Table Of Contents - KYMCO DINK 125 Service Manual

Table of Contents

General Information1
Table Of Contents1
Serial Number2
Specifications (Dink 50)3
Specifications (Dink 125)4
Service Precautions5
Symbols8
Torque Values9
Special Tools12
Lubrication Points14
Frame15
Cable & Harness Routing (Dink 125)16
Cable And Harness Routing (Dink 50)31
Troubleshooting36
Engine Will Not Start Or Is Hard To Start36
Engine Lacks Power37
Poor Performance (Especially At Idle And Low Speeds)38
Poor Performance (At High Speeds)39
Engine Noise40
Clutch, Drive And Driven Pulleys41
Starter Motor Won't Turn42
Starter Motor Turns Slowly Or Idles42
Starter Motor Does Not Stop Turning42
No Spark At Spark Plug43
Poor Charging (Battery Over Discharging Or Overcharging)44
Fuel Gauge Troubleshooting45
Pointer Does Not Register Correctly (Ignition Switch On)45
Pointer Fluctuates Or Swings (Ignition Switch On)45
Steering Handlebar Does Not Track Straight46
Poor Suspension Performance46
Poor Brake Performance46
Exhaust Muffler/Frame Covers47
Schematic Drawing48
Exhaust Muffler/Frame Covers - Service Information49
Fastener Removal And Installation50
Seat51
Luggage Box51
Frame Covers Removal/Installation51
Center Cover52
Rear Spoiler/Rear Spoiler Stay52
Upper/Lower Handlebar Cover53
Windshield/Windshield Garnish54
Front Meter Visor55
Front Cover55
Front Fender56
Right/Left Foot Skirt56
Front Lower Cover57
Rear Fender57
Body Cover57
Rear Combination Light Under Cover58
Floorboard58
Under Cover59
Meter Panel60
Inner Cover61
Exhaust Muffler Removal/Installation62
Inspection/Adjustment63
Inspection/Adjustment - Service Information64
Inspection/Adjustment - Specifications64
Coolant Capacity64
Tire Specifications64
Maintenance Schedule65
Fuel Line/Fuel Filter Check67
Throttle Operation Check67
Engine Oil Recommendation68
Engine Oil Capacity68
Engine Oil Level Check69
Engine Oil Replacement69
Oil Strainer Screen Clean71
Oil Filter Replacement (Dink 125 Only)72
Transmission Oil Change74
Air Cleaner Element Replacement75
Secondary Air Supply System Check76
Spark Plug Check77
Valve Clearance (Dink 125) Check78
Valve Clearance (Dink 50) Check79
Carburetor Idle Speed Check80
Cylinder Compression Check81
Drive Belt81
Headlight Aim82
Clutch Shoe Wear82
Coolant (Dink 125 Only) Inspection83
Coolant Recommendation83
Brake Fluid Level Check84
Brake Pad Wear Check84
Nuts/Bolts/Fasteners Check85
Wheels/Tires Check85
Tire Pressure85
Steering Handlebar Check86
Suspension Check86
Rear Suspension Adjustment86
Side Stand Check87
Lubrication System88
Lubrication System (Dink 125) View89
Lubrication System (Dink 50) View90
Lubrication System - Service Information91
Lubrication System Specifications91
Lubrication System Troubleshooting91
Lubrication System Diagram91
Oil Pump (Dink 125) Removal92
Oil Pump(125)92
Oil Pump (Dink 125) Installation93
Oil Pump (Dink 125) Disassembly94
Oil Pump (Dink 125) Inspection94
Oil Pump (Dink 125) Assembly95
Oil Pump (Dink 50) Removal96
Oil Pump (Dink 50) Disassembly97
Oil Pump (Dink 50) Inspection97
Oil Pump (Dink 50) Assembly98
Oil Pump (Dink 50) Installation99
Engine Removal/Installation101
Engine Removal/Installation - Service Information102
Engine Removal/Installation - Specifications102
Engine Removal/Installation - Torque Values102
Engine Hanger102
Engine (Dink 125) Removal103
Engine Removal/Installation(Dink 50)103
Engine (Dink 125) Installation107
Engine (Dink 125) Inspection108
Engine Hanger Removal/Installation/Inspection109
Engine (Dink 50) Removal110
Engine Hanger Bracket Removal113
Engine Hanger Bracket Inspection114
Engine (Dink 50) Installation114
Cylinder Head/Valves115
Cylinder Head/Valves Schematic Drawing (Dink 125)116
Cylinder Head/Valves Schematic Drawing (Dink 50)117
Cylinder Head/Valves Service Information118
Cylinder Head/Valves Specifications (Dink 125)118
Cylinder Head/Valves Specifications (Dink 50)119
Cylinder Head/Valves Torque Values (Dink 125)120
Cylinder Head/Valves - Special Tools120
Cylinder Head/Valves Troubleshooting120
Cylinder Head Cover (Dink 125) Removal/Installation121
Camshaft Holder Removal122
Camshaft Holder Installation122
Camshaft Holder Disassembly123
Camshaft Holder Inspection123
Camshaft Holder Assembly124
Camshaft Removal125
Camshaft Inspection126
Cam Chain Tensioner Inspection126
Camshaft Installation127
Cylinder Head Removal129
Cylinder Head Installation130
Cylinder Head Disassembly131
Cylinder Head Inspection132
Valve/Valve Guide Check132
Valve Spring Check132
Cylinder Head Check133
Cylinder Head Assembly133
Cylinder Head Cover Removal134
Cylinder Head Cover Installation134
Camshaft/Camshaft Holder Removal134
Camshaft136
Camshaft Inspection/Installation138
Valve/Valve Guide Inspection141
Valve Spring Inspection142
Valve Spring Compressor E040143
Cylinder/Piston145
Cylinder/Piston Schematic Drawing (Dink 125)146
Cylinder/Piston Schematic Drawing (Dink 50)147
Cylinder/Piston Service Information148
Cylinder/Piston Specifications (Dink 125)148
Cylinder/Piston Specifications (Dink 50)149
Cylinder/Piston Troubleshooting149
Cylinder/Piston (Dink 125) Removal150
Piston Ring Inspection151
Piston/Piston Pin Inspection152
Cylinder Inspection153
Piston Ring Installation154
Cylinder/Piston (Dink 50) Removal157
Cylinder/Piston (Dink 50) Inspection158
Cylinder Inspection (Dink 50)160
Piston Ring Installation (Dink 50)161
Piston Installation (Dink 50)162
Cylinder Installation (Dink 50)162
Drive And Driven Pulleys/Kick Starter163
Drive And Driven Pulleys/Kick Starter Schematic Drawing (Dink 125)164
Drive And Driven Pulleys/Kick Starter Schematic Drawing (Dink 50)165
Drive And Driven Pulleys/Kick - Service Information166
Drive And Driven Pulleys/Kick Starter Specifications166
Drive And Driven Pulleys/Kick Torque Values167
Drive And Driven Pulleys/Kick Troubleshooting167
Left Crankcase Cover (Dink 125) Removal/Installation168
Left Crankcase Cover (Dink 125) Disassembly170
Left Crankcase Cover (Dink 125) Inspection171
Left Crankcase Cover (Dink 125) Assembly172
Drive Pulley, Drive Belt And Driven Pulley Removal173
Drive Belt Inspection174
Clutch Out Inspection174
Drive Pulley, Drive Belt And Driven Pulley Installation175
Drive Pulley Disassembly177
Drive Pulley Inspection178
Weight Rollers Check178
Movable Drive Face/Slide Pieces/Drive Pulley Face Check178
Drive Pulley Assembly179
Driven Pulley Disassembly181
Driven Pulley Inspection183
Driven Pulley Assembly184
Kick Starter (Dink 50) - Left Crankcase Cover Removal185
Kick Starter Spindle Removal185
Kick Starter Spindle Inspection186
Kick Starter Installation187
Left Crankcase Cover Installation188
Drive Belt Inspection/Replacement189
Drive Belt Installation190
Drive Pulley Removal191
Movable Drive Face Disassembly191
Movable Drive Face Inspection192
Starter Gear Removal/Inspection/Installation193
Clutch/Driven Pulley Removal194
Clutch/Driven Pulley Disassembly194
Clutch/Driven Pulley Inspection195
Clutch/Driven Pulley Assembly197
Clutch/Driven Pulley Installation198
Final Reduction199
Final Reduction Schematic Drawing (Dink 125)200
Final Reduction Schematic Drawing (Dink 50)201
Schematic Drawing(Dink 50)201
Final Reduction - Service Information202
Final Reduction Specifications202
Final Reduction Troubleshooting202
Final Reduction(Dink 125)202
Final Reduction Removal203
Final Reduction Inspection204
Final Reduction Installation205
Bearing Replacement207
Transmission Case Cover207
Transmission Case207
Driveshaft Bearing208
Final Reduction Disassembly (Dink 50)209
Final Reduction Inspection (Dink 50)209
Bearing Replacement (Transmission Case Cover)211
Bearing Replacement (Left Crankcase Cover)211
Final Reduction Assembly212
Generator/Starter Clutch215
Generator/Starter Clutch Schematic Drawing (Dink 125)216
Generator/Starter Clutch Schematic Drawing (Dink 50)217
Schematic Drawing(Dink 50)-1217
Schematic Drawing(Dink 50)-2218
Generator/Starter Clutch - Service Information219
Generator/Starter Clutch Specifications219
Generator/Starter Clutch Troubleshooting219
Alternator Stator (Dink 125) Removal220
Alternator Stator (Dink 125) Inspection221
Alternator Stator (Dink 125) Installation221
Starter Clutch (Dink 125) Removal223
Starter Clutch (Dink 125) Inspection224
Starter Clutch (Dink 125) Installation225
Ac Generator (Dink 50) Removal227
Ac Generator Installation228
Crankcase/Crankshaft231
Crankcase/Crankshaft Schematic Drawing (Dink 125)232
Crankcase/Crankshaft Schematic Drawing (Dink 50)233
Crankcase/Crankshaft - Service Information234
Crankcase/Crankshaft Specifications234
Crankcase/Crankshaft Troubleshooting234
Crankcase Separation (Dink 125)235
Crankshaft Inspection236
Crankcase Assembly237
Crankcase/Crankshaft (Dink 50) Removal240
Crankshaft Inspection (Dink 50)242
Crankcase/Balancer Installation243
Cooling System244
Cooling System Schematic Drawing245
Cooling System(Dink 125 Only)245
Cooling System - Service Information246
Cooling System Torque Values246
Cooling System Troubleshooting246
Cooling System Specifications247
Goolant Gravity247
Coolant Mixture (With Anti-Rust And Anti-Freezing Effects)247
Cooling System Testing248
Radiator Cap Inspection248
Coolant Replacement/Air Bleeding249
Radiator Removal252
Radiator Installation253
Fan Motor Removal254
Fan Motor Inspection254
Fan Motor Installation254
Fan Motor Switch Removal255
Fan Motor Switch Inspection255
Fan Motor Switch Installation255
Water Pump256
Mechanical Seal (Water Seal) Inspection256
Water Pump/Impeller Removal256
Water Pump Shaft Removal258
Mechanical Seal Replacement259
Water Pump Shaft Installation259
Water Pump/Impeller Installation260
Water Temperature Sensor Removal262
Water Temperature Sensor Inspection262
Water Temperature Sensor Installation263
Thermostat Removal264
Thermostat Installation264
Thermostat Disassembly265
Thermostat Inspection266
Thermostat Technical Data266
Thermostat Assembly266
Fuel System/Carburetor/Fuel Pump/Fuel Tank267
Fuel System View (Dink 125)268
Fuel System Schematic Drawing (Dink 125)269
Fuel System Schematic Drawing (Dink 50)270
Fuel System/Carburetor/Fuel Pump/Fuel Tank Service Information271
Fuel System/Carburetor/Fuel Pump/Fuel Tank Specifications271
Fuel Pump Construction272
Fuel System/Carburetor/Fuel Pump/Fuel Tank Troubleshooting273
Carburetor (Dink 125) Removal/Installation274
Carburetor (Dink 125) Disassembly276
Carburetor (Dink 125) Inspection280
Carburetor Body/Jets Cleaning280
Carburetor (Dink 125) Assembly284
Auto Choke Removal285
Auto Choke Inspection285
Auto Choke Installation286
Carburetor Heater Inspection/Replacement288
Fuel Pump Removal/Installation289
Fuel Pump Testing289
Fuel Pump Disassembly290
Fuel Pump Inspection290
Fuel Pump Assembly291
Fuel Strainer Removal/Installation292
Fuel Strainer Inspection292
Fuel Tank Removal/Installation293
Air Cleaner Removal/Installation295
Carburetor (Dink 50) Removal296
Vacuum Chamber Disassembly297
Vacuum Piston Inspection298
Float Chamber Disassembly298
Float Valve Inspection299
Jets/Screws Removal299
Auto Bystarter Inspection301
Auto Bystarter Removal301
Air Cut-Off Valve (Acv) Removal302
Carburetor Body Cleaning303
Accelerator Pump Disassembly/Inspection304
Auto Bystarter Installation304
Float Chamber Assembly305
Float Level Inspection306
Vacuum Chamber Assembly306
Carburetor Installation307
Fuel Pump Removal309
Fuel Pump Installation309
Fuel Tank Removal (Dink 50)310
Fuel Strainer Removal310
Fuel Strainer Installation310
Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Steering Stem311
Handlebar Removal315
Handlebar Installation316
Handlebar Disassembly317
Handlebar Assembly318
Front Wheel Removal319
Axle Runout Inspection319
Wheel Rim Inspection319
Front Wheel Installation320
Front Wheel Disassembly321
Front Brake Fluid Check323
Front Brake Fluid Replacement/Air Bleeding323
Brake Fluid Draining324
Brake Fluid Filling/Air Bleeding325
Front Brake Pad Replacement327
Brake Disc Inspection329
Brake Master Cylinder Removal330
Brake Master Cylinder Installation331
Brake Master Cylinder Disassembly333
Brake Master Cylinder Assembly333
Brake Master Cylinder Inspection334
Front Brake Caliper Disassembly335
Front Brake Caliper Assembly337
Front Brake Caliper Inspection338
Front Shock Absorber Removal339
Front Shock Absorber Installation339
Front Shock Absorber Inspection339
Steering Stem Removal340
Steering Stem Installation342
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber343
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber Drawings344
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber Specifications346
Service Information346
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber Troubleshooting347
Rear Brake Fluid (Dink 125 Only)348
Brake Fluid Draining (Rear)349
Brake Fluid Filling/Air Bleeding (Rear)350
Rear Brake Pad (Dink 125) Replacement352
Brake Disc Inspection (Rear)354
Brake Master Cylinder Removal (Rear)355
Brake Master Cylinder Installation (Rear)356
Brake Master Cylinder Disassembly (Rear)358
Brake Master Cylinder Assembly (Rear)358
Brake Master Cylinder Inspection (Rear)359
Rear Brake Caliper Disassembly360
Rear Brake Caliper Assembly362
Rear Brake Caliper Inspection363
Rear Wheel/Rear Fork Removal364
Rear Wheel/Rear Fork Inspection365
Rear Fork Bearing Replacement365
Rear Fork Bearing Installation367
Rear Shock Absorber Removal/Inspection/Installation369
Rear Wheel (Dink 50) Removal370
Rear Wheel (Dink 50) Inspection370
Rear Wheel (Dink 50) Installation370
Rear Brake Check371
Rear Brake Lining Inspection371
Rear Brake Disassembly371
Rear Brake Assembly372
Rear Shock Absorber Removal373
Rear Shock Absorber Installation373
Battery/Charging System374
Charging System Layout (Dink 125)375
Charging Circuit Diagram (Dink 125)375
Charging Circuit Diagram (Dink 50)376
Charging System Layout (Dink 50)376
Battery/Charging System Service Information377
Battery/Charging System Specifications378
Battery/Charging System Troubleshooting379
Battery (Dink 125) Removal/Installation380
Voltage Inspection381
Battery Charging381
Charging System Inspection382
Current Leakage Test382
Charging Voltage Inspection383
Alternator Charging Coil Inspection384
Regulator/Rectifier - Wire Harness Inspection385
Battery Line Check385
Ground Line Check385
Regulator/Rectifier Removal/Installation386
Charging Coil Line Check386
Regulator/Rectifier Inspection (Dink 50)387
Ignition System388
Ignition System Layout (Dink 125)389
Ignition Circuit Diagram (Dink 125)389
Ignition System Layout (Dink 50)390
Ignition System - Service Information391
Ignition System Specifications391
Ignition System Troubleshooting391
Ignition Coil Inspection392
Ignition Coil Primary Peak Voltage392
Ignition Pulse Generator Inspection393
Ignition Coil Removal/Installation393
Cdi Removal/Installation394
Cdi Resistance Inspection394
Cdi (Dink 50) Removal/Installation396
Cdi (Dink 50) Resistance Inspection396
Starting System397
Starting System Layout (Dink 125)398
Starting Circuit (Dink 125)398
Starting System Layout (Dink 50)399
Starting Circuit (Dink 50)399
Starting System Service Information400
Starting System Specifications400
Starting System Troubleshooting400
Starter Motor Inspection401
Starter Motor Removal401
Starter Motor Installation402
Starter Relay Inspection403
Lights/Meters/Switches407
Lights/Meters/Switches - Service Information408
Position Light Bulb Replacement409
Headlight Bulb Replacement410
Front Turn Signal Light Bulb Replacement411
Taillight/Brake Light/Rear Turn Signal Light Bulb Replacement411
Rear Turn Signal Light Bulb Replacement412
Taillight/Brake Light Bulb Replacement412
License Light Bulb Replacement412
Brake Light Switch413
Ignition Switch Inspection413
Handlebar Switch Inspection414
Right Handlebar Switch414
Left Handlebar Switch415
Luggage Box Light Switch Inspection416
Fuel Unit Removal417
Fuel Unit Inspection418
Fuel Unit Installation419
Side Stand Switch (Dink 125 Only) Inspection420
Side Stand Switch (Dink 125 Only) Removal420
Side Stand Switch (Dink 125 Only) Installation420
Horn Inspection421
Horn Removal/Installation421
Heater Controller Unit (Dink 125 Only) Inspection422
Heater Controller Unit (Dink 125 Only) Removal/Installation422
Dink 125 Wiring Diagram423
Dink 50 Wiring Diagram424