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KYMCO Dink 50, Service Manual

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5

. ENGINE REMOVAL/INSTALLATION

 

 

 

5-2

      DINK 50/125 

 

 
 

ENGINE 
REMOVAL/INSTALLATION 

(DINK 125) 
REMOVAL 

 
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) 

 

Loosen the rear axle nut. 
Support the scooter securely on its main 
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 
connector (4). 
 
 
 
 
 
 
 
 
 
 
 
 
 
Release the rubber cap and remove the 
terminal screw (5) to disconnect the start 
motor cable from the start motor. 
 
 
 
 
 
 
 
 
 

 

 
 
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Summary of Contents for Dink 50

Page 1: ...__________________________________________________________________________ _________________________________________________________________________________________ GENERAL INFORMATION _______________...

Page 2: ...1 GENERAL INFORMATION 1 1 DINK50 125 SERIAL NUMBER Location of Engine Serial Number 1 Location of Frame Serial Number DINK 50 DINK 125...

Page 3: ...aust 0 05 mm 0 02 in Idle speed rpm 2000 2200rpm Lubrication type Forced pressure Wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity 0 85 L 0 748 lmp qt 0...

Page 4: ...le 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 Sys...

Page 5: ...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 wo...

Page 6: ...rotruding 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 for...

Page 7: ...s 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 wires...

Page 8: ...ing 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 connec...

Page 9: ...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 10: ...28 14 6 1 10 7 2 1 2 12 8 6 5 5 55 40 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 Ex...

Page 11: ...rber 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 Rear...

Page 12: ...120E00003 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 CLU...

Page 13: ...he special tools may differ slightly from those shown in the figure of this manual Bearing puller A120E00037 Valve spring compressor Refer to the CYLINDER HEAD section in the chapter 6 A120E00040 Lock...

Page 14: ...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 mova...

Page 15: ...se 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 Engi...

Page 16: ...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 swi...

Page 17: ...r brake hose 3 Speedometer 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 1...

Page 18: ...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 b...

Page 19: ...INFORMATION 1 18 DINK 50 125 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 g...

Page 20: ...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 C...

Page 21: ...ble 2 AICV air inlet hose 3 Harness wire 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 th...

Page 22: ...9 Starter motor cable 10 Heater control connector DINK 125 11 Auto choke connector DINK 125 12 Frame ground terminal 13 Seat lock cable 14 Harness wire 15 Ground cable 16 Luggage box light connector...

Page 23: ...DINK 50 125 1 Heater control connector 2 Auto choke connector 3 Heater connector 4 Fuse box 5 Battery 6 Luggage box light switch 7 Seat lock cable 8 Battery negative cable 9 Harness wire 10 Frame grou...

Page 24: ...ttery negative terminal 2 Luggage box light connector 3 Battery positive terminal 4 A C G Regulator Rectifier Starter relay connectors 5 Light ASSY RR combination connector 6 Fuse box 7 Harness A Pass...

Page 25: ...s 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 the...

Page 26: ...fuel filter 2 Fuel hose 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 thr...

Page 27: ...er hose between the water pump and cylinder 6 Upper radiator hose connect the thermostat 7 Lower radiator hose 8 Rear brake hose A Pass the rear brake hose through the guide B Pass the rear brake hose...

Page 28: ...hose 10 Rear brake hose 11 Starter motor cable 12 Engine ground terminal connect the starter motor 13 A C G Regulator Rectifier Starter relay connectors 14 Harness wire A Pass the starter motor cable...

Page 29: ...en fuel filter and fuel tank 9 DINK 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 F...

Page 30: ...GENERAL INFORMATION 1 29 DINK50 125 1 AICV vacuum hose 2 Air inlet hose 3 AICV control solenoid valve 4 Air supply hose 5 Air inlet pipe 6 Reed valve cover A Pass the AICV vacuum hose through the guid...

Page 31: ...TION 1 30 DINK 50 125 CABLE HARNESS ROUTING DINK 50 Rear Brake Switch Rear Brake Cable Front Brake Switch Front Brake Cable Throttle Cable Horn Resistor Ignition Switch Connector Speedometer Cable Reg...

Page 32: ...1 GENERAL INFORMATION 1 31 DINK50 125 Ignition Coil Wire Ignition Coil CDI Unit Throttle Cable Breather Tube Vacuum Tube Secondary Air Tube Harness Wire...

Page 33: ...1 GENERAL INFORMATION 1 32 DINK 50 125 Fuel Tube Fuse Box Starter Relay Fuel Vacuum Tube...

Page 34: ...1 GENERAL INFORMATION 1 33 DINK50 125 Front Brake Cable Speedometer Cable Ignition Switch Fuel Hose Harness Wire Fuel Unit Wire Fuel Tube...

Page 35: ...1 GENERAL INFORMATION 1 34 DINK 50 125 Ignition Coil Wire Secondary Air Vacuum Tube Fuel Out Tube Fuel Unit Tube A C G Tube Choke Tube Fuel Strainer Fuel Pump Vacuum Tube Fuel Tank...

Page 36: ...nd piston rings gBlown cylinder head gasket hFlaws in cylinder head iSeized valve jImproper valve timing cFaulty auto bystarter dAir leaking through intake pipe eIncorrect ignition timing fIncorrectly...

Page 37: ...gnition timing too early jAir in cooling system cExcessive carbon build up in combustion chamber dPoor quality fuel eClutch slipping fMixture too lean g Ignition timing too early Start engine and acce...

Page 38: ...rator fFaulty ignition coil gBroken or shorted high tension wire hFaulty ignition switch cDamaged air cut off valve diaphragm dDamaged air cut off valve spring Remove spark plug and install it into sp...

Page 39: ...tube cClean and unclog cCam timing gear aligning marks not aligned cFaulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor jets for clogging Check fuel pump...

Page 40: ...cessive carbon build up in combustion chamber cDamaged cam chain tensioner dWorn cam gear teeth eWorn or damaged cam chain fExtended cam chain cFaulty crankshaft bearing dWorn crank pin bearing cWorn...

Page 41: ...arings fWeak driven face spring gWorn or seized driven pulley bearings cWorn or slipping drive belt dWorn weight rollers eWorn or seized driven pulley bearings cOil or grease fouled drive belt dWorn d...

Page 42: ...ter pinion cStarter relay shorted or stuck closed Inspection Adjustment Inspection Adjustment Inspection Adjustment Symptom Symptom Symptom Check operation of brake light switch by applying brake Stop...

Page 43: ...nition 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 Abnor...

Page 44: ...gulator rectifier eBroken or poorly connected regulator rectifier black wire cLimit voltage too high Start engine and test limit voltage of battery terminals Measure battery limit voltage with an elec...

Page 45: ...Symptom 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 rem...

Page 46: ...ing stem nut POOR BRAKE PERFORMANCE cWorn brake linings dForeign matter on brake linings eRough brake drum contacting area cWorn brake linings dForeign matter on brake linings eRough brake drum contac...

Page 47: ..._____________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFF...

Page 48: ...2 EXHAUST MUFFLER FRAME COVERS 2 1 DINK 50 125 SCHEMATIC DRAWING...

Page 49: ...aged 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 50: ...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 beco...

Page 51: ...ve 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 Disco...

Page 52: ...ve 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 remov...

Page 53: ...of removal UPPER LOWER HANDLEBAR COVER Remove the six screws Remove the two screws then remove the upper handlebar cover Disconnect the throttle cable refer to the CARBURETOR section in the chapter 13...

Page 54: ...2 7 DINK 50 125 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 55: ...emove 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 7 Remove the two screws a...

Page 56: ...everse order of removal FRONT FENDER Remove the six 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 Rem...

Page 57: ...ation is 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 se...

Page 58: ...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 Re...

Page 59: ...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 stop...

Page 60: ...ation is in the reverse order of removal METER PANEL Disconnect the speedometer cable Disconnect the meter connectors Remove the two screws Remove the four screws from the inner cover then remove the...

Page 61: ...oorboard 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 disconnect the...

Page 62: ...nt bolts and muffler and gasket INSTALLATION Replace the gasket with new ones Install the exhaust muffler and three mounting bolt but do not tighten them Install and tighten the two exhaust pipe joint...

Page 63: ...ON ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE 3 2 FUEL LINE FUEL FILTER 3 4 THROTTLE OPERATION 3 4 ENGIN...

Page 64: ...1700 rpm DINK 125 1950 2150 rpm DINK 50 Cylinder compression 15 kgf cm 1500 kPa DINK 125 14 kgf cm 1400 kPa DINK 50 Engine oil capacity At disassembly 1 1 L 0 968 lmp qt 1 166 US qt DINK 125 0 85 L D...

Page 65: ...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 KYMCO dealer should road test your scooter after...

Page 66: ...3 INSPECTION ADJUSTMENT 3 3 DINK50 125 MAINTENANCE SCHEDULE DINK125 Only DINK125 Only...

Page 67: ...nd replace with a new one if it is clogged THROTTLE OPERATION Check the throttle grip for smooth movement Measure the throttle grip free play Free Play 2 6 mm 0 08 0 24 in Major adjustment of the thro...

Page 68: ...endation Use a premium quality 4 stroke motor oil to ensure longer service life of your scooter Use only oils which are rated SG under the API service classification The recommended viscosity is SAE 1...

Page 69: ...pstick 4 If required add the specified oil up to the upper level mark Do not overfill 5 Reinstall the oil filler cap dipstick Check for oil leaks Engine oil replacement Engine oil quality is the chief...

Page 70: ...p dipstick 1 from the right crankcase cover 2 Place a container under the left crankcase 3 Remove the oil drain plug 2 to drain the oil 4 Reinstall the drain plug and tighten the drain plug to specifi...

Page 71: ...creen 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 screen cap torqu...

Page 72: ...1 from 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...

Page 73: ...il 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 th...

Page 74: ...ear 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 transmission case with r...

Page 75: ...n 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 reverse order of rem...

Page 76: ...never 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 mono...

Page 77: ...g cleaner or a wire brush Specified Spark Plug NGK DP7EA9 DINK 125 NGK CR7HSA DINK50 Measure the spark plug gap Spark Plug Gap 0 9 mm 0 036 in DINK125 0 7 mm 0 028 in DINK50 Torque 0 9 kgf m 9 N m 6 5...

Page 78: ...tor 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 camsha...

Page 79: ...the cam sprocket are facing down turn the crankshaft clockwise one full turn and realign the timing marks with the cylinder head surface so it is facing up Insert a thickness gauge between the valve...

Page 80: ...Valve adjuster A120E00036 After tightening the lock nut recheck the valve clearance Install the removed parts in the reverse order of removal CARBURETOR IDLE SPEED Warm up the engine before this oper...

Page 81: ...psi DINK 125 18 kgf cm 1800 kPa DINK 50 If the compression is low check for the following Leaky valves Valve clearance to small Leaking cylinder head gasket Worn pistons Worn piston cylinder If the c...

Page 82: ...in or out as necessary Obey local laws and regulations CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually If the scooter tends to creep or the en...

Page 83: ...ng corrosion protection inhibitors specifically recommended for use in aluminum engines See antifreeze container label Use only low mineral drinking water or distilled water as a part of the antifreez...

Page 84: ...rioration or cracks in the hoses and fittings BRAKE PAD WEAR Brake pad wear depends upon the severity of usage the type of riding and road conditions Generally the pads will wear faster on wet and dir...

Page 85: ...ability 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 Be...

Page 86: ...mpressing 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 eng...

Page 87: ...loss of tension and the side stand assembly for freedom of movement Check the side stand ignition cut off system DINK 125 only 1 Place the scooter on its center stand 2 Put the side stand up and start...

Page 88: ...____________________________________________________ __________________________________________________________________________________ ________________________________________________________________...

Page 89: ...4 LUBRICATION SYSTEM 4 1 DINK 50 125 LUBRICATION SYSTEM DINK 125 Oil Pump Oil Strainer Screen Crankshaft Rocker Arm Shaft Oil Filter Screen...

Page 90: ...4 LUBRICATION SYSTEM 4 2 DINK 50 125 LUBRICATION SYSTEM DINK 50 Oil Pump Oil Filter Screen Crankshaft Rocker Arm Shaft...

Page 91: ...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 clea...

Page 92: ...TARTER 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 s...

Page 93: ...en 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 94: ...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 clearan...

Page 95: ...rvice 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 pun...

Page 96: ...the oil 3 8 Remove the A C generator flywheel 8 3 Remove the A C generator stator and pulsar coil 8 3 Remove the eight right crankcase cover bolts and the right crankcase cover Remove the oil pump ge...

Page 97: ...K 50 125 Bolts Outer Rotor Pump Body Remove O rings and dowel pin DISASSEMBLY Remove the screws and disassemble the oil pump INSPECTION Measure the pump body to outer rotor clearance Service Limit 0 2...

Page 98: ...arance Service Limit 0 12mm ASSEMBLY Install the outer rotor inner rotor and pump shaft into the pump body Install the dowel pin Install the pump cover by aligning the hole in the cover with the dowel...

Page 99: ...rings and dowel pin Install the oil pump and tighten the bolts Make sure that the pump shaft rotates freely without binding Install the oil pump gear and tighten the nut Inspect the O rings and repla...

Page 100: ...4 LUBRICATION SYSTEM 4 12 DINK 50 125 Install the right crankcase cover and tighten the bolts Right Crankcase Cover Bolts...

Page 101: ...___________________________________ __________________________________________________________________________________ _________________________________________________________________________________...

Page 102: ...removed first Be careful not to bend or twist the brake fluid tube SPECIFICATIONS DINK 125 Engine oil capacity at disassembly 1 1 L 0 968 lmp qt 1 166 US qt at change 0 9 L 0 792 lmp qt 0 954 US qt C...

Page 103: ...section in the chapter 13 Loosen the rear axle nut Support the scooter securely on its main stand Remove the three bolts 1 from rear brake hose clamps Remove the two bolts 2 then remove the rear brake...

Page 104: ...TION 5 3 DINK 125 Remove the bolt 6 and engine ground cable Remove the two nuts 7 then remove the intake manifold from cylinder head Remove the bolt 8 then remove the thermostat from cylinder head Rem...

Page 105: ...INSTALLATION 5 4 DINK 50 125 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 low...

Page 106: ...LLATION 5 5 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 engin...

Page 107: ...k 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 lbf...

Page 108: ...5 ENGINE REMOVAL INSTALLATION 5 7 DINK 125 INSPECTION Inspect the engine mount bolt Band Damage Replace Do not attempt to straighten a bent engine mount bolt...

Page 109: ...olt 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 ft...

Page 110: ...er A C generator and starter motor wire connector Remove the spark plug cap Disconnect the secondary air apply hose and crankcase breather hose Disconnect vacuum tube Loosen the air cleaner connecting...

Page 111: ...0 DINK 50 125 Remove the bolts from air cleaner housing Release the wire band auto bystarter A C generator starter motor wire Remove the carburetor Remove rear brake adjusting nut arm pin and spring B...

Page 112: ...r brake cable from the transmission cover Remove the rear shock absorber lower mount bolt Disconnect the inlet hose Remove the right and left engine mounting nuts Take out the right and left engine mo...

Page 113: ...orward to separate it from the engine and be careful not to damage the rear fender ENGINEHANGERBRACKETREMOVAL Remove the engine hanger bracket nuts Remove the engine hanger bracket bolts and engine ha...

Page 114: ...with new ones if necessary ENGINE INSTALLATION Install the engine in the reverse order of removal Torque Values Engine mounting bolt 4 5 5 5kg m Rear shock absorber lower mount bolt 2 4 3 0kg m Perfor...

Page 115: ...__________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD VALVES _____________________...

Page 116: ...6 CYLINDER HEAD VALVES 6 1 DINK 50 125 SCHEMATIC DRAWING DINK 125...

Page 117: ...6 CYLINDER HEAD VALVES 6 2 DINK50 125 SCHEMATIC DRAWING DINK 50...

Page 118: ...parts in order When assembling install them in the reverse order of removal SPECIFICATIONS DINK 125 Unit mm in Item Standard Service Limit IN 0 1 0 004 EX 0 1 0 004 Cylinder head compression pressure...

Page 119: ...rpage IN 25 7611 25 3 Camshaft cam height EX 25 5628 25 2 IN 10 000 10 015 10 10 Valve rocker arm I D EX 10 00 10 015 10 10 IN 9 972 9 987 9 91 Valve rocker arm shaft O D EX 9 972 9 987 9 91 IN 1 0 1...

Page 120: ...ssion test or by tracing engine top end noises Poor performance at idle speed White smoke from exhaust muffler Compression too low Worn valve stem or valve guide Damaged valve stem oil seal Compressio...

Page 121: ...ove 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...

Page 122: ...r cylinder head nuts to the specified torque Torque 2 2 kgf m 22 N m 15 8 lbf ft Adjust valve clearance refer to the VALVE CLEARANCE section in the chapter 3 Camshaft Holder Dowel Pins Diagonally loos...

Page 123: ...spect 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 124: ...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 Valve Rocker Arms 6mm Bolt Rocker Arm Shaf...

Page 125: ...ft 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 tensi...

Page 126: ...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 damage Replace the camshaft assem...

Page 127: ...d 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 ca...

Page 128: ...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 129: ...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 R...

Page 130: ...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 131: ...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 all...

Page 132: ...lve 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 Val...

Page 133: ...s 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 stem...

Page 134: ...the cylinder head cover INSTALLATION Install a new cylinder head cover O ring and gasket Install the cylinder head cover Install and tighten the cylinder head cover bolts and nuts Torque 0 8 1 2kgf m...

Page 135: ...mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke Remove the four camshaft holder nuts and washers Remove the camshaft hold...

Page 136: ...m bolt Remove the valve rocker arms and arm shafts CAMSHAFT HOLDER INSPECTION Inspect the camshaft holder for wear or damage Inspect the rocker arm shaft for blue discoloration or grooves If any defec...

Page 137: ...e then inspect lubrication system Measure each rocker arm shaft O D Measure the I D of each valve rocker arm Measure arm to shaft clearance Replace as a set if out of specification Service limits 0 10...

Page 138: ...cts are found replace the camshaft with a new one then inspect lubrication system INSTALLATION Reverse the CAMSHAFT REMOVAL procedures Note the following points 1 Turn the flywheel so that the T mark...

Page 139: ...ll spring and tensioner cap then tighten the tensioner cap 3 Adjust the valve clearance Refer to the VALVE CLEARANCE section in the chapter 3 Apply engine oil to the threads of the cylinder head nuts...

Page 140: ...n the chapter 12 Remove the exhaust muffler Refer to the EXHAUST MUFFLER REMOVE section in the chapter 13 Remove the two nuts and then remove the carburetor intake manifold and insulator Remove the co...

Page 141: ...in the guide Measure each valve 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 06mm repl...

Page 142: ...uter valve springs Service Limit Inner 28 4mm replace if below Outer 31 5mm replace if below Measure compressed force valve spring and installed length Replace if out of specification Service limits I...

Page 143: ...retainers Compress the valve springs using the valve spring compressor then install the valve cotters Valve Spring Compressor E040 Tap the valve stems gently with a plastic hammer for 2 3 times to fir...

Page 144: ...LINDER HEAD VALVES 6 29 DINK 50 125 INSTALLATION Install the dowel pins and a new cylinder head gasket Reverse the CYLINDER HEAD REMOVAL procedures Torque Cylinder head bolt 0 8 1 2kgf m Dowel Pin Gas...

Page 145: ..._____________________________________________ __________________________________________________________________________________ _______________________________________________________________________...

Page 146: ...7 CYLINDER PISTON 7 1 DINK 50 125 SCHEMATIC DRAWING DINK 125...

Page 147: ...7 CYLINDER PISTON 7 2 DINK50 125 SCHEMATIC DRAWING DINK 50...

Page 148: ...roundness 0 05 0 002 Ring 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 Piston Ring end gap Second 0 15 0 3 0 0...

Page 149: ...2008 0 52032 13 04 0 536 Piston pin O D 14 994 15 0 59976 0 6 14 96 0 5984 Piston to piston pin clearance 0 002 0 014 0 00008 0 00056 0 02 0 0008 Connecting rod small end I D bore 13 016 13 034 0 5206...

Page 150: ...om 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...

Page 151: ...r 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 152: ...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 in Measure the piston pin O...

Page 153: ...cylinder wear Service Limit 52 5 mm 2 1 in Calculate the piston to cylinder clearance Take a maximum reading to determine the clearance Service Limit 0 1 mm 0 004 in Calculate the taper and out of rou...

Page 154: ...ngs 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 en...

Page 155: ...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 156: ...all 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 tighten...

Page 157: ...move the two dowel pins and cylinder head gasket Remove cam chain guide and then remove cylinder Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder surface Dowel Pin...

Page 158: ...pect the piston wall for wear scratches damage If any defects are found replace the piston with a new one Install the piston rings onto the piston and measure the piston ring to groove clearance Servi...

Page 159: ...piston ring end gap Service Limit Top 0 5mm replace if over 2nd 0 65mm replace if over Oil ring 0 9mm replace if over Measure the piston pin hole I D Service Limit 13 04mm replace if over Measure the...

Page 160: ...Y directions Cylinder I D Service Limit 39 1mm replace if over Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if over The true roundness is the difference between the...

Page 161: ...ll end I D Service Limit 13 06mm replace if over Measure the connecting rod to piston pin clearance Service Limit 0 06mm replace if over Be careful not to damage or break the piston and piston rings A...

Page 162: ...er bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Intake Side Guide Exhaust Side Guide IN Mark Be careful not to drop f...

Page 163: ...__________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS KICK STARTER ____________...

Page 164: ...8 DRIVE AND DRIVEN PULLEYS KICK STARTER 8 1 DINK 50 125 SCHEMATIC DRAWING DINK 125...

Page 165: ...8 DRIVE AND DRIVEN PULLEYS KICK STARTER 8 2 DINK 50 125 SCHEMATIC DRAWING DINK 50...

Page 166: ...15852 0 16148 2 0 08 Clutch outer I D 130 130 2 5 2 5 208 130 5 5 22 Driven face spring free length 88 3 3 532 83 2 3 328 Driven face O D 33 965 33 985 1 3586 1 3594 33 94 1 3576 Movable driven face...

Page 167: ...f ft DINK125 5 0 6 0kgf m DINK50 SPECIAL TOOLS Bearing installer A120E00014 DINK 125 Universal holder A120E00017 DINK125 50 Clutch spring compressor A120E00034 DINK125 50 TROUBLESHOOTING Engine starts...

Page 168: ...eight left crankcase cover bolts and then remove the left crankcase cover Remove the gasket and dowel pins INSTALLATION Install the new driveshaft bearing into the left crankcase cover using a specia...

Page 169: ...125 Install the left crankcase cover Install and tighten the eight bolts diagonally to specified torque Torque 1 kgf m 10 N m 7 2 lbf ft Do not pull out the kick starter spindle Press in the kick star...

Page 170: ...m 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 the frict...

Page 171: ...ct 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 gear fo...

Page 172: ...o 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 Starter Driven...

Page 173: ...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 S...

Page 174: ...the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 17 5mm 0 7 in Clutch out inspection Inspect the clutch outer for wear or damage Measure t...

Page 175: ...y 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 A...

Page 176: ...Install the drive pulley face and ratchet Use the special tool to hold drive pulley face then tighten the nut to the specified torque Torque 5 5 kgf m 55 N m 40 lbf ft Special tool Universal holder A...

Page 177: ...RIVEN PULLEYS KICK STARTER 8 14 DINK 50 125 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 178: ...damage Measure outside diameter Service limit 16 mm 0 64 in Movable drive face Slide pieces Drive pulley face Check the slide pieces and movable drive face splines for wear cracks or damage Check the...

Page 179: ...ve 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 Plat...

Page 180: ...8 DRIVE AND DRIVEN PULLEYS KICK STARTER 8 17 DINK 50 125 Install the drive face boss Boss...

Page 181: ...tch 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 182: ...ven 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 Driven...

Page 183: ...e as a set Check 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...

Page 184: ...e 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 185: ...cover bolts left crankcase cover and dowel pins Inspect the left crankcase cover seal rubber for damage or deterioration KICK STARTER SPINDLE REMOVAL Remove the kick lever from the kick starter spind...

Page 186: ...TION Inspect the kick starter spindle and gear for wear or damage Inspect the return spring for weakness or damage Inspect the kick starter spindle bushing for wear or damage Check the kick starter dr...

Page 187: ...nd return spring onto the left crankcase cover Properly install the kick starter driven gear and friction spring as the figure shown If the hooks of the return spring can not be installed properly use...

Page 188: ...ON First install the dowel pins and then the seal gasket Install the left crankcase cover and tighten the ten bolts diagonally Connect the drive belt cooling air tube and install the circlip For drum...

Page 189: ...ENT Remove the ten left crankcase cover bolts and left crankcase cover 9 3 Hold the clutch outer with the universal holder and remove the 10mm clutch outer nut and clutch outer Universal holder E017 H...

Page 190: ...hen install a new drive belt Set the drive belt on the drive pulley Install the drive pulley face starting ratchet and 12mm drive face nut then tighten the drive face nut Torque 3 5 4 0kg m When insta...

Page 191: ...holder and remove the 12mm drive face nut Remove the starting ratchet and drive pulley face MOVABLE DRIVE FACE DISASSEMBLY Remove the movable drive face and drive pulley collar from the crankshaft Re...

Page 192: ...ABLE DRIVE FACE INSPECTION Check each weight roller for wear or damage Measure each roller O D Service Limit 15 4mm replace if below DRIVE PULLEY INSTALLATION Install the drive pulley collar and movab...

Page 193: ...ey Remove the starter gear INSPECTION Inspect the starter pinion seat for wear Inspect the starter pinion for smooth operation Inspect the starter pinion shaft forcing parts for wear and damage INSTAL...

Page 194: ...outer Universal holder E017 Remove the clutch driven pulley Remove the drive belt from the clutch driven pulley CLUTCH DRIVEN PULLEY DIS ASSEMBLY Compress the clutch driven pulley spring with the clut...

Page 195: ...de roller pins from the driven pulley and then remove the O rings and oil seal from the driven pulley CLUTCH DRIVEN PULLEY INSPECTION Inspect the clutch outer for wear or damage Measure the clutch out...

Page 196: ...e spring free length Service Limit 82 6mm replace if below Check the driven face assembly for wear or damage Measure the driven face O D Service Limit 33 94mm replace if below Check the movable driven...

Page 197: ...to the driven face with the mark facing up CLUTCH DRIVEN PULLEY ASSEMBLY First install the movable driven face onto the driven face Then install the guide roller pins O rings and a new oil seal Instal...

Page 198: ...que 5 0 6 0kg m Universal holder E034 CLUTCH DRIVEN PULLEY INSTALLATION Install the drive belt on the clutch driven pulley and then install the clutch driven pulley onto the drive shaft Install the cl...

Page 199: ...______________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION ______________________________...

Page 200: ...9 FINAL REDUCTION 9 1 DINK 125 50 SCHEMATIC DRAWING DINK 125...

Page 201: ...9 FINAL REDUCTION 9 2 DINK 125 50 SCHEMATIC DRAWING DINK 50...

Page 202: ...liter 0 17 lmp qt 0 21 US qt DINK 125 At change 0 18 liter 0 16 lmp qt 0 19 US qt DINK 125 At disassembly 0 12liter DINK 50 At change 0 11liter DINK 50 TORQUE VALUES Transmission case cover bolt 1 4...

Page 203: ...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 204: ...d 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 sei...

Page 205: ...mission 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 Sha...

Page 206: ...s 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 4 kgf m 14 N m 10 lbf ft Fill the transmission case wi...

Page 207: ...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 208: ...se 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 usi...

Page 209: ...nsmission gear oil into a clean container Remove the transmission case cover attaching bolts Remove the transmission case cover Remove the gasket and dowel pins Remove the final gear and countershaft...

Page 210: ...e drive 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 Do not remove the transmission c...

Page 211: ...puller E037 Drive new bearings into the transmission case cover Oil seal bearing install E014 BEARING REPLACEMENT Left Crankcase Cover Remove the drive shaft Remove the drive shaft oil seal Remove th...

Page 212: ...he left crankcase Install a new drive shaft oil seal Oil seal bearing install E014 FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Install the final gear and final shaft into...

Page 213: ...o the left crankcase Install the resin 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 R...

Page 214: ...d Gear Oil SAE90 Oil Capacity at disassembly 0 12 liter at change 0 11 liter Install and tighten the oil check bolt Torque 1 0 1 5kg m Start the engine and check for oil leaks Place the motorcycle on...

Page 215: ...__________________________________________________ __________________________________________________________________________________ A C GENERATOR STARTER CLUTCH _____________________________________...

Page 216: ...10 A C GENERATOR STARTER CLUTCH 10 1 DINK 50 125 SCHEMATIC DRAWING DINK 125...

Page 217: ...10 A C GENERATOR STARTER CLUTCH 10 2 DINK 50 125 SCHEMATIC DRAWING DINK 50 1 A C G...

Page 218: ...10 A C GENERATOR STARTER CLUTCH 10 3 DINK 50 125 SCHEMATIC DRAWING DINK 50 2 R COVER...

Page 219: ...he water jacket Refer to chapter 16 for A C generator inspection SPECIFICATIONS Engine oil SAE 10W 30 DINK125 Only API SG Oil capacity at change 0 9 liter 0 79 lmp qt 0 95 US qt Coolant distilled wate...

Page 220: ...3 Disconnect the alternator stator connectors refer to the chapter 16 Remove the nine bolts from the right crankcase cover and then remove the cover Remove the two dowel pins and gasket Remove the two...

Page 221: ...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 coil...

Page 222: ...10 A C GENERATOR STARTER CLUTCH 10 7 DINK 50 125 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 223: ...section 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...

Page 224: ...ise 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 g...

Page 225: ...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 226: ...ERATOR STARTER CLUTCH 10 11 DINK 50 125 Hold the flywheel with the special tool and tighten the flywheel nut Torque 4 kgf m 10 N m 29 lbf ft Special tool Flywheel holder A120E00021 Flywheel Nut Flywhe...

Page 227: ...right side cover Remove the four bolts attaching the cooling fan cover to remove the fan cover Remove the cooling fan by removing the four cooling fan attaching bolts Hold the flywheel with an univer...

Page 228: ...ver Stator 4 0kg m 0 9kg m 0 5kg m Remove the A C generator wire connector Remove the A C generator wire set plate Remove the pulser coil bolts Remove the A C generator wire rubber sleeve and pulser c...

Page 229: ...and pulser coil bolts Torques Pulser Coil 0 45 0 6kgf m Stator 0 8 1 2kgf m Install the A C generator wire rubber sleeve and A C generator wire set plate Connect the A C generator wire connector Clea...

Page 230: ...woodruff key Hold the flywheel with the universal holder and tighten the flywheel nut Torque 3 5 4 5kgf m Universal Holder Install the cooling fan Torque 0 8 1 2kgf m Install the fan cover Install the...

Page 231: ...____________________________________________________________________ __________________________________________________________________________________ CRANKCASE CRANKSHAFT ___________________________...

Page 232: ...11 CRANKCASE CRANKSHAFT 11 1 DINK50 125 SCHEMATIC DRAWING DINK 125...

Page 233: ...11 CRANKCASE CRANKSHAFT 11 2 DINK 50 125 SCHEMATIC DRAWING DINK 50...

Page 234: ...linder 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 15 Starter motor chapter 18 Oil pump ch...

Page 235: ...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 crankshaf...

Page 236: ...move 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 1...

Page 237: ...he 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 238: ...e 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 Crankcas...

Page 239: ...CRANKSHAFT 11 8 DINK 50 125 Install the cam chain Install the cam chain tensioner slipper Install and tighten the cam chain tensioner slipper bolt Torque 1 kgf m 10 N m 7 2 lbf ft Cam Chain Tensioner...

Page 240: ...ut the bolts from center stand Remove spring and center stand from crankcase Remove the crankcase attaching bolt Separate the left and right crankcase halves Nuts Bolts Spring Bolt Center Stand Do not...

Page 241: ...crankshaft from the left crankcase Remove the cam chain Remove the gasket and dowel pins Clean off all gasket material from the crankcase mating surfaces Dowel Pins Gasket Radial Axial Avoid damaging...

Page 242: ...ft Measure the crankshaft run out B Service Limit 0 10mm replace if over Measure the connecting rod big end side clearance C Service Limit 0 05mm replace if over Measure the crank width D Out of speci...

Page 243: ...dowel pins and a new gasket onto the left crankcase Install the crankshaft into the left crankcase Install the right crankcase Tighten the crankcase attaching bolt Torque 0 8 1 2kgf m Bolt Place the r...

Page 244: ..._________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM DINK 125 ONLY ______________________...

Page 245: ...12 COOLING SYSTEM 12 1 DINK50 125 SCHEMATIC DRAWING...

Page 246: ...ater 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 ha...

Page 247: ...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 1...

Page 248: ...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 Tester...

Page 249: ...enance 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 COVER...

Page 250: ...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 sur...

Page 251: ...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 l...

Page 252: ...iphon 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 connecto...

Page 253: ...12 9 DINK50 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 sectio...

Page 254: ...diator 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 INSTALLATION...

Page 255: ...switch 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 O ring Ti...

Page 256: ...igns 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 R...

Page 257: ...l 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 i...

Page 258: ...ter 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 t...

Page 259: ...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 Mechanic...

Page 260: ...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 t...

Page 261: ...ump 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 Do...

Page 262: ...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 ohmmeter...

Page 263: ...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 perfor...

Page 264: ...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 c...

Page 265: ...12 COOLING SYSTEM 12 21 DINK50 125 DISASSEMBLY Remove the two bolts and separate the thermostat housing halves Remove the thermostat from the thermostat housing Thermostat Bolts Thermostat...

Page 266: ...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 thermos...

Page 267: ...______________________________________________ __________________________________________________________________________________ FUEL SYSTEM CARBURETOR FUEL PUMP FUEL TANK ___________________________...

Page 268: ...13 FUEL SYSTEM CARBURETOR FUELPUMP FUEL TANK 13 1 DINK 50 125 FUEL SYSTEM DINK 125...

Page 269: ...13 FUEL SYSTEM CARBURETOR FUELPUMP FUEL TANK 13 2 DINK 50 125 SCHEMATIC DRAWING DINK 125...

Page 270: ...13 FUEL SYSTEM CARBURETOR FUELPUMP FUEL TANK 13 3 DINK 50 125 SCHEMATIC DRAWING DINK 50...

Page 271: ...with compressed air When the machine is not used for over one month drain the residual gasoline from the float chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel SPECIFICAT...

Page 272: ...gative 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 suction valve and outlet valve FUEL PUM...

Page 273: ...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 bystarter va...

Page 274: ...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 275: ...K 50 125 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 section i...

Page 276: ...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 loosen o...

Page 277: ...URETOR FUELPUMP FUEL TANK 13 10 DINK 50 125 Remove the spring and piston valve Remove the spring retainer jet needle Remove the four screws and float chamber Spring Piston Valve Spring Retainer Jet Ne...

Page 278: ...lder and needle jet Remove the pilot screw spring washer and O ring Pilot Screw Spring Washer O ring Float Valve Float Pin Float Slow Jet Main Jet Needle Jet Holder Needle Jet Before pilot screw remov...

Page 279: ...e 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 O ring Auto Choke...

Page 280: ...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 and...

Page 281: ...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 Check...

Page 282: ...he 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 pilot...

Page 283: ...ck 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 arm...

Page 284: ...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 taking co...

Page 285: ...EMOVAL 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 the a...

Page 286: ...riching 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 mouth If...

Page 287: ...13 FUEL SYSTEM CARBURETOR FUELPUMP FUEL TANK 13 20 DINK 50 125 Install the cap Cap...

Page 288: ...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 screw...

Page 289: ...t 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 outlet tu...

Page 290: ...LPUMP FUEL TANK 13 23 DINK 50 125 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 for dam...

Page 291: ...er 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 enter...

Page 292: ...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 clogg...

Page 293: ...ION 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 nuts 5...

Page 294: ...5 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 Remove t...

Page 295: ...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 breather h...

Page 296: ...AL Remove the met in box Disconnect the auto by starter connector Disconnect the fuel tube from carburetor Loosen the throttle cable adjusting nut and lock nut and disconnect the throttle cable from t...

Page 297: ...ing tube band screw and carburetor intake manifold band screw and then remove the carburetor VACUUM CHAMBER DISASSEMBLY Loosen the drain screw and drain the fuel from the float chamber Remove the two...

Page 298: ...he piston VACUUM PISTON INSPECTION Inspect the vacuum piston and jet needle for wear or damage Inspect the diaphragm for deterioration and tears FLOAT CHAMBER DISASSEMBLY Remove the three float chambe...

Page 299: ...VALVE INSPECTION Inspect the float valve seat contact area for wear JETS SCREWS REMOVAL Before removing the pilot screw turn the pilot screw clockwise until it seats lightly and record the rotating t...

Page 300: ...e slow jet Clean the removed the main jet needle jet holder needle jet and slow jet with detergent oil Check the pilot screw spring washer and O ring for bend wear or damage Be sure to use clean deter...

Page 301: ...auto by starter green black wire to the positive terminal of a battery and black white wire to the negative terminal Wait 5 minutes and blow the hose with mouth If the passage is blocked the auto by s...

Page 302: ...ace the auto bystarter with a new one AIR CUT OFF VALVE A C V REMOVAL Remove the two screws and then remove throttle cable holder Remove the two screws and the air cut off valve cover Remove the sprin...

Page 303: ...cut off valve body securely Install the diaphragm spring and cover Install and tighten the two screws attaching the air cut off valve cover Install the throttle cable holder and tighten the two screw...

Page 304: ...ks damage or deterioration Replace if necessary Assemble the accelerating pump in the reverse order of disassembly AUTOBYSTARTERINSTALLATION Install the auto bystarter and set plate Install and tighte...

Page 305: ...nstall the needle jet needle jet holder and main jet Install the slow jet Install the pilot screw Install the float valve float and float pin Install and tighten the screw Be sure to record the rotati...

Page 306: ...float chamber Datum plane VACUUM CHAMBER ASSEMBLY First install the jet needle and spring into the vacuum chamber and then install the needle holder Install the vacuum piston into the carburetor body...

Page 307: ...ke manifold and tighten the band screw Install the air cleaner connecting tube and tighten the band screw Connect the throttle cable to the carburetor Connect the fuel tube and vacuum tube to the carb...

Page 308: ...UEL TANK 13 41 DINK 50 125 Connect the auto bystarter connector Perform the following inspections and adjustments Throttle grip free play 3 16 Idle speed 3 10 Idle Speed 1800 100rpm Install the met in...

Page 309: ...nd the fuel pump FUEL PUMP INSTALLATION Install 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 Me...

Page 310: ...The installation sequence is the reverse of removal FUEL STRAINER REMOVAL Remove the fuel strainer from the fuel tank Inspection Inspect if the fuel strainer is clogged and clean it with compressed ai...

Page 311: ...________________________________________________________ __________________________________________________________________________________ HANDLEBAR FRONTWHEEL FRONTBRAKE FRONTSHOCKABSORBER STEERINGS...

Page 312: ...14 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 14 1 DINK 50 125 SCHEMATIC DRAWING...

Page 313: ...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 nu...

Page 314: ...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 315: ...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 cylind...

Page 316: ...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 317: ...BER STEERING STEM 14 6 DINK 50 125 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 t...

Page 318: ...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 screw...

Page 319: ...ve 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 total...

Page 320: ...meter 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 th...

Page 321: ...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 they...

Page 322: ...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 323: ...een 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 reduces...

Page 324: ...TEM 14 13 DINK 50 125 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 325: ...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 fl...

Page 326: ...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 327: ...BER STEERING STEM 14 16 DINK 50 125 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 replace...

Page 328: ...erly 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 329: ...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 330: ...r 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 brake...

Page 331: ...witch 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 h...

Page 332: ...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 333: ...rake 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 c...

Page 334: ...NK 50 125 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 335: ...draulic 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 B...

Page 336: ...ut 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 rep...

Page 337: ...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 338: ...NG STEM 14 27 DINK 50 125 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 we...

Page 339: ...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 absor...

Page 340: ...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 341: ...e 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 bottom...

Page 342: ...9 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 ti...

Page 343: ...________________________________________________________________________________ REARBRAKE REARFORK REARWHEEL REARSHOCKABSORBER ________________________________________________________________________...

Page 344: ...15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 1 DINK 50 125 SCHEMATIC DRAWING DINK 125...

Page 345: ...15 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 15 2 DINK50 125 SCHEMATIC DRAWING DINK 50...

Page 346: ...012 Dink 50 Unit mm in Item Standard Service Limit Rear wheel rim runout 2 0 08 Rear brake drum I D 110 4 4 111 4 44 Rear brake lining thickness 4 0 0 16 2 0 0 08 Rear shock absorber spring free leng...

Page 347: ...ring installer A120E00014 TROUBLESHOOTING Rear wheel wobbling Poor brake performance Bent rim Air in brake system Faulty tire Deteriorated brake fluid Axle not tightened properly Contaminated brake pa...

Page 348: ...n 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 reduces s...

Page 349: ...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 hos...

Page 350: ...ent 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 when...

Page 351: ...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 ste...

Page 352: ...ORBER 15 9 DINK 50 125 REAR BRAKE PAD DINK 125 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...

Page 353: ...all 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 calip...

Page 354: ...KE 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 the...

Page 355: ...bar 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 piv...

Page 356: ...nd 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 wi...

Page 357: ...ilicone 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 2...

Page 358: ...id 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 Dur...

Page 359: ...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 mm...

Page 360: ...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 s...

Page 361: ...ston 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 n...

Page 362: ...ll 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 363: ...15 20 DINK50 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 me...

Page 364: ...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 t...

Page 365: ...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 FORK...

Page 366: ...n 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 the...

Page 367: ...ial 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 to...

Page 368: ...f 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 th...

Page 369: ...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 absorber...

Page 370: ...ear axle nut to remove the rear wheel INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over INSTALLATION Install the rear wheel and apply...

Page 371: ...brake drum I D Service Limit 95 5mm replace if over BRAKE LINING INSPECTION Measure the brake lining thickness Service Limit 2 0mm replace if below REAR BRAKE DISASSEMBLY Remove the rear brake adjust...

Page 372: ...ply engine oil to the felt seal and install it to the brake cam Install the wear indicator plate Install the brake arm onto the brake cam Install and tighten the brake arm bolt Install the brake arm r...

Page 373: ...OVAL Remove the rear body cover Remove the air cleaner case Remove the rear shock absorber upper and lower mount bolts to remove the rear shock absorber INSTALLATION Install the rear shock absorber In...

Page 374: ..._________________ __________________________________________________________________________________ BATTERY CHARGING SYSTEM ___________________________________________________________________________...

Page 375: ...16 BATTERY CHARGING SYSTEM 16 1 DINK50 125 CHARGING SYSTEM LAYOUT DINK 125 CHARGING CIRCUIT DINK125...

Page 376: ...16 BATTERY CHARGING SYSTEM 16 2 DINK 50 125 CHARGING SYSTEM LAYOUT DINK 50 CHARGING CIRCUIT DINK 50 Regulator Rectifier Resistor A C Generator Battery...

Page 377: ...th electrolyte will generate voltage within a certain time and it should be recharged when the capacity is insufficient Recharging a new battery will prolong its service life Inspect the charging syst...

Page 378: ...apacity 33W 5000rpm A C Generator Charging coil resistance 20 Yellow Yellow 0 4 0 6 Regulator Rectifier Limit voltage 14 5 0 5V Item DINK 50 Standard Capacity 12V4AH Voltage Fully charged 13 1V Batter...

Page 379: ...ery 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 sh...

Page 380: ...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 381: ...charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal Charging current time Standard 0 8 A 5 10 hours Quick 4 A 1 hours Quick char...

Page 382: ...eck 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 383: ...rt 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 wh...

Page 384: ...ternator 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 gr...

Page 385: ...n 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 White wire terminal and g...

Page 386: ...ector Check for continuity between each Yellow wire terminal regulator rectifier side and ground There should be no continuity REMOVAL INSTALLATION Remove the side body cover refer to the FRAME COVERS...

Page 387: ...ces between the terminals Replace the regulator rectifier if the readings are not within the specifications in the table below Probe Probe A R B W C Y D G A R 3 4M B W 6 8M C Y 14 15M D G 14 15M Due t...

Page 388: ...__________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________...

Page 389: ...17 IGNITION SYSTEM 17 1 DINK 50 125 IGNITION SYSTEM LAYOUT DINK 125 IGNITION CIRCUIT DINK 125...

Page 390: ...17 IGNITION SYSTEM 17 2 DINK 50 125 IGNITION SYSTEM LAYOUT DINK 50 Ignition Coil A C Generator Exciter Coil Pulser Coil C D I Unit...

Page 391: ...tch according to the continuity table specified in page 20 3 Inspect the spark plug referring to chapter 3 Remove the A C generator and pulser coil referring to chapter 10 SPECIFICATIONS DINK 125 Item...

Page 392: ...sconnect 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 Turn the ignition switch to O...

Page 393: ...ter 2 Disconnect the ignition pulse generator connector 1 Measure the ignition pulse generator resistance between the Green White wire and Blue Yellow wire Standard 106 20 C 68 F IGNITION COIL REMOVAL...

Page 394: ...LLATION Remove the luggage box refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the CDI connectors 1 and remove the CDI 2 RESISTANCE INSPECTION Measure the resistance...

Page 395: ...NK 125 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...

Page 396: ...tors and remove the CDI RESISTANCE INSPECTION Measure the resistance between the terminals Connector Green Black Yellow Black Blue Yellow CDI Unit Due to the semiconductor in circuit it is necessary t...

Page 397: ...______________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM ______________________...

Page 398: ...18 STARTING SYSTEM 18 1 DINK50 125 STARTING SYSTEM LAYOUT DINK 125 STARTING CIRCUIT DINK 125 Starter motor...

Page 399: ...18 STARTING SYSTEM 18 2 DINK 50 125 STARTING SYSTEM LAYOUT DINK 50 STARTING CIRCUIT DINK 50 Battery Starter Motor Starter Relay...

Page 400: ...rvice Limit mm Starter motor brush length 12 5mm 8 5mm 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 bat...

Page 401: ...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 402: ...ne 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 403: ...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 404: ...ARTING SYSTEM 18 7 DINK50 125 STARTER RELAY INSPECTION Remove the met in box Remove the body cover Disconnect the starter relay coupler and then remove the starter relay Starter Relay Starter Relay DI...

Page 405: ...necessary Apply grease to the O ring and install the starter motor Tighten the two mounting bolts Torque 0 8 1 2kgf m INSTALLATION Coat a new O ring with engine oil and install it into the start moto...

Page 406: ...18 STARTING SYSTEM 18 9 DINK50 125 Battery Starter Motor Battery Terminal STARTER MOTOR INSPECTION Connect a battery across the starter motor and check for its operation...

Page 407: ...________________________________________________________________________________ __________________________________________________________________________________ LIGHTS METERS SWITCHES _____________...

Page 408: ...an 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 requ...

Page 409: ...ULB REPLACE MENT 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 410: ...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 he...

Page 411: ...ews 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 LIGHT...

Page 412: ...eplace 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 reve...

Page 413: ...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 c...

Page 414: ...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 Continuity should exis...

Page 415: ...dlebar 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 H...

Page 416: ...EMOVAL 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 no...

Page 417: ...MOVAL 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 Turn...

Page 418: ...ee 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 419: ...0 125 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 retainer...

Page 420: ...continuity 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...

Page 421: ...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 422: ...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 i...

Page 423: ...20 WIRING DIAGRAMS DINK 50 125 20 DINK 125 20...

Page 424: ...20 WIRING DIAGRAMS DINK 50 125 DINK 50...

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