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1

. GENERAL INFORMATION

1-18

DINK 200

Starter Relay

Fuel Tube

Battery

Ignition Coil

Thermostat

Air Injection Air

Cleaner

Fuel Tube

CDI Unit

Auto  Bystarter

Spark Plug Cap

Battery

Fuel Pump

Fuel Tube

Wire Harness

Spark Plug Cap

Throttle Cable

Positive Crankcase

Ventilation (PCV)

Vacuum Tee

Vacuum Tee

Fuel Pump

Ground Wire

Fuel Pump Vacuum Tube

Fuel Filter

Air Injection

Air Cleaner

Ignition Coil

Reed Valve

Summary of Contents for DINK 200

Page 1: ...ystem 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 SAL...

Page 2: ...INE SERIAL NUMBER 1 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 H...

Page 3: ...lose 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 capaci...

Page 4: ...tening 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 t...

Page 5: ...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...

Page 6: ...cified 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 connec...

Page 7: ...d 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 mak...

Page 8: ...ke 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 ed...

Page 9: ...tact 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 shea...

Page 10: ...n 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 Whe...

Page 11: ...t the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Apply grease for lubrication Transmission Gear O...

Page 12: ...d cap nut Valve adjusting lock nut Cam chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Flywheel nut Oil pump bolt Cylinder head cover bolt Spark plug Cam chain tensioner...

Page 13: ...anical seal removal installation Kick starter spring remover Kick starter spring removal Gear remover Starter gear removal Valve adjuster Tapper adjustment Float level gauge Carburetor fuel level chec...

Page 14: ...ecting rod big end Crankshaft Crankshaft one way clutch movable part Oil pump drive chain Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable...

Page 15: ...ly 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 Rear Wheel Bearing Grease Speedometer Cable T...

Page 16: ...RNESS ROUTING Front Stop Switch Rear Stop Switch Throttle Cable Fuel Vapor Recovery Tube Wire Connectors Radiator Front Brake Fluid Tube Rear Brake Fluid Tube Speedometer Cable Horn Water Hose Fuel Va...

Page 17: ...1 15 DINK 200 Fuel Vapor Recovery Tube Radiator Air Vent Tube Front Brake Fluid Tube Rear Brake Fluid Tube Fuel Tank Inlet Tube Water Hose Ignition Switch Fuel Filler Water Hoses Thermostatic Switch F...

Page 18: ...N 1 16 DINK 200 Throttle Cable Speedometer Cable Fuel Vapor Recovery Tube Rear Brake Fluid Tube Fuel Tank Inlet Tube Water Hose Fuel Filler Fuel Tank Breather Tube Throttle Cable Front Stop Switch Wir...

Page 19: ...1 GENERAL INFORMATION 1 17 DINK 200 Starter Relay Oil Vapor Recovery Tube Carburetor Fuel Tube Ignition Coil Auto Bystarter Wire Thermostat Carburetor Overflow Tube Air Cut off Valve A C V...

Page 20: ...ction Air Cleaner Fuel Tube CDI Unit Auto Bystarter Spark Plug Cap Battery Fuel Pump Fuel Tube Wire Harness Spark Plug Cap Throttle Cable Positive Crankcase Ventilation PCV Vacuum Tee Vacuum Tee Fuel...

Page 21: ...1 GENERAL INFORMATION 1 19 DINK 200 WIRING DIAGRAM...

Page 22: ...n 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 adjusted pilot...

Page 23: ...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 obs...

Page 24: ...lty 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 plug cap t...

Page 25: ...lean 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 fuel...

Page 26: ...xcessive 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 dam...

Page 27: ...ngs 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 belt...

Page 28: ...pinion Starter relay shorted or stuck Inspection Adjustment Inspection Adjustment Inspection Adjustment Symptom Symptom Symptom Check operation of stop switch by applying brake Stoplight does not come...

Page 29: ...lty ignition coil Replace with a new spark plug and inspect again Check CDI unit coupler for looseness Inspection Adjustment Symptom Probable Cause Normal Abnormal Normal Abnormal Normal Abnormal Abno...

Page 30: ...r 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 tes...

Page 31: ...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 o...

Page 32: ...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 area...

Page 33: ..._______________________________________________ __________________________________________________________________________________ _____________________________________________________________________...

Page 34: ...2 EXHAUST MUFFLER FRAME COVERS 2 1 DINK 200 SCHEMATIC DRAWING...

Page 35: ...t claws may be damaged Make sure to route cables and harnesses according to the Cable Harness Routing TORQUE VALUES Exhaust muffler lock bolt 3 5kg m Exhaust muffler joint lock nut 1 2kg m TROUBLESHOO...

Page 36: ...ect the third stoplight wire connector on the rear carrier Remove the rear carrier and hand rail FRAME BODY COVER REMOVAL Remove the two screws on the bottom of the center cover Remove the center cove...

Page 37: ...lock wire Remove the frame body cover FLOOR BOARD REMOVAL Remove the floor mat Remove the center cover 2 3 Remove the eight screws and two bolts attaching the front right and left side covers Remove t...

Page 38: ...attaching the front lower cover Remove the four screws on the back of the front lower cover Disconnect the right left turn signal light wire connectors Remove the front lower cover The installation se...

Page 39: ...Remove the front upper cover 2 5 Remove the front lower cover 2 5 Remove the screws which combines inner fender A with inner fender B Remove the two bolts attaching the inner fender A Separate inner f...

Page 40: ...____________________________________________________ INSPECTION ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDU...

Page 41: ...IONS ENGINE Throttle grip free play 2_ 6mm Spark plug NGK DP7EA9 Spark plug gap 0 8_ 1 0mm Valve clearance IN 0 1mm EX 0 1mm Idle speed 1500 100rpm SH25AA 1700 100rpm Engine oil capacity Cylinder comp...

Page 42: ...Cleaner Note 2 3 I R R Spark plug Clean at every 3000km and replace if necessary Brake system I I I I I I I I I I I I Drive belt I Suspension I I I Nut bolt fastener I Tire I I I Steeringhead bearing...

Page 43: ...nt Measure the throttle grip free play Free Play 2_ 6mm Major adjustment of the throttle grip free play is made with the adjusting nut at the carburetor side Adjust by loosening the lock nut and turni...

Page 44: ...ded oil through the oil filler hole Oil Capacity At disassembly 1 1 liter At change 0 8 liter RecommendedOil SAE 15W40 API SG CD Start the engine and check for oil leaks Stop the engine and recheck th...

Page 45: ...ck the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug NGK DP7EA9 Measure the spark plug gap Spark Plug Gap 0 8_ 1 0m...

Page 46: ...justing nut Valve Wrench CARBURETOR IDLE SPEED Lift up the seat and remove the inspection cover Warm up the engine before this operation Start the engine and connect a tachometer Turn the throttle sto...

Page 47: ...engine before compression test Remove the center cover and spark plug cap Remove the spark plug Insert a compression gauge Open the throttle valve fully and push the starter button to test the compre...

Page 48: ...ill the final reduction with the recommended oil SAE90 Gear Oil Capacity At disassembly 200cc At change 195cc Reinstall the oil check bolt and check for oil leaks DRIVE BELT Remove the left crankcase...

Page 49: ...upper and lower level lines If necessary fill the reserve tank with recommended coolant to the F level line Recommended Coolant SIGMA Coolant Standard Concentration 30 COOLANT REPLACEMENT Remove the f...

Page 50: ...lever free plays BRAKE FLUID Turn the steering handlebar upright and check if the front rear brake fluid level is at the upper limit If the brake fluid is insufficient fill to the upper limit Specifie...

Page 51: ...ront wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing SUSPENSION Check the acti...

Page 52: ...________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM _________________...

Page 53: ...4 LUBRICATION SYSTEM 4 1 DINK 200 LUBRICATION SYSTEM Oil Pump Oil Filter Screen Crankshaft Rocker Arm Shaft...

Page 54: ...is installed check each part for oil leaks SPECIFICATIONS OIL PUMP Standard mm Service Limit mm Inner rotor to outer rotor clearance 0 15 0 20 Outer rotor to pump body clearance 0 15_ 0 20 0 25 Rotor...

Page 55: ...Remove the oil filter screen and spring Check the oil filter screen for clogging or damage and replace if necessary Check the filter screen O ring for damage and replace if necessary Install the oil f...

Page 56: ...3 Remove the A C generator starter driven gear 10 4 Remove the attaching bolt and oil separator cover Pry the circlip off and remove the oil pump driven gear then remove the oil pump drive chain Remo...

Page 57: ...the inner rotor to outer rotor clearance Service Limit 0 20mm replace if over Measure the rotor end to pump body clearance Service Limit 0 12mm replace if over OIL PUMP ASSEMBLY Install the outer rot...

Page 58: ...g OIL PUMP INSTALLATION Install the oil pump and oil separator and tighten the two bolts Make sure that the pump shaft rotates freely The arrow of oil pump is upside Install the pump drive chain and d...

Page 59: ...______________________________________________________________ __________________________________________________________________________________ ______________________________________________________...

Page 60: ...5 ENGINE REMOVAL INSTALLATION 5 1 DINK 200 SCHEMATIC DRAWING 3 0kg m 5 0kg m 4 0kg m...

Page 61: ...g the engine After the engine is installed fill 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 th...

Page 62: ...connect the water hose Disconnect the starter motor wire that goes to the starter relay Disconnect the fuel tube and vacuum tube that go to the carburetor from the fuel pump Disconnect the vacuum tube...

Page 63: ...ounting bolts and pull out the engine with the engine hanger backward ENGINE HANGER REMOVAL Remove the engine hanger bolts to remove the engine hanger Inspect the engine hanger bushings and stopper ru...

Page 64: ...ar shock absorber upper mount bolts Torque 4 0kg m After installation inspect and adjust the following Throttle grip free play 3 3 Fill the rear brake reservoir with brake fluid and bleed air from the...

Page 65: ..._________________________________________ __________________________________________________________________________________ CYLINDER HEAD VALVES ______________________________________________________...

Page 66: ...6 CYLINDER HEAD VALVES 6 1 DINK 200 SCHEMATIC DRAWING...

Page 67: ...imit mm Item SH40AA SH40AA IN 0 10 EX 0 10 Cylinder head compression pressure 15kg cm_ Cylinder head warpage 0 05 IN 30 8763 30 75 EX 30 4081 30 26 IN 10 00_ 10 018 10 10 EX 10 00_ 10 018 10 10 Valve...

Page 68: ...tem oil seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment Incorrect valve timing Sticking valve or broken valve sp...

Page 69: ...kcase Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke Remove the two bolts attaching cam chain tensioner and the tensioner First re...

Page 70: ...imits SH40AA IN 30 75mm replace if below Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play CAMSHAFT HOLDER DI...

Page 71: ...iator and water jacket then remove the thermostat water hose Remove the camshaft 6 4 Remove the carburetor and intake manifold Remove the bolt attaching the thermostat housing and the thermostat housi...

Page 72: ...g a valve spring compressor Remove carbon deposits from the exhaust port and combustion chamber Valve Spring Compressor Cylinder Head Be sure to compress the valve springs with a valve spring compress...

Page 73: ...ner IN EX 29 3mm replace if below Outer IN EX 32 0mm replace if below VALVE VALVE GUIDE Inspect each valve for bending burning scratches or abnormal stem wear Check valve movement in the guide Measure...

Page 74: ...all the intake and exhaust valve rocker arms then installtherocker arm shafts Gasket Cam Chain Guide Valve Rocker Arms Plastic Hammer Cam Chain Cylinder Head Camshaft Holder Be careful not to damage t...

Page 75: ...camshaft gear Install the dowel pins Install the camshaft holder washers and nuts on the cylinder head Tighten the four cylinder head nuts and the two bolts between the cylinder head and cylinder Tor...

Page 76: ...tighten the sealing bolt Torque 2 9_ 5 8N m CYLINDER HEAD COVER INSTALLATION Adjust the valve clearance 3 6 Install a new cylinder head cover O ring and install the cylinder head cover Install and tig...

Page 77: ..._____________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLI...

Page 78: ...7 CYLINDER PISTON 7 1 DINK 200 SCHEMATIC DRAWING...

Page 79: ...n O D measuring position 9mm from bottom of skirt Piston to cylinder clearance 0 010_ 0 040 0 01 Piston pin hole I D 15 002_ 15 008 15 04 Piston pin O D 14 994_ 15 000 14 96 Piston to piston pin clear...

Page 80: ...sioner Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface PISTON REMOVAL Remove the piston pin clip Press the piston pin out of the piston Cylinder Base Bolt...

Page 81: ...oove clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Measure the piston ring end gap Service...

Page 82: ...the piston pin in both X and Y directions Service Limit 62 10mm repair or replace if below Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if over The true roundness is...

Page 83: ...PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oil to each piston ring Second Side Rail Top Be careful not to damage the piston and piston rings during assembly All ri...

Page 84: ...h clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Gasket Cylinder Dowel Pin Be careful not to drop foreign matters into the crankcase Piston Piston Pin Cl...

Page 85: ...ylinder base bolt Install the cam chain guide Connect the water hose to the cylinder Install the cylinder head 6 9 Tighten the cylinder base bolt Insert the tab on the cam chain guide into the cylinde...

Page 86: ..._______________________________ __________________________________________________________________________________ __________________________________________________________________________________ DR...

Page 87: ...8 DRIVE AND DRIVEN PULLEYS KICK STARTER 8 1 DINK 200 SCHEMATIC DRAWING...

Page 88: ...037 2 0 Clutch outer I D 130 0_ 130 2 130 5 Driven face spring free length 88 3 83 2 Driven face O D 33 965_ 33 985 33 94 Movable driven face I D 34 00_ 34 025 34 06 Weight roller O D 16 99_ 17 00 16...

Page 89: ...ubber and dowel pins INSTALLATION Install the dowel pins and the seal rubber Install the left crankcase cover Install the cable clamp to the specified location Install and tighten the left crankcase c...

Page 90: ...and remove the drive face nut Remove the drive pulley face Universal Holder Remove the drive belt from the movable drive face INSPECTION Check the drive belt for cracks separation or abnormal or exces...

Page 91: ...y Remove the drive pulley collar DISASSEMBLY Remove the ramp plate Remove the weight rollers INSPECTION Check each weight roller for wear or damage Measure each weight roller O D Service Limit 16 00mm...

Page 92: ...bushing assemblyy I D Service Limit 27 20mm replace if over Check the drive pulley collar for wear or damage Measure the O D of the drive pulley collar sliding surface Service Limit 26 90mm replace if...

Page 93: ...ulley collar into the movable drive face INSTALLATION Install the movable drive face onto the crankshaft Lay the drive belt on the driven pulley Set the drive belt on the drive pulley collar Drive Pul...

Page 94: ...ver 8 3 Remove the drive pulley and drive belt 8 4 Hold the clutch outer with the universal holder and remove the clutch outer nut Universal Holder Remove the clutch outer INSPECTION Inspect the clutc...

Page 95: ...driven pulley assembly with the clutch spring compressor Clutch Spring Compressor Set the tool in a vise and remove the clutch drive plate nut Lock Nut Wrench 39mm Loosen the clutch spring compressor...

Page 96: ...om the driven face Remove the oil seal from the movable driven face INSPECTION Measure the driven face spring free length Service Limit 83 2mm replace if below Check the driven face assembly for wear...

Page 97: ...earing out of the driven pulley face Remove the snap ring and drive the outer bearing out of the driven face Apply grease to the outer bearing Drive a new outer bearing into the driven face with the s...

Page 98: ...12 DINK 200 Press a new needle bearing into the driven face Bearing Driver CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch Circlips Retainer Plate Special Keep gre...

Page 99: ...ll the clutch weights shoes and clutch springs onto the drive plate Install the retainer plate and secure with the circlips CLUTCH DRIVEN PULLEY ASSEMBLY Clean the pulley faces and remove any grease f...

Page 100: ...the drive plate nut Set the tool in a vise and tighten the drive plate nut to the specified torque Torque 49 0_ 58 8N m Clutch Spring Compressor Outer Driver 32x35mm INSTALLATION Install the clutch d...

Page 101: ...ver 8 3 Remove the seal rubber and dowel pins Remove the kick lever Remove the circlip and washer from the kick starter spindle Remove three bolts on the plate Gently turn the kick starter spindle to...

Page 102: ...forcing parts for wear or damage INSTALLATION Install the kick starter spindle bushings and return spring onto the left crankcase cover Install the starter driven gear and friction spring as the figur...

Page 103: ...IVEN PULLEYS KICK STARTER 8 17 DINK 200 Install the kick lever Install the left crankcase cover and tighten the cover bolts diagonally Install the air cleaner and tighten the bolts Left Crankcase Cove...

Page 104: ...____________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL...

Page 105: ...9 FINAL REDUCTION 9 1 DINK 200 SCHEMATIC DRAWING...

Page 106: ...NS Specified Oil SAE 90 Oil Capacity At disassembly 0 2 liter At change 0 195 liter TORQUE VALUES Transmission case cover bolt 25 5_ 31 4N m Oil check bolt 9 8_ 14 7N m SPECIAL TOOLS Bearing remover 1...

Page 107: ...kcase cover 8 3 Remove the clutch driven pulleys 8 4 Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove...

Page 108: ...shaft and gear for wear or damage Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Drive Shaft Bearing Final Shaft Bearing...

Page 109: ...bearing remover Remove the final shaft oil seal Drive new bearings into the transmission case cover BEARING REPLACEMENT LEFT CRANKCASE COVER Remove the drive shaft Remove the drive shaft oil seal Remo...

Page 110: ...ve new bearings into the left crankcase Install a new drive shaft oil seal FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Install the final gear and final shaft into the left...

Page 111: ...n washer onto the counter shaft Install the dowel pins and a new gasket Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley Insta...

Page 112: ...18 liter Install and tighten the oil check bolt Torque 9 8_ 14 7N m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper l...

Page 113: ...______________________________________________________________ __________________________________________________________________________________ A C GENERATOR STARTER CLUTCH _________________________...

Page 114: ...10 A C GENERATOR STARTER CLUTCH 10 1 DINK 200 SCHEMATIC DRAWING...

Page 115: ...cover is installed fill with the recommended engine oil and coolant Then bleed air from the water jacket Refer to page 18 4 for A C generator inspection SPECIFICATIONS Engine oil SAE15W 40 API SG CD O...

Page 116: ...screws and the pulser coil Remove the three A C generator stator bolts and the stator FLYWHEEL REMOVAL Hold the flywheel with a flywheel holder and remove the flywheel nut Remove the flywheel with a...

Page 117: ...PECTION Inspect the starter driven gear for wear or damage Measure the starter driven gear I D and O D Service Limits I D 20 15mm replace if over O D 41 00mm replace if below Inspect the starter idle...

Page 118: ...INSTALLATION Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel Hold the flywheel with the flywheel holder and tighten the flywheel nut Torq...

Page 119: ...e two dowel pins and a new gasket Install the right crankcase cover over the crankcase aligning the water pump shaft groove with the oil pump shaft Tighten the nine right crankcase cover bolts Connect...

Page 120: ...________________________________________ __________________________________________________________________________________ ____________________________________________________________________________...

Page 121: ...11 CRANKCASE CRANKSHAFT 11 1 DINK 200 SCHEMATIC DRAWING...

Page 122: ...e separating the crankcase Cylinder head 6 4 Cylinder piston 7 3 Right crankcase cover drive and driven pulley 8 3 A C generator starter clutch 10 3 Rear wheel rear shock absorber 15 4 Starter motor 1...

Page 123: ...g bolts 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 cranksh...

Page 124: ...he oil seal from the left crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 6mm replace if over Measure the connecting rod small end I D Service Limit 1...

Page 125: ...ankshaft bearing play Service Limits Axial 0 20mm replace if over Radial 0 05mm replace if over CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces Install a new oil se...

Page 126: ...ace the right crankcase over the crankshaft and onto the left crankcase Install and tighten the right and left crankcase attaching bolts Torque 7 8_ 10 8N m Left Crankcase Gasket Right Crankcase Dowel...

Page 127: ...ANKCASE CRANKSHAFT 11 7 DINK 200 Install the cam chain Install the cam chain tensioner slipper Install and tighten the cam chain tensioner slipper bolt Torque 7 8_ 11 8N m Cam Chain Tensioner Slipper...

Page 128: ...__________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING...

Page 129: ...12 COOLING SYSTEM 12 1 DINK 200 SCHEMATIC DRAWING Torque 1 0_ 1 4kg m Left Hand Threads...

Page 130: ...coolant with fresh 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 0_ 1 4kg m...

Page 131: ...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 1 050 1 047 45 1 080 1 078 1 076 1 074 1 072 1 069 1 056 1 063 1 062 1 057 1...

Page 132: ...tor and apply specified pressure to it It must hold specified pressure for at least six seconds Check the water hoses and connectors for leaks RADIATOR RADIATOR INSPECTION Remove the front upper cover...

Page 133: ...insects etc are clogging the radiator wash them off Carefully straighten any bent fins RADIATOR REMOVAL Drain the coolant 3 9 Disconnect the air vent tube from the radiator filler Remove the overflow...

Page 134: ...connect the thermostatic switch wire coupler Disconnect the fan motor wire coupler Remove the four screws and the radiator RADIATOR DISASSEMBLY Remove the four bolts and then remove the fan shroud fro...

Page 135: ...ttery RADIATOR BRACKET REMOVAL INSTALLATION Remove the two nuts to remove the radiator bracket The installation sequence is the reverse of removal Install the fan shroud on the radiator with the four...

Page 136: ...onnect the upper and lower hoses and secure them with hose bands Connect the thermostatic switch wire and fan motor wire couplers Install the heat screen Connect the overflow tube and secure with the...

Page 137: ...9 After installation check for coolant leaks WATER PUMP MECHANICAL SEAL WATER SEAL INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage If the mechanical seal is leaking...

Page 138: ...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 im...

Page 139: ...r 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 the...

Page 140: ...seal using a mechanical seal driver WATERPUMP SHAFT INSTALLATION Drive a new water pump shaft outer bearing into the water pump assembly from the inside Mechanical Seal Water Seal Mechanical Seal Dri...

Page 141: ...assembly to the right crankcase cover Tighten the 3 bolts to secure the water pump assembly WATERPUMP IMPELLER INSTALLATION When the mechanical seal is replaced a new seal washer must be installed to...

Page 142: ...the water pump shaft Torque 1 0_ 1 4kg m Install the two dowel pins and a new gasket Install the water pump cover and tighten the 4 bolts Torque 0 8_ 1 2kg m Impeller Left Hand Threads Dowel Pins Wate...

Page 143: ...sistance through the sensor as the water heats up Temperature 50 80 100 120 Resistance 154 52 27 16 THERMOSENSOR INSTALLATION Apply 3 BOND No 1212 sealant or equivalent to the thermosensor threads and...

Page 144: ...ect the water hose from the thermostat housing Disconnect the air vent tube from the thermostat housing Remove the mounting bolt and the thermostat housing from the cylinder head Remove the two bolts...

Page 145: ...ION The installation sequence is the reverse of removal Fill the cooling system with the specified coolant 3 9 Do not let the thermostat touch the pan as it will give a false reading Replace the therm...

Page 146: ...__________________________ FUEL SYSTEM CARBURETOR FUEL PUMP __________________________________________________________________________________ SCHEMATIC DRAWING 13 1 SERVICE INFORMATION 13 4 TROUBLESH...

Page 147: ...13 FUEL SYSTEM CARBURETOR FUEL PUMP 13 1 DINK 200 FUEL SYSTEM...

Page 148: ...13 FUEL SYSTEM CARBURETOR FUEL PUMP 13 2 DINK 200 SCHEMATIC DRAWING...

Page 149: ...p 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 the suc...

Page 150: ...wires must be routed and secured at correct locations SPECIFICATIONS Venturi dia mm VE26 Identification number VE090 Float level mm 18 5 Pilot screw opening 2 _ Main jet 102 Slow jet 35 Idle speed 160...

Page 151: ...essively Clogged diaphragm hole Faulty float valve Float level too high Lean mixture Clogged air jets Clogged fuel jets Auto bystarter valve set plate installed in Clogged fuel tank cap breather hole...

Page 152: ...the throttle cable adjusting nut and lock nut and disconnect the throttle cable from the carburetor Loosen the air cleaner connecting tube band and carburetor intake manifold band and then remove the...

Page 153: ...Remove the needle holder spring and jet needle from the piston VACUUM PISTON INSPECTION Inspect the vacuum piston and jet needle for wear or damage Inspect the diaphragm for deterioration and tears Va...

Page 154: ...ISASSEMBLY Remove the four float chamber screws and the float chamber Remove the float pin float and float valve FLOAT VALVE INSPECTION Inspect the float valve seat contact area for wear Float Chamber...

Page 155: ...edle jet holder needle jet and slow jet with detergent oil Pilot Screw P S Pilot Screw Slow Jet Be sure to use clean detergent oil Main Jet Needle Jet Holder Before removing the pilot screw turn the p...

Page 156: ...he carburetor Connect the auto bystarter yellow wire to the positive terminal of a battery and green wire to the negative terminal Wait 5 minutes and blow the hose with mouth If the passage is blocked...

Page 157: ...e If any faulty part is found replace the auto bystarter with a new one AIR CUT OFF VALVE A C V A C V REMOVAL Remove the two screws and the air cut off valve cover Remove the spring diaphragm and O ri...

Page 158: ...Blow compressed air through all passages of the carburetor body A C V ASSEMBLY Install the O ring onto the air cut off valve body and then install the valve body to the carburetor with the two screws...

Page 159: ...e hose AUTO BYSTARTER INSTALLATION Install the auto bystarter and set plate Install and tighten the two screws Auto Bystarter Screws Install the O ring with the flat face toward the valve body side Sp...

Page 160: ...eedle jet and needle jet holder Install the main jet Install the slow jet Install the pilot screw Install the float valve float and float pin Float Valve Float Float Pin Pilot Screw Needle Jet Holder...

Page 161: ...ck the operation of the float and then reinstall the float chamber VACUUM CHAMBER ASSEMBLY First install the jet needle and spring into the vacuum chamber and then install the needle holder Install th...

Page 162: ...ter wire Connect the fuel tube and vacuum tube to the carburetor Perform the following inspections and adjustments Throttle grip free play 3 3 Idle speed 3 6 Install the seat met in box and frame cent...

Page 163: ...tall the fuel pump and secure it with the two bolts Connect the fuel pump inlet outlet and vacuum tubes Install the seat met in box and frame center cover Measure the fuel pump output Start the engine...

Page 164: ...SPECTION Inspect if the fuel strainer is clogged and clean it with compressed air INSTALLATION Install the fuel strainer with its arrow mark toward the fuel pump When removing the fuel strainer do not...

Page 165: ..._____________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HAN...

Page 166: ...14 STEERINGHANDLEBAR FRONTWHEEL FRONT BRAKE FRONTSHOCKABSORBER FRONTFORK 14 1 DINK 200 SCHEMATIC DRAWING 4 0_ 5 0kg m 4 0_ 5 0kg m 8 0_ 12kg m 2 0_ 2 5kg m 0 5_ 1 3kg m...

Page 167: ...0 Front brake pad thickness 4 0 2 0 Front shock absorber spring free length 240 6 233 Brake disk thickness 3 8_ 4 2 3 0 Brake disk runout 0 30 Brake master cylinder I D 12 700_ 12 743 12 755 Brake mas...

Page 168: ...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 o...

Page 169: ...e leg shield 2 5 Remove the four screws attaching the right and left handlebar switches Disconnect the throttle cable from the throttle grip and remove the throttle grip from the handlebar Remove the...

Page 170: ...EMOVAL Jack the motorcycle front wheel off the ground Remove the front axle nut to pull out the axle Remove the front wheel and the speedometer gear unit INSPECTION AXLE RUNOUT Set the axle in V block...

Page 171: ...ove the side collar and dust seal Turn the inner race 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 bearing...

Page 172: ...igning the speedometer gear unit groove with the front shock absorber tab Insert the axle and tighten the axle nut Torque 4 5_ 5 0kg m Do not allow the bearings to tilt while driving them in Drive in...

Page 173: ...bolt and the brake lever Remove the piston rubber cover and snap ring from the brake master cylinder Remove the washer main piston and spring from the brake master cylinder Clean the inside of the ma...

Page 174: ...ing and snap ring Install the rubber cover Install the brake lever Place the brake master cylinder on the handlebar and install the holder with the up mark facing up Also align the punch mark with the...

Page 175: ...brake fluid until there is no air bubbles in the brake fluid Then tighten the bleed valve Repeat these steps until the brake system is free of air Brake fluid spilled on brake pads or brake disk will...

Page 176: ...caliper Remove the brake pads Remove the piston from the brake caliper If necessary use compressed air to squeeze out the piston through the brake fluid inlet opening and place a shop towel under the...

Page 177: ...bricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Wipe off excessive brake fluid with a clean shop towel Apply silicon greas...

Page 178: ...fluid tube to the brake caliper and tighten the fluid tube bolt Torque 24 5_ 34 3N m Fill the brake reservoir with the specified brake fluid and bleed air from the brake system 14 10 Fluid Tube Bolt...

Page 179: ...emove the circlip Set the front shock absorber in a vise Remove the damper rod hex bolt and copper washer Pull out the front shock absorber tube Set the front shock absorber tube in a vise Remove the...

Page 180: ...Inspect the following items and replace if necessary Front shock absorber tube bending damage or wear Weak front shock absorber spring Damper and damper rod bending Oil seal damage or wear Measure th...

Page 181: ...n the damper rod hex bolt Add engine oil into the front shock absorber Torque 4 9_ 29 4N m Specified Oil SS 8 Oil Capacity 81cc Install the oil seal Install the circlip Install the dusts seal and dust...

Page 182: ...ce and remove the steering stem lock nut Remove the top cone race and remove the front fork Inspect the ball races cone races and steel balls for wear or damage Replace if necessary BOTTOMCONERACEREPL...

Page 183: ...m right and left several times to make steel balls contact each other closely Install the steering stem lock nut and tighten it while holding the top cone race Torque 8 0_ 12 0kg m Install the front w...

Page 184: ..._______________________________________ __________________________________________________________________________________ _____________________________________________________________________________...

Page 185: ...15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 1 DINK 200 SCHEMATIC DRAWING...

Page 186: ...25 45 25 45 Rear brake caliper piston O D 25 335_ 25 368 25 30 TORQUE VALUES SPECIAL TOOLS Exhaust muffler lock bolt 29 4_ 39 2N m Rear shock absorber remover Rear axle nut 78 4_ 98N m Shock absorber...

Page 187: ...e rear brake caliper 14 11 Inspect and assemble the rear brake caliper 14 12 Note The rear brake caliper and front brake caliper have the same specification INSTALLATION Install the brake caliper to t...

Page 188: ...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 they fit loosely in the...

Page 189: ...C position hard When you adjust rear cushion the spring preload of rear cushions must be the same REAR SHOCK ABSORBER REMOVAL Remove the rear carrier and hand rail 2 3 Remove the met in box 2 3 Remov...

Page 190: ...oration or damage Measure the front shock absorber spring free length Service Limit Right 226mm Left 226mm ASSEMBLY Assemble the rear shock absorbers in the reverse order of disassembly INSTALLATION I...

Page 191: ...___ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY CHARGING SYSTEM ______...

Page 192: ...16 BATTERY CHARGING SYSTEM 16 1 DINK 200 CHARGING SYSTEM LAYOUT CHARGING CIRCUIT Fuse Regulator Rectifier A C Generator Battery...

Page 193: ...ot disconnect and soon reconnect the power of any electricalequipment because the electronic parts in the regulator rectifier will be damaged Turn off the ignition switch before operation It is not ne...

Page 194: ...ction Disconnected battery 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 bat...

Page 195: ...ard 0 9A Quick 4A Charging time Standard 5_ 10 hours Quick 30 minutes After charging Open circuit voltage 12 8Vmin Battery Cover Screw When disconnecting the battery positive cable do not touch the fr...

Page 196: ...ANCE TEST Engine Speed 2500rpm 5000rpm Charging Current 6A min 8A min If the readings do not meet the specified values check the regulator rectifier A C GENERATOR INSPECTION Remove the frame center co...

Page 197: ...rmal Direction Continuity Probe Probe I Yellow Green II Red White Yellow Reverse Direction No Continuity Probe Probe I Green Yellow II Yellow Red White VOLTAGE REGULATION TEST Connect a voltmeter acro...

Page 198: ...41 K 14_ 2 6 K Charging indicator inspection 1 Turn on the ignition switch The Charging lamp should be lighten 2 Start the engine The Charging lamp should be went out 3 Inspect the output voltage of C...

Page 199: ...____________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYST...

Page 200: ...17 IGNITION SYSTEM 17 1 DINK 200 IGNITION SYSTEM LAYOUT IGNITION CIRCUIT Pulser Coil Ignition Switch Spark Plug CDI Unit A C Generator...

Page 201: ...tor and pulser coil referring to Section 10 SPECIFICATIONS Item Standard Standard type NGK DP7EA9 Spark plug Hot type NGK DP6EA9 Cold type NGK DP8EA9 Spark plug gap 0 8_ 1 0mm Ignition timing F mark F...

Page 202: ...coil with a new one IGNITION COIL CONTINUITY TEST Inspect the continuity of the ignition coil primary coil and secondary coil Measure the ignition coil resistances at 20 Primary coil 0 16_ 0 20 Secon...

Page 203: ...lue white_ Green white 50_ 170 For pulser coil replacement refer to pages 10 3 and 10 6 CDI UNIT INSPECTION Remove the met in box 2 3 Disconnect the CDI coupler and remove the CDI unit Inspect the CDI...

Page 204: ...llow 75 100 50 70 50 70 Green White 7 10 50 70 Blue Yellow 7 10 50 70 Green Different data from different supplier Green White Green Black Yellow Black Blue Blue Yellow Due to the semiconductor in cir...

Page 205: ..._______________________________ __________________________________________________________________________________ __________________________________________________________________________________ ST...

Page 206: ...18 STARTING SYSTEM 18 1 DINK 200 STARTING SYSTEM LAYOUT STARTING CIRCUIT Starter Relay Starter Button Starter Motor Stop Switches...

Page 207: ...RQUE VALUES Starter motor mounting bolt 0 7_ 1 1kg m Starter motor case screw 0 3_ 0 5kg m Starter clutch bolt 1 0_ 1 4kg m SPECIAL TOOLS Flywheel holder Flywheel puller TROUBLESHOOTING Starter motor...

Page 208: ...damage or discoloration Replace if necessary Clean the commutator if there is metal powder between the segments Check for continuity between pairs of the commutator segments and there should be contin...

Page 209: ...inuity between the wire terminal and each brush Replace if necessary Measure the length of the brushes Service Limit 8 5mm replace if below Check for continuity between the brushes If there is continu...

Page 210: ...motor case aligning the tab on the motor case with the groove on the front cover Tighten the starter motor case screws INSTALLATION Connect the starter motor cable Check the O ring for wear or damage...

Page 211: ...heck the starter button for continuity and inspect the wire OPERATION TEST Connect the electric tester to the starter relay larger terminals that connect to the battery positive cable and the starter...

Page 212: ...___ __________________________________________________________________________________ __________________________________________________________________________________ SWITCHES HORN FUEL UNIT THERMO...

Page 213: ...AUGE INSTRUMENTS LIGHTS 19 1 DINK 200 ELECTRICAL EQUIPMENT LAYOUT Turn Signal Switch Stop Switches Horn Button Headlight Dimmer Switch Fuel Unit Starter Button Horn Ignition Switch Auto Bystarter Ther...

Page 214: ...ure gauge does not register switch is ON correctly Burned bulb Faulty temperature gauge Faulty switch Faulty thermosensor Poorly connected broken or shorted wire Broken or shorted wire between tempera...

Page 215: ...LOCK ON OFF HEADLIGHT SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the headlight switch wire couplers Check for continuity between the wire terminals Color Position Blue White Brown...

Page 216: ...als Color Position Light Blue White Gray Orange White L N R DIMMER SWITCH INSPECTION Remove the frame front covers 2 5 Disconnect the headlight dimmer switch wire couplers Turn on the dimmer switch an...

Page 217: ..._ 45 500_ 850 L W_ G 400_ 700 100_ 200 Y W_ L W 450_ 750 450_ 750 FUEL GAUGE INSPECTION Connect the fuel unit wire connectors and turn the ignition switch ON Check the fuel gauge needle for correct in...

Page 218: ...es black and green wires Turn the ignition switch ON The thermostatic switch is faulty if the cooling fan motor runs properly If it does not start check for voltage between the fan motor coupler wire...

Page 219: ...e four instrument cover and leg shield screws Remove the two instrument holder bolts Remove the instruments DISASSEMBLY ASSEMBLY Remove the three instrument holder nuts Remove the holder Remove the fo...

Page 220: ...emove the front upper cover 2 5 Disconnect the headlight and turn signal light wire couplers Remove the bulb sockets by turning them counterclockwise Remove the bulbs and replace them with new ones FR...

Page 221: ...__________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUSTEMISSIONCONTROLS...

Page 222: ...jection Cut off Valve Prevent exhaust muffler noise and backfiring at sudden deceleration The air injection cut off valve usually opens to lead air into the exhaust muffler in which air is re burned t...

Page 223: ...ulty air cut off valve 5 Leaking vacuum tube Exhaust muffler noise 1 Faulty air injection cut off valve 2 Broken vacuum tube 3 Faulty reed valve SERVICE INFORMATION GENERAL INSTRUCTIONS During operati...

Page 224: ...ow should be at least 1 6 liter min when a vacuum of 320mm Hg is applied Check each connecting tube for cracks or damage and replace if necessary INSTALLATION The installation sequence is the reverse...

Page 225: ...e cover and the reed valve INSPECTION Check the reed valve for cracks damage big clearance or weak reeds Replace if necessary Check the gasket and O ring for damage or deterioration and replace if nec...

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