KYMCO DINK 200 Manuals

KYMCO DINK 200 Manuals

Manuals and User Guides for KYMCO DINK 200. We have 1 KYMCO DINK 200 manual available for free PDF download: Manual

KYMCO DINK 200 Manual

KYMCO DINK 200 Manual (225 pages)

Brand: KYMCO | Category: Scooter | Size: 43 MB

Table of Contents

Preface

1
- Table of Contents
  1
- Engine Serial Number
  
  2
- Specification
  
  3
- Service Precautions
  
  4
- Torque Values
  
  12
- Special Tools
  
  13
- Lubrication Points
  
  14
- Wiring Diagram
  
  21
- Troubleshooting
  
  22
  - General Information
    27
  - Inspection/Adjustment
    28
2. Exhaust Muffler/Frame Covers 2

33
- Exhaust Muffler/Frame Covers
  33
- Schematic Drawing
  34
- Service Information
  35
- Troubleshooting
  35
- Frame Covers Removal
  36
- Exhaust Muffler Removal
  39
. Inspection/Adjustment 3

40
- Service Information
  41
- Maintenance Schedule
  42
- Fuel Line/Fuel Filter
  43
- Throttle Operation
  43
- Engine Oil
  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
  54
  - Lubrication System Diagram
    54
  - Service Information
    54
  - Troubleshooting
    54
  - Specifications
    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
5. Engine Removal/Installation 5

59
- Schematic Drawing
  60
- Service Information
  61
- Engine Removal
  62
- Engine Removal/Installation
  63
  - Engine Installation
    64
Cylinder Head/Valves

65
- Cylinder Head/Valves
  66
- Schematic Drawing
  66
- Service Information
  67
  - Specifications
    67
  - Torque Values
    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
  87
  - Schematic Drawing
    87
  - Service Information
    88
  - Troubleshooting
    88
  - Drive and Driven Pulleys/ Kick Starter
    89
  - Left Crankcase Cover
    89
  - Drive Pulley
    90
  - Clutch/Driven Pulley
    94
  - Kick Starter
    96
9. Final Reduction 9

104
- Schematic Drawing
  105
- Service Information
  106
- Troubleshooting
  106
- Final Reduction
  107
  - 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
    123
  - Crankcase Assembly
    125
12. Cooling System 12

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

146
- Fuel System/Carburetor/Fuel Pump
  146
  - Schematic Drawing
    148
  - Service Information
    150
  - Troubleshooting
    150
  - Carburetor Removal
    152
  - Vacuum Chamber Disassembly
    152
  - Float Chamber Disassembly
    154
  - Auto Bystarter Inspection/Removal
    156
  - Air Cut-Off Valve (A.C.V.)
    157
  - Auto Bystarter Installation
    159
  - Float Chamber Assembly
    160
  - Float Level Inspection
    161
  - Vacuum Chamber Assembly
    161
  - Carburetor Installation
    162
  - Fuel Pump Removal/Disassembly
    163
  - Fuel Pump Installation
    163
Steering Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Front Fork

165
- Brake/Front Shock Absorber/Front Fork
  166
- Schematic Drawing
  166
- Service Information
  167
- Troubleshooting
  168
- Steering Handlebar/Front Wheel/Front Brake/Front
  169
  - Steering Handlebar
    169
  - Front Wheel
    170
  - Front Brake
    173
  - Front Shock Absorber
    179
  - Front Fork
    182
- Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
  184
  - Rear Fork
    188
  - Rear Wheel
    188
  - Rear Shock Absorber
    189
16. Battery/Charging System 16

191
- Battery/Charging System
  191
- Battery/Charging System
  193
  - Troubleshooting
    194
  - Battery
    195
  - Charging System
    196
  - A.C. Generator Inspection
    196
  - Regulator/Rectifier Inspection
    197
  - Charging Indicator Inspection
    198
17. Ignition System 17

199
- Ignition System
  199
- Ignition System Layout
  200
- Service Information
  201
- Troubleshooting
  201
- Ignition Coil Inspection
  202
- Spark Plug
  202
- A.C. Generator Inspection
  203
- CDI Unit Inspection
  203
- Starting System
  207
  - Service Information
    207
  - Troubleshooting
    207
  - Starter Motor
    208
  - Starter Clutch Inspection
    210
  - Starter Relay Inspection
    211
- Thermostatic
  213
  - Switches/Horn/Fuel Unit/Thermostatic Switch/Temperature Gauge/ Instruments/Lights
    213
  - Electrical Equipment Layout
    213
  - Service Information
    214
  - Troubleshooting
    214
  - Switches
    215
  - Horn Inspection
    217
  - Fuel Unit
    217
  - Temperature Gauge
    218
  - Instruments
    219
  - Lights
    220
- Exhaust Emission Control System
  221
  - Schematic Drawing
    222
  - Exhaust Emission Control System
    222
  - Troubleshooting
    223
  - Secondary Air Cleaner
    224
  - Air Injection Cut-Off Valve (A.I.C.V.)
    224
  - Reed Valve
    225

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