KYMCO DINK50 User manual

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

EXHAUST MUFFLER/FRAME COVERS

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/CYLINDER/PISTON

KICK STARTER/DRIVE

PULLEY/CLUTCH/DRIVEN PULLEY

FINAL REDUCTION

A.C. GENERATOR

CRANKCASE/CRANKSHAFT

COOLING SYSTEM

CARBURETOR/FUEL PUMP

STEERING HANDLEBAR/FRONT

WHEEL/FRONT BRAKE/FRONT

SHOCK ABSORBER/FRONT FORK

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER`

FUEL TANK

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

SWITCHES/HORN/FUEL UNIT /

T HERMO-STATIC

SWITCH/TEMPERATURE

GAUGE/INSTRUMENTS/ LIGHTS

TIR

HIGH-SPEED TIRE (TUBELESS TIRE)

The information and contents included in

this manual may be different from the

motorcycle in case specifications are

changed.

CHASSIS EQUIPMENT

ENGINE

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1. GENERAL INFORMATION

1-0

ENGINE SERIAL NUMBER

Location of Engine Serial Number

ENGINE SERIAL NUMBER

---

1- 0 TOOLS

----------------------------

1-14

SPECIFICATION

-----------------

1- 1 LUBRICATION POINTS

--------

1-16

SERVICE PRECAUTIONS

------

1- 3 WIRING DIAGRAM

--------------

1-17

TORQUE VALUES

---------------

1-13 CABLE &HARNESS ROUTING

1-22

TROUBLESHOOTING

-----------

1-24

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1. GENERAL INFORMATION

1-1

SPECIFICATIONS

Name & Model No.

SH10BA

Overall length

1950mm

Overall width

735mm

Overall height

1180mm

Wheel base

1350mm

Engine type

Air cooled 2-stroke

Displacement

49.4cc

Fuel Used

92# nonleaded gasoline

Front wheel

Net weight (kg)

Rear wheel

61.5

Total

106.5

Front wheel

Gross weight(kg)

Rear wheel

149

Total

229

Front wheel

110/70-12

Rear wheel

130/70-12

Ground clearance

155mm

Perform

Braking distance (m)

4.4m /30km/HV

ance

Min. turning radius

2150mm

Starting system

Starting motor &

kick starter

Type

Gasoline, 2-stroke

Cylinder arrangement

Single cylinder, flat

Combustion chamber type

Semi-sphere

Bore x stroke (mm)

39 x 41.4

Compression ratio

7.2:1

Compression pressure

(kg/cm_-rpm)

11.8

Max. output (ps/rpm)

5.2/7000

Max. torque (kg m/rpm)

0.56/6500

Intake

Open

Automatic controlled

Port

(1mm)

Automatic controlled

timin

Exhaust

Open

(1mm)

Valve

Intake

clearance (cold)

Exhaust

Idle speed (rpm)

2000±100rpm

Lubrication type

Separate type

Oil pump type

Plunger type

Oil filter type

Full-flow filtration

Oil capacity

1.1 liters

Cooling Type

Air cooling

Air cleaner type & No

Paper element, wet

Lubrication oil

capacity

1.5. liters

Fuel capacity

10. liters

Type

Piston dia.

Venturi dia.

14 equivalent

Throttle type

Type

CDI

Ignition timing

13.5°/2000rpm

Contact breaker

Spark plug

NGK

BR8HSA

Spark plug gap

0.6_0.7mm

Battery

Capacity

12V4AH

Clutch

Type

Dry multi-disc clutch

Type

Non-stage transmission

Operation

Automatic centrifugal

type

Type

Two-stage reduction

Reduction

1st

ratio

2nd

Front

Caster angle

Axle

Connecting rod

Tire pressure

Front

1.75

(kg/cm_)

Rear

2.25

Turning

Left

42.5°

angle

Right

42.5°

Brake system

Front

Disk brake

type

Rear

Expanding

Suspension

Front

Telescope

type

Rear

Unit swing

Shock absorber

Front

Telescope

type

Rear

Double swing

Frame type

Under bone

Tires

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Reduction

Gear

Moving Device Damping

Device

Engine

System

Transmis-

sion Gear

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1. GENERAL INFORMATION

1-2

SPECIFICATIONS

Name & Model No.

SH10AA

Overall length

1950mm

Overall width

735mm

Overall height

1180mm

Wheel base

1350mm

Engine type

Water cooled 2stroke

Displacement

49.4cc

Fuel Used

92# nonleaded gasoline

Front wheel

Net weight (kg)

Rear wheel

61..5

Total

106.5

Front wheel

Gross weight(kg)

Rear wheel

149

Total

229

Front wheel

110/70-12

Rear wheel

130/70-12

Ground clearance

155mm

Perform

Braking distance (m)

4.4m /30km/HV

ance

Min. turning radius

2150mm

Starting system

Starting motor &

kick starter

Type

Gasoline,2-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Bore x stroke (mm)

39 x 41.4

Compression ratio

7.2:1

Compression pressure

(kg/cm_-rpm)

11.8

Max. output (ps/rpm)

5.7/7000

Max. torque (kg m/rpm)

0.6/6500

Intake

Open

Automatic controlled

Port

(1mm)

Automatic controlled

timin

Exhaust

Open

(1mm)

Valve

Intake

clearance (cold)

Exhaust

Idle speed (rpm)

2000±100rpm

Lubrication type

Separate type

Oil pump type

Plunger type

Oil filter type

Full-flow filtration

Oil capacity

1.1 liters

Cooling Type

Water cooling

Air cleaner type & No

Paper element, wet

Lubrication oil

capacity

1.5 liters

Fuel capacity

10 liters

Type

ＰＢ

Piston dia.

Venturi dia.

14 equivalent

Type

CDI

Ignition timing

13.5°/2000rpm

Spark plug

NGK

BR6HSA

Spark plug gap

0.6_0.7mm

Battery

Capacity

12V4AH

Clutch

Type

Dry multi-disc clutch

Type

Non-stage transmission

Operation

Automatic

centrifugal

type

Type

Two-stage reduction

Reduction

1st

ratio

2nd

Front

Caster angle

Axle

Connecting rod

Tire pressure

Front

1.75

(kg/cm_)

Rear

2.25

Turning

Left

42.5°

angle

Right

42.5°

Brake system

Front

Disk brake

type

Rear

Expanding

Suspension

Front

Telescope

type

Rear

Unitswing

Shock absorber

Front

Telescope

type

Rear

Double swing

Frame type

Under bone

Tires

Engine

Fuel System

Carburetor

Electrical Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving Device Damping

Device

System

Ignition System

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1. GENERAL INFORMATION

1-3

SERVICE PRECAUTIONS

Make sure to install new gaskets, O-

rings, circlips, cotter pins, etc. when

reassembling.

When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

Use genuine parts and lubricants.

When servicing the motorcycle, be sure to

use special tools for removal and

installation.

After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

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1. GENERAL INFORMATION

1-4

Apply or add designated greases and

lubricants to the specified lubrication

points.

After reassembly, check all parts for

proper tightening and operation.

When two persons work together, pay

attention to the mutual working safety.

Disconnect the battery negative (-)

terminal before operation.

When using a spanner or other tools,

make sure not to damage the motorcycle

surface.

After operation, check all connecting

points, fasteners, and lines for proper

connection and installation.

When connecting the battery, the positive

(+) terminal must be connected first.

After connection, apply grease to the

battery terminals.

Terminal caps shall be installed securely.

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1. GENERAL INFORMATION

1-5

If the fuse is burned out, find the cause

and repair it. Replace it with a new one

according to the specified capacity.

After operation, terminal caps shall be

installed securely.

When taking out the connector, the lock

on the connector shall be released before

operation.

Hold the connector body when

connecting or disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is

bending, protruding or loose.

Confirm

Capacity

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1. GENERAL INFORMATION

1-6

The connector shall be inserted

completely.

If the double connector has a lock, lock

it at the correct position.

Check if there is any loose wire.

Before connecting a terminal, check for

damaged terminal cover or loose

negative terminal.

Check the double connector cover for

proper coverage and installation.

Insert the terminal completely.

Check the terminal cover for proper

coverage.

Do not make the terminal cover opening

face up.

Secure wire harnesses to the frame with

their respective wire bands at the

designated locations.

Tighten the bands so that only the

insulated surfaces contact the wire

harnesses.

Snapping!

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1. GENERAL INFORMATION

1-7

After clamping, check each wire to make

sure it is secure.

Do not squeeze wires against the weld or

its clamp.

After clamping, check each harness to

make sure that it is not interfering with

any moving or sliding parts.

When fixing the wire harnesses, do not

make it contact the parts which will

generate high heat.

Route wire harnesses to avoid sharp

edges or corners. Avoid the projected

ends of bolts and screws.

Route wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

No Contact !

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1. GENERAL INFORMATION

1-8

Route harnesses so they are neither

pulled tight nor have excessive slack.

Protect wires and harnesses with

electrical tape or tube if they contact a

sharp edge or corner.

When rubber protecting cover is used to

protect the wire harnesses, it shall be

installed securely.

Do not break the sheath of wire.

If a wire or harness is with a broken

sheath, repair by wrapping it with

protective tape or replace it.

When installing other parts, do not press

or squeeze the wires.

Do not pull too

tight!

Do not press or

squeeze the wire.

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