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KYMCO 125 DINK -, Service Manual

The KYMCO 125 DINK service manual is a comprehensive guide for maintaining and repairing your scooter. This manual covers everything from routine maintenance to complex repairs. Download it for free from our website to keep your KYMCO running smoothly for years to come.

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5

. ENGINE REMOVAL/INSTALLATION

 

5-2

  DINK200i/DINK 125

ENGINE
REMOVAL/INSTALLATION

REMOVAL

DINK 125 only:
Remove the air cleaner (refer to the

“AIR CLEANER”

 section in the

chapter 13).

Remove the carburetor (refer to the

“CARBURETOR”

 section in the

chapter 13).

• •

DINK 200i only:
Remove the air cleaner (refer to the

“AIR CLEANER”

 section in the

chapter 14)

Remove the two bolts from the intake
manifold.

Disconnect the O2 heater/O2 sensor
connector (refer to the 

“EXHAUST

MUFFLER”

 section in the chapter 2).

• •

DINK 200i only:
Remove a bolt from fuel hose guide (1).
Disconnect the fuel hose (2) from fuel
injector.
Disconnect the fuel vacuum hose (3)
and AICV vacuum hose (4) from the
intake manifold.
Disconnect the WTS connector (5)
from WTS.
Disconnect the coolant temperature
sensor connector (6) from coolant
temperature sensor.
Remove the throttle body and intake
manifold together from the cylinder
head.

• •

Summary of Contents for 125 DINK -

Page 1: ...0i 125 By KWANG YANG Motor Co Ltd First Edition Jan 2007 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T100...

Page 2: ...ting 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 EX...

Page 3: ...____________________________________________________________________________ _________________________________________________________________________________________ GENERAL INFORMATION _____________...

Page 4: ...1 GENERAL INFORMATION 1 1 DINK200i 125 SERIAL NUMBER Location of Engine Serial Number 1 Location of Frame Serial Number...

Page 5: ...mm 0 004 in Idle speed rpm 1660 100rpm Lubrication type Forced pressure Wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity 1 1 L 0 968 lmp qt 1 166 US qt L...

Page 6: ...dle speed rpm 1700 150rpm Lubrication type Forced pressure Wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity 1 1 L 0 968 lmp qt 1 166 US qt Lubrication Sy...

Page 7: ...engine oil before reassembly 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 w...

Page 8: ...protruding or loose 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 fo...

Page 9: ...ws Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws Route harnesses so they are neither pulled tight nor have excessive slack Protect wire...

Page 10: ...ting 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 conne...

Page 11: ...m lbf ft Remarks MAINTENANCE Spark plug Tappet ADJ nut Engine oil strainer screen cap Engine oil filter cap bolt Engine oil drain plug Transmission gear oil drain bolt Transmission gear oil fill bolt...

Page 12: ...12 28 14 6 1 10 7 2 1 2 12 8 6 5 8 58 42 5 5 55 40 5 5 55 40 5 5 55 40 5 5 55 40 1 2 12 8 6 FRAME Item Q ty Thread dia mm Torque kgf m N m lbf ft Remarks EXHAUST MUFFLER Exhaust muffler mounting bolt...

Page 13: ...orber lower mount bolt Rear fork BRAKE Front caliper Rear caliper Brake hose oil bolt Master cylinder holder bolt Master cylinder reservoir cover screw Brake caliper bleeder OTHERS Start relay nut Rea...

Page 14: ...A120E00003 Oil seal and bearing installer A120E00014 Universal holder Refer to the DRIVE PULLEY DRIVE BELT AND DRIVEN PULLEY section in the chapter 8 A120E00017 Flywheel holder Refer to the STARTER CL...

Page 15: ...igure of this manual Bearing puller A120E00037 Valve spring compressor Refer to the CYLINDER HEAD section in the chapter 6 A120E00040 AFI diagnostic tool pda Refer to the SELF DIAGNOSTIC PROCEDURES US...

Page 16: ...Connecting rod big end Crankshaft Cranksahft one way clutch movable part Oil pump drive chain Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing mov...

Page 17: ...ose grease for parts not listed Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle Seat Lock Grease Eng...

Page 18: ...e 3 Throttle cable Note 4 Left handlebar switch 5 Brake light switch Rear brake 6 Rear brake hose 7 Right handlebar switch A Pass the front brake hose rear brake hose throttle cable right handlebar sw...

Page 19: ...peedometer cable 4 Instrument connectors 5 Fuel fill cap ground wire connector 6 Fuel cap lock cable 7 Radiator bleed hose 8 Flashing relay 9 Coolant fill hose 10 Radiator bleed hose 11 Siphon hose 12...

Page 20: ...handlebar switch 6 Left handlebar switch 7 Harness wire 8 Fuel fill hose 9 Throttle cable 10 Seat lock cable 11 Siphon hose 12 Left turn signal light connector 13 Headlight connector 14 Horn 15 High...

Page 21: ...NFORMATION 1 18 DINK 200i 125 1 Throttle cable 2 Harness wire 3 Seat lock cable 4 Speedometer cable A Pass the harness wire and throttle cable through the guide B Pass the seat lock cable through the...

Page 22: ...cable 2 Harness wire 3 Seat lock cable 4 Siphon hose 5 Fuel tank breather hose 6 Fuel fill hose A Pass the harness wire through the guide B Pass the harness wire and throttle cable through the guide...

Page 23: ...e 4 Seat lock cable 5 Side stand switch wire A Pass the seat lock cable through the guide B Pass the seat lock cable and harness wire through the guide C Pass the seat lock cable and harness wire thro...

Page 24: ...l connector DINK 125 11 Auto choke connector DINK 125 12 Frame ground terminal 13 Harness wire 14 Seat lock cable 15 Ground cable 16 Luggage box light connector 17 Side stand switch connector 18 Ignit...

Page 25: ...DINK 125 3 Heater connector DINK 125 4 Fuse box 5 Battery 6 Luggage box light switch 7 Seat lock cable 8 Engine stop control unit DINK 200i 9 Battery negative cable 10 Harness wire 11 Frame ground ter...

Page 26: ...3 Battery positive terminal 4 A C G Regulator Rectifier Starter relay connectors 5 Combination light connector 6 Fuse box 7 Harness 8 Engine stop control unit DINK 200i A Pass the harness wire throug...

Page 27: ...es 5 Fan motor switch 6 Upper radiator hose 7 Right turn signal light wire 8 Lower radiator hose 9 Front brake hose 10 Lower radiator pipe 11 Upper radiator pipe A Pass the front brake hose through th...

Page 28: ...e between the fuel filter and fuel tank 3 Lower radiator pipe 4 Upper radiator pipe 5 Bleed hose 6 Rear brake hose 7 Water flow hose A Pass the fuel hose and water flow hose through the guide B Pass t...

Page 29: ...K 200i 10 O2 sensor connector DINK 200i A Pass the rear brake hose through the guide B Pass the rear brake hose through the guide C Pass the fuel hose DINK 125 and water flow hose through the guide D...

Page 30: ...starter motor 13 A C G Regulator Rectifier Starter relay connectors 14 Harness wire DINK 125 15 Regulator Rectifier DINK 200i 16 Harness wire DINK 200i 17 ECU DINK 200i 18 Fuel pump relay DINK 200i A...

Page 31: ...INK 125 Fuel filter 10 DINK 125 Fuel hose between fuel filter and fuel pump 11 DINK 125 Fuel pump vacuum hose 12 DINK 125 Fuel pump 13 Upper radiator hose 14 DINK 125 Fuel hose between fuel pump and c...

Page 32: ...1 GENERAL INFORMATION 1 29 DINK200i 125 1 AICV vacuum hose 2 Air inlet hose 3 AICV control solenoid valve 4 Air supply hose 5 Air inlet pipe 6 AICV A Pass the AICV vacuum hose through the guide...

Page 33: ...i 5 Fuel vacuum hose DINK 200i 6 AICV vacuum hose 7 Fuel injector DINK 200i 8 WTS sensor DINK 200i 9 Fuel pump connector DINK 200i 10 Fuel pump DINK 200i 11 Fuel hose DINK 200i 12 Harness wire DINK 20...

Page 34: ...and piston rings Blown cylinder head gasket Seized valve Improper valve timing Faulty start clutch Air leaking through intake pipe Faulty fuel pressure regulator Clogged ABV hose Broken or shorted AB...

Page 35: ...in combustion chamber Excessive carbon buildup in combustion chamber Poor quality fuel Mixture too lean Clutch slipping Start engine and accelerate lightly for observation Inspection Adjustment Sympt...

Page 36: ...aulty A C generator Faulty ignition coil Faulty ignition switch Fouled fuel injector Faulty fuel pump Remove spark plug and install it into spark plug cap to test spark by connecting it to engine grou...

Page 37: ...ose Throttle body clogged or Air cleaner clogged Faulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check throttle body for clogging Check fuel pump for fuel supply Corre...

Page 38: ...Excessive carbon build up in combustion chamber Damaged cam chain tensioner Worn cam gear teeth Worn or damaged cam chain Extended cam chain Faulty crankshaft bearing Worn crank pin bearing Worn or d...

Page 39: ...rings Weak driven face spring Worn or seized driven pulley bearings Worn or slipping drive belt Worn weight rollers Worn or seized driven pulley bearings Oil or grease fouled drive belt Worn drive bel...

Page 40: ...nion Starter relay shorted or stuck closed Inspection Adjustment Inspection Adjustment Inspection Adjustment Symptom Symptom Symptom Check operation of brake light switch by applying brake Stoplight d...

Page 41: ...heck DTC and correct problems Replace with a new spark plug and inspect again Check ignition unit coupler for looseness Inspection Adjustment Symptom Probable Cause Abnormal Normal Abnormal Measure re...

Page 42: ...ulator rectifier Broken or poorly connected regulator rectifier black wire Limit voltage too high Start engine and test limit voltage of battery terminals Measure battery limit voltage with an electri...

Page 43: ...emove fuel unit and check operation of pointer by moving float up and down Remove fuel unit and check operation of pointer by moving float up and down Signals operate properly Signals dim remain on or...

Page 44: ...g stem nut POOR BRAKE PERFORMANCE Worn brake linings Foreign matter on brake linings Rough brake drum contacting area Worn brake linings Foreign matter on brake linings Rough brake drum contacting are...

Page 45: ...and piston rings Blown cylinder head gasket Flaws in cylinder head Seized valve Improper valve timing Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjus...

Page 46: ...ing too early Air in cooling system Excessive carbon build up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early Start engine and accelerate lightly for...

Page 47: ...tor Faulty ignition coil Broken or shorted high tension wire Faulty ignition switch Damaged air cut off valve diaphragm Damaged air cut off valve spring Remove spark plug and install it into spark plu...

Page 48: ...be Clean and unclog Cam timing gear aligning marks not aligned Faulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor jets for clogging Check fuel pump for f...

Page 49: ...Excessive carbon build up in combustion chamber Damaged cam chain tensioner Worn cam gear teeth Worn or damaged cam chain Extended cam chain Faulty crankshaft bearing Worn crank pin bearing Worn or d...

Page 50: ...rings Weak driven face spring Worn or seized driven pulley bearings Worn or slipping drive belt Worn weight rollers Worn or seized driven pulley bearings Oil or grease fouled drive belt Worn drive bel...

Page 51: ...on Starter relay shorted or stuck closed Inspection Adjustment Inspection Adjustment Inspection Adjustment Symptom Symptom Symptom Check operation of brake light switch by applying brake Stoplight doe...

Page 52: ...n coil Replace with a new spark plug and inspect again Check ignition unit coupler for looseness Inspection Adjustment Symptom Probable Cause Normal Abnormal Normal Abnormal Normal Abnormal Abnormal M...

Page 53: ...ator rectifier Broken or poorly connected regulator rectifier black wire Limit voltage too high Start engine and test limit voltage of battery terminals Measure battery limit voltage with an electric...

Page 54: ...m Remove fuel unit and check operation of pointer by moving float up and down Remove fuel unit and check operation of pointer by moving float up and down Signals operate properly Signals dim remain on...

Page 55: ...g stem nut POOR BRAKE PERFORMANCE Worn brake linings Foreign matter on brake linings Rough brake drum contacting area Worn brake linings Foreign matter on brake linings Rough brake drum contacting are...

Page 56: ...___________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUS...

Page 57: ...2 EXHAUST MUFFLER FRAME COVERS 2 1 DINK 200i 125 SCHEMATIC DRAWING...

Page 58: ...maged Make sure to route cables and harnesses according to the Cable Harness Routing TORQUE VALUES Exhaust muffler mounting bolt 3 3 kgf m 33 N m 24m lbf ft Exhaust muffler mounting nut 2 kgf m 20 N m...

Page 59: ...e Pull out the fastener INSTALLATION Let the center piece stick out toward the head so that the pawls close Insert the fastener into the installation hole Push in the head of center piece until it bec...

Page 60: ...ove the two nuts and the seat Installation is in the reverse order of removal LUGGAGE BOX Unlock the seat with the ignition key Open the seat Remove the screw and four bolts then lift luggage box Disc...

Page 61: ...ove the center cover Installation is in the reverse order of removal REAR SPOILER REAR SPOILER STAY Unlock the seat with the ignition key Open the seat Remove the three bolts Remove the bolt then remo...

Page 62: ...ER Remove the six screws Remove the two screws then remove the upper handlebar cover Disconnect the throttle cable DINK 125 refer to the CARBURETOR section in the chapter 13 DINK 200i refer to the THR...

Page 63: ...7 DINK 200i 125 WINDSHIELD WINDSHIELD GARNISH Remove the three bolts and windshield garnish Remove the two screws Remove the two screws from the inner cover then remove the windshield Installation is...

Page 64: ...ee page 2 7 Remove the three fasteners and two screws then remove the front meter visor Installation is in the reverse order of removal FRONT COVER Remove the front meter visor see page 2 8 Remove the...

Page 65: ...everse order of removal FRONT FENDER Remove the four screws and front fender Installation is in the reverse order of removal RIGHT LEFT FOOT SKIRT Kick the button and make the passenger footpeg out Re...

Page 66: ...in the reverse order of removal REAR FENDER Remove the two bolts and two nuts then remove the rear fender Installation is in the reverse order of removal BODY COVER Remove the center cover see page 2...

Page 67: ...r of removal REAR COMBINATION LIGHT UNDER COVER Remove body cover see page 2 10 Remove the two bolts and rear combination light under cover Installation is in the reverse order of removal FLOORBOARD R...

Page 68: ...25 Remove the four bolts then remove the floorboard Disconnect the air inlet hose of the air cleaner Installation is in the reverse order of removal UNDER COVER Remove the four bolts and side stand st...

Page 69: ...ation is in the reverse order of removal METER PANEL Disconnect the speedometer cable Disconnect the meter connectors Remove the two screws Remove the two screws from the inner cover then remove the m...

Page 70: ...e the floorboard see page 2 11 Turn the fuel fill cap garnish counterclockwise and remove it Turn the ignition key garnish counterclockwise and remove it Remove the bolt Remove three screws and discon...

Page 71: ...R FRAME COVERS 2 15 DINK 200i 125 EXHAUST MUFFLER REMOVAL DINK 200i only Disconnect the O2 heater O2 sensor 2 connector 1 Remove the two exhaust pipe joint nuts Remove three muffler mount bolts and mu...

Page 72: ...sket with new ones Install the exhaust muffler and three mounting bolt but do not tighten them Install and tighten the two exhaust pipe joint nuts to the specified torque Torque 20 N m 2 kgf m 14 lbf...

Page 73: ...NSPECTION ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE 3 2 FUEL LINE FUEL FILTER 3 4 THROTTLE OPERATION 3...

Page 74: ...036 in Valve clearance IN 0 1 mm 0 004 in EX 0 1 mm 0 004 in Idle speed DINK 125 1700 rpm DINK 200i 1660 rpm Cylinder compression DINK 125 15 kgf cm 1500 kPa 213 psi DINK 200i 16 kgf cm 1600 kPa 227 2...

Page 75: ...unless the owner has the proper tools and service data and is mechanically qualified In the interest of safety we recommend these items be serviced only by your KYMCO dealer KYMCO recommends that your...

Page 76: ...3 INSPECTION ADJUSTMENT 3 3 DINK 200i125 MAINTENANCE SCHEDULE...

Page 77: ...for dirty or clogged fuel filter 1 and replace with a new one if it is clogged DINK 200i Check the fuel lines 1 and replace any parts which show signs of deterioration damage or leakage THROTTLE OPER...

Page 78: ...the adjusting nut 2 at the carburetor side Adjust by loosening the lock nut 1 and turning the adjusting nut Minor adjustment is made with the adjusting nut at the throttle grip side Slide the rubber...

Page 79: ...h day before riding the scooter The level must be maintained between the upper 1 and lower level 2 marks on the oil filler cap dipstick 1 Start the engine and let it idle for a few minutes 2 Stop the...

Page 80: ...suggest you take it in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash or pour it on the ground or down a drain Used engine oil may c...

Page 81: ...plug torque 25 N m 2 5 kgf m 18lbf ft 5 Fill the crankcase with the recommended grade oil and install the oil fill cap Oil capacity after draining 0 9 liter 0 95 US qt 0 8 lmp qt 6 Start the engine a...

Page 82: ...oil strainer screen 4 Check that the oil strainer screen sealing rubber and drain plug O ring are in good condition 5 Install the oil strainer screen spring and oil strainer screen cap Oil strainer sc...

Page 83: ...om the right crankcase cover 2 Place a drain pan under the crankcase Remove three bolts and then remove the oil filter cap 2 and O ring 3 The spring 4 will come out when the filter cap is removed Let...

Page 84: ...oil and install the oil filler cap Oil capacity after draining 0 9 liter 0 95 US qt 0 8 lmp qt 8 Start the engine and let it idle for 2 3 minutes 9 Stop the engine and check that the oil level is at t...

Page 85: ...wly turn the rear wheel and drain the oil After draining the oil completely install the oil drain bolt with a new sealing washer and tighten it Torque 13 N m 1 3 kgf m 9 5 lbf ft 5 Fill the transmissi...

Page 86: ...leaner cover 2 then remove air cleaner cover 3 Remove six screws from the air cleaner element 3 then remove and discard this air cleaner element 4 The new air cleaner element installation is in the re...

Page 87: ...henever there is negative pressure pulse in the exhaust system This charged secondary air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon mo...

Page 88: ...osits with a spark plug cleaner or a wire brush Specified Spark Plug DINK 125 NGK DP7EA9 DINK 200i NGK DPR6EA9 Measure the spark plug gap Spark Plug Gap 0 9 mm 0 036 in Torque 0 9 kgf m 9 N m 6 5 lbf...

Page 89: ...flywheel clockwise to the top dead center TDC on the compression stroke so that the T mark 6 on the flywheel aligns with the index mark 5 on the left crankcase cover The punch mark 7 on the camshaft...

Page 90: ...he valve clearance Install the removed parts in the reverse order of removal IDLE SPEED Warm up the engine before this operation Start the engine and connect a tachometer Turn the throttle stop screw...

Page 91: ...a 213 psi DINK 200i 16 kgf cm 1600 kPa 227 2 psi If the compression is low check for the following Leaky valves Valve clearance to small Leaking cylinder head gasket Worn pistons Worn piston cylinder...

Page 92: ...f the scooter tends to creep or the engine stalls check the clutch shoes for wear and replace if necessary refer to the DRIVE PULLEY DRIVE BELT AND DRIVEN PULLEY section in the chapter 8 HEADLIGHT AIM...

Page 93: ...use only high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines See antifreeze container label Use only low mineral dri...

Page 94: ...3 INSPECTION ADJUSTMENT 3 21 DINK 200i125 check the cooling system frequently and add higher concentrations of antifreeze up to a maximum of 60 antifreeze if required...

Page 95: ...tainer or an equivalent Other checks Make sure there are no fluid leaks Check for deterioration or cracks in the hoses and fittings BRAKE PAD WEAR Brake pad wear depends upon the severity of usage the...

Page 96: ...tability of the scooter Under inflated tires make smooth cornering difficult and overinflated tires decrease the amount of tire in contact with the ground which can lead to skids and loss of control B...

Page 97: ...ompressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the en...

Page 98: ...mage or loss of tension and the side stand assembly for freedom of movement Check the side stand ignition cut off system 1 Place the scooter on its center stand 2 Put the side stand up and start the e...

Page 99: ..._________________________________________________________________ __________________________________________________________________________________ ___________________________________________________...

Page 100: ...4 LUBRICATION SYSTEM 4 1 DINK 200i 125 LUBRICATION SYSTEM DIAGRAM Oil Pump Oil Strainer Screen Crankshaft Rocker Arm Shaft Oil Filter Screen...

Page 101: ...aks SPECIFICATIONS Unit mm in Standard Service Limit Inner rotor to outer rotor clearance 0 15 0 006 0 2 0 008 Outer rotor to pump body clearance 0 15 0 2 0 006 0 008 0 25 0 01 Rotor end to pump body...

Page 102: ...TER CLUTCH section in the chapter 10 Remove the bolt and then oil separator cover Pry the snap ring off and remove the oil pump driven gear then remove the oil pump drive chain Remove the two oil sepa...

Page 103: ...ten the two bolts Install the pump drive chain and driven gear then set the snap ring securely on the pump shaft Install the oil separator cover properly Oil Separator Pump Drive Chain Snap Ring Arrow...

Page 104: ...Rotor Pump Cover Screw Outer Rotor Inner Rotor Dowel Pin Pump Body Pump Shaft DISASSEMBLY Remove the screw and disassemble the oil pump as shown INSPECTION Measure the pump body to outer rotor cleara...

Page 105: ...ervice Limit 0 2 mm 0 008 in Measure the rotor end to pump body clearance Service Limit 0 12 mm 0 0048 in ASSEMBLY Install the outer rotor inner rotor and pump shaft into the pump body There is one pu...

Page 106: ...__________________________________________________________________________ __________________________________________________________________________________ __________________________________________...

Page 107: ...the cooling system with coolant and be sure to bleed air from the water jacket Start the engine to check for coolant leaks Before removing the engine the rear brake caliper must be removed first Be c...

Page 108: ...r 14 Remove the two bolts from the intake manifold Disconnect the O2 heater O2 sensor connector refer to the EXHAUST MUFFLER section in the chapter 2 DINK 200i only Remove a bolt from fuel hose guide...

Page 109: ...stand Remove the three bolts 1 from rear brake hose clamps Remove the two bolts 2 then remove the rear brake caliper Disconnect the alternator connector 3 Disconnect the ignition pulse generator conne...

Page 110: ...NK200i DINK 125 Remove the bolt 6 and engine ground cable DINK 125 only Remove the two nuts 7 then remove the intake manifold from cylinder head Remove the bolt 8 then remove the thermostat from cylin...

Page 111: ...ALLATION 5 5 DINK 200i DINK 125 Disconnect the air supply hose 10 from cylinder head cover Disconnect the lower radiator hose 11 from lower radiator pipe Remove the right and left rear shock absorber...

Page 112: ...ON 5 6 DINK200i DINK 125 Remove the engine mount nut 13 Pull out the engine mount bolt Remove the engine from the frame At removing the engine be careful not to catch your hand or finger between the e...

Page 113: ...hock absorber lower mount bolts to the specified torque Torque 2 7 kgf m 27 N m 19 lbf ft Install the rear brake caliper and tighten the mount bolts to the specified torque Torque 3 2 kgf m 32 N m 23...

Page 114: ...5 ENGINE REMOVAL INSTALLATION 5 8 DINK200i DINK 125 INSPECTION Inspect the engine mount bolt Band Damage Replace Do not attempt to straighten a bent engine mount bolt...

Page 115: ...t bolt and collar 4 Remove the engine from frame INSTALLATION Installation is in the reverse order of removal Tighten the engine hanger mount bolts to the specified torque Torque 5 kgf m 50 N m 36 lbf...

Page 116: ...______________________________________ __________________________________________________________________________________ ______________________________________________________________________________...

Page 117: ...6 CYLINDER HEAD VALVES 6 1 DINK 200i 125 SCHEMATIC DRAWING...

Page 118: ...m 1500 kpa 213 psi Cylinder head warpage 0 05 0 002 IN 31 2365 1 24946 31 1 1 244 DINK 200i EX 30 9262 1 237048 30 75 1 23 IN 30 8763 1 235052 30 75 1 23 Camshaft cam height DINK 125 EX 30 4081 1 2163...

Page 119: ...valve guide Damaged valve stem oil seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment Incorrect valve timing Sticki...

Page 120: ...the cylinder head cover INSTALLATION Install a new cylinder head cover O ring and install the cylinder head cover Install and tighten the cylinder head cover bolts and nuts to the specified torque in...

Page 121: ...o the specified torque Torque DINK 200i 2 3 kgf m 23 N m 16 6 lbf ft DINK 125 2 kgf m 20 N m 14 4 lbf ft Adjust valve clearance refer to the VALVE CLEARANCE section in the chapter 3 Camshaft Holder Do...

Page 122: ...nspect the rocker arm bore cam lobe contact surface and adjuster surface for wear pitting scratches blue discoloration If any defects are found replace the rocker arm shaft with a new one then inspect...

Page 123: ...Service limits 0 1 mm 0 004 in ASSEMBLY Apply engine oil to the rocker arms and rocker arm shafts Install the rocker arms and shafts into the camshaft holder 6mm Bolt Valve Rocker Arms Rocker Arm Sha...

Page 124: ...aft gear facing up and the location is the top dead center on the compression stroke Remove the tensioner sealing bolt and spring Remove the two bolts from cam chain tensioner and then remove the tens...

Page 125: ...5 mm 1 23 in DINK 125 IN 30 75 mm 1 23 in EX 30 26 mm 1 2104 in If any defects are found replace the camshaft with a new one then inspect lubrication system Check each camshaft bearing for play or dam...

Page 126: ...und hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the cam chain over the...

Page 127: ...tensioner gasket Install the cam chain tensioner and tighten the two bolts to the specified torque Torque 0 9 kgf m 9 N m 6 5 lbf ft Install the tensioner spring and tighten the sealing bolt Torque 0...

Page 128: ...refer to the CAMSHAFT REMOVAL section in this chapter Remove the two cylinder head bolts from the cylinder head Remove the two nuts and intake manifold Remove the bolt and then remove the thermostat...

Page 129: ...t securely Install the camshaft refer to the CAMSHAFT section in this chapter Install the camshaft holder refer to the CAMSHAFT HOLDER section in this chapter Install and tighten the two cylinder head...

Page 130: ...il seals and valves using a valve spring compressor Special tool Valve Spring Compressor A120E00040 Valve Spring Compressor Be sure to compress the valve springs with a valve spring compressor Mark al...

Page 131: ...alve stem O D Measure each valve guide I D Subtract each valve stem O D from the corresponding guide I D to obtain the stem to guide clearance Service limits IN 0 08 mm 0 0032 in EX 0 1 mm 0 004 in Va...

Page 132: ...des Install the valve springs and retainers Compress the valve springs using the valve spring compressor then install the valve cotters Special tool Valve Spring Compressor A120E00040 Tap the valve st...

Page 133: ...________________________________________________________________ __________________________________________________________________________________ ____________________________________________________...

Page 134: ...7 CYLINDER PISTON 7 1 DINK 200i 125 SCHEMATIC DRAWING...

Page 135: ...ng to groove Top 0 015 0 05 0 006 0 002 0 09 0 0036 clearance Second 0 015 0 05 0 006 0 002 0 09 0 0036 Top 0 15 0 3 0 006 0 012 0 5 0 02 Ring end gap Second 0 15 0 3 0 006 0 012 0 5 0 02 Oil side rai...

Page 136: ...n Compression too low or uneven compression Excessive smoke from exhaust muffler Worn or damaged cylinder and piston rings Worn or damaged piston rings Worn stuck or broken piston rings Worn or damage...

Page 137: ...the cylinder Remove the two cylinder bolts washers 2 Remove the cylinder Remove the cylinder gasket 4 and dowel pins 3 Clean any gasket material from the cylinder surface Remove the piston pin clip 6...

Page 138: ...ir grooves without catching Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring to groove clearance Service Limits Top 0 09 mm 0 0036 in 2nd 0...

Page 139: ...0 2 in DINK 125 52 3 mm 2 092 in at A 9 mm 0 36 in Calculate the cylinder to piston clearance Measure the piston pin hole Take the maximum reading to determine the I D Service Limit 15 04 mm 0 6016 i...

Page 140: ...ar Service Limit DINK200i 62 1mm 2 484in DINK125 52 5mm 2 1in Calculate the piston to cylinder clearance Take a maximum reading to determine the clearance Service Limit 0 1mm 0 004in Calculate the tap...

Page 141: ...ings into the piston ring grooves with the markings facing up Do not confuse the top and second rings To install the oil ring install the oil ring then install the side rails Stagger the piston ring e...

Page 142: ...l to the connecting rod small end and piston pin hole Install the piston with the IN mark face intake side and piston pin Place a clean shop towel over the crankcase prevent the clip from falling into...

Page 143: ...tall the cylinder over the piston Install the two cylinder bolts washers 1 and after the cylinder head and camshaft holder has installed refer to the CYLINDER HEAD section in the chapter 6 then tighte...

Page 144: ..._________________________________________ __________________________________________________________________________________ ___________________________________________________________________________...

Page 145: ...8 DRIVE AND DRIVEN PULLEYS KICK STARTER 8 1 DINK 200i 125 SCHEMATIC DRAWING...

Page 146: ...125 18 8 0 752 17 3 0 692 Clutch lining thickness 3 963 4 037 0 15852 0 16148 2 0 08 Clutch outer I D 130 130 2 5 2 5 208 130 5 5 22 DINK 200i 135 5 4 130 5 2 Driven face spring free length DINK 125...

Page 147: ...e starts but motorcycle won t move Lack of power Worn drive belt Worn drive belt Broken ramp plate Weak driven face spring Worn or damaged clutch lining Worn weight roller Broken driven face spring Fa...

Page 148: ...ase cover Remove the gasket and dowel pins INSTALLATION Install the dowel pins and new gasket Install the left crankcase cover Install and tighten the eight bolts diagonally to specified torque Torque...

Page 149: ...bolt from the kick lever then remove the kick lever Remove the snap ring and washer from the kick starter spindle Gently turn the kick starter spindle to remove the starter driven gear together with t...

Page 150: ...ly Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushings for wear or damage Inspect the starter driven...

Page 151: ...gear into the left crankcase cover Apply grease to the driven gear shaft Install the washer onto the left crankcase cover Install the starter driven gear and friction spring as the figure shown Starte...

Page 152: ...the drive pulley then remove the nut and ratchet Special tool Universal holder A120E00017 Remove the drive pulley face Hold the clutch outer with the universal holder and remove the clutch outer nut...

Page 153: ...r cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit DINK 200i 17 5 mm 0 7 in DINK 125 17 3 mm 0 692 in Clutch out inspection Inspect the clutch outer for wear...

Page 154: ...ey assembly clutch outer and drive belt together Use the special tool to hold clutch outer then tighten the nut to the specified torque Torque 5 5 kgf m 55 N m 40 lbf ft Special tool Universal holder...

Page 155: ...ley face and ratchet Use the special tool to hold drive pulley face then tighten the nut to the specified torque Torque DINK 200i 5 8 kgf m 58 N m 42 lbf ft DINK 125 5 5 kgf m 55 N m 40 lbf ft Special...

Page 156: ...IVEN PULLEYS KICK STARTER 8 12 DINK 200i 125 DRIVE PULLEY DISASSEMBLY Remove the drive face boss Remove the ramp plate and four slide pieces Remove the six weight rollers Ramp Plate Weight Roller Boss...

Page 157: ...damage Measure outside diameter Service limit 19 8 mm 0 792 in Movable drive face Slide pieces Drive pulley face Check the slide pieces and movable drive face splines for wear cracks or damage Check...

Page 158: ...ive face drive pulley face weight rollers slide pieces ramp plate and drive face boss Install the weight rollers Install the slide pieces and ramp plate Remove any excess grease Weight Roller Ramp Pla...

Page 159: ...8 DRIVE AND DRIVEN PULLEYS KICK STARTER 8 15 DINK 200i 125 Install the drive face boss Boss...

Page 160: ...utch driven pulley assembly with the clutch spring compressor Special tool Clutch Spring Compressor A120E00034 Set the tool in a vise and remove the clutch drive plate nut Remove the clutch Be sure to...

Page 161: ...iven face Remove the three guide pins rollers then remove the movable driven face Remove the needle bearing from driven face Remove the snap ring then remove the bearing from driven face Movable Drive...

Page 162: ...ck the torque cam grooves for wear or damage Check guide pins and rollers for wear or damage If any scratches or damage is found then replace as a set Check the spring for damage Measure the spring fr...

Page 163: ...se and install them into the movable driven face grooves Install the movable driven face onto the driven face Install the guide rollers and guide roller pins Filling 5 g of grease to each guide groove...

Page 164: ...______________________________________________________ __________________________________________________________________________________ ______________________________________________________________...

Page 165: ...9 FINAL REDUCTION 9 1 DINK 200i125 SCHEMATIC DRAWING...

Page 166: ...l SAE 90 Oil Capacity At disassembly 0 2 liter 0 17 lmp qt 0 21 US qt At change 0 18 liter 0 16 lmp qt 0 19 US qt TORQUE VALUES Transmission case cover bolt 1 2 kgf m 12 N m 8 6 lbf ft SPECIAL TOOLS O...

Page 167: ...e chapter 3 Remove the driven pulley refer to the DRIVE PULLEY DRIVE BELT AND DRIVEN PULLEY section in the chapter 8 Remove the nine bolts from the transmission case cover then remove the transmission...

Page 168: ...nd final gear Press the driveshaft out from the drive belt compartment INSPECTION Inspect the countershaft and gear for wear or damage Inspect the final gear and final gear shaft for wear damage or se...

Page 169: ...smission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage INSTALLATION Install the driveshaft Install the final gear and final gear shaft Drive Sh...

Page 170: ...ns Install the transmission case cover Install and tighten the nine bolts to the specified torque in a crisscross pattern in 2 or 3 steps Torque 1 2 kgf m 12 N m 8 6 lbf ft Fill the transmission case...

Page 171: ...l Special tool Bearing puller A120E00037 Install the new bearings or new oil seal into the transmission case cover by using the special tool Special tool Oil seal and bearing installer A120E00014 TRAN...

Page 172: ...ase by using the special tool Special tool Oil seal and bearing installer A120E00014 DRIVESHAFT BEARING Remove the driveshaft refer to the FINAL REDUCTION sectioninthischapter Remove the bearing by us...

Page 173: ...______________________________________________________ __________________________________________________________________________________ ______________________________________________________________...

Page 174: ...10 A C GENERATOR STARTER CLUTCH 10 1 DINK 200i125 SCHEMATIC DRAWING...

Page 175: ...ngine oil and coolant Then bleed air from the water jacket Refer to chapter 17 for A C generator inspection SPECIFICATIONS Engine oil SAE 10W 30 API SG Oil capacity at change 0 9 liter 0 79 lmp qt 0 9...

Page 176: ...sconnect the alternator stator connectors refer to the chapter 17 Remove the nine bolts from the right crankcase cover and then remove the cover Remove the two dowel pins and gasket Remove the two pul...

Page 177: ...d tighten the stator mount bolts to the specified torque Torque 1 kgf m 10 N m 7 2 lbf ft Apply sealant to the grommet seating surface and install it to the cover groove properly Install the pulse coi...

Page 178: ...10 A C GENERATOR STARTER CLUTCH 10 5 DINK 200i125 Install the dowel pins and gasket Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 or 3 steps...

Page 179: ...tion in this chapter Hold the flywheel with a special tool and remove the flywheel nut Special tool Flywheel holder A120E00021 Remove the flywheel driven gear by using the special tool Special tool Fl...

Page 180: ...wise smoothly but the gear should not turn counterclockwise Remove the starter driven gear by turning the driven gear Check the starter driven gear teeth for wear or damage Measure the starter driven...

Page 181: ...ion gear shaft Install the starter reduction gear and shaft to the right crankcase Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel Groove...

Page 182: ...RATOR STARTER CLUTCH 10 9 DINK 200i125 Hold the flywheel with the special tool and tighten the flywheel nut Torque 5 5 kgf m 55 N m 40 lbf ft Special tool Flywheel holder A120E00021 Flywheel Nut Flywh...

Page 183: ..._____________________________________ __________________________________________________________________________________ _______________________________________________________________________________...

Page 184: ...11 CRANKCASE CRANKSHAFT 11 1 DINK 200i 125 SCHEMATIC DRAWING...

Page 185: ...ylinder head chapter 6 Cylinder piston chapter 7 Drive and driven pulley chapter 8 A C generator starter clutch chapter 10 Rear wheel rear shock absorber chapter 16 Starter motor chapter 19 Oil pump c...

Page 186: ...ts Remove the five left crankcase bolts Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase Remove the gasket and dowel pins Remove the crankshaft f...

Page 187: ...Remove the oil seal from the left crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6 mm 0 024 in Measure the connecting rod small end I D Service Limit...

Page 188: ...the crankshaft bearing play Service Limits Axial 0 2 mm 0 008 in Radial 0 05 mm 0 002 in CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces Install a new oil seal into...

Page 189: ...the right crankcase over the crankshaft and onto the left crankcase Install and tighten the right and left crankcase attaching bolts Torque 1 kgf m 10 N m 7 2 lbf ft Left Crankcase Gasket Right Crankc...

Page 190: ...ANKSHAFT 11 7 DINK 200i 125 Install the cam chain Install the cam chain tensioner slipper Install and tighten the cam chain tensioner slipper bolt Torque 1 2 kgf m 12 N m 8 6 lbf ft Cam Chain Tensione...

Page 191: ..._________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM ____________________________...

Page 192: ...12 COOLING SYSTEM 12 1 DINK 200i 125 SCHEMATIC DRAWING...

Page 193: ...water as soon as possible After servicing the system check for leaks with a cooling system tester SPECIAL TOOL Mechanical seal driver TORQUE VALUES Water pump impeller 1 2 kgf m 12 N m 9 lbf ft Left h...

Page 194: ...025 30 1 053 1 051 1 051 1 049 1 047 1 045 1 043 1 041 1 038 1 035 1 032 35 1 063 1 062 1 060 1 058 1 056 1 054 1 052 1 049 1 046 1 043 1 040 40 1 072 1 070 1 068 1 066 1 064 1 062 1 059 1 056 1 053...

Page 195: ...i Pressurize the radiator engine and hoses and check for leaks Repair or replace components if the system will not hold the specified pressure for at least six seconds Radiator Cap Cap Tester Cap Test...

Page 196: ...ntenance schedule Mix only distilled low mineral water with the antifreeze Recommended mixture 1 1 Distilled water and antifreeze REPLACEMENT AIR BLEEDING Remove the front cover refer to the FRAME COV...

Page 197: ...3 and reserve tank lid 4 Remove the reserve tank cap 5 and drain the coolant from the reserve tank Reinstall and tighten the drain bolt securely Place the scooter on its center stand on a flat level s...

Page 198: ...ed air from the system as follow 1 Start the engine and let it idle for 2 3 minutes 2 Snap the throttle three to four times to bleed air from the system 3 Stop the engine and add coolant to the proper...

Page 199: ...siphon hose 1 and air bleed hose 2 Remove the bolt 3 Loosen the hose bands then disconnect the upper radiator hose 4 and lower radiator hose 5 from the radiator Disconnect the fan motor switch connect...

Page 200: ...2 9 DINK 200i 125 Remove the three nuts 10 and then remove the radiator from frame INSTALLATION Installation is in the reverse order of removal Refill the coolant refer to the COOLANT REPLACEMENT sect...

Page 201: ...adiator refer to the RADIATOR section in this chapter Remove the three mounting bolts 1 and then remove the fan motor 2 INSPECTION Check the fan motor to operate using an available battery INSTALLATIO...

Page 202: ...witch starts to operate If the switch operating temperature is not within the specified range replace the switch with a new one OFF ON Over 88 92 C ON OFF Lower 88 92 C INSTALLATION Fit the new O ring...

Page 203: ...signs of mechanical seal coolant leakage If the mechanical seal is leaking remove the right crankcase cover and replace the mechanical seal WATER PUMP IMPELLER REMOVAL Drain the coolant see page 12 5...

Page 204: ...el pins Remove the water pump impeller Inspect the mechanical water seal and seal washer for wear or damage Impeller Left Hand Threads Mechanical Seal Seal Washer Porcelain Water Pump Cover Bolts The...

Page 205: ...water pump assembly Remove the water pump assembly gasket and dowel pins Remove the water pump bearing snap ring from the water pump assembly Remove the water pump shaft and shaft inner bearing Remove...

Page 206: ...w mechanical seal using a mechanical seal driver WATER PUMP SHAFT INSTALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside Mechanical Seal Water Seal Mechan...

Page 207: ...mp assembly to the right crankcase cover Tighten the 3 bolts to secure the water pump assembly WATER PUMP IMPELLER INSTALLATION When the mechanical seal is replaced a new seal washer must be installed...

Page 208: ...pump shaft Torque 1 2 kgf m 12 N m 9 lbf ft Install the two dowel pins and a new gasket Install the water pump cover and tighten the 4 bolts Torque 1 kgf m 10 N m 7 lbf ft Impeller Left Hand Threads D...

Page 209: ...er temperature sensor to the ohmmeter and dip it in oil contained in a pan which is placed on an electric heater Gradually raise oil temperature while reading the thermometer in the pan and the ohmmet...

Page 210: ...ed to the threaded part tighten the water temperature sensor Torque 0 8 kgf m 8 N m 5 8 lbf ft Connect the sensor connectors After the water temperature sensor has been installed fill coolant and perf...

Page 211: ...e sensor connectors 1 Disconnect the water hose 2 from the thermostat housing Disconnect the air bleed hose 3 from the thermostat housing Remove the mounting bolt 4 and the thermostat housing from the...

Page 212: ...12 COOLING SYSTEM 12 21 DINK 200i 125 DISASSEMBLY Remove the two bolts and separate the thermostat housing halves Remove the thermostat from the thermostat housing Thermostat Bolts Thermostat...

Page 213: ...6 180 F Full open 90 C 198 F Valve lift 3 5 mm 0 14 in minimum ASSEMBLY Thermostat assembly is in the reverse order of disassembly O ring Thermostat Housing Thermostat Thermometer Do not let the therm...

Page 214: ...________________________________________________________________________ __________________________________________________________________________________ DINK 125 FUEL SYSTEM CARBURETOR FUEL PUMP FU...

Page 215: ...13 DINK 125 FUELSYSTEM CARBURETOR FUELPUMP FUEL TANK 13 1 DINK 2000i 125 FUEL SYSTEM...

Page 216: ...13 DINK 125 FUELSYSTEM CARBURETOR FUELPUMP FUEL TANK 13 2 DINK 200i 125 SCHEMATIC DRAWING...

Page 217: ...n cleaning the carburetor air and fuel jets the O rings and diaphragm must be removed first to avoid damage Then clean with compressed air When the machine is not used for over one month drain the res...

Page 218: ...l pump which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through th...

Page 219: ...xture Damaged vacuum piston diaphragm Auto bystarter valve opens excessively Clogged diaphragm hole Faulty float valve Float level too high Lean mixture Clogged air jets Clogged fuel jets Auto bystart...

Page 220: ...the FRAME COVERS REMOVAL section in the chapter 2 Disconnect the auto choke connector 1 Disconnect the vacuum hose 2 Disconnect the TPS connector 3 Disconnect the carburetor heater connector 4 Loosen...

Page 221: ...DINK 2000i 125 Remove the carburetor Disconnect the fuel hose from the carburetor Installation is in the reverse order of removal Adjust the throttle grip free play refer to the THROTTLE OPERATION sec...

Page 222: ...Bend the guide straight then remove the auto choke wire Remove the two screws and top cap Top Cap Guide Keep sparks and flames away from the work area Drain gasoline into a clean container Do not loo...

Page 223: ...ARBURETOR FUELPUMP FUEL TANK 13 9 DINK 2000i 125 Remove the spring and piston valve Remove the spring retainer jet needle Remove the four screws and float chamber Spring Piston Valve Spring Retainer J...

Page 224: ...et holder and needle jet Remove the pilot screw spring washer and O ring Float Valve Float Pin Float Slow Jet Main Jet Needle Jet Holder Needle Jet Pilot Screw Spring Washer O ring Before pilot screw...

Page 225: ...Remove the two screws and casting enrichment valve cover and then take out the spring Remove the casting enrichment valve Remove the two screws and auto choke seat Then remove the O ring Spring Casti...

Page 226: ...t and varnish Blow the body dry using compressed air After cleaning reassemble the carburetor with new seals Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive...

Page 227: ...alve and valve seat for foreign substance clogging or damage Check the tip of the float valve where it contacts the valve seat for stepped wear or contamination Check the operation of the float valve...

Page 228: ...eck the diaphragm 1 of the coasting enrichment valve for tears Check the spring 2 and cover 3 of the coasting enrichment for damage Check jet needle needle jet slow jet needle jet holder main jet and...

Page 229: ...f stick is found replace the part with a new carburetor Check the float level after checking the float valve valve seat and float Set the carburetor so that the float valve end just contacts the float...

Page 230: ...der 9 Float valve 10 Float pin 11 Float chamber 12 Float chamber O ring 13 Float 14 Main jet 15 Heater 16 Slow jet 17 Casting enrichment valve 18 Cover 19 Spring 20 Pilot screw Assemble the parts taki...

Page 231: ...HOKE REMOVAL Remove the cap Remove the two screws then remove the auto choke and set plate INSPECTION Check the auto chake valve and needle for nicks wear or damage If any faulty part is found replace...

Page 232: ...el enriching circuit of the carburetor Connect the auto choke yellow wire to the positive terminal of a battery and green black wire to the negative terminal Wait 5 minutes and blow the hose with mout...

Page 233: ...13 DINK 125 FUELSYSTEM CARBURETOR FUELPUMP FUEL TANK 13 19 DINK 2000i 125 Install the cap Cap...

Page 234: ...ater with battery If the heater is getting hot means the heater without problem otherwise the heater has to be changed Remove the carburetor refer to the CARBURETOR section in this chapter Remove the...

Page 235: ...outlet hose 1 and vacuum hose 3 Remove the two nuts and the fuel pump Installation is in the reverse order of removal TESTING Measure the fuel pump output Start the engine and disconnect the fuel out...

Page 236: ...FUELPUMP FUEL TANK 13 22 DINK 200i 125 DISASSEMBLY Remove the four fuel pump body screws Disassemble the fuel pump INSPECTION Inspect the fuel pump diaphragms A and B for damage Inspect each gasket fo...

Page 237: ...e order of disassembly Spring Suction Valve Outlet Valve Relief Valve Spring During assembly be sure to install the gaskets and diaphragms properly to avoid damage Do not allow any foreign matter to e...

Page 238: ...ATION section in the chapter 2 Disconnect the fuel hoses 1 and remove the fuel strainer 2 Install the fuel strainer with its arrow mark toward the fuel pump INSPECTION Inspect if the fuel strainer is...

Page 239: ...TALLATION section in the chapter 2 Disconnect the fill cap ground wire connector 1 Disconnect the fill cap lock cable 2 Disconnect the fuel hose 3 Disconnect the fuel unit connector 4 Remove the four...

Page 240: ...0i 125 Remove the two nuts 7 from right fuel tank plate and remove a bolt 8 from radiator pipe Remove the right fuel tank plate 9 Remove the two nuts 10 and then remove the left fuel tank plate 11 Rem...

Page 241: ...FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Loosen the air cleaner clamp screw 1 Disconnect the crankcase breather hose 2 from the air cleaner Disconnect the transmission gear case brea...

Page 242: ...L MENU USING DIAGNOSTIC TOOL 14 20 MAINTENANCE MENU USING DIAGNOSTIC TOOL 14 24 THROTTLE POSITION SENSOR INITIAL PROCEDURE 14 26 RESET THE AIR BY PASS VALVE 14 27 ADAPT AIR FLOW PER CYCLE APC 14 28 AP...

Page 243: ...or T MAP 4 Ignition Switch 5 Throttle Position Sensor TPS 6 Idle Air By Pass Valve ABV 7 Battery 8 Ignition Coil 9 Fuel Injector 10 Throttle Body 11 Engine temperature Sensor WTS 12 Crankshaft positio...

Page 244: ...0 i FUEL SYSTEM Auto Control Fuel Injection System 14 2 SYSTEM LOCATION Intake Manifold Injector Air Cleaner Air Throttle Body Air Temperature Manifold Absolute Pressure Sensor Fuel and Air Fuel Pump...

Page 245: ...14 DINK 200i FUEL SYSTEM Auto Control Fuel Injection System 14 3...

Page 246: ...14 DINK 200 i FUEL SYSTEM Auto Control Fuel Injection System 14 4...

Page 247: ...68 F 21 5 15 Inductive ignition coil resistance 20 C 68 F 0 57 0 66 Water temperature sensor resistance 703 8 40 9 60 C 260 7 15 1 90 C 111 1 7 8 120 C Throttle position sensor voltage resistance 20 C...

Page 248: ...ing during acceleration Battery voltage too low Ignition system malfunction Fuel level too low Pinched or clogged fuel hose Poor performance drive ability and poor Faulty fuel pump operating system fu...

Page 249: ...ctivates the CELP with a lower value priority number takes precedence over one with a higher value priority number i e 1 is the highest priority Faults with a level 1 priority shall cause the CELP to...

Page 250: ...s no memory of problem data If the CELP light or blink stop the engine and read the failure codes perform the following 1 Turn ignition switch to OFF then open and hold the throttle fully 2 Turn ignit...

Page 251: ...1 to 24 but there are not number 20 and 23 5 When more than one failure occurs the CELP shows the blinks in the order of lowest number to highest number For example if the indicator blinks once after...

Page 252: ...open and hold the throttle fully 2 Turn ignition switch to ON while the CELP comes on after 2 seconds the CELP will be off 3 Close the throttle fully when the CELP comes on again 4 When the CELP begi...

Page 253: ...not to connect 2 The position sensor of checking the crank know whether the machine deals with contact combine or not appropriate Does connecting line break road 3 The position sensor of checking the...

Page 254: ...alve body TPS abnormality or not 6 P0560 Battery voltage range fault 1 1 Confirming the electric cell electric voltage leads low or lead high 2 Confirm three mutually does the generator ACG refresh wh...

Page 255: ...hether in the specification new car 30 40 Does the old car 180 also confirm to reduce expenses whether the valve body accumulates carbon to jam or not enter current of air quantity shortage 2 Confirm...

Page 256: ...t connect line and haven t moved and break road after the electrical appliance the ECU pin 5 2 If still appear an abnormality change a new fuel pump to confirm after the electrical appliance whether f...

Page 257: ...l or not soon 0 68 s 0 05 5 Does the CVT leather belt split 16 P0115 Engine temperature sensor fault 2 1 Confirming the sensor know the machine electric resistance whether in the specification 2 Does...

Page 258: ...Angle detect sensor fault 2 1 Confirming the sensor know the machine outputs electric voltage whether in the specification 2 Does confirming the sensor know the machine deals with contact connects lin...

Page 259: ...KYMCO SELF DIAGNOSTIC PROCEDURES LOAD DTC 1 Connect PDA PDA cable and diagnostic cable 2 Put the side stand up and engine stop switch is at RUN 3 Turn the ignition switch to ON 4 Connect the diagnosti...

Page 260: ...7 Select the Find ECU then the ECU will be find automatically 8 Select the DTC mark to enter DTC inspect menu 9 Select Load DTC to appear Active failure codes in DTC List Read All DTC Active Occurred...

Page 261: ...Active Occurred or history by select option block then to select option 2 Select Clear DTC to clear OK Ding mark Load DTC Clear DTC Option block DTC option Select the Ding mark then select ok to leav...

Page 262: ...Select windmill mark to enter Recive Signal menu 3 Select RUN to read signal data Select PageUp to enter next page Select PageDn to enter last page There are 7 page in this section to displays the sco...

Page 263: ...Air Temp sensor volt V Engine Temp C Engine Temp sensor volt V Atm Press kPa Page 02 Engine speed rpm Throttle Position Standard Close fully 0 Open fully 100 TPS sensor volt for primary V Standard Clo...

Page 264: ...ucer power supply volt V Standard 5 0 1V Idle speed setpoint rpm Standard 1660 100 rpm Page 04 ABVOnTimeOfs ms Standard 0 AirflowAdap Ofs g s Standard 0 Manual TPI initialisation Cut Out switch volt V...

Page 265: ...uel Injection System 14 23 Page 06 Engine speed rpm Secondary TPI initial adaptation ISCAdapMean ABVAngDurMech Page 07 Accumulated eng run time Fuel pump state Primary TPI AdapInit V O2 sensor voltage...

Page 266: ...set Select Load Select Reset to reset the ABVOnTimeOfs ms value To adapt the ABV plus or minus 0 1 unit at a time select the options To adapt the ABV plus or minus 1 unit at a time select the options...

Page 267: ...rning Reset Select LOAD Select Reset to reset the AirflowAdapOfs g s value To adapt the APC plus or minus 0 01 unit at a time select the options To adapt the APC plus or minus 0 1 unit at a time selec...

Page 268: ...14 DINK 200 i FUEL SYSTEM Auto Control Fuel Injection System 14 26 THROTTLE POSITION SENSOR INITIAL PROCEDURE To reset the throttle position sensor when the throttle body is replaced...

Page 269: ...14 DINK 200i FUEL SYSTEM Auto Control Fuel Injection System 14 27 RESET THE AIR BY PASS VALVE ABV To reset the ABV when the throttle body air by pass valve cylinder head or cylinder is replaced...

Page 270: ...14 DINK 200 i FUEL SYSTEM Auto Control Fuel Injection System 14 28 ADAPT AIR FLOW PER CYCLE APC To reset the APC Adapt Offset Value when throttle body is cleaned up...

Page 271: ...14 DINK 200i FUEL SYSTEM Auto Control Fuel Injection System 14 29 APC ADAPTION PROCEDURE When the vehicle ride on the road the ECU will automatic adapt the APC if the condition has been meet...

Page 272: ...OOD When no failure code occurs and pressing starter switch repeatedly still can not start the engine maybe the spark plug is flood by fuel perform the spark plug anti flood to purge the fuel in the e...

Page 273: ...witch to OFF and Disconnect the ECU connector Turn ignition switch to ON Connect the multimeter probe to the red wire and the multimeter probe to the green wire There should be battery voltage at all...

Page 274: ...PURGE DRIVER 13 AIND IDEL AIR VALVE DRIVER 3 FIND FUEL INJECTOR 14 FPDD O2 HEATER 4 LSD2 CHECK ENGINE LIGHT DRIVER 15 DRVP DRIVER POWER BATTERY 5 LSD3 PUMP RELAY DRIVE 16 XDRG TRANSDUCER GROUND 6 IMMS...

Page 275: ...ble multimeter Input voltage Turn ignition switch to ON with the engine stop switch in the run position and put the side stand up Disconnect the T MAP sensor connector Connect the multimeter probe to...

Page 276: ...Br B terminals Standard 14260 16022 20 C 2353 2544 20 C 568 9 597 4 60 C Using diagnostic tool Enter RECIVE SIGNAL MENU refer to the RECIVE SIGNAL MENU USING DIAGNOSTIC TOOL section in this chapter R...

Page 277: ...other than shown in this manual Do not loosen or tighten the painted bolts and screws of the throttle body Loosening or tightening them can cause throttle and idle valve synchronization failure REMOVA...

Page 278: ...rottle position sensor connector Connect the multimeter probe to the violet red wire and the multimeter probe to the violet green wire to measure the voltage from the ECU input to throttle position se...

Page 279: ...U USING DIAGNOSTIC TOOL section in this chapter Read page 02 Throttle position Standard 0 close throttle fully 100 open throttle fully TPS sensor volt for primary V Standard 0 68 0 05V 0 4 1 0 1V 100...

Page 280: ...he multimeter probe to the red wire terminal and the multimeter probe to the green black wire terminal Turn the ignition weitch to ON and measure the voltage between the terminals There should be batt...

Page 281: ...gnostic tool Enter RECIVE SIGNAL MENU refer to the RECIVE SIGNAL MENU USING DIAGNOSTIC TOOL section in this chapter Read page 04 Check the value of ABVOnTimeOfs ms is 0 if not perform the ABV reset re...

Page 282: ...14 DINK 200 i FUEL SYSTEM Auto Control Fuel Injection System 14 40 THROTTLE BODY INSPECTION Check throttle valve for free movement If stick is found replace the part with a new throttle body...

Page 283: ...nector then remove WTS INSTALLATION Replace a new washer Install and tighten the WTS to the specified torque Torque 2 kgf m 20 N m 14 lbf ft Connect the WTS connector INSPECTION Using a commercially a...

Page 284: ...d data in page 01 refer to the RECIVE SIGNAL MENU USING DIAGNOSTIC TOOL section in this chapter Read the data Engine Temp C Engine Temp sensor volt FUEL INJECTOR REMOVAL Disconnect the connector from...

Page 285: ...3 INSTALLATION Install fuel hose joint onto the fuel injection Install the spring clip into the groove on the fuel injection Place the tension seal onto the intake manifold Coat O rings with clean eng...

Page 286: ...olt securely Connect the connector INSPECTION Using a commercially available multimeter Measure the fuel injection resistance Standard 11 3 10 20 C 68 F Using diagnostic tool Enter RECIVE SIGNAL MENU...

Page 287: ...connect the fuel vacuum hose from the intake manifold Disconnect fuel pump and fuel unit connectors Remove the inner cover refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Remov...

Page 288: ...Remove four nuts and fuel tank bridge plate Disconnect the fuel hoses from the fuel pump Disconnect the fuel vacuum hose from the intake manifold Disconnect fuel pump connector Remove six bolts Remov...

Page 289: ...wire and make sure the fuel hose joint on fuel pump facing rear Tighten the bolts using crisscross pattern Connect the fuel hose fuel vacuum hose and fuel pump connector INSPECTION Inspect the O ring...

Page 290: ...the multi meter probe to the Red Black terminal and the multi meter probe to the Green terminal Turn the ignition switch to ON and measure the voltage between the terminals There should be battery vol...

Page 291: ...ic tool Enter RECIVE SIGNAL MENU and then read data in page 07 refer to the RECIVE SIGNAL MENU USING DIAGNOSTIC TOOL section in this chapter Read the data Fuel pump state When the engine is stopping c...

Page 292: ...moval INSPECTION Remove the fuel pump relay Connect the ohmmeter to the fuel pump relay connector terminals Connection Red Red Black Connect he 12 V battery to the following fuel pump relay connector...

Page 293: ...data should be outputted only when its temperature over 350 C O2 heater heat O2 sensor to over 350 C earlier than exhaust muffler The data of O2 sensor is one of the data that control fuel injector op...

Page 294: ...l Injection System 14 52 Using diagnostic tool Enter RECIVE SIGNAL MENU and then read data in page 07 refer to the RECIVE SIGNAL MENU USING DIAGNOSTIC TOOL section in this chapter Read the data O2 sen...

Page 295: ...onnector Remove the two screws washers and angle detect sensor Installation is in the reverse order of the removal INSPECTION The engine should stop as you incline the bank angle sensor approximately...

Page 296: ...14 DINK 200 i FUEL SYSTEM Auto Control Fuel Injection System 14 54 AIR CLEANER HOUSING REMOVAL INSTALLATION Refer to the AIR CLEANER section in the chapter 13...

Page 297: ..._________________________________________________________ __________________________________________________________________________________ HANDLEBAR FRONTWHEEL FRONTBRAKE FRONTSHOCKABSORBER STEERING...

Page 298: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 15 1 DINK 200i125 SCHEMATIC DRAWING...

Page 299: ...e caliper piston O D 25 33 25 36 1 0132 1 0144 25 3 1 012 Brake caliper cylinder I D 25 4 25 45 1 016 1 018 25 45 1 018 TORQUE VALUES Handlebar lock nut 45 N m 4 5 kgf m 32 lbf ft Steering stem lock n...

Page 300: ...e or does not track straight Improperly tightened axle nut Uneven front shock absorbers Soft front shock absorber Bent front fork Weak shock springs Bent front axle or uneven tire Insufficient damper...

Page 301: ...s 1 and disconnect the brake light switch wire 2 then remove the rear brake master cylinder Remove the two bolts 3 and disconnect the brake light switch wire 4 then remove the front brake master cylin...

Page 302: ...k nut and bolt Tighten the bolt to the specified torque Torque 4 5 kgf m 45 N m 32 lbf ft Connect the right and left handlebar switch connectors Install the front and rear master cylinders and connect...

Page 303: ...ER STEERING STEM 15 6 DINK 200i 125 DISASSEMBLY Remove the two screws 1 from right handlebar switch Disconnect the throttle cable 2 from the throttle grip Remove the right handlebar switch Remove the...

Page 304: ...n the two screws securely Install the right handlebar switch Lubricate the throttle grip front end with grease and then connect the throttle cable to the throttle grip Install and tighten the two scre...

Page 305: ...ove the nut 1 then pull out the axle 2 Remove the front wheel and collar Axle runoutn inspection Set the axle in V blocks and measure the runout using a dial gauge The actual runout is 1 2 of the tota...

Page 306: ...ometer gear unit by aligning its retaining pawl with the hub cutout Install the front wheel by aligning the speedometer gear unit groove with the front shock absorber tab Insert the axle and tighten t...

Page 307: ...of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if the...

Page 308: ...l Special tool Bearing puller A120E00037 ASSEMBLY Install the front wheel bearing 5 by using the special tool Special tool Bearing installer A120E00014 Install the distance collar Install the front wh...

Page 309: ...been opened or if the brake feels spongy the system must bled When using a commercially available brake bleeder follow the manufacturer s operating instructions A contaminated brake disc or pad reduce...

Page 310: ...TEM 15 13 DINK 200i125 Brake fluid draining Make sure that the master cylinder parallel to the ground before removing the reservoir cover Remove the two screws 1 Remove the reservoir cover 2 diaphragm...

Page 311: ...to prevent air from being pumped into the system When using a brake bleeding tool follow the manufacture s operating instructions Pump the brake bleeder and loosen the front caliper bleed valve Add f...

Page 312: ...close the bleed valve 2 Release the brake lever slowly until the bleed valve has been closed Add fluid when the fluid level in the master cylinder is low to prevent drawing air into the system 3 Repe...

Page 313: ...ER STEERING STEM 15 16 DINK 200i 125 FRONT BRAKE PAD BRAKE PAD REPLACEMENT Remove the two pad pins 1 Remove the two caliper mounting bolts 2 then remove the caliper Remove the brake pads Always replac...

Page 314: ...perly Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper Install the front caliper onto the fork leg and then install and tighten the new...

Page 315: ...i 125 BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks Measure the brake disc thickness Service limits 3 mm 0 12 in Replace the brake disc if the smallest measurement is less...

Page 316: ...er handlebar cover refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Drain the front brake hydraulic system refer to the FRONT BRAKE FLUID section in this chapter Remove the brak...

Page 317: ...switch and tighten the screw to the specified torque Torque 1 N m 0 1 kgf m 0 7 lbf ft Align the pin on the master cylinder holder with the hole on the handlebar Install the front master cylinder and...

Page 318: ...t Apply silicone grease to the master piston tip Install the brake lever Apply silicone grease to the brake lever pivot bolt sliding surface Install and tighten the pivot bolt to the specified torque...

Page 319: ...brake fluid ASSEMBLY Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber cup Install the main piston spring and new snap ring Install the new rubber...

Page 320: ...NK 200i125 INSPECTION Measure the brake master cylinder I D Inspect the master cylinder for scratches or cracks Service Limit 12 75 mm 0 5 in Measure the brake master cylinder piston O D Service Limit...

Page 321: ...ydraulic system refer to the FRONT BRAKE FLUID section in this chapter Remove the oil bolt 1 sealing washers and brake hose from the brake caliper Remove the brake pads and caliper refer to the FRONT...

Page 322: ...out the piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and re...

Page 323: ...g Apply silicon grease to the boots inside Install the caliper bracket to the caliper Install the pads and then install the front caliper onto the fork leg refer to the FRONT BRAKE PAD section in this...

Page 324: ...G STEM 15 27 DINK 200i125 INSPECTION Check the piston for scratches or wear Measure the piston O D with a micrometer gauge Service Limit 25 3 mm 1 012 in Check the caliper cylinder for scratches or we...

Page 325: ...from right front shock absorber Remove the bolt 2 and then remove the speedometer cable guide from left front shock absorber Remove the two mounting bolts 3 and then remove the right front shock abso...

Page 326: ...refer to the FRONT SHOCK ABSORBER section in this chapter Remove the front brake hose 1 from the guide Hold the steering stem top cone race and remove the steering stem lock nut by using the special...

Page 327: ...ge Replace if necessary Remove the top balls Remove the upper ball race by using a chisel if necessary Remove the bottom balls Remove the bottom ball race by using a pipe if necessary Remove the botto...

Page 328: ...19 new steel balls on the bottom ball race Install the steering stem Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several t...

Page 329: ..._________________________________________________________________________ __________________________________________________________________________________ REARBRAKE REARFORK REARWHEEL REARSHOCKABSOR...

Page 330: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 1 DINK 200i 125 SCHEMATIC DRAWING...

Page 331: ...1 0144 25 45 1 018 Rear brake caliper piston O D 25 33 25 36 1 0132 1 0144 25 3 1 012 TORQUE VALUES Rear axle nut 120 N m 12 kgf m 86 lbf ft Rear shock absorber lower mount bolt 27 N m 2 7 kgf m 19 l...

Page 332: ...e system Faulty tire Deteriorated brake fluid Axle not tightened properly Contaminated brake pad surface Worn brake pads Soft rear shock absorber Clogged brake fluid line Weak shock absorber spring De...

Page 333: ...ed or if the brake feels spongy the system must bled When using a commercially available brake bleeder follow the manufacturer s operating instructions A contaminated brake disc or pad reduces stoppin...

Page 334: ...Make sure that the master cylinder parallel to the ground before removing the reservoir cover Remove the two screws 1 Remove the reservoir cover 2 diaphragm plate 3 and diaphragm 4 Connect a bleed ho...

Page 335: ...vent air from being pumped into the system When using a brake bleeding tool follow the manufacture s operating instructions Pump the brake bleeder and loosen the rear caliper bleed valve Add fluid whe...

Page 336: ...he bleed valve 2 Release the brake lever slowly until the bleed valve has been closed Add fluid when the fluid level in the master cylinder is low to prevent drawing air into the system 3 Repeat the s...

Page 337: ...ABSORBER 16 8 DINK 200i 125 REAR BRAKE PAD BRAKE PAD REPLACEMENT Remove the two pad pins 1 Remove the two caliper mounting bolts 2 then remove the caliper Remove the brake pads Always replace the bra...

Page 338: ...tall the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper Install the rear caliper onto the rear fork and then install and tighten the new two cali...

Page 339: ...AKE DISC INSPECTION Visually inspect the brake disc for damage or cracks Measure the brake disc thickness Service limits 3 mm 0 12 in Replace the brake disc if the smallest measurement is less than th...

Page 340: ...lebar cover refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Drain the rear brake hydraulic system refer to the REAR BRAKE FLUID section in this chapter Remove the brake lever p...

Page 341: ...and tighten the screw to the specified torque Torque 1 N m 0 1 kgf m 0 7 lbf ft Align the pin on the master cylinder holder with the hole on the handlebar Install the rear master cylinder and holder w...

Page 342: ...silicone grease to the master piston tip Install the brake lever Apply silicone grease to the brake lever pivot bolt sliding surface Install and tighten the pivot bolt to the specified torque Torque...

Page 343: ...uid ASSEMBLY Before assembly apply brake fluid to all removed parts Install the spring together with the 1st rubber cup Install the main piston spring and new snap ring Install the new rubber cover Du...

Page 344: ...25 INSPECTION Measure the brake master cylinder I D Inspect the master cylinder for scratches or cracks Service Limit 12 75 mm 0 5 in Measure the brake master cylinder piston O D Service Limit 12 64 m...

Page 345: ...system refer to the REAR BRAKE FLUID section in this chapter Remove the oil bolt 1 sealing washers and brake hose from the brake caliper Remove the brake pads and caliper refer to the REAR BRAKE PAD...

Page 346: ...piston through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed piston Check the piston cylinder for scratches or wear and replace if...

Page 347: ...all the pad spring Apply silicon grease to the boots inside Install the caliper bracket to the caliper Install the pads and then install the rear caliper onto the rear fork refer to the REAR BRAKE PAD...

Page 348: ...19 DINK 200i 125 INSPECTION Check the piston for scratches or wear Measure the piston O D with a micrometer gauge Service Limit 25 3 mm 1 012 in Check the caliper cylinder for scratches or wear and m...

Page 349: ...2 Loosen the rear axle nut 1 Support the scooter securely on its main stand Remove the rear shock absorber lower mount bolt 2 Remove the three bolts 3 and brake hose clamps from the rear fork Remove...

Page 350: ...25 Remove the rear wheel INSTECTION Wheel Check the wheel rim runout using dial indicator Actual urnout is 1 2 the total indicator reading Service Limits Radial 2 mm 0 08 in Axial 2 mm 0 08 in REAR FO...

Page 351: ...rn the inner race of the bearing with your finger The bearing should turn smoothly and quietly Also check that the bearing outer race fits tightly in the rear fork Remove and discard the bearing if th...

Page 352: ...ecial tools Special tool Bearing installer A120E00014 Install the snap ring to the groove of the rear fork securely Apply grease to the new dust seal lip and install it to the rear fork Apply grease t...

Page 353: ...gf m 19 lbf ft Install and tighten the rear axle nut 1 to temporarily Install and tighten the rear shock absorber lower mount bolt 2 to the specified torque Torque 27 N m 2 7 kgf m 19 lbf ft Install t...

Page 354: ...ve the rear shock absorber upper mount bolt 2 and shock absorber INSTECTION Check the damper unit for leakage or other damage Check the upper joint bushing for wear or damage Replace the shock absorbe...

Page 355: ...__________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY CHARGIN...

Page 356: ...17 BATTERY CHARGING SYSTEM 17 1 DINK 200i 125 CHARGING SYSTEM LAYOUT CHARGING CIRCUIT...

Page 357: ...ystem according to the sequence specified in the Troubleshooting Do not disconnect and soon reconnect the power of any electrical equipment because the electronic parts in the regulator rectifier will...

Page 358: ...ttery cable Loose charging system connection Fuse burned out Loose connection or short circuit in Faulty ignition switch ignition system Low power Charging system failure Weak battery Loose broken or...

Page 359: ...d then remove the battery retainer 2 4 Pull battery out to expose the terminal leads 5 Disconnect the negative terminal lead 3 from the battery first then disconnect the positive terminal lead 4 6 Rem...

Page 360: ...battery positive terminal Connect the charger negative cable to the battery negative terminal Charging current time DINK 200i Standard 1 A 5 10 hours Quick 5 A 1 hours DINK 125 Standard 0 8 A 5 10 ho...

Page 361: ...heck for current leakage When measuring current using a tester set it to a high range and then bring the range down to an appropriate level Current flow higher than the range selected may blow out the...

Page 362: ...hort make absolutely certain which are the positive and negative terminals or cable With the headlight on and turned to the high beam position restart the engine Measure the voltage on the multimeter...

Page 363: ...ernator connector 1 Measure the resistance between each Yellow wire terminals Standard 0 4 0 6 20 C 68 F Check for continuity between each Yellow wire terminal of the alternator side connector and gro...

Page 364: ...AL INSTALLATION section in the chapter 2 Disconnect the regulator rectifier connectors 1 Check the connectors for loose contacts of corroded terminals Battery line Measure the voltage between the Red...

Page 365: ...ground There should be continuity at all times Charging coil line Measure the resistance between each Yellow wire terminals Standard 0 4 0 6 20 C 68 F Disconnect the regulator rectifier connector Chec...

Page 366: ...INSTALLATION Remove the side body cover refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the regulator rectifier connectors 1 Remove the two bolts 2 regulator rectif...

Page 367: ..._____________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM _______________________...

Page 368: ...18 IGNITION SYSTEM 18 1 DINK 200i 125 IGNITION SYSTEM LAYOUT DINK 200i IGNITION CIRCUIT DINK 200i...

Page 369: ...18 IGNITION SYSTEM 18 2 DINK 200i 125 IGNITION SYSTEM LAYOUT DINK 125 IGNITION CIRCUIT DINK 125 FUSE LOCATION...

Page 370: ...pter 10 for ignition pulse generator removal installation See chapter 14 for ECU removal installation inspection See section 20 for those components Ignition switch Engine stop switch GENERAL INSTRUCT...

Page 371: ...ulty ignition pulse generator Faulty ignition control module PEAK VOLTAGE IS NORMAL BUT NO SPARK JUMPS AT THE PLUG Faulty spark plug or leaking ignition coil secondary current Faulty ignition coil DIN...

Page 372: ...isconnect the spark plug cap 2 from the spark plug Connect known good spark plug to the spark plug cap and ground the spark plugs to the cylinder as done in the spark test DINK 200i Turn the ignition...

Page 373: ...me The battery voltage should be measured If the initial voltage cannot be measured check the power supply circuit IGNITION PULSE GENERATOR INSPECTION Remove the luggage box refer to the FRAME COVERS...

Page 374: ...connect the spark plug cap from the spark plug 1 DINK 200i Disconnect the ignition coil primary connector 2 Remove the two bolts 3 and the ignition coil 4 Installation is in the reverse order of remov...

Page 375: ...INSTALLATION section in the chapter 2 Disconnect the CDI connectors 1 and remove the CDI 2 RESISTANCE INSPECTION Measure the resistance between the terminals Due to the semiconductor in circuit it is...

Page 376: ...nit L Y V B G B G B W V R B R B Y L Y 0 27M 1K 2K 6K 0 32M V B 0 27M 0 27M 0 27M 0 27M 0 58M G B 7 74M 8M 7 74M 7 74M 7 74M 8M G 1K 0 27M 1K 5K 0 32M B W V R 2K 0 27M 1K 6K 0 32M B R 6K 0 27M 4 94K 6K...

Page 377: ...______________________________________ __________________________________________________________________________________ ______________________________________________________________________________...

Page 378: ...19 STARTING SYSTEM 19 1 DINK 200i 125 STARTING SYSTEM LAYOUT STARTING CIRCUIT...

Page 379: ...ling system TORQUE VALUES Starter motor mounting bolt 1 kgf m 10 N m 7 lbf ft TROUBLESHOOTING Starter motor won t turn Lack of power Fuse burned out Weak battery Weak battery Loose wire or connection...

Page 380: ...al 3 If the start motor does not turn the starter motor is faulty REMOVAL Remove the air cleaner refer to the CARBURETOR section in the chapter 13 Turn the ignition switch turned to OFF Release the ru...

Page 381: ...ine oil and install it into the start motor groove Install the starter motor into the crankcase Install the two mounting bolts and engine ground cable then tighten the bolts securely Connect the start...

Page 382: ...clicks Release the rubber caps 1 and remove the nuts 2 then disconnect the start motor cable battery positive cable and harness wire Disconnect the start MAG switch connector 3 and then remove start M...

Page 383: ..._____________________________________________________________________________ __________________________________________________________________________________ LIGHTS METERS SWITCHES ________________...

Page 384: ...ean it with a cloth moistened with alcohol to prevent its early failure Be sure to install the dust cover after replacing the bulb Check the battery condition before performing any inspection that req...

Page 385: ...BULB REPLACEMENT POSITION LIGHT Remove the front cover refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Remove the bulb socket 1 Remove the bulb 2 and replace with a new one Ins...

Page 386: ...4 from the headlight case Install a new bulb in the headlight case by aligning the bulb tab with the case groove Hook the retainer Install the dust cover properly on to the headlight and connect the h...

Page 387: ...rews then remove the front turn signal light cover Push and turn the bulb counterclockwise to remove it then replace with a new one Installation is in the reverse order of removal TAILLIGHT BRAKE LIGH...

Page 388: ...replace with a new one Installation is in the reverse order of removal Taillight Brake light Push and turn the bulb counterclockwise to remove it then replace with a new one Installation is in the rev...

Page 389: ...s 1 There should be continuity with the front or rear brake lever squeezed and there should be no continuity with the front or rear brake lever is released IGNITION SWITCH INSPECTION Remove the front...

Page 390: ...he FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Right handlebar switch Disconnect the right handlebar switch connector and check for continuity at switch side connector terminals Continu...

Page 391: ...ndlebar switch Disconnect the left handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wires as follows Dimmer Switch...

Page 392: ...REMOVAL INSTALLATION section in the chapter 2 Disconnect the luggage box light switch connector 2 and check the luggage box light switch 1 for continuity between the switch terminals There should be n...

Page 393: ...EMOVAL Remove the floorboard refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Remove the four nuts 1 and then remove the bridge plate 2 Disconnect the fuel unit connectors 3 Tur...

Page 394: ...ree From Much to Less Apply From Less to Much The fuel meter is normal if it operates as above indicated If not check for poorly connected terminals or shorted wires Measure the resistance between the...

Page 395: ...0i 125 INSTALLATION Install the O ring 1 and fuel unit 2 Install the fuel unit retainer Align the groove on the fuel unit with the flange on the fuel tank Align the arrow mark on the fuel unit retaine...

Page 396: ...nuity between the Yellow Green and Green with the side stand retracted There should be continuity between the Yellow Black and Green with the side stand applied REMOVAL Disconnect the side stand switc...

Page 397: ...n the chapter 2 Disconnect the horn connectors 1 from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the 12 V battery is connected across the horn terminals...

Page 398: ...after keeping the temperature under 10 4 3 Start engine and if the temperature of heater controller unit is under 10 4 Check if the white yellow wire of heater controller unit has output voltage If it...

Page 399: ...21 WIRING DIAGRAMS 21 0 DINK 200i 125 21 21 DINK 200i...

Page 400: ...21 WIRING DIAGRAMS 21 1 DINK 200i 125 DINK 125...

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