KYMCO DINK 200 User Manual

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.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
EXHAUST MUFFLER/FRAME COVERS
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/VALVES
6
CYLINDER/PISTON
7
DRIVE AND DRIVEN PULLEYS/KICK
STARTER
8
FINAL REDUCTION
9
A.C. GENERATOR/STARTER CLUTCH
10
CRANKCASE/CRANKSHAFT
11
COOLING SYSTEM
12
FUEL SYSTEM/CARBURETOR/FUEL
PUMP
13
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
14
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
15
BATTERY/CHARGING SYSTEM
16
IGNITION SYSTEM
17
STARTING SYSTEM
18
SWITCHES/HORN/FUEL UNIT /
T HERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
19
E/M
EXHAUST EMISSION CONT ROL SYST EM
20
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
CHASSIS
EQUIPMENT
ENGINE

KYMCO DINK 200 Specifications

General

Brand	KYMCO
Model	DINK 200
Category	Scooter
Language	English

Summary

Preface

1. General Information

Service Precautions

Guidelines for safe and proper maintenance procedures.

Torque Values

Specifications for tightening bolts and nuts.

Troubleshooting

Guides for diagnosing and resolving engine starting issues.

Engine Lacks Power

Diagnostic flowchart for engine power loss issues.

2. Exhaust Muffler/Frame Covers

Frame Covers Removal

Step-by-step instructions for removing frame covers.

Exhaust Muffler Removal

Instructions for removing the exhaust muffler and related parts.

3. Inspection/Adjustment

Maintenance Schedule

Periodic maintenance schedule based on mileage.

Engine Oil

Procedures for inspecting and changing engine oil.

Valve Clearance

Procedure for inspecting and adjusting valve clearance.

Brake System

Inspection of brake levers, fluid, disks, and pads.

4. Lubrication System

Engine Oil/Oil Filter

Procedures for checking engine oil level and changing oil/filter.

Oil Pump Removal

Steps to remove the oil pump from the engine.

5. Engine Removal/Installation

Engine Removal

Detailed steps for removing the engine from the motorcycle.

Engine Installation

Steps for installing the engine back onto the motorcycle.

6. Cylinder Head/Valves

Cylinder Head Removal

Steps to remove the cylinder head assembly.

Cylinder Head Disassembly

Disassembling the cylinder head components like springs and seals.

Cylinder Head Installation

Steps to install the cylinder head assembly.

Camshaft Installation

Procedure for installing the camshaft and related parts.

7. Cylinder/Piston

Cylinder Removal

Steps to remove the cylinder from the engine.

Piston Removal

Procedure for removing the piston and pin.

Piston Installation

Steps for installing the piston, pin, and clip.

Cylinder Installation

Final steps for cylinder installation, including base bolts.

8. Drive and Driven Pulleys/Kick Starter

Drive Pulley

Inspection and removal of the drive pulley and belt.

Clutch/Driven Pulley

Inspection and removal of the clutch outer.

Kick Starter

Steps for removing and installing the kick starter mechanism.

9. Final Reduction

Final Reduction Disassembly

Steps to disassemble the final reduction gears and case.

Final Reduction Inspection

Checking final gears, shafts, and bearings for wear or damage.

10. A.C. Generator/Starter Clutch

Right Crankcase Cover Removal

Steps to remove the right crankcase cover.

Stator Removal

Procedure for removing the A.C. generator stator and pulser coil.

Flywheel Removal

Steps to remove the flywheel using a puller.

Starter Clutch

Inspection and removal of starter clutch components.

11. Crankcase/Crankshaft

Crankcase Separation

Steps to separate the crankcase halves.

Crankshaft Inspection

Measuring connecting rod big end clearance and small end ID.

12. Cooling System

Cooling System Testing

Procedures for testing radiator cap and checking for leaks.

Radiator Removal

Steps to remove the radiator, including disconnecting hoses.

Water Pump

Inspecting the water pump mechanical seal and removing the pump assembly.

Thermosensor

Inspection, removal, and installation of the thermosensor.

13. Fuel System/Carburetor/Fuel Pump

Carburetor Removal

Steps to remove the carburetor from the motorcycle.

Auto Bystarter Inspection/Removal

Inspecting and removing the auto bystarter.

Fuel Pump Removal

Removing the fuel pump and disconnecting tubes.

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

Steering Handlebar

Steps for removing and installing the steering handlebar.

Front Wheel

Removing and inspecting the front wheel and axle.

Front Brake

Major safety system maintenance and component removal.

Front Shock Absorber

Steps to remove and disassemble the front shock absorber.

15. Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber

Rear Brake

Major safety system maintenance and component removal.

Rear Fork

Steps to remove the rear fork assembly.

Rear Wheel

Removing and inspecting the rear wheel and rim.

Rear Shock Absorber

Steps to remove and disassemble the rear shock absorbers.

16. Battery/Charging System

Battery Service

Steps for removing and installing the battery.

Charging System Tests

Performing current and performance tests on the charging system.

Regulator/Rectifier Inspection

Checking the regulator/rectifier for continuity and voltage regulation.

17. Ignition System

Ignition System Layout

Layout of the ignition system components.

Ignition Coil Inspection

Inspection and performance testing of the ignition coil.

A.C. Generator Inspection

Checking exciter coil and pulser coil resistance.

CDI Unit Inspection

Inspecting CDI unit performance using a CDI tester.

18. Starting System

Starter Motor Service

Steps for removing, disassembling, and inspecting the starter motor.

Starter Relay Inspection

Checking starter relay continuity and performing an operation test.

19. Switches/Horn/Fuel Unit/Thermosensor/Gauge/Instruments/Lights

Switches Inspection

Inspection of ignition, headlight, and starter switches for continuity.

Fuel Unit Inspection

Inspecting the fuel unit resistance and fuel gauge operation.

Thermostatic Switch

Inspecting the thermostatic switch for cooling fan operation.

Instruments Service

Steps for removing, disassembling, and assembling the instrument cluster.

20. Exhaust Emission Control System

Exhaust Emission Control System Function

Explanation of how the system minimizes exhaust emissions.

Troubleshooting (Emission Control)

Diagnosing high CO, backfiring, and muffler noise issues.