.
Page 255 5. Final Drive > Transmission Oil G-Dink 125i Remove the transmission oil level check bolt with a 12 mm socket. The oil level is correct when oil flows from the bolt hole. Install the oil level check bolt and tighten it to specification with a 12 mm socket.
Page 256 5. Final Drive > Transmission Oil G-Dink 125i Place a suitable container under the drain plug to capture the final drive oil. Loosen the oil drain plug with a 12 mm socket. Remove the drain plug and slowly rotate the rear wheel to drain the transmission oil.
Page 257 5. Final Drive > Transmission Oil G-Dink 125i Install the oil drain plug and washer with a 12 mm socket. Tighten to specification. Torque Thread Item size (mm) kgf-m lb-ft 0.8-1.2 5.79-8.68 Final drive oil drain bolt Filling Fill the final drive oil with a syringe until oil begins to flow from the level check bolt hole.
Page 258 5. Final Drive > Transmission Oil G-Dink 125i Thread in the final drive oil level check bolt. Install the oil check plug and torque it to specification with a 12 mm socket. Torque Thread Item kgf-m lb-ft size (mm) Final drive oil check bolt 0.8 - 1.2...
Page 259 6. Wheels G-Dink 125i Wheels This chapter covers the location and servicing of the wheels for the KYMCO G-Dink 125 . • Front Wheel • Rear Wheel 7-15 • Wheel Inspection 16-17 • Bearing Replacement 18-21 Troubleshooting Front wheel wobbling •...
Page 260 6. Wheels > Front Wheel G-Dink 125i Front Wheel SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Loosen the front axle with an 8 mm socket. Lift the front end of the vehicle with a suitable stand or jack so that the...
Page 261 6. Wheels > Front Wheel G-Dink 125i Support the front wheel and slide the front axle out from the left side. Guide the front wheel out from the fork legs and the brake disc out from between the pads. Do not squeeze the brake lever while the disc is not...
Page 262 6. Wheels > Front Wheel G-Dink 125i Remove the collars from right side of the wheel. Inspect the bearing seals and the O-rings seals on the collars. Replace the seals if they are in poor condition. Inspect the wheels and axle. See the Wheel Inspection topic for more information.
Page 263 6. Wheels > Front Wheel G-Dink 125i Make sure the tire direction of rotation marker is correct. Slide the front wheel into the fork. Fit the brake disc between the brake pads in the front caliper. Apply a light coat of grease to the front axle. Insert the axle from the left side.
Page 264 6. Wheels > Front Wheel G-Dink 125i Torque the axle to specification with an 8 mm Allen. Thread Torque Item size (mm) kgf-m lb-ft Front axle 1.5-2.5 10.84-18.08 Pump the front brake lever to establish pressure and to seat the pads against the disc. If the Brakes do not pump up correctly check the brake fluid.
Page 265 5. Wheels > Rear Wheel G-Dink 125i SAFETY FIRST: Protective gloves and eyewear are recommended at this point. • When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding. • During servicing, keep oil or grease off the brake pads and brake disk.
Page 266 5. Wheels > Rear Wheel G-Dink 125i Move the rear shock out of the way. Hold the rear brake to keep the rear wheel from turning. Remove the rear axle nut with a 24 mm socket. Remove the rear brake caliper. See the Rear Brake Caliper topic for more information.
Page 267 5. Wheels > Rear Wheel G-Dink 125i Slide the rear fork out and remove it from the right side of the vehicle. Remove the rear axle washer from the right side of the rear axle.
Page 268 5. Wheels > Rear Wheel G-Dink 125i To remove the rear wheel support the right rear shock absorber so that it is out of the way or remove it. Remove the upper shock absorber mounting bolt with a 12 mm socket.
Page 269 5. Wheels > Rear Wheel G-Dink 125i Installation Line up the splines on the rear wheel with those of the rear axle. Slide the rear wheel on to the axle so that the brake disc sits on the right side.
Page 270 5. Wheels > Rear Wheel G-Dink 125i Fit the rear fork into place. Install the two rear fork mounting bolts and tighten them securely with a 14 mm socket.
Page 271 5. Wheels > Rear Wheel G-Dink 125i Install the rear axle nut and tighten it to specification with a 24 mm socket. Torque Thread Item Remarks size (mm) kgf-m lb-ft Rear axle nut 11-13 79.56-94.03 U-nut Fit the shock absorber into place. Make sure the preload arrow indicator...
Page 272 5. Wheels > Rear Wheel G-Dink 125i Install the upper shock absorber mounting bolt and torque it to specification with a 12 mm socket. Torque Item kgf-m lb-ft shock absorber mounting bolt 28.93...
Page 273 5. Wheels > Rear Wheel G-Dink 125i Install the lower shock absorber mounting bolt and torque it to specification with a 12 mm socket. Torque Item kgf-m lb-ft shock absorber mounting bolt 28.93 Install the rear brake caliper. See the Rear Brake Caliper topic for more information.
Page 274 6. Wheels > Wheel Inspection G-Dink 125i Wheel Inspection SAFETY FIRST: Protective gloves and eyewear are recommended at this point. 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 275 6. Wheels > Wheel Inspection G-Dink 125i Check for radial hop. The service limit is 2.0 mm (0.08 in) or less. Check the front axle runout. The axle runout specification is half of the total indicator reading. Replace the axle if the measurement exceeds 0.2 mm or 0.008 in.
Page 276 6. Wheels > Bearing Replacement G-Dink 125i Wheel Bearing Replacement SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Replace bearings as a set, and do not reuse old bearings. Place the new bearings in the freezer about an hour before you plan to install them.
Page 277 6. Wheels > Bearing Replacement G-Dink 125i Remove one of the bearings with a bearing puller. Special Tools- Bearing Puller: E00037 Remove the distance collar. Repeat the procedure and remove the other bearing and seal. The seal should be replaced with a new item.
Page 278 6. Wheels > Bearing Replacement G-Dink 125i Heat the bearing area of the wheel with a heat gun, take the bearing out of the freezer and install it. You can use a bearing installer tool or a socket with the same outside diameter as the bearing. Make sure the bearing is fully seated and the marked side is facing out.
Page 279 6. Wheels > Bearing Replacement G-Dink 125i Drive in the other bearing. The bearing should fit against the distance collar. Do not continue to force the bearing in or the distance collar will begin to push the right bearing back out.
Page 280 7. Steering G-Dink 125i Steering This chapter covers the location and servicing of the steering components for the KYMCO G-Dink 125i. • Steering Stem and Bearing Removal • Steering Stem and Bearing Installation 8-12 • Handlebar 13-21 TROUBLESHOOTING Hard steering (heavy) •...
Page 281 If the movement is to tight or loose the steering stem adjusting nut may need to be adjusted. The KYMCO G-Dink 125i uses ball bearings in the steering. Always replace the races at the same time as the bearings.
Page 282 7. Steering > Removal G-Dink 125i A special lock nut wrench is needed to loosen the steering stem lock nut. Special Tool - Lock Nut Wrench: A120F00002 Slide the special tool over the steering stem and loosen the lock nut.
Page 283 7. Steering > Removal G-Dink 125i Slide off the lock washer. Support the steering stem and loosen the steering stem adjusting nut with a pin spanner. Remove the steering stem adjusting nut.
Page 284 7. Steering > Removal G-Dink 125i Remove the dust cover and grease seal. Lower the steering stem out of the frame. Remove the upper bearing inner race.
Page 285 7. Steering > Removal G-Dink 125i Lift out the upper ball bearings. Slide the lower ball bearings up and off of the steering stem. Inspect the bearings and races for wear and damage. Replace them as needed. Use a chisel to remove the bottom bearing inner race and dust seal. Do...
Page 286 7. Steering > Removal G-Dink 125i Use the special tools or a drift and hammer to drive out the bearing races in the steering head. Have the drift set against the lip of the race, and work around the race evenly to drive it out.
Page 287 7. Steering > Installation G-Dink 125i Steering Stem Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Coat the new dust seal in grease and slide it down the steering stem. Drive the new lower bearing inner race onto the steering stem with a pipe with the same outside diameter as the bearing race.
Page 288 7. Steering > Installation G-Dink 125i Lubricate the upper bearing with grease and set it into place. Lubricate the new lower bearing with grease and place it on the steering stem. Set the upper bearing inner race into the upper bearing.
Page 289 7. Steering > Installation G-Dink 125i Guide the steering stem into the steering head of the frame. Lubricate the grease seal with grease. Set the grease seal and dust cover into place over the steering stem. Thread on the steering stem adjusting nut.
Page 290 7. Steering > Installation G-Dink 125i Tighten the steering stem adjusting nut. Turn the steering stem lock-to- lock several times to seat the bearings. Loosen the adjusting nut 1/4 to 1/2 half turn. Adjust the nut so the steering moves correctly. The adjusting nut should be tight enough so that the steering doesn't flop back and forth and vertical movement is eliminated.
Page 291 7. Steering > Installation G-Dink 125i Torque the steering stem lock nut to specification with the lock nut wrench special tool. Torque Thread Item kgf-m lb-ft size (mm) Steering Stem lock nut 6.0-6.5 43.40-46.80 Special Tool - Lock Nut Wrench: A120F00002 Install the front fork.
Page 292 7. Steering > Handlebar G-Dink 125 Handlebar SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the handlebar covers. See the Handlebar Covers topic for more information. Remove the front cover. See the Front Cover topic for more information. Bar Ends Remove the bar ends with a 6 mm Allen.
Page 293 7. Steering > Handlebar G-Dink 125 Separate the switch housing from the handlebar. Disconnect the throttle cables and free the right switch housing from the handlebar. Slide off the throttle grip. Remove the two left switch housing mounting screws with a #2 Phillips screwdriver.
Page 294 7. Steering > Handlebar G-Dink 125 Disconnect the switch. Separate the left switch housing from the handlebar. Handlebar Route the cables and lines from the handlebar cable guide.
Page 295 7. Steering > Handlebar G-Dink 125 Hold the handlebar lock bolt with a 14 mm wrench and loosen the nut with a 17 mm socket. Remove the handlebar lock nut and bolt. Remove the handlebar.
Page 296 7. Steering > Handlebar G-Dink 125 Grips If you plan to replace the grips you can slice them lengthwise with a razor blade and peel them off. To remove the grips without cutting them use a screwdriver to open a gap between the grip and the handlebar. Spray in contact cleaner to break up the grip cement.
Page 297 7. Steering > Handlebar G-Dink 125 Install the handlebar onto the steering stem and align the holes. Install the handlebar lock bolt and thread on the nut. Hold the handlebar lock bolt with a 14 mm wrench and tighten the nut to specification with a 17 mm socket.
Page 298 7. Steering > Handlebar G-Dink 125 Route the cables and lines through the handlebar cable guide. Switch Housings and Throttle Align the left switch housing and install on the handlebar. Insert the two housing screws and tighten them securely with a #2 Phillips screwdriver.
Page 299 7. Steering > Handlebar G-Dink 125 Slide the throttle grip onto the right side of the handlebar. Install the right switch and throttle housing. The post on the housing should fit into the hole in the bar. Lubricate the end of the throttle in grease. Fit the ends of the throttle cables into the throttle tube.
Page 300 7. Steering > Handlebar G-Dink 125 Insert the two housing screws and tighten them securely with a #2 Phillips screwdriver. Tighten the front bolt before the rear. Install the brake master cylinders. See the Master Cylinders topic for more information. Bar Ends Install the bar ends with a 6 mm Allen.
Page 301 8. Brakes G-Dink 125i Brakes This chapter covers the location and servicing of the brake system components for the KYMCO G-Dink 125i. • Master Cylinders 2-10 • Front Caliper 11-18 • Discs Brakes 19-25 • Brake Pad Replacement 26-35 GENERAL INSTRUCTIONS •...
Page 302 8. Brakes > Master Cylinders G-Dink 125i Master Cylinders SAFETY FIRST: Protective gloves and eyewear are recommended at this point. NOTE: Brake fluid is a corrosive chemical and can damage paints and some plastics. Avoid contact with skin. Removal The master cylinders for the front and rear brakes are essentially the same.
Page 303 8. Brakes > Master Cylinders G-Dink 125i Unplug the brake light switch connector. Remove the two master cylinder mounting bolts with an 8 mm socket. Remove the master cylinder clamp. Remove the master cylinder.
Page 304 8. Brakes > Master Cylinders G-Dink 125i Remove the two master cylinder cover screws with a #2 Phillips head screwdriver. Remove the master cylinder cover, plastic piece and rubber accordion diaphragm. Pour out any remaining brake fluid. Disassembly Brake Levers...
Page 305 8. Brakes > Master Cylinders G-Dink 125i Loosen the brake lever pivot nut with a 10 mm socket and the pivot bolt with a flat blade screwdriver. Remove the pivot nut and bolt.
Page 306 8. Brakes > Master Cylinders G-Dink 125i Remove the brake lever. Brake Light Switch Remove the brake light switch mounting bolt with a #2 Phillips screwdriver. Remove the brake light switch.
Page 307 8. Brakes > Master Cylinders G-Dink 125i Brake Light Switch Install the brake light switch. Tighten the mounting screw securely with a #2 Phillips screwdriver. Brake Levers Install the brake lever.
Page 308 8. Brakes > Master Cylinders G-Dink 125i Apply a light coat of grease to brake lever pivot bolt. Insert the pivot bolt from above and thread on the nut. Tighten the brake lever bolt with a flat blade screwdriver and then tighten the nut with a 10 mm socket.
Page 309 8. Brakes > Master Cylinders G-Dink 125i Install the master cylinder clamp. Be sure to insert the pin on the clamp into the hole on the handlebar. Install the two master cylinder mounting bolts and tighten them securely with an 8 mm socket.
Page 310 8. Brakes > Master Cylinders G-Dink 125i Install the brake hose to the master cylinder with the banjo bolt. Use new sealing washers. Tighten the banjo bolt to specification with a 12 mm socket. Torque Item lb-ft Banjo bolt 25.8 Fill the master cylinder reservoir/s with brake fluid and bleed the system.
Page 311 8. Brakes > Front Brake Caliper G-Dink 125i Front Caliper SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Loosen the brake pad pin with a 5 mm Allen. Drain the brake fluid if the caliper is to be disassembled. See the Brake Fluid topic for more information.
Page 312 8. Brakes > Front Brake Caliper G-Dink 125i Place a suitable container under the banjo bolt to catch any remaining brake fluid. Remove the banjo bolt that holds the brake hose to the caliper using a 12 mm socket. Discard the two sealing washers.
Page 313 8. Brakes > Front Brake Caliper G-Dink 125i Brake Pad Removal Remove the brake pad pin. Remove the brake pads. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven.
Page 314 8. Brakes > Front Brake Caliper G-Dink 125i Disassembly Remove the pad spring. Remove the pad retainer from the brake caliper bracket. Place a 1/4" thick strip of wood or a shop rag between the caliper pistons and the inside surface of the brake caliper. Blow compressed air into the banjo bolt opening to remove the caliper pistons.
Page 315 8. Brakes > Front Brake Caliper G-Dink 125i Assembly NOTE: Brake fluid is a corrosive chemical and can damage paints and some plastics. Avoid contact with skin. Install the pad retainer clip onto the caliper bracket. Install the brake pad spring as shown. Note the long middle tab on the spring points toward the caliper pistons.
Page 316 8. Brakes > Front Brake Caliper G-Dink 125i Fit the ends of the pads into the pad retainer as shown. Apply a light coat of waterproof grease to the brake pad pin. Push the pads against the pad spring and insert the brake pad pin.
Page 317 8. Brakes > Front Brake Caliper G-Dink 125i Installation Install the front caliper. Guide the brake disc between the pads. Line up the caliper bracket mounts with the fork. Install the two caliper bracket mounting bolts. Tighten the mounting bolts to specification.
Page 318 8. Brakes > Front Brake Caliper G-Dink 125i Torque Item lb-ft Banjo bolt 25.8 Tighten the brake pad pin securely with a 5 mm Allen. Refill and bleed the brake fluid. See the Brake Fluid topic for more information. Pump the brake lever to seat the caliper pistons against the pads. Check...
Page 319 8. Brakes > Brake Disc G-Dink 125i Disc Brake SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Inspection Measure the thickness of the brake rotor with a Vernire caliper or micrometer. ITEM STANDARD SERVICE LIMIT 4±0.2mm 3.7mm Brake disc thickness (0.16±0.008in)
Page 320 8. Brakes > Brake Disc G-Dink 125i Check if the brake rotor runout is within service limit. Measure the runout of the brake disc with a dial gauge. If the reading is out of specification remove the disc from the wheel and recheck.
Page 321 8. Brakes > Brake Disc G-Dink 125i Remove the five brake disc mounting bolts with an Allen wrench. Remove the front brake disc.
Page 322 8. Brakes > Brake Disc G-Dink 125i Inspect the brake disc for wear and damage. Replace the parts as needed. Set the front brake disc in place on the front wheel. Installation Coat the threads of the disc bolts in a non-permanent thread locking agent.
Page 323 8. Brakes > Brake Disc G-Dink 125i Insert the front brake disc mounting bolts. Tighten the bolts to specification with an Allen socket. Torque Thread Item kgf-m lb-ft size (mm) Disk bolt 3.2-3.8 23.15-27.48 Install the front wheel. See the Front Wheel topic for more information.
Page 324 8. Brakes > Brake Disc G-Dink 125i Remove the five brake disc mounting bolts with an Allen wrench. Lift the brake disc off of the rear wheel.
Page 325 8. Brakes > Brake Disc G-Dink 125i Installation Coat the threads of the disc bolts in a non-permanent thread locking agent. Thread in the bolts and torque them to specification with an Allen socket. Set the rear brake disc in place as shown.
Page 326 8. Brakes > Brake Pad Replacement G-Dink 125i Brake Pad Replacement SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven.
Page 327 8. Brakes > Brake Pad Replacement G-Dink 125i Remove the two caliper mounting bolts with a 12 mm socket. Remove the front caliper. Remove the brake pad pin.
Page 328 8. Brakes > Brake Pad Replacement G-Dink 125i Remove the brake pads. Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven. Insert new brake pads as needed. Fit the ends of the pads into the pad retainer as shown.
Page 329 8. Brakes > Brake Pad Replacement G-Dink 125i Apply a light coat of waterproof grease to the brake pad pin. Push the pads against the pad spring and insert the brake pad pin. It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the new pads.
Page 330 8. Brakes > Brake Pad Replacement G-Dink 125i Install the two caliper bracket mounting bolts. Tighten the mounting bolts to specification. Torque Item lb-ft Front/Rear caliper bolt 25.8 Tighten the brake pad pin securely with a 5 mm Allen. Pump the brake lever to seat the caliper pistons against the pads.
Page 331 8. Brakes > Brake Pad Replacement G-Dink 125i Rear Remove the muffler. See the Exhaust System topic for more information. If the caliper is to be disassembled the brake hose must be removed. Drain the rear brake fluid. See the Brake Fluid topic for more information.
Page 332 8. Brakes > Brake Pad Replacement G-Dink 125i Remove the two rear caliper mounting bolts with a 12 mm socket. Remove the rear caliper from the swingarm. One at a time, move the brake pads to the center gap in the pad retainers and lift the pad out.
Page 333 8. Brakes > Brake Pad Replacement G-Dink 125i Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven. One at a time, fit the brake pads into the center gap in the pad retainers and then move the pad into the retainer.
Page 334 8. Brakes > Brake Pad Replacement G-Dink 125i Install the two caliper bracket mounting bolts. Tighten the mounting bolts to specification. Torque Item lb-ft Front/Rear caliper bolt 25.8...
Page 335 8. Brakes > Brake Pad Replacement G-Dink 125i Fit the rear brake hose guide into place. Insert the rear brake hose clamp bolts and tighten them securely with a 8mm socket. Fill the rear brake system with fresh brake fluid and bleed out the air.
Page 336 9. Front Suspension G-Dink 125i Front Suspension This chapter covers the location and servicing of the front fork components for the KYMCO G-Dink 125i. • Front Fork Removal and Installation • Fork Disassembly 6-15 • Fork Assembly 16-22 TROUBLESHOOTING Soft front shock absorber •...
Page 337 9. Front Suspension > Front Fork Removal G-Dink 125i Front Fork Removal and Installation SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the front cover. See the Front Cover topic for more information. Remove the front fender. See the Front Fender topic for more information.
Page 338 9. Front Suspension > Front Fork Removal G-Dink 125i Loosen the fork clamp pinch bolts with a 12 mm socket. The top bolts must be removed. Slide the forks legs down and out of the fork clamp using a twisting motion.
Page 339 9. Front Suspension > Front Fork Removal G-Dink 125i Installation Slide the fork legs up into fork clamp using a twisting motion. Install the fork legs so that the upper fork clamp bolt hole lines up with the groove on the inner fork tube. Insert the fork clamp upper bolt.
Page 340 9. Front Suspension > Front Fork Removal G-Dink 125i Tighten the fork clamp bolts securely and evenly with a 12 mm socket. Install the front wheel. See the Front Wheel topic for more information. Install the front brake caliper. See the Front Caliper topic for more information.
Page 341 9. Front Suspension > Fork Disassembly G-Dink 125i Fork Disassembly SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the front forks. See the Front Fork Removal and Installation topic for more information. Clean the outside of the forks before disassembly and inspect them for...
Page 342 9. Front Suspension > Fork Disassembly G-Dink 125i Remove the rubber fork cap. Place the fork leg in a soft jawed vice. Push down on the top plug and remove the snap ring.
Page 343 9. Front Suspension > Fork Disassembly G-Dink 125i Remove the top plug. Lift out the fork spring. Dump the fork oil into a suitable container. Pump the fork through its stroke several times to free as much oil as possible. Hold the fork...
Page 344 9. Front Suspension > Fork Disassembly G-Dink 125i Use a flat blade screwdriver to pop the dust seal out of the fork slider. Take care to avoid scratching the fork tube. Use a small flat blade screwdriver to pry out the fork oil seal stopper ring.
Page 345 9. Front Suspension > Fork Disassembly G-Dink 125i Place the axle holder of the outer fork tube in a soft jawed. Insert an 8 mm Allen socket into the damper rod. Hold the damper rod and loosen the fork bottom bolt with an 8 mm Allen wrench.
Page 346 9. Front Suspension > Fork Disassembly G-Dink 125i Separate the inner and outer fork tubes by pulling them apart using a slide hammer motion. Remove the oil lock piece. The oil lock piece may come out with the damper rod in the inner fork tube or it may be left in the slider.
Page 347 9. Front Suspension > Fork Disassembly G-Dink 125i Inspect the oil seal and the bushing in the fork slider. Place a rag across the top of the fork slider and pry our the oil seal as shown. Remove the oil seal and spacer from the fork slider.
Page 348 9. Front Suspension > Fork Disassembly G-Dink 125i Inspection Inspect the top plug O-ring O-ring and replace it if needed. Insect the slider bushing and replace it as needed.
Page 349 9. Front Suspension > Fork Disassembly G-Dink 125i Inspect the fork springs for signs of fatigue. Replace the fork springs if they vary dramatically in length. Inspect the damper rod and seal. Replace the components as needed.
Page 350 9. Front Suspension > Fork Disassembly G-Dink 125i Inspect the inner fork tube for bends and damage. Replace it as needed. For assembly see the Fork Assembly topic.
Page 351 9. Front Suspension > Fork Assembly G-Dink 125i Fork Assembly SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Clean all of the fork components with aerosol brake cleaner and a lint free cloth. Coat the bushing and seals with fork oil before installation.
Page 352 9. Front Suspension > Fork Assembly G-Dink 125i Place the spacer into the fork slider. Insert the inner fork tube into the inner fork tube.
Page 353 9. Front Suspension > Fork Assembly G-Dink 125i Place a new sealing washer on the fork bottom bolt. Insert the fork bottom bolt into the bottom the fork slider and thread it into the damper rod. Place the axle holder of the outer fork tube in a soft jawed.
Page 354 9. Front Suspension > Fork Assembly G-Dink 125i Drive in the fork oil seal with the fork seal driver. Insert the stopper ring into its groove.
Page 355 9. Front Suspension > Fork Assembly G-Dink 125i Install the dust seal securely into the outer fork tube. Compress the fork tube all the way. Fill the fork tube with the specified quantity of fork oil 145±1 cc. Use fork oil type SS#8 (10W).
Page 356 9. Front Suspension > Fork Assembly G-Dink 125i Fully extend the fork and insert the fork spring with its tightly coiled end facing down towards the axle. Lubricate the top plug O-ring with fresh fork oil and insert the plug into the top of the inner fork tube as shown.
Page 357 9. Front Suspension > Fork Assembly G-Dink 125i Install the rubber fork cap. Fit the fork protectors into place so that they face forward. Install the front fork. See the Front Fork Removal and Installation topic for more information.
Page 358 G-Dink 125i Service Manual 10. Rear Suspension Rear Suspension This chapter provides information on the rear suspension components of the KYMCO G-Dink 125i. • Shock Absorbers • Swingarm 9-13 TROUBLESHOOTING Soft rear shock absorber • Weak shock absorber spring • Damper oil leaks...
Page 359 10. Rear Suspension > Shock Absorbers G-Dink 125i Shock Absorbers SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Pre-Load Setting Each shock absorber on the scooter has 5 spring preload adjustment positions for different load or riding conditions.
Page 360 10. Rear Suspension > Shock Absorbers G-Dink 125i Removal Place the vehicle on its center stand. Remove the seat. See the Seat topic for more information. Remove the rear carrier. See the Rear Carrier topic for more information. Remove the body cover to access the upper shock absorber mounts.
Page 361 10. Rear Suspension > Shock Absorbers G-Dink 125i Remove the two Swingarm mounting bolt with a 12 mm socket. Remove the upper shock absorber mounting bolt with a 14 mm & 17mm socket. Free the shock absorber from the frame.
Page 362 10. Rear Suspension > Shock Absorbers G-Dink 125i Remove the left shock absorber in the same manner as the right. Inspect the shock absorbers for wear and damage. Replace the shock absorbers as needed. Check over the shock absorber for damage and oil leaks. Replace the shock absorber if needed.
Page 363 10. Rear Suspension > Shock Absorbers G-Dink 125i Install the upper shock absorber mounting bolt&nut and torque it to specification with a 14 mm & 17 mm socket. Item Torque kgf-m lb-ft Shock absorber mounting bolt 28.93...
Page 364 10. Rear Suspension > Shock Absorbers G-Dink 125i Install the lower shock absorber mounting bolt&nut and torque it to specification with a 12 mm socket. Torque Item kgf-m lb-ft Shock absorber mounting bolt 19.44 Install the other shock absorber in the same manner.
Page 365 10. Rear Suspension > Shock Absorbers G-Dink 125i Install the rear carrier. See the Rear Carrier topic for more information. Install the luggage box. See the Luggage Box topic for more information. Install the seat. See the Seat topic for more information.
Page 366 10. Rear Suspension > Swingarm G-Dink 125i Rear Fork SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Place the vehicle on its center stand. Remove the muffler. See the Exhaust System topic for more information. Remove the rear fender. See the Rear Fender topic for more information.
Page 367 10. Rear Suspension > Swingarm G-Dink 125i Hold the rear brake to keep the rear wheel from turning. Remove the rear axle nut with a 24 mm socket. Remove the rear brake caliper. See the Rear Brake Caliper topic for more information.
Page 368 10. Rear Suspension > Swingarm G-Dink 125i Installation Fit the rear fork into place. Install the two rear fork mounting bolts and tighten them securely with a 12 mm socket.
Page 369 10. Rear Suspension > Swingarm G-Dink 125i Install the rear axle nut and tighten it to specification with a 24 mm socket. Thread Torque Item Remarks kgf-m lb-ft size (mm)
Page 370 10. Rear Suspension > Swingarm G-Dink 125i Rear axle nut 11-13 79.56-94.03 U-nut Install the rear brake caliper. See the Rear Brake Caliper topic for more information. Install the rear fender. See the Rear Fender topic for more information. Install the lower shock absorber mounting bolt and torque it to specification with a 12 mm socket.
Page 371 11. Electrical Systems G-Dink 125i Electrical Systems This chapter covers the location and servicing of the electrical systems for the KYMCO G-Dink 125i. • Battery 6-10 • Charging System • Ignition System 12-15 • Starting System 16-20 • Starter Motor •...
Page 372 11. Electrical Systems G-Dink 125i • Check the load of the whole charging system. • Do not quick charge the battery. Quick charging should only be done in an emergency. • Remove the battery from the motorcycle for charging. • When replacing the battery, do not use a traditional battery.
Page 373 11. Electrical Systems G-Dink 125i • The ignition timing cannot be adjusted since the ignition control module is already adjusted in factory. • The ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is "ON", the excessive voltage may damage the ignition control module or ECU.
Page 374 11. Electrical Systems G-Dink 125i TROUBLESHOOTING Starter motor will not turn • Fuse burned out • Weak battery • Faulty ignition switch • Faulty starter clutch or gear • Faulty front or rear stop switch • Faulty starter relay • Poorly connected, broken or shorted wire •...
Page 375 11. Electrical Systems G-Dink 125i TROUBLESHOOTING Lights do not come on when ignition switch is “ON” • Burned bulb • Faulty switch • Poorly connected, broken or shorted wire Temperature gauge does not register correctly • Faulty temperature gauge • Faulty thermosensor •...
Page 376: Battery
11. Electrical System > Battery G-Dink 125i Battery SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Warning: The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin. eyes, or clothing.
Page 377 11. Electrical System > Battery G-Dink 125i The battery is located in the back of the vehicle. Remove the negative battery cable bolt with a 10 mm socket or #3 Phillips screwdriver. Free the negative cable from the battery. Remove the positive battery cable bolt with a 10 mm socket or #3...
Page 378 11. Electrical System > Battery G-Dink 125i Lift the battery out of the battery tray. Testing Check the battery voltage with a multi-meter. Place the positive probe onto the positive battery terminal and the negative probe to the negative battery terminal. If the battery reads under 12.3 V it is undercharged.
Page 379 11. Electrical System > Battery G-Dink 125i Fit the battery into the battery tray. Connect the positive battery cable and install the bolt with a 10 mm socket or #3 Phillips screwdriver. Connect the negative battery cable and install the bolt with a 10 mm...
Page 380 11. Electrical System > Battery G-Dink 125i Install the battery cover. Install the four battery cover screws and tighten them securely. Battery Charging Charge the battery with a motorcycle specific battery charger at the specified rate. Connect the charger leads to their appropriate battery terminals.
Page 381: Charging System
11. Electrical System > Charging System G-Dink 125i Charging System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. You will need a digital multimeter to inspect the charging system. Charging Voltage Inspection Remove the battery cover. See the Battery topic for more information.
Page 382: Ignition System
11. Electrical System > Ignition System G-Dink 125i Ignition System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. The ignition timing is set at the factory and is not adjustable. Perform the following checks. Before performing any tests make sure the electrical connections are not loose or corroded.
Page 383 11. Electrical System > Ignition System G-Dink 125i Turn the ignition switch to ON, lift the side stand, hold in one of the brake levers, and push the engine start button. The plug should spark. Caution: Do not touch the spark plug or spark plug wire while cranking or running the engine as this can result in a severe shock.
Page 384 11. Electrical System > Ignition System G-Dink 125i Remove the ignition coil leads. Remove the two ignition coil mounting bolts with an 8 mm socket. Remove the ignition coil. Ignition Coil Resistance Primary Set the multimeter to read ohms of resistance (Ω).
Page 385 11. Electrical System > Ignition System G-Dink 125i Touch the positive and negative meter leads to the ignition coil terminals as shown. Measure the resistance. 0.55 – 0.75 Ω Ignition Coil Primary Resistance AC Generator Inspection Crank Position Sensor Inspection Note: This test is performed with the stator installed in the engine.
Page 386: Starting System
11. Electrical System > Starting System G-Dink 125i Starting System SAFETY FIRST: Protective gloves and eyewear are recommended at this point. You will need a digital multimeter to inspect the starting system. Starter Relay Inspection Remove the body cover. See the Body Cover topic for more information.
Page 387 11. Electrical System > Starting System G-Dink 125i Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire and green/yellow wire. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the...
Page 388 11. Electrical System > Starting System G-Dink 125i Operation Test Remove the battery cover. See the Battery topic for more information. Turn the ignition switch to "OFF". Remove the negative battery cable bolt with a 10 mm socket or #3 Phillips screwdriver.
Page 389 11. Electrical System > Starting System G-Dink 125i Remove the nuts that hold the starter motor lead and battery lead wires to the starter relay with a 10 mm socket. Remove the leads from the starter relay. Disconnect the starter relay wire connector.
Page 390 11. Electrical System > Starting System G-Dink 125i Connect the electric meter to the starter relay terminals that connect to the battery positive cable and the starter motor cable. Connect a fully charged battery across the starter relay yellow/red and green/yellow wire terminals.
Page 391: Starter Motor
11. Electrical System > Starter Motor G-Dink 125i Starter Motor SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Removal Remove the battery cover. See the Battery topic for more information. Turn the ignition switch to "OFF". Remove the negative battery cable bolt with a 10 mm socket or #3 Phillips screwdriver.
Page 392: Fuses
11. Electrical System > Fuses G-Dink 125i Fuses SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Fuse Box Remove the seat and the luggage box. See the Seat topic for more information. The fuse box is located on top of the battery.
Page 393: Ecu Removal
11. Electrical System > ECU Removal G-Dink 125i ECU Removal Remove the seat and luggage box. See the seat and luggage box topic for more information. Note: The ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is “ ON" . The excessive voltage may damage the ignition control module or ECU.
Page 394 11. Electrical System > ECU Removal G-Dink 125i Loose two nuts attaching to the holder intake pipe. Remove the ECU. Inspection...
Page 395 11. Electrical System > ECU Removal G-Dink 125i Disconnect and remove the ECU. Check for continuity between pin H4 of the ECU side connector and body frame. There should be continuity at all times. Check for continuity between each pin B1 and D1 of the ECU side connector.
Page 396: Self-Diagnosis
11. Electrical System > Self-Diagnosis G-Dink 125i Self-Diagnosis SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Note: No matter when the CELP illuminated while riding condition, should find out the cause of the problem as soon as possible.
Page 397 11. Electrical System > Self-Diagnosis G-Dink 125i Place the scooter on its main stand and put the side stand up. Set the engine stop switch to the “RUN” position. ● Turn key to On position. ● The CELP will be lighting for two seconds and then off.
Page 398 Crank Position Sensor (CPS) Fault 3.Check crankshaft runout. 4.Use ohm meter to check circuit resistance (100-130 ohms with engine cool). 1.Use KYMCO AFI Diagnostic Tool to reset code. Ensure TPS is within specs. (With throttle plate closed-0.68 volts +/- 0.03 volts). P1120 Throttle Position Sensor (TPS) Fault 2.Check TPS wiring and connections.
Page 399 2.Check ECU wiring and connections pin 8. P0105 Atmosphere Pressure Sensor Fault 3.Use Diagnostic Tool to check pressure (101.3 +/- 3 KPA). 1.Use KYMCO AFI Diagnostic Tool Check sensor voltage (3.5~4.7 volts ). P1110 Bank Angle Detector Sensor Fault 2.Check ECU wiring and connections pin 11.
Page 400 11. Electrical System > Self-Diagnosis G-Dink 125i FAILURE CODES LIST With Special Tool See the Fuel Injection Diagnostic Tool topic. Self-Diagnosis Reset Procedure Note: The self-diagnosis cannot be reset when has still problem inside the system. After excluding trouble, how the DTC can be cleared? Confirm the failure is excluded.
Page 401 11. Electrical System > Self-Diagnosis G-Dink 125i Spark Plug Anti-Flood When no failure code occurs and pressing starter switch repeatedly can still not start the engine the spark plug maybe fouled be a flooded engine. Perform the spark plug anti-flood to purge the fuel in the engine.
Page 402 11. Electrical System > Horn G-Dink 125i Horn SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Remove the front cover. See the Front Cover for more information. Disconnect the horn connectors from the horn. Connect a 12 V battery to the horn terminals.
Page 403 11. Electrical System > Lights G-Dink 125i Lights SAFETY FIRST: Protective gloves and eyewear are recommended at this point. For general information and troubleshooting for the lights see the Electrical Systems chapter landing page. Headlight Bulb Replacement Make sure the machine has been off for several minutes before removing the headlight bulb.
Page 404 11. Electrical System > Lights G-Dink 125i Remove the headlight bulbs from the lamp. Unplug the bulb from its connector. Do not touch the bulb with your bare hands if you plan to reuse it. Do not touch your new bulb with your bare hand. The oils on your hand can cause an early failure of the headlight bulb.
Page 405 11. Electrical System > Lights G-Dink 125i Fit the rubber cover into place. Make sure the rubber covers are secured in place. Turn the screws to adjust the head light aim as needed.
Page 406 11. Electrical System > Lights G-Dink 125i Front Turn Signals Remove the front cover. See the Front Cover topic for more information. Turn the turn signal bulb socket counterclockwise and free it from the lamp. Push in on the bulb and rotate it clockwise to remove if from the socket.
Page 407 11. Electrical System > Lights G-Dink 125i Insert the turn signal bulb and socket into place. Turn the socket clockwise to lock it into place. Taillights Bulb Replacement Lift the seat. See the Seat topic for more information. Remove the turn signal sockets with bulbs from the turn signal lamps.
Page 408 11. Electrical System > Lights G-Dink 125i Replace the bulbs as needed. Push in and turn the bulbs counterclockwise to remove the and clockwise to install them. Install the taillight socket into the lamp and turn it clockwise to lock it into...
Page 409 11. Electrical System > Lights G-Dink 125i Rear Turn Signals Remove the rear cover. See the Body Cover topic for more information. Turn the socket counterclockwise and remove it from the lamp. Push in the bulb and turn it counterclockwise. Remove the bulb. Insert...
Page 410 11. Electrical System > Lights G-Dink 125i License Tag Light Remove the license tag light from the mud flap. See the Body Cover topic for more information. Pull the rubber tag light socket out of its housing. Pull the bulb straight out and insert a new one.
Page 411 11. Electrical System > Relays G-Dink 125i Relays SAFETY FIRST: Protective gloves and eyewear are recommended at this point. Starter Relay See the Starting System topic for more information. High/Low Beam Relays Remove the front cover. See the Front Cover for more information.
Page 412 11. Electrical System > Relays G-Dink 125i Fuel Pump Relay Remove the front cover. See the Front Cover for more information. The fuel pump relay is located in the front under the dash panel. Remove and disconnect the fuel pump relay.
Page 413 11. Electrical System > Relays G-Dink 125i ECU Relay Remove the front cover. See the Front Cover for more information. The ECU relay is located in the front under the dash panel, to the left of the start relay. Remove and disconnect the ECU relay. Disconnect...
Page 414 11. Electrical System > Switches G-Dink 125i Switches SAFETY FIRST: Protective gloves and eyewear are recommended at this point. You will need a digital multimeter to inspect the switches. Ignition Switch Remove the front cover. See the Front Cover topic for more information.
Page 415 11. Electrical System > Switches G-Dink 125i Removal Remove the front cover. See the Front Cover topic for more information. Remove the front center cover. See the Front Center Cover topic for more information. Remove the dash. See the Dash topic for more information.
Page 416 11. Electrical System > Switches G-Dink 125i Remove the seat latch cable cover. Loosen the seat latch cable screw with a #2 Phillips screwdriver. Remove the seat latch cable screw and free the seat latch cable from the ignition switch.
Page 417 11. Electrical System > Switches G-Dink 125i To remove the anti-tamper bolts use a punch and a hammer to strike the bolts so that they rotate loose. Turn the bolts clockwise to loosen them. Installation Install new anti-tamper bolts and tighten them securely.
Page 418 11. Electrical System > Switches G-Dink 125i Install the seat latch cable cover. Tilt Switch Remove the front cover. See the Front Cover topic for more information. Remove the front center cover. See the Front Center Cover topic for more information.
Page 419 11. Electrical System > Switches G-Dink 125i Remove the two tilt switch nuts with a 10mm socket. Place the tilt switch vertical as shown and the ignition switch “ON”. Measure the voltage as below. Terminal Standard Violet/Red (+) ~ Green/Pink (-)
Page 420 11. Electrical System > Switches G-Dink 125i Disconnect the connector to remove the tilt switch. Handlebar Switches Remove the front cover. See the Front Cover topic for more information. To remove the handle bar switches see the Handlebar topic. Unplug the green connector for the right handlebar switches.
Page 421 11. Electrical System > Switches G-Dink 125i Right Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches. Continuity should exist between the wires as indicated.
Page 422 11. Electrical System > Switches G-Dink 125i Left Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches. Continuity should exist between the wires as indicated.
Page 423 11. Electrical System > Switches G-Dink 125i Luggage Box Switch Remove the luggage box. See the Luggage Box topic for more information. Unplug the two-pin luggage box light switch connector with green and green/red wires.
Page 424 11. Electrical System > Switches G-Dink 125i Side Stand Switch Remove the luggage box. See the Luggage Box topic for more information. Place the vehicle on the center stand. Unplug the three-pin side stand switch connector. Use a digital multimeter to check for continuity.
Page 425 11. Electrical System > Switches G-Dink 125i With the side stand retracted there should be continuity between the yellow/green wire and the green wire terminals. With the side stand extended there should be continuity between the yellow/black wire and the green wire terminals.
Page 426 11. Electrical System > Switches G-Dink 125i Unplug the brake light switch connectors. Check for continuity between the brake light switch connectors. There should be continuity when the lever is pulled and none when released. To remove the brake light switch see the Master Cylinder topic.
Page 427 11. Quick Reference > Specifications G-Dink 125i KYMCO G-Dink 125i Specifications General Information Item Standard Charging voltage of battery > 12V Voltage from the ECU to every sensor 5±0.1V Fuel injector resistance (20°C/68°F) 10.6Ω~15.9Ω Idle (0°) = 0.23±0.05V Throttle position sensor voltage Throttle fully (>90°...
Page 431 11. Quick Reference > Specifications G-Dink 125i KYMCO G-Dink 125i Diagnostic Report Item Remark Standard Data ECU No Hardware Ver Software Ver QK0A00 Calibration Ver O4LHG8QKAA Model Name LHG8 Engine Temp.(Coiling) environ.temp ± 2 °C Air Temp.(°C) environ.temp ± 2 °C The ambient pressure drop about 12 kpa at the altitude 101.3 ±...
Page 432 12. Quick Reference G-Dink 125i Quick Reference This chapter provides a quick reference source of technical specifications and information for KYMCO G-Dink 125i models. • G-Dink 125i Specifications ____________________________________ 1-3 • Component Location • Special Tools • Torque Specifications ______________________________________10-12 •...
Page 433 Quick Reference > Specifications G-Dink 125i KYMCO G-Dink 125i Specifications General Information ITEM G-DINK 125i SPECIFICATIONS Overall length (mm) 2110 Overall width (mm) Overall height (mm) 1255 Wheelbase (mm) 1450 GROUND CLEARANCE (mm) Min.Turning radius R/L (mm) 2250 / 2250...
Page 434 ITEM G-DINK 125i FUEL Fuel type 92# nonleaded gasoline Air cleaner type Paper element, wet Fuel tank capacity 12.5 L Fuel tank reserve capacity 2.2 L THROTTLE BODY Maker KYMCO Type THROTTLE BODY Number Size of bore (mm) Adjust control method...
Page 435 ITEM G-DINK 125i SUSPENSION TELESCOPE/ Type(FR/RR) SWING ARM Stroke (FR/RR) 110 / 100 LUBRICATION ENGINE OIL Oil pump type Inner/outer rotor type Capacity type 1100 cc , 15W40 Exchanging capacity 900 cc Oil filter type Filter GEAR OIL Capacity type 0.23L #90...
Page 436 12. Quick Reference > Component Location G-Dink 125i Component Location • Winker Relay (Turn Signal Relay) • Horn • DC Power Socket • Instrument Cluster • Ignition Switch • Radiator Cap...
Page 437 12. Quick Reference > Component Location G-Dink 125i • Fuel Pump Relay • Tilt Switch • ECU Relay • High Beam Relay • Low Beam Relay • Start Relay • Throttle Body • ECU • Fuel Injector • WTS...
Page 438 12. Quick Reference > Component Location G-Dink 125i • Regulator/Rectifier • Ignition Coil • Starter Relay • Oxygen Sensor (O sensor) • Coolant Reserve Tank • Stator and Crank Pulse Sensor (Pulser Coil)
Page 439 12. Quick Reference > Special Tools G-Dink 125i Special Tools Description Tool No. Photo Flywheel puller A120E00003 Oil seal and bearing installer A120E00014 Universal holder A120E00017 Flywheel holder A120E00021 Clutch spring compressor A120E00034 Valve adjuster A120E00036 Bearing puller A120E00037 Cylinder Compression Gauage...
Page 440 12. Quick Reference > Special Tools G-Dink 125i Description Tool No. Photo Valve spring compressor A120E00040 Fuel Pressure Gauage A120E00048 INJECTOR CLEANER for A120E00075 Synerjet Wires Injector Connector A120E00090 Lock nut wrench A120F00002 Lower/Upper Race Remover & A120F00008 Installer Steering Stem Top Thread...
Page 441 12. Quick Reference > Special Tools G-Dink 125i Description Tool No. Photo Electric Repair Kit A120F00032...
Page 442 12. Quick Reference > Torque Specifications G-Dink 125i Torque Specifications Engine Torque Specifications General Torque Specifications...
Page 443 12. Quick Reference > Torque Specifications G-Dink 125i Frame Torque Specifications...
Page 444 12. Quick Reference > Torque Specifications G-Dink 125i General Torque Specifications...
Page 445 12. Troubleshooting G-Dink 125i Troubleshooting Vehicle can not be started Preliminary 6 Step Inspection 1. Is the battery fully charged (12 V or higher). See the Battery topic for more information. 2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay (It will turn off automatically in 5-10 seconds) 3.
Page 446 12. Troubleshooting G-Dink 125i General Troubleshooting ENGINE WILL NOT START OR IS HARD TO START Possible cause 1. Check for operation of the fuel pump Abnormal  Faulty fuel pump Normal 2. Inspect the fuel flow Abnormal  Faulty pressure regulator Normal 3.
Page 447 12. Troubleshooting G-Dink 125i ENGINE LACKS POWER Possible cause 1. Raise wheel off the ground Wheels do not  Brake dragging and spin by hand spin freely  Worn or damaged wheel bearing Wheel spins freely 2. Check tire pressure Pressure low ...
Page 448 12. Troubleshooting G-Dink 125i Possible cause 9. Check oil level and condition Incorrect  Oil level too high  Oil level too low  Contaminated oil Correct 10. Remove cylinder head cover Valve train not  Clogged oil and inspect lubrication lubricated properly ...
Page 449 12. Troubleshooting G-Dink 125i POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause 1. Check ignition timing Incorrect  Improper ignition timing Correct 2. Inspect the fuel flow Abnormal  Faulty pressure regulator Normal 3. Inspect the fuel injector Abnormal ...
Page 450 12. Troubleshooting G-Dink 125i POOR PERFORMANCE AT HIGH SPEED Possible cause 1. Check ignition timing Incorrect  Faulty ECU Correct 2. Inspect the fuel flow Abnormal  Faulty pressure regulator Normal 3. Inspect the fuel injector Abnormal  Faulty injector Normal 4.
Page 451 12. Quick Reference > VIN and Engine Number Location G-Dink 125i VIN and Engine Number Location The VIN is stamped on the body frame under the luggage box. The engine serial number is stamped on bottom of the left crankcase.

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