KYMCO 125 DINK - Manuals

Manuals and User Guides for KYMCO 125 DINK -. We have 6 KYMCO 125 DINK - manuals available for free PDF download: Service Manual, Owner's Manual, Specifications

KYMCO 125 DINK - Service Manual (425 pages)

Brand: KYMCO | Category: Scooter | Size: 33.9 MB

Table of Contents
1
General Information
1
Serial Number
2
- Specifications (DINK 50)
  3
- Specifications (DINK 125)
  4
Service Precautions
5
Symbols
8
Torque Values
9
Special Tools
12
Lubrication Points
14
Frame
15
Cable & Harness Routing (Dink 125)
16
- Cable and Harness Routing (DINK 50)
  31
- Engine will Not Start or Is Hard to Start
  36
Troubleshooting
36
- Engine Lacks Power
  37
- Poor Performance (Especially at Idle and Low Speeds)
  38
- Poor Performance (at High Speeds)
  39
- Engine Noise
  40
- Clutch, Drive and Driven Pulleys
  41
- Starter Motor Does Not Stop Turning
  42
- Starter Motor Turns Slowly or Idles
  42
- Starter Motor Won‘t Turn
  42
- No Spark at Spark Plug
  43
- Poor Charging (Battery over Discharging or Overcharging)
  44
- Fuel Gauge Troubleshooting
  45
- Pointer Does Not Register Correctly (Ignition Switch ON)
  45
- Pointer Fluctuates or Swings (Ignition Switch ON)
  45
- Poor Brake Performance
  46
- Poor Suspension Performance
  46
- Steering Handlebar Does Not Track Straight
  46
- Exhaust Muffler/Frame Covers
  47
- Schematic Drawing
  48
- Exhaust Muffler/Frame Covers - Service Information
  49
- Troubleshooting
  49
- Fastener Removal and Installation
  50
- Frame Covers Removal/Installation
  51
  - Luggage Box
    51
  - Seat
    51
  - Center Cover
    52
  - Rear Spoiler/Rear Spoiler Stay
    52
  - Upper/Lower Handlebar Cover
    53
  - Windshield/Windshield Garnish
    54
  - Front Cover
    55
  - Front Meter Visor
    55
  - Front Fender
    56
  - Right/Left Foot Skirt
    56
  - Body Cover
    57
  - Front Lower Cover
    57
  - Rear Fender
    57
  - Floorboard
    58
  - Rear Combination Light under Cover
    58
  - Under Cover
    59
  - Meter Panel
    60
  - Inner Cover
    61
  - Exhaust Muffler Removal/Installation
    62
  - Inspection/Adjustment
    63
  - Coolant Capacity
    64
  - Inspection/Adjustment - Service Information
    64
  - Inspection/Adjustment - Specifications
    64
  - Tire Specifications
    64
- Maintenance Schedule
  65
  - Fuel Line/Fuel Filter Check
    67
  - Throttle Operation Check
    67
  - Engine Oil Capacity
    68
  - Engine Oil Recommendation
    68
  - Engine Oil Level Check
    69
  - Engine Oil Replacement
    69
  - Oil Strainer Screen Clean
    71
  - Oil Filter Replacement (DINK 125 Only)
    72
  - Transmission Oil Change
    74
  - Air Cleaner Element Replacement
    75
  - Secondary Air Supply System Check
    76
  - Spark Plug Check
    77
  - Valve Clearance (DINK 125) Check
    78
  - Valve Clearance (DINK 50) Check
    79
  - Carburetor Idle Speed Check
    80
  - Cylinder Compression Check
    81
- Drive Belt
  81
- Clutch Shoe Wear
  82
- Headlight Aim
  82
  - Coolant (DINK 125 Only) Inspection
    83
  - Coolant Recommendation
    83
  - Brake Fluid Level Check
    84
  - Brake Pad Wear Check
    84
  - Nuts/Bolts/Fasteners Check
    85
  - Tire Pressure
    85
  - Wheels/Tires Check
    85
  - Rear Suspension Adjustment
    86
  - Steering Handlebar Check
    86
  - Suspension Check
    86
  - Side Stand Check
    87
  - Lubrication System
    88
  - Lubrication System (DINK 125) View
    89
  - Lubrication System (DINK 50) View
    90
  - Lubrication System - Service Information
    91
- Lubrication System Diagram
  91
- Oil Pump(125)
  92
- Engine Hanger
  102
- Engine Removal/Installation(Dink 50)
  103
  - Engine (DINK 125) Installation
    107
  - Engine (DINK 125) Inspection
    108
  - Engine Hanger Removal/Installation/Inspection
    109
  - Engine (DINK 50) Removal
    110
  - Engine Hanger Bracket Removal
    113
  - Engine (DINK 50) Installation
    114
  - Engine Hanger Bracket Inspection
    114
  - Cylinder Head/Valves
    115
  - Cylinder Head/Valves Schematic Drawing (DINK 125)
    116
  - Cylinder Head/Valves Schematic Drawing (DINK 50)
    117
  - Cylinder Head/Valves Service Information
    118
  - Cylinder Head/Valves Specifications (DINK 125)
    118
  - Cylinder Head/Valves Specifications (DINK 50)
    119
  - Cylinder Head/Valves - Special Tools
    120
  - Cylinder Head/Valves Torque Values (DINK 125)
    120
  - Cylinder Head/Valves Troubleshooting
    120
  - Cylinder Head Cover (DINK 125) Removal/Installation
    121
  - Camshaft Holder Installation
    122
  - Camshaft Holder Removal
    122
  - Camshaft Holder Disassembly
    123
  - Camshaft Holder Inspection
    123
  - Camshaft Holder Assembly
    124
  - Camshaft Removal
    125
  - Cam Chain Tensioner Inspection
    126
  - Camshaft Inspection
    126
  - Camshaft Installation
    127
  - Cylinder Head Removal
    129
  - Cylinder Head Installation
    130
  - Cylinder Head Disassembly
    131
  - Cylinder Head Inspection
    132
  - Valve Spring Check
    132
  - Valve/Valve Guide Check
    132
  - Cylinder Head Assembly
    133
  - Cylinder Head Check
    133
  - Camshaft/Camshaft Holder Removal
    134
  - Cylinder Head Cover Installation
    134
  - Cylinder Head Cover Removal
    134
- Camshaft
  136
- Schematic Drawing(Dink 50)
  201
- Final Reduction(Dink 125)
  202
  - Final Reduction Removal
    203
  - Final Reduction Inspection
    204
  - Final Reduction Installation
    205
  - Bearing Replacement
    207
  - Transmission Case
    207
  - Transmission Case Cover
    207
  - Driveshaft Bearing
    208
  - Final Reduction Disassembly (DINK 50)
    209
  - Final Reduction Inspection (DINK 50)
    209
  - Bearing Replacement (Left Crankcase Cover)
    211
  - Bearing Replacement (Transmission Case Cover)
    211
  - Final Reduction Assembly
    212
  - Generator/Starter Clutch
    215
  - Generator/Starter Clutch Schematic Drawing (DINK 125)
    216
  - Generator/Starter Clutch Schematic Drawing (DINK 50)
    217
- Schematic Drawing(Dink 50)-1
  217
- Schematic Drawing(Dink 50)-2
  218
- Crankshaft Inspection
  236
- Crankcase Assembly
  237
  - Crankcase/Crankshaft (DINK 50) Removal
    240
  - Crankshaft Inspection (DINK 50)
    242
  - Crankcase/Balancer Installation
    243
  - Cooling System
    244
  - Cooling System Schematic Drawing
    245
- Cooling System(Dink 125 Only)
  245
- Cooling System Testing
  248
  - Radiator Cap Inspection
    248
  - Coolant Replacement/Air Bleeding
    249
  - Radiator Removal
    252
  - Radiator Installation
    253
  - Fan Motor Inspection
    254
  - Fan Motor Installation
    254
  - Fan Motor Removal
    254
  - Fan Motor Switch Inspection
    255
  - Fan Motor Switch Installation
    255
  - Fan Motor Switch Removal
    255
  - Mechanical Seal (Water Seal) Inspection
    256
- Water Pump
  256
  - Water Pump/Impeller Removal
    256
  - Water Pump Shaft Removal
    258
  - Mechanical Seal Replacement
    259
  - Water Pump Shaft Installation
    259
  - Water Pump/Impeller Installation
    260
  - Water Temperature Sensor Inspection
    262
  - Water Temperature Sensor Removal
    262
  - Water Temperature Sensor Installation
    263
  - Thermostat Installation
    264
  - Thermostat Removal
    264
  - Thermostat Disassembly
    265
  - Thermostat Assembly
    266
  - Thermostat Inspection
    266
  - Thermostat Technical Data
    266
  - Fuel System/Carburetor/Fuel Pump/Fuel Tank
    267
  - 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 Information
    271
  - Fuel System/Carburetor/Fuel Pump/Fuel Tank Specifications
    271
- Fuel Pump Construction
  272
  - Fuel System/Carburetor/Fuel Pump/Fuel Tank Troubleshooting
    273
  - Carburetor (DINK 125) Removal/Installation
    274
  - Carburetor (DINK 125) Disassembly
    276
  - Carburetor (DINK 125) Inspection
    280
  - Carburetor Body/Jets Cleaning
    280
  - Carburetor (DINK 125) Assembly
    284
  - Auto Choke Inspection
    285
  - Auto Choke Removal
    285
  - Auto Choke Installation
    286
  - Carburetor Heater Inspection/Replacement
    288
  - Fuel Pump Removal/Installation
    289
  - Fuel Pump Testing
    289
  - Fuel Pump Disassembly
    290
  - Fuel Pump Inspection
    290
  - Fuel Pump Assembly
    291
  - Fuel Strainer Inspection
    292
  - Fuel Strainer Removal/Installation
    292
  - Fuel Tank Removal/Installation
    293
  - Air Cleaner Removal/Installation
    295
  - Carburetor (DINK 50) Removal
    296
  - Vacuum Chamber Disassembly
    297
  - Float Chamber Disassembly
    298
  - Vacuum Piston Inspection
    298
  - Float Valve Inspection
    299
  - Jets/Screws Removal
    299
  - Auto Bystarter Inspection
    301
  - Auto Bystarter Removal
    301
  - Air Cut-Off Valve (ACV) Removal
    302
  - Carburetor Body Cleaning
    303
  - Accelerator Pump Disassembly/Inspection
    304
  - Auto Bystarter Installation
    304
  - Float Chamber Assembly
    305
  - Float Level Inspection
    306
  - Vacuum Chamber Assembly
    306
  - Carburetor Installation
    307
  - Fuel Pump Installation
    309
  - Fuel Pump Removal
    309
  - Fuel Strainer Installation
    310
  - Fuel Strainer Removal
    310
  - Fuel Tank Removal (DINK 50)
    310
  - Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Steering Stem
    311
- Troubleshooting
  314
  - Handlebar Removal
    315
  - Handlebar Installation
    316
  - Handlebar Disassembly
    317
  - Handlebar Assembly
    318
  - Axle Runout Inspection
    319
  - Front Wheel Removal
    319
  - Wheel Rim Inspection
    319
  - Front Wheel Installation
    320
  - Front Wheel Disassembly
    321
  - Front Brake Fluid Check
    323
  - Front Brake Fluid Replacement/Air Bleeding
    323
  - Brake Fluid Draining
    324
  - Brake Fluid Filling/Air Bleeding
    325
  - Front Brake Pad Replacement
    327
- Brake Disc Inspection
  329
- Service Information
  346
  - Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber Troubleshooting
    347
  - Rear Brake Fluid (DINK 125 Only)
    348
  - Brake Fluid Draining (Rear)
    349
  - Brake Fluid Filling/Air Bleeding (Rear)
    350
  - Rear Brake Pad (DINK 125) Replacement
    352
  - Brake Disc Inspection (Rear)
    354
  - Brake Master Cylinder Removal (Rear)
    355
  - Brake Master Cylinder Installation (Rear)
    356
  - Brake Master Cylinder Assembly (Rear)
    358
  - Brake Master Cylinder Disassembly (Rear)
    358
  - Brake Master Cylinder Inspection (Rear)
    359
  - Rear Brake Caliper Disassembly
    360
  - Rear Brake Caliper Assembly
    362
  - Rear Brake Caliper Inspection
    363
  - Rear Wheel/Rear Fork Removal
    364
  - Rear Fork Bearing Replacement
    365
  - Rear Wheel/Rear Fork Inspection
    365
  - Rear Fork Bearing Installation
    367
  - Rear Shock Absorber Removal/Inspection/Installation
    369
  - Rear Wheel (DINK 50) Inspection
    370
  - Rear Wheel (DINK 50) Installation
    370
  - Rear Wheel (DINK 50) Removal
    370
  - Rear Brake Check
    371
  - Rear Brake Disassembly
    371
  - Rear Brake Lining Inspection
    371
  - Rear Brake Assembly
    372
  - Rear Shock Absorber Installation
    373
  - Rear Shock Absorber Removal
    373
  - Battery/Charging System
    374
  - Charging Circuit Diagram (DINK 125)
    375
  - Charging System Layout (DINK 125)
    375
  - Charging Circuit Diagram (DINK 50)
    376
  - Charging System Layout (DINK 50)
    376
  - Battery/Charging System Service Information
    377
  - Battery/Charging System Specifications
    378
  - Battery/Charging System Troubleshooting
    379
  - Battery (DINK 125) Removal/Installation
    380
  - Battery Charging
    381
  - Voltage Inspection
    381
  - Charging System Inspection
    382
  - Current Leakage Test
    382
  - Charging Voltage Inspection
    383
  - Alternator Charging Coil Inspection
    384
  - Battery Line Check
    385
  - Ground Line Check
    385
  - Regulator/Rectifier - Wire Harness Inspection
    385
  - Charging Coil Line Check
    386
  - Regulator/Rectifier Removal/Installation
    386
  - Regulator/Rectifier Inspection (DINK 50)
    387
  - Ignition System
    388
  - Ignition Circuit Diagram (DINK 125)
    389
  - Ignition System Layout (DINK 125)
    389
  - Ignition System Layout (DINK 50)
    390
  - Ignition System - Service Information
    391
  - Ignition System Specifications
    391
  - Ignition System Troubleshooting
    391
  - Ignition Coil Inspection
    392
  - Ignition Coil Primary Peak Voltage
    392
  - Ignition Coil Removal/Installation
    393
  - Ignition Pulse Generator Inspection
    393
  - CDI Removal/Installation
    394
  - CDI Resistance Inspection
    394
  - CDI (DINK 50) Removal/Installation
    396
  - CDI (DINK 50) Resistance Inspection
    396
  - Starting System
    397
  - Starting Circuit (DINK 125)
    398
  - Starting System Layout (DINK 125)
    398
  - Starting Circuit (DINK 50)
    399
  - Starting System Layout (DINK 50)
    399
  - Starting System Service Information
    400
  - Starting System Specifications
    400
  - Starting System Troubleshooting
    400
  - Starter Motor Inspection
    401
  - Starter Motor Removal
    401
  - Starter Motor Installation
    402
  - Starter Relay Inspection
    403
  - Lights/Meters/Switches
    407
  - Lights/Meters/Switches - Service Information
    408
  - Position Light Bulb Replacement
    409
  - Headlight Bulb Replacement
    410
  - Front Turn Signal Light Bulb Replacement
    411
  - Taillight/Brake Light/Rear Turn Signal Light Bulb Replacement
    411
  - License Light Bulb Replacement
    412
  - Rear Turn Signal Light Bulb Replacement
    412
  - Taillight/Brake Light Bulb Replacement
    412
- Brake Light Switch
  413
- Ignition Switch Inspection
  413
- Right Handlebar Switch
  414
- Handlebar Switch Inspection
  414
- Left Handlebar Switch
  415
- Luggage Box Light Switch Inspection
  416
- Fuel Unit Removal
  417
- Fuel Unit Inspection
  418
- Fuel Unit Installation
  419
- Side Stand Switch (DINK 125 Only) Inspection
  420
- Side Stand Switch (DINK 125 Only) Removal
  420
- Side Stand Switch (DINK 125 Only) Installation
  420
- Horn Inspection
  421
- Horn Removal/Installation
  421
- Heater Controller Unit (DINK 125 Only) Inspection
  422
- Heater Controller Unit (DINK 125 Only) Removal/Installation
  422
- DINK 125 Wiring Diagram
  423
- DINK 50 Wiring Diagram
  424

KYMCO 125 DINK - Service Manual (400 pages)

Brand: KYMCO | Category: Scooter | Size: 13.04 MB

Preface

2
- Table of Contents
  2
- General Information
  3
- Serial Number
  4
- General Information
  4
- SPECIFICATION (DINK 200I)
  5
- Specification (Dink 125)
  6
- Torque Values
  11
- Special Tools
  14
- Lubrication Points
  16
- Cable & Harness Routing
  18
  - General Information Dink
    21
- Inspection/Adjustment
  34
- TROUBLESHOOTING (DINK 200I)
  34
- Troubleshooting (Dink 125)
  45
2. Exhaust Muffler/Frame Covers

56
- Schematic Drawing
  57
- Service Information
  58
- Troubleshooting
  58
- Fastener Removal and Reinstallation
  59
- Frame Covers Removal/Installation
  60
- Exhaust Muffler
  71
3. Inspection/Adjustment

73
- Service Information
  74
- Maintenance Schedule
  75
- Fuel Line/Fuel Filter
  77
- Throttle Operation
  77
- Engine Oil
  79
- Transmission Oil
  85
- Air Cleaner
  86
- Secondary Air Supply System
  87
- Spark Plug
  88
- Valve Clearance
  89
- Idle Speed
  90
- Cylinder Compression
  91
- Drive Belt
  91
- Clutch Shoe Wear
  92
- Headlight Aim
  92
- Coolant
  93
- Brake Fluid
  95
- Brake Pad Wear
  95
- Nuts/Bolts/Fasteners
  96
- Wheels/Tires
  96
- Steering Handlebar
  97
- Suspension
  97
- Side Stand
  98
4. Lubrication System

99
- Lubrication System
  99
  - Lubrication System
    100
  - Lubrication System Diagram
    100
  - Service Information
    101
  - Troubleshooting
    101
  - Oil Pump
    102
- Engine Removal/Installation
  106
6 Cylinder Head/Valves

116
- Cylinder Head/Valves
  117
- Schematic Drawing
  117
- Service Information
  118
- Troubleshooting
  119
- Cylinder Head Cover
  120
- Camshaft Holder
  121
- Camshaft
  124
- Cylinder Head
  128
7. Cylinder/Piston

133
- Cylinder/Piston
  133
  - Cylinder/Piston
    134
  - Schematic Drawing
    134
  - Service Information
    135
  - Troubleshooting
    136
  - Cylinder and Piston
    137
8. Drive and Driven Pulleys/

144
- Drive and Driven Pulleys/Kick Starter
  144
  - Drive and Driven Pulleys/ Kick Starter
    145
  - Schematic Drawing
    145
  - Service Information
    146
  - Troubleshooting
    147
  - Left Crankcase Cover
    148
  - Drive Pulley, Drive Belt and Driven Pulley
    152
9. Final Reduction

164
- Final Reduction
  164
  - Final Reduction
    165
  - Schematic Drawing
    165
  - Service Information
    166
  - Troubleshooting
    166
  - Final Reduction
    166
  - Bearing Replacement
    171
10. A.C. Generator/Starter Clutch

173
- Generator/Starter Clutch
  173
  - Generator/Starter Clutch
    174
  - Schematic Drawing
    174
  - Service Information
    175
  - Troubleshooting
    175
  - Alternator Stator
    176
  - Starter Clutch
    179
11. Crankcase/Crankshaft

183
- Crankcase/Crankshaft
  183
  - Crankcase/Crankshaft
    184
  - Schematic Drawing
    184
  - Service Information
    185
  - Troubleshooting
    185
  - Crankcase Separation
    186
  - Crankshaft Inspection
    187
  - Crankcase Assembly
    188
12. Cooling System

191
- Cooling System
  191
  - Cooling System
    192
  - Schematic Drawing
    192
- Dink
  192
  - Service Information
    193
  - Troubleshooting
    193
  - Cooling System Testing
    195
  - Coolant Replacement
    196
  - Radiator
    199
  - Fan Motor
    201
  - Fan Motor Switch
    202
  - Water Pump
    203
  - Water Temperature Sensor
    209
  - Thermostat
    211
Dink 125:Fuel System/Carburetor/ Fuel Pump/Fuel Tank

214
- Fuel System
  215
  - Dink 125:Fuel System/Carburetor/ Fuel Pump/Fuel Tank
    215
  - Schematic Drawing
    216
  - Service Information
    217
  - Fuel Pump Construction
    218
  - Troubleshooting
    219
  - Carburetor
    220
  - Auto Choke
    231
  - Carburetor Heater
    234
  - Fuel Pump
    235
  - Fuel Strainer
    238
  - Fuel Tank
    239
  - Air Cleaner
    241
14 Dink 200 I: Fuel System (Auto Control Fuel Injection System) 14

242
- DINK 200 I: FUEL SYSTEM (Auto Control Fuel Injection System)
  244
- System Location
  244
- Service Information
  247
- Troubleshooting
  248
- Check Engine Lamp (Celp)
  249
- Self-Diagnosis Procedures Without Dignostic Tool
  250
- Celp Failure Codes Chart
  253
- Diagnostic Tool (Pda)
  259
- Maintenance Menu (Using Diagnostic Tool)
  266
- Throttle Position Sensor Initial Procedure
  268
- Reset the Air by Pass Valve
  269
- Adapt Air Flow Per Cycle (Apc)
  270
- Apc Adaption Procedure
  271
- Spark Plug Anti-Flood
  272
- Engine Control Unit (Ecu)
  273
- Pressure Sensor (T-Map)
  275
- Temperature/Manifold Absolute
  275
- Throttle Body/Throttle Position Sensor
  277
- Water Temperature Sensor (Wts)
  283
- Fuel Injector
  284
- Fuel Pump
  287
- Fuel Tank
  287
- Fuel Pump Relay
  288
- O2/O2 Ht Sensor
  293
- Angle Detect Sensor
  295
- Air Cleaner
  296
Handlebar/Front Wheel/Front Brake/ Front Shock Absorber/Steering Stem

297
- Handlebar/Front Wheel/Front Brake/Front Shock
  297
  - Troubleshooting
    300
  - Handlebar
    301
  - Front Wheel
    305
  - Front Brake Fluid
    309
  - Front Brake Pad
    313
  - Brake Disc Inspection
    315
  - Brake Master Cylinder
    316
  - Front Brake Caliper
    321
  - Front Shock Absorber
    325
  - Steering Stem
    326
Rear Brake/Rear Fork/Rear Wheel/ Rear Shock Absorber

329
- Rear Brake/Rear Fork/Rear
  329
  - Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
    330
  - Schematic Drawing
    330
  - Service Information
    331
  - Troubleshooting
    332
  - Rear Brake Fluid
    333
  - Rear Brake Pad
    337
  - Brake Disc Inspection
    339
  - Brake Master Cylinder
    340
  - Rear Brake Caliper
    345
  - Rear Wheel/Rear Fork
    349
- Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
  329

KYMCO 125 DINK - Service Manual (224 pages)

Brand: KYMCO | Category: Scooter | Size: 23.2 MB

Preface

1
- Table of Contents
  1
- General Information
  2
- Engine Serial Number
  3
- General Information
  3
- Specification
  4
- Service Precautions
  6
- Torque Values
  10
- Special Tools
  11
- Lubrication Points
  12
- Cable & Harness Routing
  14
  - Rear View
    15
- Wiring Diagram
  19
- Troubleshooting
  20
- Inspection/Adjustment
  26
2. Exhaust Muffler/Frame Covers 2

31
- Schematic Drawing
  32
- Service Information
  33
- Troubleshooting
  33
- Frame Covers Removal
  34
  - Front Cover Removal
    37
  - Back Cover Removal
    37
  - Bottom Cover Removal
    38
  - Front Fender Removal
    38
- Exhaust Muffler Removal
  38
3. Inspection/Adjustment 3

40
- Service Information
  41
- Maintenance Schedule
  42
- Fuel Line/Fuel Filter
  43
- Throttle Operation
  43
- Engine Oil
  44
  - Oil Filter Screen Inspection
    44
- Air Cleaner
  45
- Spark Plug
  45
- Carburetor Idle Speed
  46
- Valve Clearance
  46
- Cylinder Compression
  47
- Ignition Timing
  47
- Drive Belt
  48
- Final Reduction Gear Oil
  48
- Clutch Shoe Wear
  49
- Cooling System
  49
- Headlight Aim
  49
- Brake System
  50
- Nuts/Bolts/Fasteners
  51
- Steering Handlebar
  51
- Suspension
  51
- Wheels/Tires
  51
4. Lubrication System 4

52
- Lubrication System
  52
  - Lubrication System Diagram
    53
  - Service Information
    54
  - Troubleshooting
    54
  - Engine Oil/Oil Filter
    55
  - Oil Pump Removal
    56
  - Oil Pump Disassembly
    56
  - Oil Pump Inspection
    57
  - Oil Pump Assembly
    57
  - Oil Pump Installation
    58
Engine Removal/Installation

59
- Engine Removal/Installation
  60
- Schematic Drawing
  60
- Service Information
  61
- Engine Removal
  62
- Engine Installation
  64
Cylinder Head/Valves

65
- Cylinder Head/Valves
  66
- Schematic Drawing
  66
- Service Information
  67
- Specifications
  67
- Troubleshooting
  68
- Camshaft Removal
  69
- Cylinder Head Cover Removal
  69
- Cylinder Head Removal
  71
- Cylinder Head Disassembly
  72
- Cylinder Head Assembly
  73
- Cylinder Head Installation
  74
- Camshaft Installation
  75
- Cylinder Head Cover Installation
  76
7 Cylinder/Piston

77
- Cylinder/Piston
  78
- Schematic Drawing
  78
- Service Information
  79
- Troubleshooting
  79
- Cylinder Removal
  80
- Piston Removal
  80
  - Cylinder Inspection
    82
  - Piston Ring Installation
    83
- Cylinder Installation
  84
- Piston Installation
  84
Kick Starter 8

86
- Drive and Driven Pulleys/Kick Starter
  86
  - Drive and Driven Pulleys/ Kick Starter
    87
  - Schematic Drawing
    87
  - Service Information
    88
  - Troubleshooting
    88
  - Left Crankcase Cover
    89
  - Drive Pulley
    90
  - Clutch/Driven Pulley
    94
  - Kick Starter
    95
9. Final Reduction 9

104
- Final Reduction
  104
  - Final Reduction
    105
  - Schematic Drawing
    105
  - Service Information
    106
  - Troubleshooting
    106
  - Final Reduction Disassembly
    107
  - Final Reduction Inspection
    107
  - Final Reduction Assembly
    110
10. A.C. Generator/Starter Clutch 10

113
- Generator/Starter Clutch
  113
  - Generator/Starter Clutch
    114
  - Schematic Drawing
    114
  - Service Information
    115
  - Troubleshooting
    115
  - Right Crankcase Cover Removal
    116
  - Stator Removal
    116
  - Flywheel Removal
    116
  - Starter Clutch
    117
  - Flywheel Installation
    118
  - Stator Installation
    119
  - Right Crankcase Cover Installation
    119
11. Crankcase/Crankshaft 11

120
- Crankcase/Crankshaft
  120
  - Crankcase/Crankshaft
    121
  - Schematic Drawing
    121
  - Service Information
    122
  - Troubleshooting
    122
  - Crankcase Separation
    123
  - Crankshaft Inspection
    124
  - Crankcase Assembly
    125
12. Cooling System 12

128
- Cooling System
  128
  - Cooling System
    129
  - Schematic Drawing
    129
  - Service Information
    130
  - Troubleshooting
    130
  - Cooling System Testing
    132
  - Radiator
    132
  - Water Pump
    137
  - Thermosensor
    143
  - Thermostat
    144
13. Fuel System/Carburetor/ Fuel Pump/ Fuel Tank 13

146
- Fuel System/Carburetor/Fuel Pump Fuel Tank
  147
  - Fuel System/Carburetor/Fuel Pump
    147
  - Fuel System
    147
  - Schematic Drawing
    148
  - Operation of Carburetor Jets
    149
  - Service Information
    151
  - Carburetor Removal
    153
  - Vacuum Chamber Disassembly
    153
  - Float Chamber Disassembly
    155
  - Auto Bystarter Inspection/Removal
    157
  - Air Cut-Off Valve (A.C.V.)
    158
  - Auto Bystarter Installation
    160
  - Float Chamber Assembly
    161
  - Float Level Inspection
    162
  - Vacuum Chamber Assembly
    162
  - Carburetor Installation
    163
  - Fuel Pump Removal/Disassembly
    164
  - Fuel Pump Inspection
    165
  - Fuel Pump Assembly
    165
  - Fuel Pump Installation
    166
  - Fuel Tank Removal
    166
Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork

168
- Steering Handlebar/Front Wheel/Front Brake/Front
  168
  - Schematic Drawing
    169
  - Service Information
    170
  - Troubleshooting
    171
  - Steering Handlebar
    172
  - Front Wheel
    173
  - Front Brake
    176
  - Front Shock Absorber
    182
  - Front Fork
    182
Rear Brake/Rear Fork/Rear Wheel/ Rear Shock Absorber

187
- Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
  187
  - Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
    188
  - Schematic Drawing
    188
  - Rear Brake
    188
  - Rear Fork
    191
  - Rear Wheel
    191
  - Rear Shock Absorber
    192
16. Battery/Charging System 16

193
- Battery/Charging System
  193
  - Battery/Charging System
    194
  - Charging System Layout
    194
  - Service Information
    195
  - Troubleshooting
    196
  - Battery
    197
  - Charging System
    198
  - A.C. Generator Inspection
    198
  - Regulator/Rectifier Inspection
    199
17. Ignition System 17

200
- Ignition System
  200
- Ignition System Layout
  201
- Service Information
  202
- Troubleshooting
  202
- Ignition Coil Inspection
  203
- Spark Plug
  203
- A .C. Generator Inspection
  204
- CDI Unit Resistance Inspection
  205
- Starting System
  206
  - Starting System
    207
  - Starting System Layout
    207
  - Service Information
    208
  - Troubleshooting
    208
  - Starter Motor
    209
  - Starter Clutch Inspection
    211
  - Starter Relay Inspection
    212
- Switches/Horn/Fuel Unit/Thermostatic
  213
  - Electrical Equipment Layout
    214
  - Service Information
    215
  - Troubleshooting
    215
  - Switches
    216
  - Horn Inspection
    218
  - Fuel Unit
    218
  - Thermostatic Switch
    219
  - Temperature Gauge
    219
  - Instruments
    220
  - Lights
    221
  - Heater Wiring Diagram
    222

KYMCO 125 DINK - Owner's Manual (104 pages)

Brand: KYMCO | Category: Scooter | Size: 3.63 MB

Table of Contents
5
Scooter Safety

7
Parts Location

14
- Frame Number
  18
- Engine Number
  19
- Key Number
  20
Controls

21
- Keys
  21
- Ignition Switch
  21
- Instrument and Indicators
  22
- Right Handlebar Switch
  30
- Left Handlebar Switch
  33
- Brakes
  35
- Fuel Fill Cap
  36
- Seat
  38
- Center Compartment/Center Compartment Light
  39
- Helmet Holders
  40
- Center Hook
  41
- Passenger Footpeg
  42
- Stand
  43
- Suspension
  45
Pre-Ride Inspection

46
Operation

47
- Starting the Engine
  47
- Riding
  51
- Parking
  55
- Break-In (Running In)
  57
Inspection and Maintenance

59
- The Importance of Maintenance
  59
- Maintenance Schedule
  60
- Tool Kit
  63
- Crankcase Breather
  63
- Engine Oil
  64
- Transmission Oil
  72
- Air Cleaner
  73
- Throttle Operation
  74
- Idle Speed
  75
- Spark Plug
  76
- Coolant
  77
- Front and Rear Suspension Inspection
  79
- Side Stand
  80
- Brake Fluid
  81
- Brake Pad Wear
  82
- Battery
  83
- Fuse Replacement
  86
- Tires
  88
Cleaning

92
Storage Guide

97
Specifications

100

KYMCO 125 DINK - Specifications (1 page)

Brand: KYMCO | Category: Scooter | Size: 0.54 MB

KYMCO 125 DINK - Specifications (1 page)

Brand: KYMCO | Category: Scooter | Size: 0.5 MB

KYMCO Categories

Scooter Offroad Vehicle Motorcycle Wheelchair Engine

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KYMCO 125 DINK - Service Manual (425 pages)

Table of Contents

KYMCO 125 DINK - Service Manual (400 pages)

Table of Contents

Preface

2. Exhaust Muffler/Frame Covers

3. Inspection/Adjustment

4. Lubrication System

6 Cylinder Head/Valves

7. Cylinder/Piston

8. Drive and Driven Pulleys/

9. Final Reduction

10. A.C. Generator/Starter Clutch

11. Crankcase/Crankshaft

12. Cooling System

Dink 125:Fuel System/Carburetor/ Fuel Pump/Fuel Tank

14 Dink 200 I: Fuel System (Auto Control Fuel Injection System) 14

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

Rear Brake/Rear Fork/Rear Wheel/ Rear Shock Absorber

KYMCO 125 DINK - Service Manual (224 pages)

Table of Contents

Preface

2. Exhaust Muffler/Frame Covers 2

3. Inspection/Adjustment 3

4. Lubrication System 4

Engine Removal/Installation

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/ Fuel Tank 13

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

Rear Brake/Rear Fork/Rear Wheel/ Rear Shock Absorber

16. Battery/Charging System 16

17. Ignition System 17

KYMCO 125 DINK - Owner's Manual (104 pages)

Table of Contents

Scooter Safety

Parts Location

Controls

Pre-Ride Inspection

Operation

Inspection and Maintenance

Cleaning

Storage Guide

Specifications

KYMCO 125 DINK - Specifications (1 page)

KYMCO 125 DINK - Specifications (1 page)

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