KYMCO DINK 200i Manuals

KYMCO DINK 200i Manuals

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

KYMCO DINK 200i Service Manual

KYMCO DINK 200i Service Manual (400 pages)

Brand: KYMCO | Category: Scooter | Size: 13 MB

Table of Contents

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
17. Battery/Charging System

355
- Battery/Charging System
  355
- Troubleshooting
  358
- Battery
  359
- Charging System
  361
- Alternator Charging Coil
  363
- Regulator/Rectifier
  364
- Ignition System
  367
- Starting System
  377
- 20. Lights/Meters/Switches
  383

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