KYMCO DINK 200 Manual

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PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO DINK

CLASSIC 200.

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before any

operation is started.

Section 2 is the removal/installation

procedures for the frame covers which

are subject to higher removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules and

service information for each part, starting

from periodic maintenance.

Sections 5 through 13 give instructions

for disassembly, assembly and adjustment

of engine parts. Section 14 is the

removal/ installation of chassis. Section

16 states the testing and measuring

methods of electrical equipment. Section

20 provides the maintenance instructions

of the exhaust emission control system.

Most sections start with an assembly or

system illustration and troubleshooting

for the section. The subsequent pages

give detailed procedures for the section.

The information and contents included in

this manual may be different from the

motorcycle in case specifications are

changed.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

GENERAL INFORMATION

EXHAUST MUFFLER/FRAME COVERS

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE AND DRIVEN PULLEYS/KICK

STARTER

FINAL REDUCTION

A.C. GENERATOR/STARTER CLUTCH

CRANKCASE/CRANKSHAFT

COOLING SYSTEM

FUEL SYSTEM/CARBURETOR/FUEL

PUMP

STEERING HANDLEBAR/FRONT

WHEEL/FRONT BRAKE/FRONT

SHOCK ABSORBER/FRONT FORK

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER`

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

SWITCHES/HORN/FUEL UNIT /

T HERMO-STATIC

SWITCH/TEMPERATURE

GAUGE/INSTRUMENTS/ LIGHTS

EXHAUST EMISSION CONT ROL SYST EM

Chapters

Table of Contents

Troubleshooting

Summary of Contents for KYMCO DINK 200

Page 1: Table Of Contents
PREFACE TABLE OF CONTENTS GENERAL INFORMATION This Service Manual describes the technical features and servicing EXHAUST MUFFLER/FRAME COVERS procedures for the KYMCO DINK INSPECTION/ADJUSTMENT CLASSIC 200. LUBRICATION SYSTEM Section 1 contains the precautions for ENGINE REMOVAL/INSTALLATION all operations stated in this manual.
Page 2: Engine Serial Number
DINK 200 . GENERAL INFORMATION ENGINE SERIAL NUMBER ---- 1-0 TOOLS-----------------------------1-11 SPECIFICATION ----------------- 1-1 LUBRICATION POINTS --------1-12 SERVICE PRECAUTIONS ------ 1-2 WIRING DIAGRAM--------------1-14 TORQUE VALUES--------------- 1-9 CABLE & HARNESS ROUTING- 1-19 TROUBLESHOOTING-----------1-20 ENGINE SERIAL NUMBER Location of Engine Serial Number...
Page 3: Specification
DINK 200 . GENERAL INFORMATION SPECIFICATIONS Cooling Type Water cooling Name & Model No. SH40AA Motorcycle Name & Type Dink Classic 200 Overall length 1907mm Overall width 750mm Overall height 1170mm Wheel base 1390mm 4-stroke, Water cooled Engine type Air cleaner type & No Paper element, wet...
Page 4: Service Precautions
DINK 200 . GENERAL INFORMATION 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 DINK 200 . GENERAL INFORMATION  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 DINK 200 . GENERAL INFORMATION  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 DINK 200 . GENERAL INFORMATION  The connector shall be inserted Snapping! completely.  If the double connector has a lock, lock it at the correct position.  Check if there is any loose wire.  Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
Page 8 DINK 200 . GENERAL INFORMATION  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 DINK 200 . GENERAL INFORMATION  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 DINK 200 . GENERAL INFORMATION  After routing, check that the wire harnesses are not twisted or kinked.  Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
Page 11 DINK 200 . GENERAL INFORMATION  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 200 . GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 5mm screw 6mm bolt, nut 6mm screw, SH bolt 8mm bolt, nut 6mm flange bolt, nut 10mm bolt, nut 8mm flange bolt, nut...
Page 13: Special Tools
DINK 200 . GENERAL INFORMATION SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page Valve guide driver Valve guide removal/installation Valve guide reamer Valve guide grinding Valve spring compressor Valve removal Lock nut wrench, 39mm Clutch disassembly Bearing driver Bearing removal...
Page 14: Lubrication Points
DINK 200 . GENERAL INFORMATION LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part •Genuine KYM CO Engine Oil (SAE15W-40) Camshaft protruding surface •API SE, SF or SG Engine Oil Valve rocker arm friction surface Camshaft drive chain...
Page 15 DINK 200 . GENERAL INFORMATION FRAME The following is the lubrication points for the frame. Use general purpose grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the motorcycle.
Page 16 DINK 200 . GENERAL INFORMATION CABLE & HARNESS ROUTING Front Brake Fluid Tube Rear Brake Fluid Tube Front Stop Switch Rear Stop Switch Throttle Cable Speedometer Cable Fuel Vapor Recovery Tube Wire Connectors Horn Fuel Vapor Recovery Tube Pressure Type...
Page 17 DINK 200 . GENERAL INFORMATION Fuel Vapor Recovery Tube Ignition Switch Fuel Filler Fuel Tank Breather Tube Thermostatic Fuel Tank Switch Inlet Tube Water Hose Rear Brake Fluid Tube Front Brake Fluid Tube Radiator Air Vent Tube Water Hoses 1-15...
Page 18 DINK 200 . GENERAL INFORMATION Front Stop Switch Throttle Cable Fuel Filler Fuel Vapor Recovery Tube Rear Brake Fluid Tube Fuel Tank Inlet Tube Fuel Tank Breather Tube Speedometer Cable Fuel Unit Water Hose Wire Harness Throttle Cable 1-16...
Page 19 DINK 200 . GENERAL INFORMATION Fuel Tube Oil Vapor Recovery Tube Auto Bystarter Wire Thermostat Carburetor Overflow Tube Air Cut-off Valve (A.C.V.) Ignition Coil Starter Relay Carburetor 1-17...
Page 20 DINK 200 . GENERAL INFORMATION Auto Bystarter Air Injection Air Cleaner Ignition Coil Vacuum Tee Ground Wire Spark Plug Cap Thermostat Battery Fuel Tube Fuel Pump Starter Relay Throttle Cable Battery CDI Unit Fuel Tube Fuel Pump Vacuum Tube Air Injection...
Page 21: Wiring Diagram
DINK 200 . GENERAL INFORMATION WIRING DIAGRAM 1-19...
Page 22: Troubleshooting
DINK 200 . GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by Empty fuel tank loosening drain screw Clogged carburetor fuel inlet tube, vacuum tube or fuel tube Clogged auto fuel valve...
Page 23: Dink 200
DINK 200 . GENERAL INFORMATION ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate Clogged air cleaner lightly for observation Restricted fuel flow Clogged fuel line between fuel tank and carburetor Engine speed Engine speed does Clogged exhaust muffler...
Page 24 DINK 200 . GENERAL INFORMATION POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty A.C. generator Check carburetor pilot screw adjustment Mixture too rich (turn screw...
Page 25 DINK 200 . GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty A.C. generator Check valve clearance Improperly adjusted valve Correctly adjusted Incorrectly adjusted clearance Worn valve seat...
Page 26 DINK 200 . GENERAL INFORMATION ENGINE NOISE Symptom Probable Cause Valve clearance too large Valve noise Worn camshaft lobe Worn piston rings Worn piston pin and connecting rod Piston noise small end Excessive carbon build-up in combustion chamber Damaged cam chain tensioner Worn cam gear teeth...
Page 27: General Information
DINK 200 . GENERAL INFORMATION CLUTCH, DRIVE AND DRIVEN PULLEYS Symptom Probable Cause Worn or slipping drive belt Broken ramp plate Broken drive face spring Engine starts but Separated clutch lining motor-cycle does not move Damaged driven pulley shaft splines Damaged final gear...
Page 28: Inspection/Adjustment
DINK 200 . GENERAL INFORMATION STARTER MOTOR 1. Starter motor won‘t turn Symptom Inspection/Adjustment Probable Cause Check operation of stop switch by Burned out fuse applying brake Weak or dead battery Stoplight does not Faulty stop switch Stoplight comes come on Loose or disconnected...
Page 29 DINK 200 . GENERAL INFORMATION closed NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty spark plug Check spark plug cap and high-tension wire...
Page 30 DINK 200 . GENERAL INFORMATION POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Faulty AC generator Voltage does not Normal voltage Faulty regulator/rectifier increase Faulty battery Measure resistance...
Page 31 DINK 200 . GENERAL INFORMATION FUEL GAUGE 1. Pointer does not register correctly (Ignition switch ON) Inspection/Adjustment Symptom Probable Cause Check battery circuit by operating turn Burned out fuse signals Weak or dead battery Signals operate Signals dim, remain Faulty ignition switch properly on or don‘t...
Page 32 DINK 200 . GENERAL INFORMATION STEERING HANDLEBAR DOES NOT TRACK STRAIGHT Symptom Probable Cause (Front and rear tire pressures are normal) Steering stem nut too tight Steering is heavy Broken steering steel balls Excessive wheel bearing play Front or rear wheel is Bent rim...
Page 33: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 2-1 SERVICE INFORMATION -------------------------------------------- 2-2 TROUBLESHOOTING ------------------------------------------------- 2-2 FRAME COVERS REMOVAL----------------------------------------- 2-3 EXHAUST MUFFLER REMOVAL ----------------------------------- 2-6...
Page 34: Schematic Drawing
. EXHAUST MUFFLER/FRAME COVERS DINK 200 SCHEMATIC DRAWING...
Page 35: Service Information
. EXHAUST MUFFLER/FRAME COVERS DINK 200 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 36: Frame Covers Removal
. EXHAUST MUFFLER/FRAME COVERS DINK 200 FRAME COVERS REMOVAL Bolts/Nuts Center Cover Bolt REAR CARRIER & HAND RAIL REMOVAL Remove the met-in box: First remove the two bolts and two nuts attaching the met-in box. Remove the bolt attaching the center cover.
Page 37 . EXHAUST MUFFLER/FRAME COVERS DINK 200 Remove the screws attaching the right and left side covers. Remove the right and left side covers by pulling them backward. Screws Side Cover Seat Lock Wire Remove the right and left screws on the rear part of the frame body cover.
Page 38 . EXHAUST MUFFLER/FRAME COVERS DINK 200 FRONT UPPER COVER REMOVAL Bolts Remove the right and left rearview mirrors. Remove the two screws on the back of the front upper cover. Remove the two bolts on the front of the front upper cover.
Page 39: Exhaust Muffler Removal
. EXHAUST MUFFLER/FRAME COVERS DINK 200 HANDLEBAR COVER REMOVAL First remove the four screws attaching the handlebar front cover. Remove the handlebar front cover. Remove the two screws and one bolt attaching the handlebar rear cover. Remove the handlebar rear cover.
Page 40 DINK 200 . INSPECTION/ADJUSTMENT __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------- 3- 1 MAINTENANCE SCHEDULE ---------------------------------------- 3- 2 FUEL LINE/FUEL FILTER ------------------------------------------- 3- 2 THROTTLE OPERATION --------------------------------------------- 3- 2 ENGINE OIL ------------------------------------------------------------ 3- 4 AIR CLEANER ---------------------------------------------------------- 3- 5...
Page 41: Service Information
DINK 200 . INSPECTION/ADJUSTMENT SERVICE INFORMATION GENERAL °I 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 42: Maintenance Schedule
DINK 200 . INSPECTION/ADJUSTMENT MAINTENANCE SCHEDULE Perform the periodic maintenance at each scheduled maintenance period. I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary. A: Adjust C: Clean R: Replace T : Tighten Regular Service Mileage (km) Whichever Frequency comes first ...
Page 43: Fuel Line/Fuel Filter
DINK 200 . INSPECTION/ADJUSTMENT FUEL LINE/FUEL FILTER Remove the center cover. Check the fuel tube replace any parts which show signs of deterioration, damage or leakage. Check for dirty or clogged fuel filter and replace with a new one if it is clogged.
Page 44: Engine Oil
DINK 200 . INSPECTION/ADJUSTMENT Oil Dipstick ENGINE OIL OIL LEVEL INSPECTION Stop the engine and support the motorcycle upright on level ground. Wait for 2_ 3 minutes and check the oil level with the dipstick. Do not screw in the dipstick when making this check.
Page 45: Air Cleaner
DINK 200 . INSPECTION/ADJUSTMENT Screws AIR CLEANER Remove the seven air cleaner case cover screws and the cover. Air Cleaner Case Cover Air Cleaner Element Remove the air cleaner element. Check the element and replace it if it is excessively dirty or damaged.
Page 46: Valve Clearance
DINK 200 . INSPECTION/ADJUSTMENT Bolts VALVE CLEARANCE °Ø • Inspect and adjust valve clearance while the engine is cold (below 35¢J). Remove the center cover and the secondary air inlet tube bolt. Remove the cylinder head cover. Cylinder Head Cover “T”...
Page 47: Ignition Timing
DINK 200 . INSPECTION/ADJUSTMENT Timing Hole Cap IGNITION TIMING °Ø • The CDI unit is not adjustable. • If the ignition timing is incorrect, check the ignition system, Remove the timing hole cap. “F” Mark Check the ignition timing with a timing light.
Page 48: Final Reduction Gear Oil
DINK 200 . INSPECTION/ADJUSTMENT Oil Check Bolt Hole/Oil Filler FINAL REDUCTION GEAR OIL °Ø • Place the motorcycle on its main stand on level ground. Stop the engine and remove the oil check bolt. The oil level shall be at the oil check bolt hole.
Page 49: Headlight Aim
DINK 200 . INSPECTION/ADJUSTMENT HEADLIGHT AIM Turn the ignition switch ON. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting bolt. Headlight Aim Adjusting Bolt CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually.
Page 50: Brake System
DINK 200 . INSPECTION/ADJUSTMENT Coolant capacity : 1165cc Radiator capacity : 825cc Reserve tank capacity :340cc Start the engine and check if there is no bubbles in the coolant and the coolant level is stable. Reinstall the radiator cap. If there are bubbles in the coolant, bleed air from the system.
Page 51: Nuts/Bolts/Fasteners
DINK 200 . 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 52 DINK 200 . LUBRICATION SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM-------------------------------- 4-1 SERVICE INFORMATION -------------------------------------------- 4-2 TROUBLESHOOTING ------------------------------------------------- 4-2 ENGINE OIL/OIL FILTER -------------------------------------------- 4-3 OIL PUMP REMOVAL------------------------------------------------- 4-4 OIL PUMP DISASSEMBLY ------------------------------------------- 4-4 OIL PUMP INSPECTION ---------------------------------------------- 4-5...
Page 53 . LUBRICATION SYSTEM DINK 200 LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...
Page 54: Lubrication System
DINK 200 . LUBRICATION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed in the frame. • Drain the coolant before starting any operations. • Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 55: Engine Oil/Oil Filter
. LUBRICATION SYSTEM DINK 200 ENGINE OIL/OIL FILTER °Ø 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 56: Oil Pump Removal
DINK 200 . LUBRICATION SYSTEM Bolts OIL PUMP REMOVAL First drain the coolant. Remove the right crankcase cover. (  10-3) Remove the A.C. generator starter driven gear. (  10-4) Remove the attaching bolt and oil separator cover. Oil Separator Cover...
Page 57: Oil Pump Inspection
. LUBRICATION SYSTEM DINK 200 Outer Rotor OIL PUMP INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.25mm replace if over Pump Body Outer Rotor Inner Rotor Measure the inner rotor-to-outer rotor clearance. Service Limit: 0.20mm replace if over Measure the rotor end-to-pump body clearance.
Page 58: Oil Pump Installation
DINK 200 . LUBRICATION SYSTEM Screw Install the pump cover by aligning the hole in the cover with the dowel pin. Tighten the screw to secure the pump cover. Make sure that the pump shaft rotates freely without binding. Arrow Mark...
Page 59 . ENGINE REMOVAL/INSTALLATION DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 5-1 SERVICE INFORMATION -------------------------------------------- 5-2 ENGINE REMOVAL --------------------------------------------------- 5-3 ENGINE INSTALLATION -------------------------------------------- 5-5...
Page 60: Schematic Drawing
5. ENGINE REMOVAL/INSTALLATION DINK 200 SCHEMATIC DRAWING 4.0kg-m 3.0kg-m 5.0kg-m...
Page 61: Service Information
. ENGINE REMOVAL/INSTALLATION DINK 200 SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor 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 shop towels to protect the motorcycle body during engine removal.
Page 62: Engine Removal
5. ENGINE REMOVAL/INSTALLATION DINK 200 Wire Connectors ENGINE REMOVAL Disconnect the battery negative cable. Remove the frame body cover. (  2-3) Disconnect the engine negative cable. Disconnect all of the A.C. generator, auto bystarter, spark plug, thermosensor wire couplers and connectors.
Page 63: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION DINK 200 Rear Shock Absorber Upper Mount Bolts Remove the right/left rear shock absorber upper mount bolts. Remove the two engine mounting bolts and pull out the engine with the engine hanger backward. Engine Mounting Bolt ENGINE HANGER REMOVAL Remove the engine hanger bolts to remove the engine hanger.
Page 64: Engine Installation
5. ENGINE REMOVAL/INSTALLATION DINK 200 ENGINE INSTALLATION Install the engine in the reverse order of removal. Tighten the engine mounting bolts. Torque: 5.0kg-m Engine Hanger Bolt Engine Mounting Nuts Tighten the rear shock absorber upper mount bolts. Torque: 4.0kg-m After installation, inspect and adjust the following: •...
Page 65: Cylinder Head/Valves
. CYLINDER HEAD/VALVES DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 6- 1 SERVICE INFORMATION -------------------------------------------- 6- 2 TROUBLESHOOTING ------------------------------------------------- 6- 3 CYLINDER HEAD COVER REMOVAL ----------------------------- 6- 4 CAMSHAFT REMOVAL----------------------------------------------- 6- 4 CYLINDER HEAD REMOVAL --------------------------------------- 6- 6...
Page 66: Cylinder Head/Valves
. CYLINDER HEAD/VALVES DINK 200 SCHEMATIC DRAWING...
Page 67: Service Information
. CYLINDER HEAD/VALVES DINK 200 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first. • When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
Page 68: Troubleshooting
. CYLINDER HEAD/VALVES DINK 200 TROUBLESHOOTING • The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler • Compression too low • Worn valve stem or valve guide •...
Page 69: Cylinder Head Cover Removal
. CYLINDER HEAD/VALVES DINK 200 Cylinder Head Cover CYLINDER HEAD COVER REMOVAL Remove the center cover. (  2-3) Remove the met-in box. (  2-3) Remove the cylinder head cover four bolts and then remove the cylinder head cover.
Page 70 . CYLINDER HEAD/VALVES DINK 200 Cam Chain Remove the camshaft gear from the cam chain to remove the camshaft. Camshaft Gear CAMSHAFT INSPECTION Check each cam lobe for wear or damage. Measure the cam lobe height. Service Limits: SH40AA IN: 30.75mm replace if below...
Page 71: Cylinder Head Removal
. CYLINDER HEAD/VALVES DINK 200 Camshaft Holder CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage. °Ø If the valve rocker arm contact surface is worn, check each cam lobe for wear or damage.
Page 72: Cylinder Head Disassembly
. CYLINDER HEAD/VALVES DINK 200 Cylinder Head CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor. °Ø • Be sure to compress the valve springs with a valve spring compressor.
Page 73: Cylinder Head Assembly
. CYLINDER HEAD/VALVES DINK 200 INSPECTION Straight Edge CYLINDER HEAD Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. Service Limit: 0.05mm repair or replace if...
Page 74: Cylinder Head Installation
. CYLINDER HEAD/VALVES DINK 200 Tap the valve stems gently with a plastic Plastic Hammer hammer to firmly seat the cotters. °Ø Be careful not to damage the valves. Cylinder Head CYLINDER HEAD INSTALLATION Gasket Install the cam chain guide.
Page 75: Camshaft Installation
. CYLINDER HEAD/VALVES DINK 200 CAMSHAFT INSTALLATION Cam Chain Punch Marks Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear...
Page 76: Cylinder Head Cover Installation
. CYLINDER HEAD/VALVES DINK 200 Install a new cam chain tensioner gasket. Lock Pawl Gasket Release the lock pawl and push the push rod all the way in. Push Rod Cam Chain Tensioner Install the cam chain tensioner and tighten the...
Page 77: Cylinder/Piston
. CYLINDER/PISTON DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 7-1 SERVICE INFORMATION -------------------------------------------- 7-2 TROUBLESHOOTING ------------------------------------------------- 7-2 CYLINDER REMOVAL------------------------------------------------ 7-3 PISTON REMOVAL ---------------------------------------------------- 7-3 PISTON INSTALLATION --------------------------------------------- 7-7 CYLINDER INSTALLATION----------------------------------------- 7-7...
Page 78: Cylinder/Piston
. CYLINDER/PISTON DINK 200 SCHEMATIC DRAWING...
Page 79: Service Information
. CYLINDER/PISTON DINK 200 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 80: Cylinder Removal
. CYLINDER/PISTON DINK 200 Cylinder CYLINDER REMOVAL Remove the cylinder head. (  6-7) Remove the water hose from the cylinder. Remove the cylinder base bolt. Cylinder Base Bolt Water Hose Cam Chain Tensioner Remove the cam chain guide. Remove the cylinder.
Page 81 . CYLINDER/PISTON DINK 200 Inspect the piston, piston pin and piston rings. Remove the piston rings. • Take care not to damage or break the piston rings during removal. Clean carbon deposits from the piston ring grooves. Install the piston rings onto the piston and measure the piston ring-to-groove clearance.
Page 82: Cylinder Inspection
. CYLINDER/PISTON DINK 200 Measure the piston pin O.D. Service Limit: 14.96mm replace if below Measure the piston O.D. • Take measurement at 9mm from the bottom and 90° to the piston pin hole. Service Limit: 61.90mm replace if below Measure the piston-to-piston pin clearance.
Page 83: Piston Ring Installation
. CYLINDER/PISTON DINK 200 Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over Measure the connecting rod small end I.D. Service Limit: 15.06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston.
Page 84: Piston Installation
. CYLINDER/PISTON DINK 200 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 piston pin clip. • Position the piston “IN” mark on the intake valve side.
Page 85 . CYLINDER/PISTON DINK 200 Tighten the cylinder base bolt. Cylinder Base Bolt Install the cam chain guide. • Insert the tab on the cam chain guide into the cylinder groove. Connect the water hose to the cylinder. Install the cylinder head. (  6-9) Tighten the cylinder base bolt.
Page 86 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS/ KICK STARTER __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 8- 1 SERVICE INFORMATION -------------------------------------------- 8- 2 TROUBLESHOOTING ------------------------------------------------- 8- 2 LEFT CRANKCASE COVER------------------------------------------ 8- 3...
Page 87: Drive And Driven Pulleys/Kick Starter
. DRIVE AND DRIVEN PULLEYS/ DINK 200 KICK STARTER SCHEMATIC DRAWING...
Page 88: Service Information
. DRIVE AND DRIVEN PULLEYS/ KICK STARTER DINK 200 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 89: Drive And Driven Pulleys/ Kick Starter
. DRIVE AND DRIVEN PULLEYS/ DINK 200 KICK STARTER Air Cleaner LEFT CRANKCASE COVER REMOVAL Remove two bolts on the air cleaner. Remove the air cleaner. Bolts Bolts Remove the left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins.
Page 90: Drive Pulley
. DRIVE AND DRIVEN PULLEYS/ KICK STARTER DINK 200 Install the air cleaner and tighten the bolts. Bolts Drive Pulley Face DRIVE PULLEY REMOVAL Remove the left crankcase cover. Hold the drive pulley using an universal holder and remove the drive face nut.
Page 91 . DRIVE AND DRIVEN PULLEYS/ DINK 200 KICK STARTER Drive Pulley Collar Remove the movable drive face assembly. Remove the drive pulley collar. Movable Drive Face Assembly Ramp Plate DISASSEMBLY Remove the ramp plate. Remove the weight rollers. Weight Roller INSPECTION Check each weight roller for wear or damage.
Page 92 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER DINK 200 Measure the movable drive face bushing assemblyy I.D. Service Limit: 27.20mm replace if over Check the drive pulley collar for wear or damage. Measure the O.D. of the drive pulley collar sliding surface.
Page 93 . DRIVE AND DRIVEN PULLEYS/ DINK 200 KICK STARTER Ramp Plate Install the ramp plate. Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly...
Page 94: Clutch/Driven Pulley
. DRIVE AND DRIVEN PULLEYS/ KICK STARTER DINK 200 Drive Pulley Face Install the drive pulley face and drive face nut. Drive Face Nut Universal Holder Hold the drive pulley with the universal holder and tighten the drive face nut.
Page 95 . DRIVE AND DRIVEN PULLEYS/ DINK 200 KICK STARTER Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 2.0mm replace if below Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY DISASSEMBLY Clutch Spring Compressor Hold the clutch/driven pulley assembly with the clutch spring compressor.
Page 96: Kick Starter
. DRIVE AND DRIVEN PULLEYS/ KICK STARTER DINK 200 Guide Roller Guide Roller Pin Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Movable Driven Face Remove the oil seal from the movable driven Oil Seal face.
Page 97 . DRIVE AND DRIVEN PULLEYS/ DINK 200 KICK STARTER Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Check the bearings for play and replace them if they have excessive play.
Page 98 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER DINK 200 Press a new needle bearing into the driven face. Special Bearing Driver Circlips CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. Keep grease off the clutch •...
Page 99 . DRIVE AND DRIVEN PULLEYS/ DINK 200 KICK STARTER CLUTCH ASS EMBLY Circlips 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 100 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER DINK 200 Guide Roller Pin 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 101 . DRIVE AND DRIVEN PULLEYS/ DINK 200 KICK STARTER Clutch Outer Install the clutch outer. Hold the clutch outer with the universal holder. Install and tighten the clutch outer nut. Torque: 49.0 58.8kg-m Special Universal Holder Install the drive belt. (  8-7) Install the left crankcase cover.
Page 102 . DRIVE AND DRIVEN PULLEYS/ KICK STARTER DINK 200 Spindle Plastic Bushing INSPECTION Inspect the kick starter spindle and gear for wear or damage. Inspect the return spring for weakness or damage. Inspect the kick starter spindle bushings for wear or damage.
Page 103 . DRIVE AND DRIVEN PULLEYS/ DINK 200 KICK STARTER Air Cleaner Install the kick lever. Install the left crankcase cover and tighten the cover bolts diagonally. Install the air cleaner and tighten the bolts. Left Crankcase Cover 8-17...
Page 104 . FINAL REDUCTION DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 9-1 SERVICE INFORMATION -------------------------------------------- 9-2 TROUBLESHOOTING ------------------------------------------------- 9-2 FINAL REDUCTION DISASSEMBLY------------------------------- 9-3 FINAL REDUCTION INSPECTION---------------------------------- 9-3 FINAL REDUCTION ASSEMBLY ----------------------------------- 9-6...
Page 105: Schematic Drawing
. FINAL REDUCTION DINK 200 SCHEMATIC DRAWING...
Page 106: Service Information
. FINAL REDUCTION DINK 200 SERVICE INFORMATION GENERAL INSTRUCTIONS • The servicing operations of this section can be made with the engine installed. • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation.
Page 107: Final Reduction
. FINAL REDUCTION DINK 200 Bolts FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. (  2-6) Remove the rear brake caliper. (  15-3) Remove the right rear shock absorber. (  15-5) Remove the rear fork. (  15-4) Remove the rear wheel.
Page 108 . FINAL REDUCTION DINK 200 Inspect the final gear and final shaft for wear, damage or seizure. Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Countershaft Bearing Final Shaft Bearing Inspect the drive shaft and gear for wear or damage.
Page 109 . FINAL REDUCTION DINK 200 Bearing Remover, 12mm BEARING REPLACEMENT (TRANSMISSION CASE COVER) Remove the transmission case cover bearings using the bearing remover. Remove the final shaft oil seal. Drive Shaft Bearing Pilot, 12mm Drive new bearings into the transmission case cover.
Page 110: Final Reduction Assembly
. FINAL REDUCTION DINK 200 Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Pilot, 15mm FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase. Drive Shaft Install the final gear and final shaft into the...
Page 111 . FINAL REDUCTION DINK 200 Install the countershaft and gear into the left crankcase. Install the resin washer onto the counter- shaft. Install the dowel pins and a new gasket. Countershaft Washer Install the transmission case cover. Transmission Case Cover...
Page 112 . FINAL REDUCTION DINK 200 Oil Check Bolt Hole/Oil Filler After installation, fill the transmission case with the specified oil. • Place the motorcycle on its main stand on level ground. • Check the oil sealing washer for wear or damage.
Page 113: Generator/Starter Clutch
. A.C. GENERATOR/STARTER CLUTCH DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 10-1 SERVICE INFORMATION -------------------------------------------- 10-2 TROUBLESHOOTING ------------------------------------------------- 10-2 RIGHT CRANKCASE COVER REMOVAL-------------------------- 10-3 STATOR REMOVAL --------------------------------------------------- 10-3 FLYWHEEL REMOVAL----------------------------------------------- 10-3 STARTER CLUTCH ---------------------------------------------------- 10-4...
Page 114: Generator/Starter Clutch
DINK 200 . A.C. GENERATOR/STARTER CLUTCH SCHEMATIC DRAWING 10-1...
Page 115: Service Information
. A.C. GENERATOR/STARTER CLUTCH DINK 200 SERVICE INFORMATION GENERAL INSTRUCTIONS • All servicing operations and inspections in this section can be made with the engine installed. • Drain the coolant before removing the right crankcase cover. • Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.)
Page 116: Right Crankcase Cover Removal
DINK 200 . A.C. GENERATOR/STARTER CLUTCH Bolts Water Outlet Hose RIGHT CRANKCASE COVER REMOVAL Disconnect the water hoses from the right crankcase cover. Remove the nine bolts attaching the right crankcase cover and the cover. Bolts Water Inlet Hose STATOR REMOVAL A.C.
Page 117: Starter Clutch
. A.C. GENERATOR/STARTER CLUTCH DINK 200 Starter Idle Gear Shaft STARTER CLUTCH REMOVAL Remove the starter idle gear and shaft. Starter Driven Gear Starter Driven Gear Remove the starter driven gear. INSPECTION Inspect the starter driven gear for wear or damage.
Page 118: Flywheel Installation
DINK 200 . A.C. GENERATOR/STARTER CLUTCH Flywheel One-way Clutch Remove the flywheel. Inspect each roller for wear or damage. Roller Shaft INSTALLATION Install the starter driven gear onto the crankshaft. Install the starter idle gear and shaft. Starter Driven Gear...
Page 119: Stator Installation
. A.C. GENERATOR/STARTER CLUTCH DINK 200 A.C. Generator Stator STATOR INSTALLATION Install the A.C. generator stator on the right crankcase cover and secure it with the three bolts. Install the pulser coil on the right crankcase cover and secure it with the two screws.
Page 120: Crankcase/Crankshaft
. CRANKCASE/CRANKSHAFT DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 11-1 SERVICE INFORMATION -------------------------------------------- 11-2 TROUBLESHOOTING ------------------------------------------------- 11-2 CRANKCASE SEPARATION ----------------------------------------- 11-3 CRANKSHAFT ---------------------------------------------------------- 11-4 CRANKCASE ASSEMBLY -------------------------------------------- 11-5 11-0...
Page 121: Crankcase/Crankshaft
. CRANKCASE/CRANKSHAFT DINK 200 SCHEMATIC DRAWING 11-1...
Page 122: Service Information
. CRANKCASE/CRANKSHAFT DINK 200 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces.
Page 123: Crankcase Separation
. CRANKCASE/CRANKSHAFT DINK 200 Cam Chain Tensioner Slipper CRANKCASE SEPARATION Remove the cam chain tensioner slipper bolt. Remove the cam chain tensioner slipper and cam chain. Remove the two right crankcase attaching bolts. Bolt Cam Chain Bolts Remove the five left crankcase bolts.
Page 124 . CRANKCASE/CRANKSHAFT DINK 200 Oil Seal Remove the oil seal from the left crankcase. Left Crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.6mm replace if over Measure the connecting rod small end I.D. Service Limit: 15.06mm replace if over...
Page 125: Crankcase Assembly
. CRANKCASE/CRANKSHAFT DINK 200 Measure the crankshaft runout. Service Limit: 0.10mm replace if over Measure the crankshaft bearing play. Play Service Limits: Play Axial : 0.20mm replace if over Radial : 0.05mm replace if over Axial Radial CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces.
Page 126 . CRANKCASE/CRANKSHAFT DINK 200 Place the left crankcase down and install the crankshaft into the left crankcase. Avoid damaging the oil seal. • Apply grease to the lip of the oil • seal. Dowel Pins Install the two dowel pins and a new gasket.
Page 127 . CRANKCASE/CRANKSHAFT DINK 200 Cam Chain Tensioner Slipper Install the cam chain. Install the cam chain tensioner slipper. Install and tighten the cam chain tensioner slipper bolt. Torque: 7.8 11.8N-m Bolt 11-7...
Page 128: Cooling System
. COOLING SYSTEM DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 12- 1 SERVICE INFORMATION -------------------------------------------- 12- 2 TROUBLESHOOTING ------------------------------------------------- 12- 2 COOLING SYSTEM TESTING --------------------------------------- 12- 4 RADIATOR -------------------------------------------------------------- 12- 4 WATER PUMP ---------------------------------------------------------- 12-10...
Page 129 . COOLING SYSTEM DINK 200 SCHEMATIC DRAWING Left Hand Threads Torque: 1.0 1.4kg-m 12-1...
Page 130: Cooling System
. COOLING SYSTEM DINK 200 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 131 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071 COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water 360cc 825cc -44.5 Cautions for Using Coolant: •...
Page 132: Cooling System Testing
. COOLING SYSTEM DINK 200 COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Radiator Tester 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 cap sealing surface before testing.
Page 133 . COOLING SYSTEM DINK 200 Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator, wash them off. Carefully straighten any bent fins. RADIATOR REMOVAL Drain the coolant.
Page 134 . COOLING SYSTEM DINK 200 Thermostatic Switch Wire Loosen the hose band and disconnect the lower hose from the radiator. Disconnect the thermostatic switch wire coupler. Disconnect the fan motor wire coupler. Thermostatic Switch Lower Hose Radiator Remove the four screws and the radiator.
Page 135 . COOLING SYSTEM DINK 200 Check fan motor by battery. Nuts RADIATOR BRACKET REMOVAL/ INSTALLATION Remove the two nuts to remove the radiator bracket. The installation sequence is the reverse of removal. Radiator Bracket Bolts Radiator Install the fan shroud on the radiator with the four bolts.
Page 136 . COOLING SYSTEM DINK 200 Screws RADIATOR INSTALLATION Install the radiator on the radiator bracket with the four screws. Radiator Thermostatic Switch Wire Connect the upper and lower hoses and secure them with hose bands. Connect the thermostatic switch wire and fan motor wire couplers.
Page 137: Water Pump
. COOLING SYSTEM DINK 200 Screws Set the two tabs under the air duct into the grooves on the radiator lower part and then secure the radiator with the two screws. Fill the radiator with coolant. (  3-9) After installation, check for coolant leaks.
Page 138 . COOLING SYSTEM DINK 200 Water Pump Cover Bolts Remove the four bolts and the water pump cover, gasket and 2 dowel pins. Impeller (Left Hand Threads) Remove the water pump impeller. The impeller has left hand threads. Seal Washer (Porcelain)
Page 139 . COOLING SYSTEM DINK 200 Bolts WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove the 3 bolts attaching the water pump assembly. Remove the water pump assembly, gasket and dowel pins. Water Pump Assembly...
Page 140 . COOLING SYSTEM DINK 200 Water Pump Assembly MECHANICAL S EAL REPLACEMENT Water Pump Assembly Drive the mechanical seal out of the water pump assembly from the inside. Mechanical Seal (Water Seal) Drive in a new mechanical seal using a mechanical seal driver.
Page 141 . COOLING SYSTEM DINK 200 Snap Ring Install the water pump shaft and shaft inner bearing into the waster pump assembly. Install the snap ring to secure the inner bearing properly. Inner Bearing Water Pump Shaft Water Pump Assembly Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover.
Page 142 . COOLING SYSTEM DINK 200 Impeller (Left Hand Threads) Install the impeller onto the water pump shaft. Torque: 1.0 1.4kg-m The impeller has left hand threads. Dowel Pins Install the two dowel pins and a new gasket. Gasket Water Pump Cover Install the water pump cover and tighten the 4 bolts.
Page 143: Thermosensor
. COOLING SYSTEM DINK 200 Thermosensor THERMOSENSOR THERMOSENSOR REMOVAL Remove the seat, met-in box and center cover. Drain the coolant. Disconnect the thermosensor wire. Remove the thermosensor. Thermosensor Wire 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 144: Thermostat
. COOLING SYSTEM DINK 200 Thermostat Housing Air Vent Tube Bolt THERMOSTAT THERMOSTAT REMOVAL Remove the seat, met-in box and center cover. Drain the coolant. Disconnect the thermosensor wire from the thermosensor. Disconnect the water hose from the thermostat housing.
Page 145 . COOLING SYSTEM DINK 200 THERMOSTAT INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water Thermostat temperature to check its operation. Technical Data Thermometer Begins to open 80±2 Full-open Valve lift 4.5mm O-ring •...
Page 146: Fuel System/Carburetor/Fuel Pump
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FUEL SYSTEM/CARBURETOR/FUEL PUMP __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 13- 1 SERVICE INFORMATION -------------------------------------------- 13- 4 TROUBLESHOOTING ------------------------------------------------- 13- 4 CARBURETOR REMOVAL ------------------------------------------- 13- 6 VACUUM CHAMBER DISASSEMBLY------------------------------ 13- 6 FLOAT CHAMBER DISASSEMBLY--------------------------------- 13- 8 AUTO BYSTARTER INSPECTION/REMOVAL-------------------- 13-10 AIR CUT-OFF VALVE (A.C.V.)-------------------------------------- 13-11...
Page 147 . FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 FUEL SYSTEM 13-1...
Page 148: Schematic Drawing
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 SCHEMATIC DRAWING 13-2...
Page 149 . FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 FUEL PUMP CONSTRUCTION: The fuel pump adopted for this model is a vacuum-type fuel pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through the suction valve and outlet valve.
Page 150: Service Information
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 SERVICE INFORMATION GENERAL INSTRUCTIONS • When working with gasoline, keep away from sparks and flames. • Note the locations of O-rings when disassembling and replace them with new ones during assembly. • Before float chamber disassembly, drain the residual gasoline from the float chamber.
Page 151 . FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 Throttle does not open fully, so engine stalls Rich mixture • Damaged vacuum piston diaphragm • Auto bystarter valve opens excessively • Clogged diaphragm hole • Faulty float valve • Float level too high Lean mixture •...
Page 152: Carburetor Removal
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 Auto Bystarter CARBURETOR REMOVAL Remove the seat, met-in box and center cover. Disconnect the fuel tube and vacuum tube at the carburetor. Disconnect the auto bystarter wire. Fuel Tube Auto Bystarter Wire Intake Manifold Band...
Page 153 . FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 Screws Remove the two vacuum chamber cover screws and the cover. Vacuum Chamber Cover Spring Remove the compression spring and vacuum piston. Vacuum Piston Vacuum Piston Diaphragm Remove the needle holder, spring and jet needle from the piston.
Page 154: Float Chamber Disassembly
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 Float Chamber FLOAT CHAMBER DISASSEMBLY Remove the four float chamber screws and the float chamber. Screws Float Remove the float pin, float and float valve. Float Valve Float Pin Float Valve Seat FLOAT VALVE INSPECTION Inspect the float valve seat contact area for wear.
Page 155 . FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 JETS/SCREWS REMOVAL • Before removing the pilot screw, turn the pilot screw clockwise until it seats lightly and record the rotating turns. Do not force the pilot screw against its seat to avoid seat damage.
Page 156: Auto Bystarter Inspection/Removal
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 AUTO BYSTARTER INSPECTION /REMOVAL AUTO BYSTARTER INSPECTION Measure the resistance between the auto bystarter wire terminals. Resistance: 10Ω (10 minutes minimum after stopping the engine) If the reading is not within the limit, replace the auto bystarter with a new one.
Page 157: Air Cut-Off Valve (A.c.v.)
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks, wear or damage. If any faulty part is found, replace the auto bystarter with a new one. Bystarter Valve Bystarter Needle Air Cut-off Valve Cover AIR CUT-OFF VALVE (A.C.V.)
Page 158 . FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 Air Cut-off Valve Body Screws Disconnect the hose at the valve seat. Remove the two screws and the air cut-off valve body. Hose CARBURETOR BODY CLEANING Blow compressed air through all passages of the carburetor body.
Page 159: Auto Bystarter Installation
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 Diaphragm O-ring Install the O-ring onto the air-cut-off valve body securely. • Install the O-ring with the flat face toward the valve body side. Install the diaphragm, spring, and cover. Spring Cover Screws Install and tighten the two screws attaching the air cut-off valve cover.
Page 160: Float Chamber Assembly
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 Slow Jet Holder Main Jet Holder FLOAT CHAMBER ASSEMBLY Install the needle jet and needle jet holder. Install the main jet. Install the slow jet. Needle Jet Holder Install the pilot screw. • Be sure to record the rotating turns when it is removed.
Page 161: Float Level Inspection
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 FLOAT LEVEL INSPECTION Measure the float level at the location of the main jet (just contacting the float valve). Float Level: 18.5±1.0mm Replace the float if the level is incorrect. Check the operation of the float and then reinstall the float chamber.
Page 162: Carburetor Installation
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 Vacuum Chamber Cover Install the vacuum chamber cover and tighten it with the two screws. • Be careful not to let the diaphragm slip. • If the diaphragm cannot be positioned correctly because of expansion, dry the diaphragm before installation.
Page 163: Fuel Pump Removal/Disassembly
. FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 Outlet Tube FUEL PUMP REMOVAL Remove the frame center cover. Disconnect the fuel pump inlet, outlet and vacuum tubes. Remove the fuel pump attaching two bolts and the fuel pump. Vacuum Tube Inlet Tube...
Page 164 . FUEL SYSTEM/CARBURETOR/FUEL PUMP DINK 200 FUEL STRAINER REMOVAL Remove the fuel strainer from the inlet tube. INSPECTION Inspect if the fuel strainer is clogged and clean it with compressed air. • When removing the fuel strainer, do not allow flames or sparks near the working area and drain the residual gasoline into a container.
Page 165 . STEERING HANDLEBAR/FRONT WHEEL/FRONT DINK 200 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 14- 1 SERVICE INFORMATION -------------------------------------------- 14- 2 TROUBLESHOOTING ------------------------------------------------- 14- 3 STEERING HANDLEBAR--------------------------------------------- 14- 4...
Page 166: Brake/Front Shock Absorber/Front Fork
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK DINK 200 SCHEMATIC DRAWING 5.0kg-m 12kg-m 1.3kg-m 2.5kg-m 5.0kg-m 14-1...
Page 167: Service Information
. STEERING HANDLEBAR/FRONT WHEEL/FRONT DINK 200 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK SERVICE INFORMATION GENERAL INSTRUCTIONS • Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.
Page 168: Troubleshooting
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK DINK 200 TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling • Excessively tightened steering stem top • Bent rim cone race • Loose front axle • Broken steering balls • Bent spoke plate •...
Page 169: Steering Handlebar/Front Wheel/Front Brake/Front
. STEERING HANDLEBAR/FRONT WHEEL/FRONT DINK 200 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Brake Master Cylinders STEERING HANDLEBAR REMOVAL Remove the handlebar front and rear covers. (  2-6) Remove the front and rear brake master cylinder attaching bolts. Remove the front upper cover. (  2-5) Remove the front lower cover.
Page 170: Front Wheel
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK DINK 200 Throttle Grip Throttle Cable Lubricate the throttle grip front end with grease and then install the throttle grip. Connect the throttle cable to the throttle grip. Install the right and left handlebar switches and tighten the screws.
Page 171 . STEERING HANDLEBAR/FRONT WHEEL/FRONT DINK 200 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK WHEEL RIM Check the wheel rim runout. Service Limits: Radial: 2.0mm replace if over Axial: 2.0mm replace if over FRONT WHEEL BEARING Remove the side collar and dust seal. Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly.
Page 172 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK DINK 200 Driver Handle A Pack all bearing cavities with grease. Drive in the left bearing. Install the distance collar. Drive in the right bearing. Do not allow the bearings to tilt •...
Page 173: Front Brake
. STEERING HANDLEBAR/FRONT WHEEL/FRONT DINK 200 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Bolts FRONT BRAKE BRAKE MASTER CYLINDER REM OVAL Remove the handlebar covers. (  2-6) First drain the brake fluid from the hydraulic brake system. Disconnect the front stop switch wire connector.
Page 174 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK DINK 200 INSPECTION Measure the brake master cylinder I.D. Inspect the master cylinder for scratches or cracks. Service Limit: 12.75mm Measure the brake master cylinder piston O.D. Service Limit: 12.645mm Before assembly, inspect the lst and 2nd rubber cups for wear.
Page 175 . STEERING HANDLEBAR/FRONT WHEEL/FRONT DINK 200 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Connect the front stop switch wire connector. Install the handlebar covers. (  2-6) Stop Switch Wire Connector BRAKE FLUID REFILLING Keep the handlebar upright and remove the brake reservoir cover and diaphragm.
Page 176 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK DINK 200 Bleed Valve BRAKE CALIPER REMOVAL First drain the brake fluid from the hydraulic brake system. Remove the brake fluid tube bolt. Remove the two bolts attaching the brake caliper. Remove the brake caliper.
Page 177 . STEERING HANDLEBAR/FRONT WHEEL/FRONT DINK 200 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Check the piston for scratches or wear. Measure the piston O.D. with a micrometer gauge. Service Limit: 25.30mm Check the caliper cylinder for scratches or wear and measure the cylinder bore.
Page 178 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK DINK 200 Brake Fluid Tube Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt. Torque: 24.5 34.3N-m Fill the brake reservoir with the specified brake fluid and bleed air from the brake system.
Page 179: Front Shock Absorber
. STEERING HANDLEBAR/FRONT WHEEL/FRONT DINK 200 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Front Fork FRONT SHOCK ABSORBER REMOVAL Remove the front upper cover. (  2-5) Remove the front lower cover. (  2-5) Remove the front wheel. (  14-5) Remove the front brake caliper. (  14-11) Remove the front shock absorber upper mount bolts.
Page 180 . STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK DINK 200 Shock Absorber Tube INSPECTION Inspect the following items and replace if necessary. •Front shock absorber tube bending, damage or wear •Weak front shock absorber spring •Damper and damper rod bending •Oil seal damage or wear...
Page 181 . STEERING HANDLEBAR/FRONT WHEEL/FRONT DINK 200 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK ASSEMBLY Install the damper spring onto the damper rod and then install them into the front shock absorber tube. Install the shock absorber spring onto the front shock absorber tube.
Page 182: Front Fork
. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK DINK 200 Lock Nut Socket FRONT FORK REMOVAL Remove the handlebar covers. (  2-6) Remove the steering handlebar. (  14-4) Remove the front upper cover. (  2-5) Remove the front lower cover. (  2-5) Remove the front inner fender.
Page 183 . STEERING HANDLEBAR/FRONT WHEEL/FRONT DINK 200 BRAKE/FRONT SHOCK ABSORBER/FRONT FORK Ball Race Installation Drive in new ball races. Be sure to drive the ball races into place completely. INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race.
Page 184: Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
. REAR BRAKE/REAR FORK/REAR DINK 200 WHEEL/REAR SHOCK ABSORBER __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER __________________________________________________________________________________ SCHEMATIC DRAWING ---------------------------------------------- 15-1 SERVICE INFORMATION -------------------------------------------- 15-2 TROUBLESHOOTING ------------------------------------------------- 15-2 REAR BRAKE ----------------------------------------------------------- 15-3 REAR FORK ------------------------------------------------------------- 15-4...
Page 185 . REAR BRAKE/REAR FORK/REAR DINK 200 WHEEL/REAR SHOCK ABSORBER SCHEMATIC DRAWING 15-1...
Page 186 . REAR BRAKE/REAR FORK/REAR DINK 200 WHEEL/REAR SHOCK ABSORBER SERVICE INFORMATION GENERAL INSTRUCTIONS • 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 187 . REAR BRAKE/REAR FORK/REAR DINK 200 WHEEL/REAR SHOCK ABSORBER REAR BRAKE REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler. (  2-6) Remove the rear brake fluid tube bolt and disconnect the brake fluid tube. Remove the two bolts attaching the rear brake caliper.
Page 188: Rear Fork
. REAR BRAKE/REAR FORK/REAR DINK 200 WHEEL/REAR SHOCK ABSORBER Shock Absorber Lower Mount Bolt REAR FORK REMOVAL Remove the exhaust muffler. (  2-6) Remove the rear brake caliper. (  15-3) Remove the right rear shock absorber lower mount bolt.
Page 189: Rear Shock Absorber
. REAR BRAKE/REAR FORK/REAR DINK 200 WHEEL/REAR SHOCK ABSORBER Shock Absorber Lower Mount Bolt INSTALLATION The installation sequence is the reverse of removal. Torque: Rear shock absorber lower mount bolt: 19.6 29.4N-m Rear axle nut: 78.4 98N-m Brake Caliper Bolts...
Page 190 . REAR BRAKE/REAR FORK/REAR DINK 200 WHEEL/REAR SHOCK ABSORBER Spring Rubber INSPECTION Inspect the damper rod for bending or damage. Inspect the damper for oil leaks. Inspect the damper rubber for deterioration or damage. Damper Damper Rod Measure the front shock absorber spring free length.
Page 191: Battery/Charging System
. BATTERY/CHARGING SYSTEM DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT-------------------------------------- 16-1 SERVICE INFORMATION -------------------------------------------- 16-2 TROUBLESHOOTING ------------------------------------------------- 16-3 BATTERY---------------------------------------------------------------- 16-4 CHARGING SYSTEM -------------------------------------------------- 16-5 A.C. GENERATOR INSPECTION ------------------------------------ 16-5 REGULATOR/RECTIFIER INSPECTION --------------------------- 16-6 CHARGING INDICATOR INSPECTION ---------------------------- 16-7...
Page 192 . BATTERY/CHARGING SYSTEM DINK 200 CHARGING SYSTEM LAYOUT Battery Fuse Regulator/Rectifier A.C. Generator CHARGING CIRCUIT 16-1...
Page 193: Battery/Charging System
. BATTERY/CHARGING SYSTEM DINK 200 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 194: Troubleshooting
. BATTERY/CHARGING SYSTEM DINK 200 SPECIAL TOOLS Universal holder Flywheel puller 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 ignition system •...
Page 195: Battery
. BATTERY/CHARGING SYSTEM DINK 200 Battery Cover Screw BATTERY Remove the seat and met-in box. (  2-3) Remove the battery cover screw and the battery cover. Remove the battery. First disconnect the battery negative (-) cable and then the positive (+) cable.
Page 196: Charging System
. BATTERY/CHARGING SYSTEM DINK 200 Red Wire CHARGING SYSTEM CURRENT TEST Use a fully charged battery (12.8V min.) to check the charging system. Warm up the engine before taking readings. Connect an electric tester across the battery terminals. Disconnect the red wire from the fuse terminal and connect an ammeter between the red wire lead and the fuse terminal.
Page 197: Regulator/Rectifier Inspection
. BATTERY/CHARGING SYSTEM DINK 200 Pulser Coil A.C. Generator Stator A.C. GENERATOR REMOVAL A.C. generator removal (  10-3) A.C. generator installation (  10-6) Right Crankcase Cover Bolts REGULATOR/RECTIFIER INSPECTION Remove the frame front cover. (  2-5) Remove the regulator/rectifier wire coupler.
Page 198: Charging Indicator Inspection
. BATTERY/CHARGING SYSTEM DINK 200 CHARGING INDICATOR INSPECTION Use Sanwa electric tester for testing. Take readings in XKΩ range. Unit: D401 Probe (+) Red/ Brown Red/ Red/ Black Probe Brown/Blue Blue Green Black /Blue Red/ 35~65 21~41 KΩ KΩ Black 3.4~5.8...
Page 199: Ignition System
. IGNITION SYSTEM DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT --------------------------------------- 17-1 SERVICE INFORMATION -------------------------------------------- 17-2 TROUBLESHOOTING ------------------------------------------------- 17-2 SPARK PLUG ----------------------------------------------------------- 17-3 IGNITION COIL INSPECTION --------------------------------------- 17-3 A.C. GENERATOR INSPECTION ------------------------------------ 17-4 CDI UNIT INSPECTION----------------------------------------------- 17-4...
Page 200: Ignition System Layout
. IGNITION SYSTEM DINK 200 IGNITION SYSTEM LAYOUT CDI Unit Ignition Switch Spark Plug Pulser Coil A.C. Generator IGNITION CIRCUIT 17-1...
Page 201: Service Information
. IGNITION SYSTEM DINK 200 SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. (  1-28) • The ignition system adopts CDI unit and the ignition timing cannot be adjusted. • If the timing is incorrect, inspect the CDI unit and A.C. generator and replace any faulty parts.
Page 202: Spark Plug
. IGNITION SYSTEM DINK 200 SPARK PLUG For spark plug inspection and adjustment, refer to page 3-5. IGNITION COIL INSPECTION Remove the seat and met-in box. (  2-3) Remove the ignition coil Ignition Coil IGNITION COIL PERFORMANCE TEST Test the ignition coil using a CDI tester.
Page 203: A.c. Generator Inspection
. IGNITION SYSTEM DINK 200 A.C. GENERATOR INSPECTION EXCITER COIL/PULSER COIL INSPECTION This test is performed with the stator installed in the engine. Remove the frame right cover. (  2-4) Disconnect the A.C. generator connector. Measure the exciter coil resistance between A.C.
Page 204 . IGNITION SYSTEM DINK 200 RESISTANCE INSPECTION Measure the resistance between the terminals. (Green/White) (Black/Blue) (Black/Yellow) Replace the CDI unit if the readings are not within the specifications in the table below. • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing.
Page 205 . STARTING SYSTEM DINK 200 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT -------------------------------------- 18-1 SERVICE INFORMATION -------------------------------------------- 18-2 TROUBLESHOOTING ------------------------------------------------- 18-2 STARTER MOTOR ----------------------------------------------------- 18-3 STARTER CLUTCH INSPECTION----------------------------------- 18-5 STARTER RELAY INSPECTION ------------------------------------ 18-6 18-0...
Page 206 . STARTING SYSTEM DINK 200 STARTING SYSTEM LAYOUT Stop Switches Starter Button Starter Relay Starter Motor STARTING CIRCUIT 18-1...
Page 207: Starting System
. STARTING SYSTEM DINK 200 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • For the starter clutch removal, refer to page 10-3. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
Page 208: Starter Motor
. STARTING SYSTEM DINK 200 STARTER MOTOR REMOVAL • Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly.
Page 209 . STARTING SYSTEM DINK 200 STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush.
Page 210: Starter Clutch Inspection
. STARTING SYSTEM DINK 200 ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover.
Page 211: Starter Relay Inspection
. STARTING SYSTEM DINK 200 Yellow/Red Wire STARTER RELAY INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.
Page 212 . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH DINK 200 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH/TEMPERATURE GAUGE/ INSTRUMENTS/LIGHTS __________________________________________________________________________________ ELECTRICAL EQUIPMENT LAYOUT------------------------------ 19-1 SERVICE INFORMATION -------------------------------------------- 19-2 TROUBLESHOOTING ------------------------------------------------- 19-2 SWITCHES -------------------------------------------------------------- 19-3 HORN INSPECTION --------------------------------------------------- 19-5 FUEL UNIT-------------------------------------------------------------- 19-5...
Page 213: Thermostatic
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS DINK 200 ELECTRICAL EQUIPMENT LAYOUT Headlight Stop Switches Dimmer Switch Turn Signal Switch Horn Button Instruments Headlight Switch Ignition Switch Starter Button Horn Auto Bystarter Thermostatic Fuel Unit Switch Thermosensor 19-1...
Page 214: Service Information
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH DINK 200 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS SERVICE INFORMATION GENERAL INSTRUCTIONS • After installation of each switch, a continuity check must be performed. A continuity check can usually be made without removing the part from the motorcycle. TESTING INSTRUMENT...
Page 215: Switches
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS DINK 200 SWITCHES IGNITION SWITCH INSPECTION Remove the frame front covers. (  2-5) Disconnect the ignition switch wire couplers. Check for continuity between the wire terminals. Color Black/ Violet/ White Green Black Violet...
Page 216 . SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH DINK 200 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS HORN BUTTON INSPECTION Remove the frame front covers. (  2-5) Disconnect the horn wire couplers. Depress the horn button and check for continuity between the wire terminals. Color Light Green Brown/Blue...
Page 217: Horn Inspection
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS DINK 200 HORN INSPECTION Remove the front upper cover. (  2-5) Disconnect the horn wire couplers. The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals.
Page 218: Temperature Gauge
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH DINK 200 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS Thermostatic Switch THERMOSTATIC SWITCH INSPECTION Remove the front covers. (  2-5) Start and run the engine to make the water temperature reaches 90 ±2 check if the cooling fan motor operates.
Page 219: Instruments
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS DINK 200 Speedometer Cable INSTRUMENTS REMOVAL Remove the front upper cover. (  2-5) Disconnect the instrument wire couplers and connectors. Disconnect the speedometer cable. Remove the four instrument cover and leg shield screws.
Page 220: Lights
. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH DINK 200 /TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS Wire LIGHTS HEADLIGHT BULB REPLACEMENT Remove the front upper cover. (  2-5) Disconnect the headlight and turn signal light wire couplers. Remove the rubber boot from the bulb socket. Remove the bulb socket and replace the bulb.
Page 221: Exhaust Emission Control System
. EXHAUST EMISSION CONTROL DINK 200 SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST EMISSION CONTROL SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ............20-1 EXHAUST EMISSION CONTROL SYSTEM FUNCTION..... 20-1 TROUBLESHOOTING ..............20-2 SERVICE INFORMATION ............20-2 SECONDARY AIR CLEANER............. 20-3 AIR INJECTION CUT-OFF VALVE (A.I.C.V.)......20-3 REED VALVE ................
Page 222: Schematic Drawing
. EXHAUST EMISSION CONTROL SYSTEM DINK 200 SCHEMATIC DRAWING Air Injection Carburetor Cut-off Valve Vacuum Reed Valve Secondary Secondary Air Air Cleaner Cleaner Into Hole EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system adopted in this model utilizes the reed valve to draw secondary air into the exhaust system for re-combustion by means of exhaust pulsation so as to minimize the exhaust emission.
Page 223: Troubleshooting
. EXHAUST EMISSION CONTROL DINK 200 SYSTEM TROUBLESHOOTING High CO at idle speed 1. Damaged or clogged reed valve 2. Damaged or clogged air injection cut-off valve 3. Clogged air cleaner Backfiring at sudden deceleration 1. Damaged reed valve (malfunction) 2.
Page 224: Secondary Air Cleaner
. EXHAUST EMISSION CONTROL SYSTEM DINK 200 Secondary Air Cleaner / A.I.C.V. SECONDARY AIR CLEANER / AIR INJECTION CUT-OFF VALVE (A.I.C.V.) REMOVAL Remove the seat. (  2-4) Remove the body cover. Disconnect the secondary air cleaner /(A.I.C.V) connecting tube.
Page 225: Reed Valve
. EXHAUST EMISSION CONTROL DINK 200 SYSTEM Cylinder Head Cover Reed Valve Cover Bolt REED VALVE Bolt REMOVAL Remove the frame center cover. Remove the floor board cover. Disconnect the secondary air inlet tube connector. Remove the reed valve cover three bolts and two secondary air outlet tube bolts.

KYMCO DINK 200 Manual

Preface

Engine Serial Number

Specification

Service Precautions

Torque Values

Special Tools

Lubrication Points

Wiring Diagram

Troubleshooting

2. Exhaust Muffler/Frame Covers 2

. Inspection/Adjustment 3

4. Lubrication System 4

5. Engine Removal/Installation 5

Cylinder Head/Valves

7 Cylinder/Piston

Kick Starter 8

9. Final Reduction 9

10. A.C. Generator/Starter Clutch 10

11. Crankcase/Crankshaft 11

12. Cooling System 12

13. Fuel System/Carburetor/Fuel Pump 13

Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork

16. Battery/Charging System 16

17. Ignition System 17

Quick Links

TABLE OF CONTENTS

Chapters

Troubleshooting

Related Manuals for KYMCO DINK 200

Summary of Contents for KYMCO DINK 200