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

EXHAUST MUFFLER/FRAME COVERS

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE AND DRIVEN PULLEYS/KICK

STARTER

FINAL REDUCTION

A.C. GENERATOR/STARTER CLUTCH

CRANKCASE/CRANKSHAFT

COOLING SYSTEM

FUEL SYSTEM/CARBURETOR/FUEL

PUMP

STEERING HANDLEBAR/FRONT

WHEEL/FRONT BRAKE/FRONT

SHOCK ABSORBER/FRONT FORK

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER`

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

SWITCHES/HORN/FUEL UNIT /

T HERMO-STATIC

SWITCH/TEMPERATURE

GAUGE/INSTRUMENTS/ LIGHTS

E/M

EXHAUST EMISSION CONT ROL SYST EM

The information and contents included in

this manual may be different from the

motorcycle in case specifications are

changed.

CHASSIS EQUIPMENT

ENGINE

1. GENERAL INFORMATION

1-0

DINK 200

ENGINE SERIAL NUMBER

Location of Engine Serial Number

ENGINE SERIAL NUMBER

----

1-0 TOOLS

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

1-11

SPECIFICATION

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

1-1 LUBRICATION POINTS

--------

1-12

SERVICE PRECAUTIONS

------

1-2 WIRING DIAGRAM

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

1-14

TORQUE VALUES

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

1-9 CABLE &HARNESS ROUTING

1-19

TROUBLESHOOTING

-----------

1-20

1. GENERAL INFORMATION

1-1

DINK 200

SPECIFICATIONS

Name & Model No.

SH40AA

Motorcycle Name & Type

Dink Classic 200

Overall length

1907mm

Overall width

750mm

Overall height

1170mm

Wheel base

1390mm

Engine type

Water cooled 4-stroke,

OHC engine

Displacement

176cc

Fuel Used

92# nonleaded gasoline

Front wheel

Net weight (kg)

Rear wheel

Total

130

Front wheel

Gross weight(kg)

Rear wheel

Total

143

Front wheel

120/70-12

Rear wheel

130/70-12

Ground clearance

155mm

Perform

Braking distance (m)

7.9m(40km/hr)

ance

Min. turning radius

2350mm

Starting system

Starting motor &

Kick starter

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

O.H.C.& Center

Pivot

Bore x stroke (mm)

62 x 58.2

Compression ratio

10.9:1

Compression pressure

(kg/cm_-rpm)

Max. output (ps/rpm)

15.2/7250

Max. torque (kg-m/rpm)

1.4/6500

Intake

Open

BTDC 12°

Port

(1mm)

ATDC 35°

timin

Exhaust

Open

BDDC 28°

(1mm)

0°

Valve

Intake

0.1

clearance (cold)

Exhaust

0.1

Idle speed (rpm)

1700rpm

Lubrication type

Forced pressure &

wet sump

Oil pump type

Inner/outer rotor

type

Oil filter type

Full-flow filtration

Oil capacity

1.1 liters

Cooling Type

Water cooling

Air cleaner type & No

Paper element, wet

Fuel capacity

10 liters

Type

Piston dia.

Venturi dia.

22equivalent

Throttle type

Butterfly type

Type

CDI

Ignition timing

Repeatedly

Contact breaker

Non-contact point

type

Spark plug

NGK

DPR7EA-9

Spark plug gap

0.7mm

Battery

Capacity

12V8AH

Clutch

Type

CVT

Type

Non-stage transmission

Operation

Automatic

centrifugal

type

Type

Two-stage reduction

Reduction

1st

2.8-1.0

ratio

2nd

(46/16)x(46/15)=8.8

Front

Caster angle

Axle

Connecting rod

Tire pressure

Front

1.75

(kg/cm_)

Rear

2.0~2.25

Turning

Left

42.5°

angle

Right

42.5°

Front

Disk brake

Brake system

type

Rear

Disk brake

Front

Telescope

Suspension

type

Rear

Double swing

Shock absorber

Front

Telescope

type

Rear

Double swing

Frame type

Under bone

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Transmis-

sion Gear Reduction

Gear

Moving Device Damping

Device

1. GENERAL INFORMATION

1-2

DINK 200

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.

1. GENERAL INFORMATION

1-3

DINK 200

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.

1. GENERAL INFORMATION

1-4

DINK 200

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

1. GENERAL INFORMATION

1-5

DINK 200

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!

1. GENERAL INFORMATION

1-6

DINK 200

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 !

1. GENERAL INFORMATION

1-7

DINK 200

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.

1. GENERAL INFORMATION

1-8

DINK 200

After routing, check that the wire harnesses

are not twisted or kinked.

Wire harnesses routed along with handlebar

should not be pulled tight, have excessive

slack or interfere with adjacent or

surrounding parts in all steering positions.

When a testing device is used, make sure to

understand the operating methods

thoroughly and operate according to the

operating instructions.

Be careful not to drop any parts.

When rust is found on a terminal, remove

the rust with sand paper or equivalent

before connecting.

Do not bend or twist control cables.

Damaged control cables will not operate

smoothly and may stick or bind.

Do you understand

the instrument?

Remove Rust!

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