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KYMCO Dink 50 User Manual

KYMCO Dink 50
424 pages
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1. GENERAL INFORMATION
1-0
DINK 50/125
1
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GENERAL INFORMATION
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SERIAL NUMBER-----------------------------------------------------------1 - 1
SPECIFICATION (DINK 50)-----------------------------------------------1 - 2
SPECIFICATION (DINK 125) ---------------------------------------------1 - 3
SERVICE PRECAUTIONS-------------------------------------------------1 - 4
TORQUE VALUES ----------------------------------------------------------1 - 8
SPECIAL TOOLS ------------------------------------------------------------1-11
LUBRICATION POINTS ---------------------------------------------------1-13
CABLE & HARNESS ROUTING (DINK 125) ----------------------------1-15
CABLE & HARNESS ROUTING (DINK 50)------------------------------1-30
TROUBLESHOOTING------------------------------------------------------1-35
1

Table of Contents

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KYMCO Dink 50 Specifications

General IconGeneral
Fuel SystemCarburetor
Front SuspensionTelescopic Fork
Front BrakeDisc
Rear BrakeDrum
Tires Front120/70-12
Tires Rear130/70-12
Cooling SystemAir Cooled
TransmissionAutomatic

Summary

General Information

Serial Number Identification

Locating frame and engine serial numbers for identification purposes.

Specifications DINK 50

Detailed technical specifications for the DINK 50 model.

Specifications DINK 125

Detailed technical specifications for the DINK 125 model.

Service Precautions

Important safety and handling guidelines for motorcycle maintenance.

Lubrication Points

Identifies key lubrication points for the engine and frame components.

Troubleshooting Engine Start

Diagnosing issues when the engine fails to start or is hard to start.

Troubleshooting Starter Motor

Diagnosing problems related to starter motor operation.

Troubleshooting Ignition System

Diagnosing no spark conditions at the spark plug.

Troubleshooting Charging System

Diagnosing poor battery charging (undercharging/overcharging).

Inspection and Adjustment

Maintenance Schedule

Recommended maintenance intervals and tasks for scooter upkeep.

Engine Oil Specifications

Engine oil recommendations, capacity, and viscosity chart.

Engine Oil Level Check

Procedure for checking and maintaining the engine oil level.

Spark Plug Inspection

Inspection, gap measurement, and replacement of the spark plug.

Valve Clearance Adjustment (DINK 125)

Procedure for inspecting and adjusting valve clearance for DINK 125.

Valve Clearance Adjustment (DINK 50)

Procedure for inspecting and adjusting valve clearance for DINK 50.

Cylinder Compression Test

Procedure for testing and interpreting cylinder compression.

Brake Fluid Check

Checking brake fluid level and condition.

Brake Pad Wear Inspection

Inspecting brake pad wear and replacement.

Engine Removal/Installation

Service Information

General instructions and specifications for engine removal/installation.

Engine Removal/Installation (DINK 125) Removal

Detailed steps for removing the engine from a DINK 125.

Engine Removal/Installation (DINK 125) Installation

Steps for installing the engine back into a DINK 125.

Engine Removal (DINK 50)

Steps for removing the engine from a DINK 50.

Cylinder Head and Valves

Torque Values

Torque specifications for cylinder head components.

Troubleshooting Cylinder Head

Common cylinder head operation problems and their causes.

Camshaft Service

Removal, inspection, and installation of the camshaft.

Cylinder Head Service

Removal and installation of the cylinder head.

Cylinder and Piston

Specifications (DINK 125)

Technical specifications for DINK 125 cylinder and piston.

Specifications (DINK 50)

Technical specifications for DINK 50 cylinder and piston.

Troubleshooting Cylinder/Piston

Common cylinder/piston issues like low compression or smoke.

Cylinder and Piston (DINK 125) Removal

Steps for removing the cylinder and piston from DINK 125.

Piston and Piston Pin Measurements

Measuring piston O.D., pin hole I.D., and clearances.

Cylinder Inspection

Checking cylinder for warpage, wear, taper, and roundness.

Piston Installation

Installing piston pin, clip, and piston into the cylinder.

Cylinder Installation

Installing the cylinder over the piston.

Drive and Driven Pulleys/ Kick Starter

Troubleshooting Pulleys and Clutch

Common problems related to clutch, drive, and driven pulleys.

Drive Belt Inspection

Inspecting and replacing the drive belt.

Final Reduction

Final Reduction Removal

Steps for draining oil and removing the final reduction components.

Final Reduction Installation

Steps for installing the driveshaft, final gear, and shaft.

Final Reduction Disassembly (DINK 50)

Steps for disassembling the final reduction for DINK 50.

A.C. Generator/Starter Clutch

Starter Clutch Removal (DINK 125)

Steps for removing the starter clutch assembly from DINK 125.

Starter Clutch Inspection

Checking the operation and components of the starter clutch.

Starter Clutch Installation

Steps for installing the starter clutch assembly.

Crankcase and Crankshaft

Crankcase Separation (DINK 125)

Steps for separating the crankcase halves on DINK 125.

Crankshaft Inspection

Measuring connecting rod clearance, runout, and bearing play.

Crankcase/Balancer Installation

Installing the crankshaft, cam chain, and crankcase halves.

Crankcase/Crankshaft Removal (DINK 50)

Steps for removing crankcase and crankshaft from DINK 50.

Crankshaft Inspection (DINK 50)

Inspecting crankshaft bearings and dimensions.

Cooling System (DINK 125 Only)

Coolant Replacement

Preparation and procedure for replacing engine coolant.

Fuel System/Carburetor/Fuel Pump/Fuel Tank

Troubleshooting Fuel System

Common fuel system and carburetor problems.

Carburetor Removal/Installation (DINK 125)

Steps for removing and installing the carburetor on DINK 125.

Carburetor Removal (DINK 50)

Steps for removing the carburetor from DINK 50.

Float Level Inspection

Measuring and adjusting the carburetor float level.

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

Troubleshooting Front End

Common problems related to steering, suspension, and brakes.

Front Wheel Removal

Steps for removing the front wheel.

Front Wheel Installation

Steps for installing the front wheel.

Front Brake Fluid Replacement/Air Bleeding

Procedures for changing and bleeding front brake fluid.

Front Brake Pad Replacement

Steps for replacing the front brake pads.

Rear Brake, Rear Fork, Rear Wheel, Rear Shock Absorber

Troubleshooting Rear System

Common problems related to rear wheel, suspension, and brakes.

Rear Brake Fluid Check (DINK 125)

Checking rear brake fluid level and condition.

Rear Brake Fluid Replacement/Air Bleeding

Procedures for changing and bleeding rear brake fluid.

Rear Brake Pad Replacement (DINK 125)

Steps for replacing the rear brake pads on DINK 125.

Rear Wheel and Rear Fork Removal

Steps for removing the rear wheel and rear fork.

Rear Brake Inspection

Inspecting the rear brake drum and lining thickness.

Battery and Charging System

Troubleshooting Battery/Charging

Common problems and causes related to the battery and charging system.

Battery Removal/Installation (DINK 125)

Steps for removing and installing the battery on DINK 125.

Battery Charging Procedure

Procedure for charging the motorcycle battery.

Current Leakage Test

Procedure for testing the charging system for current leakage.

Charging Voltage Inspection

Measuring charging voltage to verify system operation.

Ignition System

Troubleshooting Ignition System

Common ignition system problems and their causes.

Ignition Coil Primary Peak Voltage

Procedure for measuring the primary peak voltage of the ignition coil.

Starting System

Troubleshooting Starting System

Common problems related to starter motor and power.

Lights, Meters, and Switches

Service Information

General instructions regarding lights, meters, and switches.

Wiring Diagrams

DINK 125 Wiring Diagram

Wiring diagram for the DINK 125 model.

DINK 50 Wiring Diagram

Wiring diagram for the DINK 50 model.

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