KYMCO Dink-R 150 Manual

Table of Contents

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PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO Dink-R 150.

Section 1 contains the precautions for all

operations stated in this manual. Read

them carefully before starting any

operation.

Section 2 is the removal/installation

procedures for the frame covers, which

are subject to higher removal/installation

frequency

during

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules and

service information for each part, starting

from periodic maintenance.

Sections 6 through 17 give instructions

for disassembly, assembly and inspection

of engine, chassis frame and electrical

equipment.

Most sections start with an assembly or

system illustration and troubleshooting

for the section. The subsequent pages

give detailed procedures for the section.

Our company reserves the right to

make any alteration in the design.

The

information

included in this manual may be

different from the motorcycle in

case specifications are changed.

KWANG YANG MOTOR CO., LTD.

QUALITY TECHNOLOGY DEPARTMENT

EDUCATION SECTION

maintenance

and

contents

GENERAL INFORMATION

FRAME COVERS/EXHAUST MUFFLER

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

FUEL SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE AND DRIVEN PULLEYS/KICK

STARTER

FINAL REDUCTION

CRANKCASE/CRANKSHAFT

COOLING SYSTEM

FRONT WHEEL/FRONT BRAKE/

FRONT SUSPENSION

REAR WHEEL /REAR BRAKE /REAR

SUSPENSION

BATTERY/CHARGING SYSTEM/A.C.

GENERATOR

IGNITION SYSTEM

STARTING SYSTEM

LIGHTS/INSTRUMENTS/SWITCHES

EVAPORATIVE EMISSION

CONTROL SYSTEM

ABS SYSTEM

Dink-R 150

Chapters

Table of Contents

Troubleshooting

Summary of Contents for KYMCO Dink-R 150

Page 1: Table Of Contents
TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION technical features and servicing FRAME COVERS/EXHAUST MUFFLER procedures for the KYMCO Dink-R 150. INSPECTION/ADJUSTMENT LUBRICATION SYSTEM Section 1 contains the precautions for all operations stated in this manual. Read FUEL SYSTEM...
Page 2: General Information
. GENERAL INFORMATION Dink-R 150 ENGINE SERIAL NUMBER ....1- 1 LUBRICATION POINTS ......1-15 SPECIFICATIONS ........1- 2 CABLE & HARNESS ROUTING ..... 1-17 SERVICE PRECAUTIONS ...... 1- 3 TROUBLESHOOTUNG ......1-20 TORQUE VALUES ........1-11 SPECIAL TOOLS ........1-12...
Page 3: Specifications
. GENERAL INFORMATION Dink-R 150 SPECIFICATIONS Name & Model Dink-R 150 Lubrication oil capacity (liter) 1.2L Overall length (mm) 1970 Exchanging capacity 1.0L Overall width (mm) Air cleaner type & No. Wet, single Gear Oil capacity Overall height (mm) 1305 0.13L...
Page 4: Service Precautions
. GENERAL INFORMATION Dink-R 150 SERVICE PRECAUTIONS  Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling.  When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
Page 5 . GENERAL INFORMATION Dink-R 150  Apply or add designated greases and lubricants to the specified lubrication points.  After reassembly, check all parts for proper tightening and operation.  When two persons work together, pay attention to the mutual working safety.
Page 6 . GENERAL INFORMATION Dink-R 150  If the fuse is burned out, find the cause and repair it. Replace it with a new one Confirm according to the specified capacity. Capacity  After operation, terminal caps shall be installed securely.
Page 7 . GENERAL INFORMATION Dink-R 150  The connector shall inserted completely. Snapping!  If the double connector has a lock, lock it at the correct position.  Check if there is any loose wire.  Before connecting a terminal, check for...
Page 8 . GENERAL INFORMATION Dink-R 150  After clamping, check each wire to make sure it is secure.  Do not squeeze wires against the weld or its clamp  After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
Page 9 . GENERAL INFORMATION Dink-R 150  Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight!  Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.
Page 10 . GENERAL INFORMATION Dink-R 150  After routing, check that the wire harnesses are not twisted or kinked.  Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack interfere with adjacent surrounding parts in all steering positions.
Page 11 . GENERAL INFORMATION Dink-R 150  Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) : Apply grease for lubrication.
Page 12: Torque Values
Dink-R 150 . GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 0.45-0.6 5mm screw 0.35-0.5 6mm bolt, nut 0.6-1.2 6mm screw, SH bolt 0.7-1.1 8mm bolt, nut 1.8-2.5 6mm flange bolt, nut 1.0-1.4...
Page 13: Special Tools
Dink-R 150 . GENERAL INFORMATION 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 A120E00039...
Page 14 Dink-R 150 . GENERAL INFORMATION 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 Wrench...
Page 15 Dink-R 150 . GENERAL INFORMATION Description Tool No. Photo Pliers Fuel Pipe A120F00031 Electric Repair Kit A120F00032 1-14...
Page 16: Lubrication Points
Dink-R 150 . GENERAL INFORMATION LUBRICATION POINTS ENGINE Lubrication Points Lubricant Genuine KYMCO Engine Oil (SAE15W-40) Valve guide/valve stem movable part APISL Engine Oil Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...
Page 17 Dink-R 150 . GENERAL INFORMATION FRAME The following is the lubrication points for the frame. Use a general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.
Page 18: Cable & Harness Routing
Dink-R 150 . GENERAL INFORMATION CABLE & HARNESS ROUTING Instrument Radiator Filler Cap Long-distance ABS ECU/Pump antenna USB controller short-distance antenna Headlight controller Keyless controller Fuel Pump Relay ECU Relay short-distance antenna ABS ECU/Pump Tank cap pull wire Headlight controller...
Page 19 Dink-R 150 . GENERAL INFORMATION Long-distance ABS ECU/Pump antenna Keyless controller USB controller Fuel Pump Relay Ignition Switch ECU Relay ECU/Throttle Fuel tube Fuel Injector Fuel Pump Crank Breather Fuel Tank Ignition Coil Spark plug cap Tube 1-18...
Page 20 Dink-R 150 . GENERAL INFORMATION Start ① Relay Tilt Switch Relay Start Relay② USB controller Radiator Filler Cap Ignition Switch Charcoal Canister/ Purge Control Valve Fuel Injector Front Wheel Speed Sensor Connector Fuel Pump Headlight controller Starter Relay② Rectifier Regulator/...
Page 21 . GENERAL INFORMATION Dink-R 150 Diagnostic Tool Connector Battery Fuse Start Relay② Regulator/Rectifier Charcoal Canister/ Purge Control Valve Rear speed sensor Ignition Coil Throttle Fuel Injector Crankcase Breather Tube Fuel Tank Side Standard Switch Fuel Pump 1-20...
Page 22 . GENERAL INFORMATION Dink-R 150 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 23 Dink-R 150 GENERAL INFORMATION General Troubleshooting ENGINE WILL NOT START OR IS HARD TO START Possible cause  Faulty fuel pump 1. Check for operation of the fuel pump Abnormal Normal  Faulty pressure regulator 2. Inspect the fuel flow...
Page 24 . GENERAL INFORMATION Dink-R 150 ENGINE LACKS POWER Possible cause  Brake dragging 1. Raise wheel off the ground Wheels do not  Worn or damaged wheel bearing and spin by hand spin freely Wheel spins freely  Faulty tire valve 2.
Page 25 Dink-R 150 GENERAL INFORMATION Possible cause  Oil level too high 9. Check oil level and condition Incorrect  Oil level too low  Contaminated oil Correct  Clogged oil 10. Remove cylinder head cover Valve train not  Clogged oil control orifice...
Page 26 . GENERAL INFORMATION Dink-R 150 POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause  Improper ignition timing 1. Check ignition timing Incorrect Correct  Faulty pressure regulator 2. Inspect the fuel flow Abnormal Normal  Faulty injector 3. Inspect the fuel injector...
Page 27 Dink-R 150 GENERAL INFORMATION POOR PERFORMANCE AT HIGH SPEED Possible cause  Faulty ECU 1. Check ignition timing Incorrect Correct  Faulty pressure regulator 2. Inspect the fuel flow Abnormal Normal  Faulty injector 3. Inspect the fuel injector Abnormal Normal ...
Page 28 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 2- 1 TROUBLESHOOTING ----------------------------------------------------- 2- 1 FASTENER REMOVAL AND REINSTALLATION ------------------ 2- 2 FRAME COVERS REMOVAL/INSTALLATION --------------------- 2- 3 EXHAUST MUFFLER ----------------------------------------------------- 2-14...
Page 29: Service Information
Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS SERVICE INFORMATION GENERAL INSTRUCTIONS  When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged.  Make sure to route cables and harnesses according to the Cable & Harness Routing.
Page 30: Fastener Removal And Reinstallation
Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS FASTENER REMOVAL AND REINSTALLATION REMOVAL Depress the head of fastener center piece . Pull out the fastener. INSTALLATION Let the center piece stick out toward the head so that the pawls  close. Insert the fastener into the installation hole.
Page 31: Frame Covers Removal/Installation
Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS Dink 150 FLAT FLOOR FRAME COVERS REMOVAL/ INSTALLATION bolts MET-IN BOX REMOVAL Unlock the seat with the ignition key. Open the seat. Remove 4 bolts attaching the met-in box. Remove the met-in box .
Page 32 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS Blots BODY COVER Remove two screws and then remove the rear center cover Rear Center Cover bolt Remove Bolt and Nut. bolt Remove two screws Remove the four fasteners attaching to the right and left the body .
Page 33 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS taillight connector Disconnect the taillight connector. , then remove the body cover. Installation is in the reverse order of removal. UPPER/LOWER HANDLEBAR COVER Remove the two screws . Remove upper handlebar cover. Screws Screws...
Page 34 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS WINDSHIELD Remove four bolts and the Remove windshield. bolts screws FRONT CENTER COVER Remove the windshield Remove two screws. Remove the front center cover. Installation is in the reverse order of removal front center cover.
Page 35 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS screws FRONT COVER Remove the two Nuts and the four screws. Nuts Fasteners Remove the two fasteners and six screws from the inner cover. screws Remove eights fasteners from the cowl under. Disconnect the headlight light connector.
Page 36 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS Remove the front cover Installation is in the reverse order of removal. FRONT FENDER Remove six bolts attaching to the front fender. Installation is in the reverse order of removal. Bolts FLOORBOARD Remove the body cover（2-3,4,5）.
Page 37 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS fasteners METER PANEL Remove the front cover. Remove the two fasteners and the two screws. Remove the four bolts. Screws meter connector Disconnect the meter connector. Remove meter panel. Installation is in the reverse order of removal.
Page 38 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS Remove the 3 screws attaching to the fuel filler cap Remove the inner cover. Installation is in the reverse order of removal. screws the top inner fender FRONT INNER FENDER Front inner fender Remove the four fasteners, connect front...
Page 39 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS UNDER COVER Remove four bolts and fasteners attaching to under cover. Remove the under cover. fastener bolts fastener FENDER,REAR INNER Remove the one fastener. Remove five bolts. Remove fender rear inner bolts 2-11...
Page 40: Frame Covers/Exhaust Muffler
Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS EXHAUST MUFFLER REMOVAL Disconnect the connector with O2 heater/O2 sensor. Nuts Remove the two exhaust pipe joint nuts Remove three muffler mount bolts and muffler and gasket. bolts 2-12...
Page 41 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS INSTALLATION Replace the gasket with a new one. Install the exhaust muffler and three mounting bolt. Install and tighten the two exhaust pipe joint nuts to the specified torque Torque: 20 N•m (2 kgf•m,)
Page 42 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS Dink-R 150 Tunnel model FRAME COVERS REMOVAL/ INSTALLATION bolts MET-IN BOX REMOVAL Unlock the seat with the ignition key. Open the seat. Remove 4 bolts attaching the met-in box. Remove the met-in box .
Page 43 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS bolt Remove Bolt and Nut. bolt Remove two screws Remove the two fasteners attaching to the right and left the body . screw fastener screw fastener 2-15...
Page 44 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS taillight connector Disconnect the taillight connector. , then remove the body cover. Installation is in the reverse order of removal. UPPER/LOWER HANDLEBAR COVER Remove the two screws . Remove upper handlebar cover. Screws Screws...
Page 45 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS WINDSHIELD Remove four bolts and the Remove windshield. bolts FRONT CENTER COVER screws Remove the windshield Remove two screws. Remove the front center cover. Installation is in the reverse order of removal front center cover.
Page 46 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS screws FRONT COVER Remove the two Nuts and the four screws. Nuts Fasteners Remove the two fasteners and six screws from the inner cover. screws Remove eights fasteners from the cowl under. Fasteners Disconnect the headlight light connector.
Page 47 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS Remove the front cover Installation is in the reverse order of removal. FRONT FENDER Remove six bolts attaching to the front fender. Installation is in the reverse order of removal. Bolts Fasteners FLOORBOARD Remove the body cover（2-3,4,5）.
Page 48 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS fasteners METER PANEL Remove the front cover. Remove the two fasteners and the two screws. Screws Remove the four bolts. meter connector Disconnect the meter connector. Remove meter panel. Installation is in the reverse order of removal.
Page 49 . EXHAUST MUFFLER/FRAME COVERS Dink-R 150 Remove the 3 screws attaching to the fuel filler cap Remove the inner cover. Installation is in the reverse order of removal. screws the top inner fender FRONT INNER FENDER Front inner fender Remove the four fasteners, connect front...
Page 50 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS UNDER COVER Remove four bolts and fasteners attaching to under cover. Remove the under cover. bolts fastener FENDER,REAR INNER Remove the one fastener. Remove five bolts. Remove fender rear inner bolts 2-22...
Page 51 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS EXHAUST MUFFLER REMOVAL Disconnect the connector with O2 heater/O2 sensor. Nuts Remove the two exhaust pipe joint nuts Remove three muffler mount bolts and muffler and gasket. bolts 2-23...
Page 52 Dink-R 150 . EXHAUST MUFFLER/FRAME COVERS INSTALLATION Replace the gasket with a new one. Install the exhaust muffler and three mounting bolt. Install and tighten the two exhaust pipe joint nuts to the specified torque Torque: 20 N•m (2 kgf•m,)
Page 53 Dink-R 150 . INSPECTION/ADJUSTMENT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 3- 1 MAINTENANCE SCHEDULE-------------------------------------------- 3- 2 FUEL LINE ------------------------------------------------------------------- 3- 3 THROTTLE OPERATION ------------------------------------------------- 3- 3 ENGINE OIL ----------------------------------------------------------------- 3- 4 TRANSMISSION OIL ------------------------------------------------------ 3- 4 AIR CLEANER -------------------------------------------------------------- 3- 5...
Page 54: Inspection/Adjustment
. INSPECTION/ADJUSTMENT Dink-R 150 SERVICE INFORMATION GENERAL ！ WARNING Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people.
Page 55: Maintenance Schedule
Dink-R 150 . INSPECTION/ADJUSTMENT MAINTENANCE SCHEDULE n order to have a safe riding, maintain good performance, prolong the scooter service life and reduce pollution, make sure to perform the periodic inspection and maintenance. I: Inspect and clean, lubricate, refill, repair or replace if necessary.
Page 56: Fuel Line
. INSPECTION/ADJUSTMENT Dink-R 150 FUEL LINE Check the fuel lines and replace any parts, which show signs of deterioration, damage or leakage. Check for dirty or clogged fuel injector and replace with a new one if it is clogged. ＊...
Page 57: Engine Oil
Dink-R 150 . INSPECTION/ADJUSTMENT ENGINE OIL Engine oil recommendation Use a premium quality 4-stroke motor oil to ensure longer service life of your scooter. Use only oils which are rated, SL under the API service classification. The recommended viscosity is SAE 15W-40.
Page 58: Air Cleaner
. INSPECTION/ADJUSTMENT Dink-R 150 AIR CLEANER Air cleaner element replacement Remove the eight screws. Remove the air cleaner cover. Remove the air cleaner element and replacement new one. ＊  The air cleaner element has a viscous type paper element.
Page 59: Valve Clearance
Dink-R 150 . INSPECTION/ADJUSTMENT VALVE CLEARANCE Dink 150 foot model ＊  Inspect and adjust valve clearance while the engine is cold (below 35℃). Remove the met-in box.( 2-3) Remove the Center 2-3) Cover Remove the four bolts on the cylinder head cover.
Page 60: Inspection/Adjustment
. INSPECTION/ADJUSTMENT Dink-R 150 Pic1 VALVE CLEARANCE Dink-R 150 Tunnel model ＊  Inspect and adjust valve clearance screw while the engine is cold (below 35℃). Remove the met-in box.( 2-3) Remove the right or left skirt. ( 2-6) Remove the two...
Page 61 Dink-R 150 . INSPECTION/ADJUSTMENT TDC check hole Turn the A.C. generator flywheel clockwise to the top dead center (TDC) on the compression stroke so that the “T” mark on the flywheel aligns with the index mark on the right crankcase cover.
Page 62: Cylinder Compression
. INSPECTION/ADJUSTMENT Dink-R 150 CYLINDER COMPRESSION Warm up the engine before compression test. Remove the center cover and spark plug cap. Remove the spark plug . Insert a compression gauge. Open the throttle valve fully and push the starter button to test the compression.
Page 63 Always add coolant to the reserve tank. Do not attempt to add coolant by removing the radiator cap. If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your KYMCO dealer for repair. Add coolant Remove the screw (1).
Page 64 . INSPECTION/ADJUSTMENT Dink-R 150 Coolant recommendation The owner must properly maintain the coolant to prevent freezing, overheating, and corrosion, use only high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines. (See antifreeze container label.)
Page 65: Headlight Aim
Dink-R 150 . INSPECTION/ADJUSTMENT HEADLIGHT ADJUSTMENT Headlight aim can be made by turning the screw in or out as necessary. Adjustment Screw BRAKE FLUID Brake fluid level: With the scooter in an upright position, check the front and rear fluid level. It should be above the lower level mark.
Page 66 . INSPECTION/ADJUSTMENT Dink-R 150 BRAKE SYSTEM There is adjuster on each brake lever. Each adjuster has four positions so that the released lever position can be adjusted to suit the rider’s hands. To adjust the distance of the lever from the...
Page 67 Dink-R 150 . INSPECTION/ADJUSTMENT NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Check the tires for cuts, imbedded nails or other damages. Check the tire pressure.
Page 68 2.Put the side stand up and start the engine. 3.Lower the side stand. The engine should stop as you put the side stand down. ＊ If the side stand system does not operate as described, see your KYMCO dealer for service. 3-15...
Page 69: Lubrication System
. LUBRICATION SYSTEM Dink-R 150 LUBRICATION SYSTEM SERVICE INFORMATION ..............4-2 TROUBLESHOOTING ................ 4-2 ENGINE OIL/OIL FILTER ..............4-3 OIL PUMP ....................4-4...
Page 70 . LUBRICATION SYSTEM Dink-R 150 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...
Page 71: Lubrication System
. LUBRICATION SYSTEM Dink-R 150 SERVICE INFORMATION 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 72: Engine Oil/Oil Filter
. LUBRICATION SYSTEM Dink-R 150 ENGINE OIL/OIL FILTER OIL LEVEL ＊  Place the motorcycle upright on level ground for engine oil level check.  Run the engine for 2～3 minutes and check the oil level after the engine is stopped for 2～3 minutes.
Page 73: Oil Pump
. LUBRICATION SYSTEM Dink-R 150 OIL PUMP REMOVAL Unscrew all mounting bolts of right crankcase cover. Remove the right crankcase cover. Remove the flywheel nut with a 14 mm wrench. Remove the A.C. generator flywheel with special tools. Special tool:...
Page 74 . LUBRICATION SYSTEM Dink-R 150 Remove the oil pump driven gear nut to remove the oil pump driven gear and drive chain. Remove the two oil pump mounting bolts and the oil pump. DISASSEMBLY Remove the screw and disassemble the oil...
Page 75 . LUBRICATION SYSTEM Dink-R 150 INSPECTION Outer Rotor Measure the pump body-to-outer rotor clearance. Service Limit: 0.12mm Pump Body Outer Rotor Measure inner rotor-to-outer rotor clearance. Service Limit: 0.12mm Inner Rotor Measure rotor end-to-pump body clearance. Service Limit: 0.2mm...
Page 76 . LUBRICATION SYSTEM Dink-R 150 ASSEMBLY Inner Rotor Outer Rotor Install the outer rotor, inner rotor and pump shaft into the pump body. ＊ Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.
Page 77 . LUBRICATION SYSTEM Dink-R 150 After the oil pump is installed, tighten the two mounting bolts. Install the pump driven gear and drive chain by aligning the pump driven gear with the cutout in the pump shaft. Install and tighten the pump driven gear nut.
Page 78 . LUBRICATION SYSTEM Dink-R 150 Install the starter idle gear and starter clutch. Install the gasket and dowel pins. Hold the flywheel with the universal holder and torque flywheel nut to specification with a 14 mm socket wrench. Torque: 5.0-6.0 kg-m...
Page 79 Dink-R 150 5. FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM SYSTEM DIAGRAM ................5 - 1 SYSTEM LOCATION ................5 - 2 SERVICE INFORMATION ..............5 - 3 TROUBLESHOOTING ................. 5 - 4 CHECK ENGINE LAMP (CELP) ............5 - 5 HOW TO SHOW THE FAILURE CODE ..........
Page 80 Dink-R 150 5. FUEL INJECTION SYSTEM INJECTION SYSTEM KEY ON FUEL PUMP T-MAP Voltage ROLL INDUCTIVE INJECTOR IGNITION COIL KEY OFF...
Page 81 5. FUEL INJECTION SYSTEM Dink-R 150 Parts Location 01:Inductive Ignition coil 02:Fuel pump 03:ECU 04:Fuel Injector 05:WTS sensor 06:T-MAP sensor 07:ISC 08:TPS 09:CPS 10:O sensor 11:Roll sensor...
Page 82: Service Information
Dink-R 150 5. FUEL INJECTION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ Gasoline is very dangerous. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area.
Page 83: Troubleshooting
5. FUEL INJECTION SYSTEM Dink-R 150 TROUBLESHOOTING Engine won’t start Backfiring or misfiring during acceleration  Battery voltage too low  Ignition system malfunction  Fuel level too low  Pinched or clogged fuel hose Poor performance (drive ability) and poor ...
Page 84: Check Engine Lamp (Celp)
Open the Ignition switch, the CLEP indicator will illuminate always. After starting it will crush out. If there is any malfunction, the CLEP indicator will still illuminate, please take your scooter to a KYMCO dealer for service as soon as possible. CELP...
Page 85: Failure Codes Chart
5. FUEL INJECTION SYSTEM Dink-R 150 Failure Code Chart NO Failure Fault description Remark Code P0562 Battery voltage low P0335 Crankshaft position sensor circuit malfunction P0563 Battery voltage high P0031 O2 sensor heater Voltage Low P0032 Lambda sensor heater Voltage High...
Page 86: Ecu
Dink-R 150 5. FUEL INJECTION SYSTEM There are 34 pins attaching the ECU. ECU PIN FUNCTION MAP content (edition issue no.) Prohibited to adjust and remove the throttle body idle screw...
Page 87: Fuel Pump
5. FUEL INJECTION SYSTEM Dink-R 150 FUEL PUMP Fuel Hose Connect the meter (+) probe to the red/black wire and the meter (-) probe to the green wire to measure the voltage from the ECU input to fuel pump unit.
Page 88 Dink-R 150 5. FUEL INJECTION SYSTEM T-MAP(Manifold Temperature Pressure) Sensor Connect the Fi diagnostic tool. Enter the Data Analyze Check if the manifold pressure data is malfunction. Turn the ignition switch to the “ON” position. If data is incorrect, and the T-map sensor is problem.
Page 89 5. FUEL INJECTION SYSTEM Dink-R 150 ETS (Engine Temperature Sensor) Connect the meter (+) probe to the V/G wire and the meter (-) probe to the G/L wire to measure the voltage Standard : 5± 0.25 V Measure the resistance of the ETS Standard 11.15±...
Page 90: O2 Sensor
O2 SENSOR Measure the resistance of the O2 sensor heater. (2 white wire pin) Standard (20°C/68°F ): 6.7 ~9.5Ω Connect the KYMCO Fi diagnostic tool. Enter the Data Analyze Check Page 05 Turn the ignition switch to the “ON” position.
Page 91: Roll Sensor
5. FUEL INJECTION SYSTEM Dink-R 150 ROLL SENSOR The engine should be stop when the vehicle incline over 65° for safety. When you place the vehicle back to normal position, you have to key-off and key-on the switch again, then it can be restarted.
Page 92: Fuel System
5. FUEL INJECTION SYSTEM Dink-R 150 Fi Diagnostic Tool Operation Instructions Part No. 3620A-LEB2-E00 Diagnostic version 1 Model No. 6 UP Button 7 Adjust(TIP and ABV reset 2 Down Button function) 8 D ATA Analyze 3 DTC indicator (Failure codes)
Page 93 5. FUEL INJECTION SYSTEM Dink-R 150 DTC INSPECTION Connect Fi diagnostic tool with the connector of harness wire located beside the Battery. ＊ Fi diagnostic tool is electrically After ● Connect Fi diagnostic tool with the connector of harness, The data can only be read after the main ●...
Page 94 5. FUEL INJECTION SYSTEM Dink-R 150 Press the " Enter " button to check the DTC number Press the " Enter " button Press the " Enter " button Display the DTC number of the DTC-List. Refer to DTC summary list.
Page 95 5. FUEL INJECTION SYSTEM Dink-R 150 Press the " UP " button Press the " Enter " button and then turn to thee previous page. Press the " UP " button Press the " Enter " button and then turn to the first page.
Page 96 5. FUEL INJECTION SYSTEM Dink-R 150 DTC CLEAR PROCEDURE Choose " DTC Inspect " Press the "Enter" button Choose " DTC Clear " Press the " Enter " button The DTC indicator is lighting at that time. Clearing DTC until the DTC indicator is off.
Page 97 5. FUEL INJECTION SYSTEM Dink-R 150 DATA ANALYSIS Choose " Data Analyze " Press the " Enter " button to enter page 01. The figure includes the engine speed, idle speed and the battery voltage. Refer to standard specification. Press the " Down " button to enter page 02.
Page 98 5. FUEL INJECTION SYSTEM Dink-R 150 The figure includes ISC and ISC learn step . Refer to standard specification. Press the "Down" button to enter page 05. The figure includes Ignition Dwell duration, fuel Injection duration and Ignition advance. Refer to standard specification.
Page 99 5. FUEL INJECTION SYSTEM Dink-R 150 Dink-R 150 E5 Diagnostic report SF : Customer : Eng. No: Production Date : Service Date : Mileage : Reason of repair: □Maintenance □Breakdown Item Data Reference Memo AKF2 ECU No Hardware Ver Software Ver...
Page 100: Engine Removal/Installation
6. ENGINE REMOVAL/INSTALLATION Dink-R 150 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION .................. 6-2 ENGINE REMOVAL.................... 6-3 ENGINE INSTALLATION ..................6-6...
Page 101 6. ENGINE REMOVAL/INSTALLATION Dink-R 150...
Page 102 6. ENGINE REMOVAL/INSTALLATION Dink-R 150 SERVICE INFORMATION GENERALINSTRUCTIONS • A jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal. • Use towels to protect the motorcycle body during engine removal.
Page 103 6. ENGINE REMOVAL/INSTALLATION Dink-R 150 ENGINE REMOVAL Battery CPS connector Remove the frame body cover(2-6). O₂ Sensor Disconnect the battery negative cable. Disconnect the engine negative cable. connector Disconnect the A.C. Generator wire and CPS connector. Disconnect the starter motor cable from the Starter relay starter relay.
Page 104 6. ENGINE REMOVAL/INSTALLATION Dink-R 150 Remove the air cleaner assy. Remove the exhaust muffler(2-7) Air cleaner assy Exhaust muffler Remove the rear brake caliper. Remove 2 bolts attaching to rear brake hose clamps. Bolts caliper. Remove the rear shock absorbers mounting bolts.
Page 105 6. ENGINE REMOVAL/INSTALLATION Dink-R 150 Bolts Remove the engine hanger bolts and pull out the engine with the engine hanger bracket backward. Engine hanger bolt ENGINE HANGER BRACKET REMOVAL Remove the engine mounting bolt. Remove the engine. Inspect the engine hanger bushings and stopper...
Page 106 6. ENGINE REMOVAL/INSTALLATION Dink-R 150 ENGINE HANGER BRACKET INSTALLATION Install the engine hanger bracket to the engine. Install and tighten the engine hanger bracket bolts. ENGINE INSTALLATION Install the engine and tighten the engine mounting bolts. Engine Hanger Bolts Torque: 5.0kg-m Tighten the rear shock absorbers mounting bolts.
Page 107 6. ENGINE REMOVAL/INSTALLATION Dink-R 150...
Page 108: Cylinder Head/Valves
Dink-R 150 7. CYLINDER HEAD/VALVES _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ CYLINDER HEAD/VALVES _________________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------------------------------------- 7- 1 TROUBLESHOOTING -------------------------------------------------------------------------------- 7- 2 CAMSHAFT REMOVAL ----------------------------------------------------------------------------- 7- 3 CYLINDER HEAD REMOVAL -------------------------------------------------------------------- 7- 6 CYLINDER HEAD DISASSEMBLY -------------------------------------------------------------- 7- 7 CYLINDER HEAD INSPECTION ------------------------------------------------------------------ 7- 8...
Page 109 7. CYLINDER HEAD/VALVES Dink-R 150...
Page 110: Service Information
Dink-R 150 7. CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL INSTRUCTIONS  The cylinder head can be serviced with the engine installed in the frame.  When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
Page 111: Troubleshooting
7. CYLINDER HEAD/VALVES Dink-R 150 TROUBLESHOOTING Poor performance at idle speed White smoke from exhaust muffler  Compression too low  Worn valve stem or valve guide  Damaged valve stem seal Compression too low  Incorrect valve clearance adjustment Abnormal noise ...
Page 112: Camshaft Removal
Dink-R 150 7. CYLINDER HEAD/VALVES CAMSHAFT REMOVAL Remove four bolts to remove the cylinder head cover. Remove the cam chain tensioner cap’s screw and the O-ring. Turn the cam chain tensioner screw clockwise to tighten it. Blots Turn the flywheel counterclockwise so that the “T”...
Page 113 7. CYLINDER HEAD/VALVES Dink-R 150 Unscrew the bolt attaching to cam sprocket gear. Remove the cam sprocket gear. Notice the cam chain to avoid drop into crankcase. Hold the cam chain while removing the camshaft. Remove the socket bolts fixing the camshaft stop plate to the cam holder..
Page 114 Dink-R 150 7. CYLINDER HEAD/VALVES CAMSHAFT INSPECTION Check each cam lobe for wear or damage. Measure the cam lobe height. Service Limits: IN :29.38mm replace if below EX:29.47mm replace if below Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or has excessive wear.
Page 115: Cylinder Head Removal
7. CYLINDER HEAD/VALVES Dink-R 150 Measure the I.D. of each valve rocket arm. Service Limits:. IN: 10.10mm replace if over EX:10.10mm replace if over Measure each rocker arm shaft O.D. Service Limits: IN: 9.91mm replace if below EX: 9.91mm replace if below CYLINDER HEAD REMOVEL Remove the throttle body.
Page 116: Cylinder Head Disassembly
Dink-R 150 7. CYLINDER HEAD/VALVES Unscrew four nuts mounting on the camshaft holder. Remove the cylinder head. Remove the dowel pins and cylinder head gasket. Remove the lower cam chain guide. CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, Springs, spring seats and valve stem using a .valve spring compressor.
Page 117: Cylinder Head Inspection
7. CYLINDER HEAD/VALVES Dink-R 150 Remove carbon deposits from the combustion chamber. Clean off any gasket residue from the cylinder head contact surface. ＊ Be careful not to damage the cylinder head mating surface. CYLINDER HEAD INPECTION Check the spark plug hole and valve areas for cracks.
Page 118: Cylinder Head Installation
Dink-R 150 7. CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY Install the valve spring seats and valve stem seals. Lubricate each valve stem with engine oil and insert the valves into the valve guides. Be sure to install new valve stem seals.
Page 119 7. CYLINDER HEAD/VALVES Dink-R 150 Install the cylinder head and make the cam chain to pass through it, then hold the cam chain to avoid dropping down. Install the cam sprocket gear and its fixture, then bolt up to the specified torque.
Page 120 Dink-R 150 7. CYLINDER HEAD/VALVES ADJUST VLAVE CLEARANCE Inspect and adjust valve clearance. Valve Clearance: IN: 0.10 mm EX: 0.10 mm Loosen the lock nut and adjust by turning the adjusting screw to the specified clearance then tighten lock nut.
Page 121: Cylinder/Piston
8. CYLINDER/PISTON Dink-R 150 _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ CYLINDER/PISTON _________________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------------------------------------- 8-1 SERVICE INFORMATION -------------------------------------------------------------------------- 8-2 TROUBLESHOOTING -------------------------------------------------------------------------------- 8-2 CYLINDER REMOVAL ------------------------------------------------------------------------------ 8-3 PISTON REMOVAL ----------------------------------------------------------------------------------- 8-3 PISTON INSTALLATION---------------------------------------------------------------------------- 8-7 CYLINDER INSTALLATION ----------------------------------------------------------------------- 8-7...
Page 122: Schematic Drawing
8. CYLINDER/PISTON Dink-R 150 SCHEMATIC DRAWING...
Page 123: Service Information
8. CYLINDER/PISTON Dink-R 150 SERVICE INFORMATION GENERAL INSTRUCTIONS  The cylinder and piston can be serviced with the engine installed in the frame.  When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.
Page 124: Cylinder Removal
8. CYLINDER/PISTON Dink-R 150 CYLINDER REMOVAL Remove the cylinder head. Remove the cam chain guide. Remove the cylinder Remove the cylinder gasket and dowel pins. Clean any gasket material from the cylinder surface. PLSTON REMOVAL Remove the piston pin clip.
Page 125 8. CYLINDER/PISTON Dink-R 150 Inspect the piston rings for movement by rotating the rings. ＊ Take care not to damage or break the piston ring during removal. Clean carbon deposits from the piston ring grooves. Insert each piston ring into the piston and measure the piston ring-to-groove clearance.
Page 126 8. CYLINDER/PISTON Dink-R 150 Measure the piston pin O.D. Service Limit: 15.96 mm replace if below Measure the piston O.D. Service Limit: 58.95mm replace if below ＊ Take measurement at 6mm from the bottom and 90°degree to the piston pin...
Page 127 8. CYLINDER/PISTON Dink-R 150 Inspect the top of the cylinder for warp. Service Limit: 0.05 mm repair or replace if over. Measure the connecting rod small end I.D. Service limit:15.06mm replace if over. PISTON RING INSTALLATION Install piston ring onto the piston.
Page 128: Piston Installation
8. CYLINDER/PISTON Dink-R 150 PISTON INSTALLATION Remove any gasket material from the crankcase surface. ＊ Be careful not to drop foreign matters into the crankcase. Install the piston, piston pin and a new piston pin clip. ＊  Position the piston “IN” mark on the intake valve side.
Page 129 Dink-R 150 9. DRIVEN PULLEYS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVEN PULLEYS __________________________________________________________________________________ SERVICE INFORMATION ----------------------------------------------------- 9-1 TROUBLESHOOTING ---------------------------------------------------------- 9-1 LEFT CRANKCASE COVER --------------------------------------------------- 9-3 DRIVE PULLEY ------------------------------------------------------------------- 9-3 CLUTCH/DRIVEN PULLEY --------------------------------------------------- 9-8...
Page 130 9. DRIVEN PULLEYS Dink-R 150...
Page 131: Service Information
Dink-R 150 9. DRIVEN PULLEYS SERVICE INFORMATION GENERAL INSTRUCTIONS The drive pulley, clutch and driven pulley can be serviced with the engine installed. Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
Page 132: Left Crankcase Cover
9. DRIVEN PULLEYS Dink-R 150 LEFT CRANKCASE COVER REMOVAL Remove 4 bolts attaching to left crankcase cover protector. Remove 8 bolts attaching to left crankcase cover. Remove the gasket and dowel pins. INSTALLATION Install the dowel pins. Install the collar.
Page 133 . DRIVEN PULLEYS Dink-R 150 INSPECTION Check the drive belt for cracks, separation or abnormal or excessive wear. Drive Pulley Collar Remove the movable drive face assembly and drive pulley collar from the crankshaft. Movable Drive Face Assembly Remove the ramp plate.
Page 134 . DRIVEN PULLEYS Dink-R 150 INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service limit : 17.9mm replace if below Measure the I.D. Of the movable drive face assembly Check the drive pulley collar for wear or damage.
Page 135 . DRIVEN PULLEYS Dink-R 150 ASSEMBLY Install the weight rollers into the movable drive face. Install the ramp plate Ramp Plate...
Page 136 . DRIVEN PULLEYS Dink-R 150 Insert the drive pulley collar into the movable drive face. Drive Pulley Collar INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly Install the Install the drive belt onto the clutch/driven pulley assembly and drive pulley collar.
Page 137: Clutch/Driven Pulley
. DRIVEN PULLEYS Dink-R 150 Install the drive pulley, and nut. Make sure to align to the crankshaft’s gear when the starting ratchet installed. Drive face nut torque:5.0-6.0kg*m Universal Holder Drive Pulley Face Hold the movable drive pulley’s nut with the universal holder.
Page 138 . DRIVEN PULLEYS Dink-R 150 Check the clutch lining for wear or damage. Measure the clutch lining thickness. Service Limit: 1.5 mm replace if below DISASSEMBLY Be sure to use a clutch spring compressor to avoid spring damage. Clutch / Driven pulley...
Page 139 . DRIVEN PULLEYS Dink-R 150 Guide Roller Pins Guide Roller Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Movable Driven Face O-Rings Remove the O-rings and oil seal from the movable driven face.
Page 140 . DRIVEN PULLEYS Dink-R 150 Check the movable driven face for wear or damage. Measure the movable driven face I.D. Inner Needle Bearing Drive the inner needle bearing out of the driven pulley face. Discard the removed bearing and replace with a new one.
Page 141 . DRIVEN PULLEYS Dink-R 150 Press a new needle bearing into the driven face. Circlips CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. Keep grease off the clutch linings. Clutch Lining Retainer Plate 9-12...
Page 142 . DRIVEN PULLEYS Dink-R 150 CLUTCH / DRIVEN PULLEY ASSEMBLY Drive Plate Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips.
Page 143 . DRIVEN PULLEYS Dink-R 150 Guide Roller Pins Guide Roller Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face.
Page 144 . DRIVEN PULLEYS Dink-R 150 Clutch Outer Install the clutch outer. Hold the clutch outer with the flywheel holder. Install and tighten the clutch outer nut. Torque: 5.0-6.0 kg-m Universal holder A120E00017 Install the drive belt. Install the left crankcase cover.
Page 145: Final Reduction
Dink-R 150 . FINAL REDUCTION _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ FINAL REDUCTION _________________________________________________________________________________________ SERVICE INFORMATION ....................10-2 TROUBLESHOOTING ..................... 10-2 FINAL REDUCTION DISASSEMBLY ................10-3 FINAL REDUCTION INSPECTION ................10-3 FINAL REDUCTION ASSEMBLY .................. 10-5 10-0...
Page 146 Dink-R 150 . FINAL REDUCTION 10-1...
Page 147 Dink-R 150 . FINAL REDUCTION SERVICE INFORMATION GENERAL INSTRUCTIONS  When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity: At change : 0.13liter At disassembly : 0.12liter...
Page 148 Dink-R 150 . FINAL REDUCTION FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. Remove the rear wheel. Remove the air cleaner cover. Remove the left crankcase cover. Remove the clutch/driven pulley. Drain the transmission gear oil into a clean container. Remove the transmission case cover attaching bolts.（10bolts）...
Page 149 Dink-R 150 . FINAL REDUCTION Drive Shaft Bearing Final Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Countershaft Bearing Drive Shaft Bearing Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage.
Page 150 Dink-R 150 . FINAL REDUCTION Use a seal pick to remove the oil seals. Use a bearing driver to install any new bearings into the crankcase and transmission Case cover. The drive should have the same Outside diameter as the bearings. The bearings should go in square and have their marking facing out.
Page 151 Dink-R 150 . FINAL REDUCTION Installation Lubricate the final drive bearings with fresh final drive oil. Coat the lips of the seals with fresh final drive oil. Press the drive shaft back into the transmission case cover as shown Insert the final shaft through the oil seal and bearing.
Page 152 Dink-R 150 . FINAL REDUCTION Install the dowel pins. Install a new gasket onto the transmission case. 10-7...
Page 153 Dink-R 150 . FINAL REDUCTION Install the transmission case cover onto the transmission. Fit the drive into its bearing in the case and make sure the gear engages correctly with the countershaft gear. Turn the drive shaft and make sure the final shaft turns.
Page 154: Crankcase/Crankshaft
Dink-R 150 11. CRANKCASE/CRANKSHAFT _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ CRANKCASE/CRANKSHAFT _________________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------------------------------------- 11-1 SERVICE INFORMATION -------------------------------------------------------------------------- 11-2 TROUBLESHOOTING -------------------------------------------------------------------------------- 11-2 CRANKCASE SEPARATION ----------------------------------------------------------------------- 11-3 CRANKSHAFT INSPECTION ---------------------------------------------------------------------- 11-4 CRANKCASE ASSEMBLY ------------------------------------------------------------------------- 11-5 11-0...
Page 155 Dink-R 150 11. CRANKCASE/CRANKSHAFT SCHEMATIC DRAWING 11-1...
Page 156 Dink-R 150 11. CRANKCASE/CRANKSHAFT SERVICE INFORMATION......11-1 CRANKSHAFT INSPECTION.....11-4 TPOUBLESHOOTING........11-1 CRANKCASE ASSEMBLY....11-5 CRANKCASE SEPARATION......11-2 SERVICE INFORMATION GENERAL INSTRUCTIONS  This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. SPECIFICATIONS Standard (mm) Service Limit (mm) Item 0.1～0.35...
Page 157 Dink-R 150 11. CRANKCASE/CRANKSHAFT CRANKCASE SEPARATION Remove the pivot bolt of cam chain tensioner and cam chain tensioner slipper. Ckeck if the O-ring damaged. Remove three bolts attaching to the right crankcase. Remove one bolt mounted on the side as left picture.
Page 158 Dink-R 150 11. CRANKCASE/CRANKSHAFT Clean off all gasket material from the crankcase mating surfaces. ＊  Avoid damaging the crankcase mating surfaces. Remove the oil seal from the right crankcase. Check the oil seal lip for wear or deterioration. The installation sequence is the reverse of removal Oil seal ＆...
Page 159 Dink-R 150 11. CRANKCASE/CRANKSHAFT Measure the crankshaft runout. Service Limit: 0.10 mm replace if over. Turn the crankshaft bearings and check for excessive play. If not turning smoothly and quietly or if the fitting is loosely in the crankshaft,replace the crankshaft as a set.
Page 160 Dink-R 150 11. CRANKCASE/CRANKSHAFT Tighten the crankcase four attaching bolts. Torque :1.0kg-m Engage the cam chain to the corresponding gear on crankshaft. Install the cam chain tension slipper. Tighten the pivot bolt of cam chain tension slipper. Torque:1.0kg-m 11-6...
Page 161: Cooling System
Dink-R 150 12. COOLING SYSTEM _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ COOLING SYSTEM _________________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------------------------------------- 12- 1 SERVICE INFORMATION -------------------------------------------------------------------------- 12- 2 TROUBLESHOOTING -------------------------------------------------------------------------------- 12- 2 COOLING SYSTEM TESTING --------------------------------------------------------------------- 12- 4 RADIATOR ---------------------------------------------------------------------------------------------- 12- 4 WATER PUMP ------------------------------------------------------------------------------------------ 12- 8...
Page 162: Schematic Drawing
12. COOLING SYSTEM Dink-R 150 SCHEMATIC DRAWING 12-1...
Page 163: Service Information
Dink-R 150 12. COOLING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS  The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame.  The engine must be cool before servicing the cooling system.
Page 164 945cc 774cc ＊  Use coolant of specified mixing rate. (The mixing rate of 860cc KYMCO SIGMA coolant concentrate + 859cc distilled water is 50%.)  Do not mix coolant concentrate of different brands.  Do not drink the coolant, which is poisonous.
Page 165: Cooling System Testing
Dink-R 150 12. COOLING SYSTEM COOLING SYSTEM TESTING Radiator Tester RADIATOR CAP INSPECTION Install the radiator cap onto the radiator tester and apply specified pressure to it. It must hold specified pressure for at least six seconds. ＊ Apply water to the sealing cap surface before testing.
Page 166 Dink-R 150 12. COOLING SYSTEM Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects are clogging the radiator, wash them off. Carefully straighten any bent fins. Radiator Radiator RADIATOR REMOVAL Drain the coolant.
Page 167 12. COOLING SYSTEM Dink-R 150 Bolts Remove three bolts on the radiator. Remove the radiator. Bolts RADIATOR DISASSEMBLY Remove three bolts and then remove the fan rubber from the radiator. Check fan motor by battery. 12-6...
Page 168 Dink-R 150 12. COOLING SYSTEM Overflow Tube RADIATOR INSTALLATION Install the fan rubber on the radiator with three bolts. Install the radiator on the radiator bracket with three bolts/nuts. Connect the upper and lower hoses and secure them with hose bands.
Page 169: Water Pump
12. COOLING SYSTEM Dink-R 150 Right Crankcase Cover Air Vent Tube WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover replace mechanical seal.
Page 170 Dink-R 150 12. COOLING SYSTEM Water Pump Shaft WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove bolts attaching the right crankcase cover. Remove the water pump bearing snap ring from the water pump assembly.
Page 171 12. COOLING SYSTEM Dink-R 150 Seal Washer (Porcelain) Impeller Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover. Tighten 9bolts to secure the right crankcase cover. ＊ When installing the water pump assembly, aligning the groove on the water pump shaft with the tab on the oil pump shaft.
Page 172: Thermosensor
Dink-R 150 12. COOLING SYSTEM THERMOSENSOR THERMOSENSOR REMOVAL Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor THERMOSENSOR INSPECTION Thermosensor Suspend the thermosensor in a pan of water over a burner and measure the resistance through the sensor as the water heats up.
Page 173: Thermostat
12. COOLING SYSTEM Dink-R 150 THERMOSTAT THERMOSTAT REMOVAL Bolts Remove the met-in box and carrier. Remove the body cover, center cover and rear fender cover A. Drain the coolant. Disconnect the water hose from the thermostat housing. Remove the mounting bolt and the thermostat housing from the cylinder head.
Page 174: Front Wheel/Front Brake/Front Suspension
STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT WHEEL/FRONT BRAKE/FRONT SUSPENSION SERVICE INFORMATION ....................13-2 TROUBLESHOOTING ...................... 13-3 FRONT WHEEL ......................... 13-4 HYDRAULIC BRAKE DRAWING .................. 13-7 HYDRAULIC BRAKE ....................... 13-8 FRONT SHOCK ABSORBER ..................13-13 STEERING HANDLEBAR ....................13-14 STEERING STEM ......................
Page 175 STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 13-1...
Page 176 STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK 13-2...
Page 177: Service Information
STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION GENERAL INSTRUCTIONS  Remove the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.  During servicing, keep oil or grease off the brake drum and brake linings.
Page 178: Troubleshooting
STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SPECIAL TOOLS Lock nut wrench Driver handle A Outer driver, 28x30mm Pilot, 10mm Ball race remover Outer driver, 37x40mm Pliers (close) Bearing remover Bearing remover head, 10mm TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling ...
Page 179: Front Wheel
STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT WHEEL REMOVAL Remove the front wheel off the ground. Remove the front axle nut and pull out the axle. Remove the front wheel. Axle Nut INSPECTION AXLE RUNOUT Axle Shaft Set the axle in V blocks and measure the runout using a dial gauge.
Page 180 STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK FRONT WHEEL BEARING Remove the side collar(1) and dust seal(2). Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly. Also check if the outer race fits tightly in the hub.
Page 181 STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Apply grease to a new dust seal lip and install the dust seal. Install the side collar. INSTALLATION Apply a thin coat of grease to the axle shaft. Install the front wheel.
Page 182: Hydraulic Brake
STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING Check the brake fluid level on level ground. ＊  When operating the brake lever, the brake reservoir cap must be tightened securely to avoid splash of brake fluid.
Page 183 STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Install the brake pads in the reverse order of removal. Tighten the brake pad pin bolt. Torque: 1.5～2.0kg-m ＊ Keep grease or oil off the brake pads to avoid brake failure.
Page 184 STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Master Cylinder Diaphragm Main Piston Remove the main piston and spring from the brake master cylinder. Clean the inside of the master cylinder and brake reservoir with brake fluid. Snap Ring...
Page 185 STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolts Place the brake master cylinder on the handlebar and install the holder with the “up” mark facing up. Also align the punch mark with the holder joint seam. First tighten the upper bolt and then tighten the lower bolt.
Page 186 STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Remove the pistons from the brake caliper. If necessary, use compressed air to squeeze out Brake piston the pistons through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed pistons.
Page 187: Front Shock Absorber
STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ASSEMBLY Clean all removed parts. Brake Pads Apply silicon grease to the pistons and oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out.
Page 188: Steering Handlebar
STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK INSPECTION Inspect the following items and replace if necessary. Front shock absorber tube bending or damage. Weak front shock absorber spring. Damper and damper rod bending. Oil seal damage or wear.
Page 189: Steering Stem
STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Remove the throttle seat from the handlebar and Lock Nut wrench disconnect the throttle cable from the throttle pipe. Remove the throttle pipe from the handlebar. Remove two screws and then remove the left handlebar switch.
Page 190 STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Top Cone Race Remove the top cone race. ＊  Be careful not to lose the steel balls (20 on top race and 15 on bottom race).  Clean the openings of frame covers with clean shop towels.
Page 191 STEERING HANDLEBAR/FRONT WHEEL/ Dink-R 150 FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Top Steel Ball INSTALLATION Install the top and bottom steel balls. Apply grease to the top and bottom ball races and install 20 steel balls on the top ball race and 15 steel balls on the bottom ball race.
Page 192: Rear Wheel/Rear Brake/Rear
. REAR WHEEL/REAR BRAKE/REAR Dink-R 150 SHOCK ABSORBER REAR WHEEL/REAR RAKE/REAR SHOCK ABSORBER SERVICE INFORMATION ....................14-2 TROUBLESHOOTING ..................... 14-2 REAR BRAKE ........................14-3 REAR WHEEL ------------------------------------------------------------------------------------------- 14-7 REAR SHOCK ABSORBER..................... 14-8 14-0...
Page 193 . REAR WHEEL/REAR BRAKE/REAR Dink-R 150 SHOCK ABSORBER 14-1...
Page 194 . REAR WHEEL/REAR BRAKE/REAR Dink-R 150 SHOCK ABSORBER SERVICE INFORMATION GENERAL INSTRUCTIONS · When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scaiding. · During servicing, keep oil or grease off the brake pads and brake disk.
Page 195 . REAR WHEEL/REAR BRAKE/REAR Dink-R 150 SHOCK ABSORBER Fluid tube bolt Caliper REAR BRAKE REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler Remove the rear brake fluid tube bolt and disconnect the brake fluid tube. Remove two bolts attaching the rear brake caliper.
Page 196 . REAR WHEEL/REAR BRAKE/REAR Dink-R 150 SHOCK ABSORBER Compressed Air Remove the piston from the brake caliper. if necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a towel under the caliper to avoid contamination caused by the removed piston.
Page 197 . REAR WHEEL/REAR BRAKE/REAR Dink-R 150 SHOCK ABSORBER ASSEMBLY Clean all removed parts. Apply silicon grease to the piston and oil seal. Lubricate the brake caliper cylinder inside wail with brake fluid. Install the brake caliper piston with grooved side facing out.
Page 198 . REAR WHEEL/REAR BRAKE/REAR Dink-R 150 SHOCK ABSORBER INSTALLATION Fluid tube bolt Install the brake caliper to the rear fork and tighten the two bolts. Torque: 27 N-m Connect the brake fluid tube to the brake caliper and install fluid tube bolt, copper washers and tighten the fluid tube bolt.
Page 199 . REAR WHEEL/REAR BRAKE/REAR Dink-R 150 SHOCK ABSORBER Brake caliper Rear shock REAR WHEEL REMOVAL Remove the exhaust muffle Remove the rear brake caliper Remove the rear fork Rear fork Remove the rear axle collar. Remove the rear wheel. Rear brake disk INSPECTION Measure the rear wheel rim runout.
Page 200 . REAR WHEEL/REAR BRAKE/REAR Dink-R 150 SHOCK ABSORBER Upper Mount Bolts REAR SHOCK ABSORBER REMOVAL Remove the front cover. Remove the met-in box. Remove the air cleaner case. Remove the rear shock absorber upper and lower mount bolts to remove the rear shock absorber.
Page 201 Dink-R 150 . BATTERY/CHARGING SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT ---------------------------------------- 15-1 CHARGING CIRCUIT ----------------------------------------------------- 15-1 SERVICE INFORMATION ------------------------------------------------ 15-2 TROUBLESHOOTING ----------------------------------------------------- 15-3 BATTERY CHARGING --------------------------------------------------- 15-5 REGULATOR/RECTIFIER ---------------------------------------------- 15-6 15-0...
Page 202: Generator
. BATTERY/CHARGING SYSTEM Dink-R 150 CHARGING SYSTEM LAYOUT Regulator/Rectifier A.C Generator 12V8.6AH 15-1...
Page 203: Service Information
Dink-R 150 . BATTERY/CHARGING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention ...
Page 204 . BATTERY/CHARGING SYSTEM Dink-R 150 TROUBLESHOOTING No power Intermittent power  Dead battery  Loose battery cable connection  Disconnected battery cable  Loose charging system connection  Fuse burned out  Loose connection or short circuit in  Faulty ignition switch...
Page 205 Dink-R 150 . BATTERY/CHARGING SYSTEM BATTERY REMOVAL Regulator/Rectifier Remove the battery cover. Disconnect the battery cables . ＊ First disconnect the battery negative (-) cable and then the positive (+) cable. Remove the battery. The installation sequence is the reverse of removal.
Page 206 Dink-R 150 . BATTERY/CHARGING SYSTEM PERFORMANCE TEST Warm up the engine. Remove the floor mat and front tool box cover. ＊ Use a fully charged battery to check the charging system output. Stop the engine and open the fuse box.
Page 207: Regulator/Rectifier
. BATTERY/CHARGING SYSTEM Dink-R 150 A.C.GENERATOR REMOVAL A.C. generator removal A.C. generator installation REGULATOR/RECTIFIER INSPECTION Remove the met-in box. Remove the regulator/rectifier wire coupler. Check the continuity between the wire terminals. Normal Direction: Continuity (+)Probe (-)Probe Ⅰ Yellow Green Regulator/Rectifier Ⅱ...
Page 208: Ignition System
Dink-R 150 16. IGNITION SYSTEM _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ IGNITION SYSTEM _________________________________________________________________________________________ IGNITION SYSTEM LAYOUT --------------------------------------------------------------- 16-1 SERVICE INFORMATION -------------------------------------------------------------------- 16-2 TROUBLESHOOTING ------------------------------------------------------------------------- 16-2 SPARK PLUG ------------------------------------------------------------------------------------- 16-3 IGNITION COIL INSPECTION -------------------------------------------------------------- 16-3 A.C. GENERATOR INSPECTION ----------------------------------------------------------- 16-4 16-0...
Page 209 Dink-R 150 16. IGNITION SYSTEM IGNITION SYSTEM LAYOUT Ignition Coil Spark Plug Ignition Switch A.C. Generator (Exciter Coil) 12V8.6AH 16-1...
Page 210 Dink-R 150 16. IGNITION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS  Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present.  When servicing the ignition system, always follow the steps in the troubleshooting on page 17-2.
Page 211 Dink-R 150 16. IGNITION SYSTEM Ignition Coil IGNITION COIL INSPECTION Remove the seat and met-in box. Remove the ignition coil. IGNITION COIL CONTINUITY TEST Inspect the continuity of the ignition coil, primary coil and secondary coil. Measure the ignition coil resistances 0.55~0.75Ω/20℃...
Page 212 Dink-R 150 16. IGNITION SYSTEM Crank Position Sensor Coupler. CRANK POSITION SENSOR INSPECTION This test is performed with the stator installed in the engine Remove the seat and met-in box. Disconnect the Crank Position Sensor Wire Coupler. Measure the resistance between the blue/white and green/white wire terminals.
Page 213 Dink-R 150 16. IGNITION SYSTEM REMOVAL/INSTALLATION Connector nuts Disconnect the connector and remove two nuts, then remove tilt switch. Installation is in the reverse order of removal. ＊ Install the tilt switch with its “up” mark facing up. Tighten the mounting screws securely.
Page 214: Starting System
Dink-R 150 17. STARTING SYSTEM _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ STARTING SYSTEM _________________________________________________________________________________________ STARTING SYSTEM LAYOUT -------------------------------------------------------------------- 17-1 SERVICE INFORMATION -------------------------------------------------------------------------- 17-2 TROUBLESHOOTING -------------------------------------------------------------------------------- 17-2 STARTER MOTOR ------------------------------------------------------------------------------------ 17-3 STARTER RELAY INSPECTION ------------------------------------------------------------------ 17-4 17-0...
Page 215 Dink-R 150 17. STARTING SYSTEM Starter Relay ② STARTING SYSTEM LAYOUT Starter Relay ① Starter Motor 17-1...
Page 216 Dink-R 150 17. STARTING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS  The removal of starter motor can be accomplished with the engine installed.  After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
Page 217 Dink-R 150 17. STARTING SYSTEM Starter Motor STARTER MOTOR REMOVAL Disconnect the starter motor cable. Remove the two bolts attaching the starter motor and remove the starter motor. The installation sequence is the reverse of removal. DISASSEMBLY Remove two starter motor case screws, front cover, rear cover, motor case and other parts.
Page 218 17. STARTING SYSTEM Dink-R 150 Pull back the rubber cover. INSTALLATION Remove the starter motor lead screw with a #3 Phillips screwdriver. Connect the starter motor cable. Free the cable lead from the starter motor. Check the O-ring for wear or damage and replace if necessary.
Page 219 Dink-R 150 17. STARTING SYSTEM Starter Relay STARTER RELAY INSPECTION Remove the frame body cover. Turn the ignition switch ON and the starter relay is normal if you hear a click when the starter button is depressed. If there is no click sound: ...
Page 220 17. STARTING SYSTEM Dink-R 150 STARTER CLUTCH REMOVAL Remove the right crankcase cover. Unscrew the mounting nut of A.C generator. Remove the A.C generator. Flywheel puller A120E00003 Universal holder A120E00017 ＊ The lock nut is left threaded Remove the starter clutch.
Page 221 Dink-R 150 17. STARTING SYSTEM Measure the starter idle gear I.D Service Limit: 9.05mm replace if over. Measure the starter idle gear shaft O.D Service Limit:8.94mm replace if below Install the starter clutch onto the crankshaft. Apply engine oil to the starter idle gear and shaft and then install them.
Page 222 . INSTRUMENT/SWITCHES/LIGHTS Dink-R 150 _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ INSTRUMENT/SWITCHES/LIGHTS _________________________________________________________________________________________ SERVICE INFORMATION ....................18-1 TROUBLESHOOTING ..................... 18-1 FUEL UNIT ........................18-2 SWITCHES ........................18-4 STOP SWITCH INSPECTION/HORN ................18-6 INSTRUMENT/HEADLIGHT ..................18-8 18-0...
Page 223 Dink-R 150 . INSTRUMENT/SWITCHES/LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS  Wires should be connected to other wires of the same color. Couplers must be connected to other couplers of the same color.  All plastic plugs have locking tabs that must be released before disconnecting, and must be aligned when reconnecting.
Page 224 . INSTRUMENT/SWITCHES/LIGHTS Dink-R 150 stay Fuel Hose FUEL PUMP REMOVAL Remove the seat and met-in. Remove the center cover. Remove the stay of floor plate. Remove the fuel pump connector Be sure to relieve the fuel pressure before removing fuel pump or fuel hose.
Page 225 Dink-R 150 . INSTRUMENT/SWITCHES/LIGHTS BRAKE LIGHT SWITCH Remove the upper handlebar cover. Disconnect front or rear brake light switch connectors check continuity between the switch terminals. There should be continuity with the front or rear brake lever squeezed, and there should be no continuity with the front or rear brake lever is released.
Page 226 . INSTRUMENT/SWITCHES/LIGHTS Dink-R 150 Dimmer Switch RIGHT HANDLEBAR SWITCH INSPECTION Remove the up and down handlebar cover. Disconnect the right handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows:...
Page 227 Dink-R 150 . INSTRUMENT/SWITCHES/LIGHTS Engine Stop Switch LEFT HANDLEBAR SWITCH INSPECTION Remove the up and down handlebar cover. Disconnect the left handlebar switch connector and check for continuity at switch side connector terminals. Continuity should exist between the color code wires as follows:...
Page 228 . INSTRUMENT/SWITCHES/LIGHTS Dink-R 150 Horn HORN INSPECTION Remove the front cover .(2-6) Remove the floorboard. (2-8) Remove the inner cover. (2-10) Disconnect the horn wire couplers. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals.
Page 229 Dink-R 150 . INSTRUMENT/SWITCHES/LIGHTS HEADLIGHT CONTROLLER The Headlight is come on when the engine starts. INSPECTION Turn the ignition switch to “ON” Connect the multimeter (+) probe to the Black/Green terminal and the multi-meter (-)probe to the Green terminal. The voltage is the battery voltage.
Page 230 . INSTRUMENT/SWITCHES/LIGHTS Dink-R 150 SIDE STAND SWITCH connector INSPECTION Remove the luggage box. Side stand switch is located on side stand. Disconnect the side stand switch connector. There should be continuity between the Yellow/Green and Green with the side stand is up.
Page 231: Evaporative Emission Control System
Dink-R 150 EVAPORATIVE EMISSION CONTROL SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM SCHEMATIC DRAWING ---------------------------------------------------------- 19-1 EVAPORATIVE EMISSION CONTROL SYSTEM FUNCTION ------------ 19-2 TROUBLESHOOTING -------------------------------------------------------------- 19-2 SERVICE INFORMATION -------------------------------------------------------- 19-3 PERGE CONTROL VALVE ------------------------------------------------------- 19-4 CHARCOAL CANISTER ----------------------------------------------------------- 19-6 19-0...
Page 232 Dink-R 150 EVAPORATIVE EMISSION CONTROL SYSTEM SCHEMATIC DRAWING Fuel tank cap Air Cleaner Fuel Injector Charcoal Canister Purge Control Valve Throttle Body 19-1...
Page 233 Dink-R 150 EVAPORATIVE EMISSION CONTROL SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM FUNCTION FOREWORD: The Evaporative Emission Control System is abbreviated to E.E.C. System. This device collects the fuel vapor from the fuel tank and then the fuel vapor is drawn into the engine for re-burning to avoid air pollution caused by the fuel vapor diffused into the air.
Page 234 Dink-R 150 EVAPORATIVE EMISSION CONTROL SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS  Do not smoke or allow flames or sparks near the working area.  Note the locations of tubes for proper installation.  Replace any damaged tube with a new one.
Page 235 Dink-R 150 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE To Throttle Body REMOVAL 1. Remove the front cover. 2. Disconnect the purge control valve vacuum tube that goes to the throttle body and the tubes that go to the air cleaner and charcoal canister.
Page 236 Dink-R 150 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE FLOW INSPECTION 1. Connect a vacuum pump to the purge control valve vacuum tube and apply vacuum pressure of 45mm/Hg. 2. Connect a pressure pump to the tube that goes to the charcoal canister and apply Pressure Pump pressure.
Page 237 Dink-R 150 EVAPORATIVE EMISSION CONTROL SYSTEM CHARCOAL CANISTER To Throttle Body REMOVAL 1. Remove the front cover. 2. Disconnect the charcoal canister tubes that go to the fuel tank and purge control valve. 3. Remove the charcoal canister. Charcoal Canister...
Page 238 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 ANTI-LOCK BRAKE SYSTEM (ABS) ABS Indicator Light ----------------------------------------- --------- 20－01 ABS Introduction -------------------------------------------- --------- 20－02 ABS Parts Location ----------------------------------------- --------- 20－03 Wheel Speed ------------------------------------------------- --------- 20－04 ABS ECU & ABS Hydraulic Unit ------------------------ --------- 20－06 ABS ECU GUARANTEE ---------------------------------- --------- 20－07...
Page 239 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 ABS Indicator Light The ABS indicator light in the meter position. This light will comes on when the ignition switch is turned on and goes off shortly after the vehicle starts moving at speed 6km/hr min. It stays off.
Page 240 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 ABS Introduction ABS is designed to help prevent the wheels from locking up when the brakes are applied hard while running straight. The ABS automatically regulates brake force. Intermittently gaining gripping force and braking force helps prevent wheel lock-up and allows stable steering control while stopping.
Page 241 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 Troubleshooting Outline The ABS indicator light lights up to alert the rider when an abnormality is detected by the system. The service codes are stored in the ABS unit memory. The codes will not be erased unless manually cleared.
Page 242 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 Pre-diagnosis Inspection Chart 5 Pre-diagnosis Inspection Chart 2 20-4...
Page 243 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 Parts Location Front Wheel speed Sensor’s connector Front Wheel speed Sensor Front Wheel speed Sensor Rotor Rear Wheel speed Sensor’s connector Rear Wheel speed Sensor Rotor Rear Wheel speed Sensor ABS diagnosis tool Connector (Near battery ABS ECU &...
Page 244 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 WH EEL SENSOR Front Wheel Speed Sensor REMOVAL & INSPECTION Remove the front wheel speed sensor. Install the front wheel speed sensor. Front Wheel Speed Sensor Rotor Remove a bolt attaching to the front wheel speed sensor Front Wheel speed Sensor’s connector...
Page 245 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 Rear Wheel Speed Sensor Remove the rear wheel speed sensor. Rear Wheel Speed Sensor Rotor Remove the connector of rear wheel speed sensor <Rear Wheel Speed Sensor> Rear Wheel speed Sensor’s connector ※ Standard clearance: Less than 0.8mm between the Rear wheel speed sensor and Rear Wheel...
Page 246 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 ABS ECU REMOVAL& INSTALLATION The coupler is used for automobile’s waterproof. Please take car of operation. Please keep a good ventilating about ECU in order to prevent the ABS ECU from high temperature. (一) Push upward (二) Take right out...
Page 247 DTC(Failure codes) 1. Connect the KYMCO Fi Diagnostic tool 2. Put the side stand upward and ENG. stop switch is at “RUN” position. 3. Connect the diagnostic tool connector. (KYMCO Fi Diagnostic tool Power comes from vehicle’s Battery) Self-Diagnostic Tool Connector...
Page 248: Abs System
ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 4. Choose ECU Version and then push down button for two times. 5. Choose No.2 ABS SYS ECU and then push up button to previous. 6. Confirming ECU Version and then enter ABS system.
Page 249 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 7. Choose ECU Version and then push “Enter” button. 8. Confirm ABS ECU Version if is AHA7C000 9. Choose DTC Inspect 20-11...
Page 250 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 10. Load DTC (Active 、Occurred、History) DTC DISPLAYED 1. Rear wheel speed sensor disconnect DTC CLEARED 1. Choose “Clear DTC” and then push “Enter” button. 20-12...
Page 251 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 2. Clearing DTC completed until the DTC red lamp is off. DATA ANALYZE 1. Choose “DATA Analyze” and then push “Enter” button 2. Front wheel speed & Rear wheel speed & Battery volt Battery volt: Standard 9.6~16.7V...
Page 252 ANTI-LOCK BRAKE SYSTEM (ABS) Dink-R 150 Bosch ABS DTC List Bosch ABS DTC LIST Code NO (Diagnostic description (PDA Tool ) 3620A- LEB2-E00 5013 Rear Inlet Valve malfunction(EV) 5014 Rear Outlet Valve malfunction (AV) 5017 Front Inlet Valve malfunction (EV)

KYMCO Dink-R 150 Manual

Preface

Exhaust Muffler/Frame Covers

. Inspection/Adjustment 3

Lubrication System

Fuel Injection System

Cylinder Head/Valves

Cylinder/Piston

Driven Pulleys

Cooling System

Front Brake/Front Shock Absorber/Front Fork 13

Battery/Charging System

Quick Links

TABLE OF CONTENTS

Chapters

Troubleshooting

Related Manuals for KYMCO Dink-R 150

Summary of Contents for KYMCO Dink-R 150

Table of Contents