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KYMCO DINK50 User Manual

KYMCO DINK50
234 pages
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PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO DINK50.
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 12 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 13 is the
removal/ installation of chassis. Section
16 states the testing and measuring
methods of electrical equipment.
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/CYLINDER/PISTON
6
KICK STARTER/DRIVE
PULLEY/CLUTCH/DRIVEN PULLEY
7
FINAL REDUCTION
8
A.C. GENERATOR
9
CRANKCASE/CRANKSHAFT
10
COOLING SYSTEM
11
CARBURETOR/FUEL PUMP
12
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
13
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
14
FUEL TANK
15
BATTERY/CHARGING SYSTEM
16
IGNITION SYSTEM
17
STARTING SYSTEM
18
SWITCHES/HORN/FUEL UNIT /
T HERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
19
TIR
E
HIGH-SPEED TIRE (TUBELESS TIRE)
20
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
CHASSIS
EQUIPMENT
ENGINE
www.PlanDeGraissage.org

Table of Contents

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KYMCO DINK50 Specifications

General IconGeneral
Fuel SystemCarburetor
Front BrakeDisc
Rear BrakeDrum
Tires Front120/70-12
Tires Rear130/70-12
Seat Height780 mm
TransmissionCVT Automatic

Summary

1. GENERAL INFORMATION

Engine Serial Number

Identifies the engine by its unique serial number.

Specifications

Details technical specifications of the motorcycle model.

Service Precautions

Outlines essential safety and handling precautions for servicing.

Torque Values

Lists specified torque values for critical fasteners.

Special Tools

Lists specialized tools required for maintenance and repair.

Lubrication Points

Illustrates and lists lubrication points on the motorcycle.

Wiring Diagram

Provides a visual schematic of the motorcycle's electrical system.

Troubleshooting

Offers guidance for diagnosing and resolving common engine performance issues.

2. EXHAUST MUFFLER/FRAME COVERS

Schematic Drawing

Exploded view illustrating exhaust and frame cover components.

Service Information

Provides general instructions and torque values for exhaust and covers.

Troubleshooting

Lists common issues related to exhaust mufflers and their probable causes.

Frame Covers Removal

Step-by-step guide for removing various frame body covers.

Exhaust Muffler Removal

Detailed procedure for removing the exhaust muffler.

3. INSPECTION/ADJUSTMENT

Inspection and Maintenance Schedule

Schedule detailing periodic checks and maintenance intervals.

Brake System

Procedures for inspecting and adjusting the front and rear brake systems.

Moving Device

Inspection and adjustment guidelines for tires and wheel rims.

Damping Device

Inspection procedures for shock absorbers.

Power Drive System

Inspection of the transmission case and oil level.

Electrical Equipment

Inspection of ignition apparatus, spark plugs, and timing.

Engine

Procedures for adjusting idle speed and inspecting the air cleaner.

Others

Covers adjustments for throttle grip free play and headlight beam.

4. LUBRICATION SYSTEM

Service Information

General instructions and specifications for the lubrication system.

Troubleshooting

Identifies common problems and their causes within the lubrication system.

Oil Pump Removal

Step-by-step instructions for removing the oil pump.

Oil Pump Inspection

Guidelines for inspecting the oil pump for wear and damage.

Oil Pump Installation

Procedures for installing the oil pump correctly.

Oil Pump Bleeding

Process for bleeding air from the oil pump and lines.

Oil Tank

Procedure for removing and installing the oil tank.

5. ENGINE REMOVAL/INSTALLATION

Service Information

General instructions and torque values related to engine servicing.

Engine Removal

Detailed steps for safely removing the engine from the frame.

Engine Installation

Procedures for reinstalling the engine and performing post-installation checks.

6. CYLINDER HEAD/CYLINDER/PISTON

Service Information

General instructions for servicing cylinder head, cylinder, and piston.

Troubleshooting

Common problems and solutions for compression and piston issues.

Cylinder Head

Procedures for removing, inspecting, and installing the cylinder head.

Cylinder/Piston

Steps for removing, inspecting, and installing the cylinder and piston.

7. KICK STARTER/DRIVE PULLEY/CLUTCH/DRIVEN PULLEY

Service Information

General instructions and specifications for the drive belt and pulley system.

Troubleshooting

Common issues with the drive belt, pulleys, and clutch.

Kick Starter

Procedures for removing, inspecting, and installing the kick starter mechanism.

Drive Belt

Steps for inspecting, replacing, and installing the drive belt.

Drive Pulley

Instructions for removing, inspecting, and installing the drive pulley.

Starter Pinion

Procedures for removing, inspecting, and installing the starter pinion.

Clutch/Driven Pulley

Steps for removing, disassembling, inspecting, and installing the clutch/driven pulley.

8. FINAL REDUCTION

Service Information

Specified oil, disassembly, and change quantities for final reduction.

Troubleshooting

Common problems related to transmission and gears in the final reduction.

Final Reduction Disassembly

Detailed steps for disassembling the final reduction unit.

Final Reduction Inspection

Guidelines for inspecting gears, bearings, and seals of the final reduction.

Final Reduction Assembly

Procedures for assembling the final reduction unit.

9. A.C. GENERATOR

Service Information

General instructions and torque value for A.C. generator servicing.

A.C. Generator Removal

Step-by-step guide for removing the A.C. generator components.

A.C. Generator Installation

Procedures for installing the A.C. generator and related parts.

10. CRANKCASE/CRANKSHAFT

Service Information

General instructions and specifications for crankcase and crankshaft servicing.

Troubleshooting

Common issues related to abnormal engine noise from bearings.

Crankcase Separation

Procedure for separating the crankcase halves.

Crankshaft Removal

Steps for removing the crankshaft from the crankcase.

Crankshaft Inspection

Methods for measuring clearances and runout of the crankshaft.

Crankshaft Installation

Procedures for installing the crankshaft and bearings.

Crankcase Assembly

Steps for assembling the crankcase halves.

11. COOLING SYSTEM

Schematic Drawing

Diagram illustrating the components of the cooling system.

Service Information

General instructions and special tools for cooling system maintenance.

Troubleshooting

Common problems related to engine temperature and coolant leaks.

Cooling System Testing

Procedures for testing the radiator cap and system for leaks.

Radiator

Steps for inspecting, removing, and installing the radiator.

Water Pump

Inspection, removal, and replacement of the water pump seal and impeller.

Thermosensor

Procedures for removing, inspecting, and installing the thermosensor.

Thermostat

Steps for removing, inspecting, and installing the thermostat.

12. CARBURETOR/FUEL PUMP

Service Information

General instructions, specifications, and special tools for carburetor service.

Troubleshooting

Common issues with engine starting, idling, and mixture.

Throttle Valve

Procedures for disassembling and installing the throttle valve.

Carburetor Removal

Steps for removing the carburetor from the engine.

Auto Bystarter

Inspection, removal, and installation of the auto bystarter component.

Float Chamber

Procedures for removing, inspecting, and assembling the float chamber.

Carburetor Installation

Steps for installing the carburetor and performing adjustments.

Air Screw Adjustment

Method for adjusting the air screw for optimal engine performance.

Reed Valve

Procedures for removing, inspecting, and installing the reed valve.

Fuel Pump

Steps for removing, disassembling, inspecting, assembling, and installing the fuel pump.

13. STEERING HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/FRONT FORK

Schematic Drawing

Exploded view of steering, wheel, brake, and fork components.

Service Information

General instructions and specifications for steering, wheel, brake, and fork systems.

Troubleshooting

Common problems related to steering, wheel, brake, and suspension.

Steering Handlebar

Procedures for removing and installing the steering handlebar.

Front Wheel

Steps for removing, inspecting, and installing the front wheel and bearings.

Front Brake

Service procedures for the front brake master cylinder and caliper.

Front Shock Absorber

Steps for removing, inspecting, and installing the front shock absorbers.

Front Fork

Procedures for removing and replacing front fork components and bearings.

14. REAR WHEEL/REAR BRAKE/REAR SHOCK ABSORBER

Service Information

Specifications and torque values for rear wheel, brake, and shock absorber.

Troubleshooting

Common issues with rear wheel wobble, brake performance, and shock absorber.

Rear Wheel

Steps for removing, inspecting, and installing the rear wheel.

Rear Brake

Procedures for inspecting, disassembling, and assembling the rear brake system.

Rear Shock Absorber

Steps for removing, disassembling, inspecting, and installing the rear shock absorber.

15. FUEL TANK

Schematic Drawing

Diagram illustrating the fuel tank and related components.

Service Information

General instructions and troubleshooting for the fuel tank system.

Troubleshooting

Common problems related to engine starting and lean fuel mixture.

Fuel Tank Removal

Procedure for safely removing the fuel tank.

Fuel Strainer Inspection

Instructions for inspecting and cleaning the fuel strainer.

16. BATTERY/CHARGING SYSTEM

Charging System Layout

Diagram showing the layout of the charging system components.

Service Information

General instructions, specifications, and testing instruments for battery service.

Troubleshooting

Common issues related to power loss and charging system failures.

Battery

Procedures for removing, inspecting, and charging the battery.

Charging System

Tests for charging system current and performance.

A.C. Generator Inspection

Measuring resistances of charging and lighting coils.

Regulator/Rectifier Inspection

Testing resistances of the regulator/rectifier.

17. IGNITION SYSTEM

Ignition System Layout

Diagram illustrating the components of the ignition system.

Service Information

General instructions and specifications for the ignition system.

Troubleshooting

Common problems related to spark and engine starting.

Spark Plug

Reference to inspection and adjustment procedures for the spark plug.

Ignition Coil Inspection

Procedures for testing the ignition coil's performance and continuity.

A.C. Generator Inspection

Measuring resistance of the pulser coil.

CDI Unit Inspection

Testing the CDI unit's performance using a CDI tester.

18. STARTING SYSTEM

Starting System Layout

Diagram showing the layout of the starting system components.

Service Information

General instructions and torque values for starter motor servicing.

Troubleshooting

Common issues with the starter motor and engine starting.

Starter Motor

Procedure for removing and installing the starter motor.

Starter Relay Inspection

Testing the starter relay for proper operation and continuity.

19. SWITCHES/HORN/FUEL UNIT/THERMOSTATIC SWITCH/TEMPERATURE GAUGE/INSTRUMENTS/LIGHTS

Electrical Equipment Layout

Diagram illustrating the location of electrical switches and components.

Service Information

General instructions for switch continuity checks and system specifications.

Troubleshooting

Common problems with lights, fuel gauge, and temperature gauge.

Switches

Inspection procedures for ignition, headlight, starter, and passing switches.

Horn Inspection

Procedure for testing the horn's functionality.

Fuel Unit

Inspection of the fuel unit and fuel gauge operation.

Oil Meter

Inspection of the oil meter and its operation.

Temperature Gauge

Test procedure for the temperature gauge.

Instruments

Procedures for removing, disassembling, and installing the instrument cluster.

Lights

Instructions for replacing headlight, position, turn signal, and taillight bulbs.

20. HIGH-SPEED TIRE

High-Speed Tire Construction & Features

Description of tubeless tire construction and characteristics.

High-Speed Tire Maintenance Precautions

Precautions for storing and handling high-speed tires.

High-Speed Tire Removal/Installation

Detailed steps for removing and installing high-speed tires safely.

High-Speed Tire Repair

Methods and procedures for repairing high-speed tires.

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