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KYMCO G-Dink 125i, Manual

The KYMCO G-Dink 125i is a sleek and powerful scooter with a user-friendly design. Easily navigate city streets with its 125cc engine and large wheels. Don't forget to download your free manual from manualshive.com to ensure you get the most out of your ride.

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11. Electrical Systems                                                                                                      G-Dink 125i

4

TROUBLESHOOTING

Starter motor will not turn

• Fuse burned out
• Weak battery
• Faulty ignition switch
• Faulty starter clutch or gear
• Faulty front or rear stop switch
• Faulty starter relay
• Poorly connected, broken or shorted wire
• Faulty starter motor

Lack of power

• Weak battery
• Loosed wire or connection
• Foreign matter stuck in starter motor

Starter motor rotates but engine does not start

• Faulty starter pinion
• Starter motor rotates in reverse
• Weak battery

LIGHTS, SWITCHES, AND FUEL PUMP

GENERAL INSTRUCTIONS

• Note the following when replacing the halogen headlight bulb

1. Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight
bulb, as

they may create hot spots on the bulb and cause it to fail.

2. If you touch the bulb with your bare hands, clean it with a cloth moistened with

alcohol to prevent its early failure.

3. Be sure to install the dust cover after replacing the bulb.

• Check the battery condition before performing any inspection that
  requires proper battery voltage.

• A continuity test can be made with the switches installed

on the scooter.

• Route the wires and cables properly after servicing each component.

Summary of Contents for G-Dink 125i

Page 1: ...rvicing of the external components for the KYMCO G Dink 125i Exhaust System 2 12 Seat 13 15 Luggage Box 16 18 Body Cover 19 31 Front Cover 32 43 Front Lower Cover 44 48 Inner Cover 49 56 Front Fender...

Page 2: ...nesses according to the Cable Harness Routing Troubleshooting Noisy exhaust muffler Damaged exhaust muffler Exhaust muffler joint air leaks Lack of power Caved exhaust muffler Clogged exhaust muffler...

Page 3: ...ernal components Exhaust System G Dink 125i 3 Remove the two exhaust pipe joint nuts with a 12 mm deep well socket Unplug the O2 sensor connector Remove the three muffler mounting bolts with a 14 mm s...

Page 4: ...1 External components Exhaust System G Dink 125i 4 Remove the exhaust system Remove the exhaust pipe gasket and discard it...

Page 5: ...he O2 sensor with a 17 mm wrench Use care not to pinch the wires The O2 sensor issues signal to ECU when the temperature is over 350 C while the engine is running Test the O2 sensor at room temperatur...

Page 6: ...Measure the resistance between the white wire terminals of the O2 sensor connector Replace the O2 sensor if the reading is out of specification ITEM SPECIFICATIONS O2 heater sensor resistance at 20 C...

Page 7: ...1 External components Exhaust System G Dink 125i 7 Remove the four muffler heat shield bolts with a 2 screwdriver if needed Remove the heat shield...

Page 8: ...ust pipe remove the two bolts with an 8 mm socket To remove the four bolts to free the heat shield on the muffler Remove the two bolts to remove the heat shield on the head pipe Loosen the clamp to se...

Page 9: ...lds Install the heat shields and tighten the bolts securely O2 Sensor Apply anti seize compound to the threads of the O2 sensor Install the O 2 sensor and tighten it to specification with a 17 mm wren...

Page 10: ...1 External components Exhaust System G Dink 125i 10 Exhaust System Insert a new exhaust pipe gasket into the exhaust port Fit the exhaust system into place...

Page 11: ...deep well socket Do not tighten Install the three muffler mounting bolts and tighten to specification with a socket Item Torque N m kgf m Muffler Mounting Bolts 20 2 Tighten the two exhaust pipe joint...

Page 12: ...k 125i 12 If the exhaust pipe and muffler were separated tighten the muffler clamp securely Plug in the O2 sensor Install the luggage box See the Luggage Box topic for more information Install the sea...

Page 13: ...onents Seat G Dink 125i 13 Seat SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Insert the key and turn it counterclockwise Remove the two luggage box hinge nuts with...

Page 14: ...seat hinge nuts with a 10 mm socket Remove the seat with the piston pivot Seat Latch Cable The seat latch cable runs from the ignition switch to the seat latches The cable must be adjusted periodical...

Page 15: ...Install the seat with the piston pivot onto the hinge Install the two seat hinge nuts and tighten securely with a 10 mm socket Install the two luggage box hinge nuts and tighten securely with a 10 mm...

Page 16: ...uggage Box G Dink 125i 16 Luggage Box SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Remove the seat See the Seat topic for more information Remove the two luggage nu...

Page 17: ...Remove the PDA panel located at the rear of the luggage box and free the PDA plug Lift up the luggage box to unplug the luggage box light connector Remove the luggage box Installation Plug in the lugg...

Page 18: ...e Box G Dink 125i 18 Mount the PDA plug and install the panel located at the rear of the luggage box Install the two luggage nuts and tighten securely with a 10 mm socket Install the seat See the Seat...

Page 19: ...ear are recommended at this point Removal Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Remove the rear carrier See the...

Page 20: ...1 External Components Body Cover G Dink 125i 20 Remove the rear center cover Remove the upper body cover bolt with a 10 mm socket...

Page 21: ...1 External Components Body Cover G Dink 125i 21 Remove the two lower body cover nuts with a 10 mm socket Unplug the taillight connector...

Page 22: ...nal Components Body Cover G Dink 125i 22 Remove the two screws from the front of the body cover Remove the two bolts on both sides of the body cover Carefully unhook the tabs on both sides of the body...

Page 23: ...1 External Components Body Cover G Dink 125i 23 Remove the body cover Disassembly Taillight Assembly...

Page 24: ...1 External Components Body Cover G Dink 125i 24 Remove the six taillight assembly screws with a 2 Phillips Unhook the taillight section and separate from the body cover...

Page 25: ...1 External Components Body Cover G Dink 125i 25 Remove the two mud flap screws with a 2 Phillips Separate the mud flap from the taillight assembly...

Page 26: ...1 External Components Body Cover G Dink 125i 26 License Light Remove the two license light assembly screws with a screwdriver Remove the license light assembly...

Page 27: ...1 External Components Body Cover G Dink 125i 27 Mud Flap Installation Fit the body cover into place...

Page 28: ...Dink 125i 28 Install the two screws on both sides of the body cover Carefully push the hooks into the corresponding tabs on both sides of the body cover Install the two screws into body cover and tigh...

Page 29: ...1 External Components Body Cover G Dink 125i 29 Plug in the taillight connector Install the two lower body cover nuts and tighten securely with a 10 mm socket...

Page 30: ...1 External Components Body Cover G Dink 125i 30 Install the upper body cover bolts and tighten securely with a 10 mm socket Carefully install the rear center cover...

Page 31: ...rear center cover screws and tighten securely with a 2 Phillips Install the rear carrier See the RearCarrier topic for more information Install the luggage box See the LuggageBox topic for more infor...

Page 32: ...125i 32 Front Cover SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Remove the windshield See the Windshield topic for more information Open the hidden bolt cover Rem...

Page 33: ...1 ExternalComponents Front Cover G Dink 125i 33 Remove the four windshield bolts with a 6mm Allen There are two bolts on each side Remove the windshield...

Page 34: ...e two screws on each side Remove the push pin Depress the head of the fastener center piece Pull out the fastener Free the two posts from the grommets Carefully pull out off the small black cover Remo...

Page 35: ...nalComponents Front Cover G Dink 125i 35 Remove the two front cover mounting nuts with a 10 mm socket Carefully pull out off the front cover with a screwdriver Gently pull the cover forward and free t...

Page 36: ...Dink 125i 36 Unplug the headlight and turn signal leads Remove the front cover Disassembly Lower Fairing Remove the four lower fairing push pins on each side Remove the six upper fairing push pins on...

Page 37: ...1 ExternalComponents Front Cover G Dink 125i 37 Light Assembly Remove the eight light assembly mounting screws with a 2 Phillips Remove the light assembly from the front cover...

Page 38: ...1 ExternalComponents Front Cover G Dink 125i 38 Side Piece Remove the eighteen side piece screws with a 2 Phillips Remove the side piece...

Page 39: ...1 ExternalComponents Front Cover G Dink 125i 39 Assembly Side Piece Install the side piece on the front cover Install the eighteen side piece screws and tighten securely with a 2 Phillips...

Page 40: ...1 ExternalComponents Front Cover G Dink 125i 40 Light Assembly Install the light assembly on the front cover Install the eight light assembly mounting screws and tighten securely with a 2 Phillips...

Page 41: ...over G Dink 125i 41 Lower Fairing Install the lower fairing Install the four lower fairing push pins on each side Install the six upper fairing push pins on the upper side Installation Plug in the hea...

Page 42: ...rnalComponents Front Cover G Dink 125i 42 Align front cover tabs Install the front cover Install the four front cover mounting screws and tighten securely with a 2 Phillips There are two screws on eac...

Page 43: ...e two front cover mounting nuts and tighten securely with a 10 mm socket Align the two posts with the grommets Carefully push on the small black cover Install the small black cover push pin Install th...

Page 44: ...Dink 125i 44 Front Lower Cover SAFETY FIRST Protective gloves and eyewear are recommended at this point The process for removing and installing the front lower covers are the same for both sides Remo...

Page 45: ...the front skirt rubber covers Remove the two upper screws under the lower rubber cover with a 2 Phillips on each side Remove the screw under the rubber cover with a 2 Phillips Remove the push pin Depr...

Page 46: ...mounting on the front lower cover with a 2 Phillips on each side Gently separate the front lower cover from the front cover Remove the front lower cover Installation Install the front lower cover Car...

Page 47: ...screws under the rubber cover with a 2 Phillips Tighten them securely Install the screw under the rubber cover with a 2 Phillips Install the lower screws mounting on the body frame with a 2 Phillips o...

Page 48: ...1 External Components Front Lower Cover G Dink 125i 48 Install the screw...

Page 49: ...nter cover See the Front Center Cover topic for more information Remove the handlebar covers See the Handlebar Covers topic for more information Remove the center cover See the Center Cover topic for...

Page 50: ...Inner Cover G Dink 125i 50 Remove the fuel cap with the key Remove the two push pins below the handlebar Depress the head of the fastener center piece Pull out the fastener There are six mounting bol...

Page 51: ...1 External Components Inner Cover G Dink 125i 51 Remove the six mounting bolts on both sides with a 10 mm socket Lift off the inner cover Remove the mounting bolt on the water reserve box...

Page 52: ...1 External Components Inner Cover G Dink 125i 52 Remove the two mounting bolts on the body frame Remove the gas cap overflow pad Remove the connector output voltage device...

Page 53: ...1 External Components Inner Cover G Dink 125i 53 Remove the inner cover Inspect the gas panel...

Page 54: ...s Inner Cover G Dink 125i 54 Installation Install the inner cover and align the bolt holes Install the gas cap overflow pad Install the two front mounting bolts on both sides and tighten them securely...

Page 55: ...r Cover G Dink 125i 55 Install the bolt attaching to the water reserve box and tighten securely with a 10 socket Install the floorboard Install the six mounting bolts and tighten them securely on both...

Page 56: ...overs See the FrontLower Cover topic for more information Install the right and left foot skirts See the Foot Skirt topic for more information Install the center cover See the Center Cover topic for m...

Page 57: ...G Dink 125i 57 Front Fender SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal The front fender is held in place with four bolts two on each side Remove the left forward...

Page 58: ...l Components Front Fender G Dink 125i 58 Remove the left rear fender bolt with a 10 mm socket Remove the right forward front fender bolt with a 6 mm Allen Remove the right rear fender bolt with a 10 m...

Page 59: ...1 External Components Front Fender G Dink 125i 59 Remove the front fender from the forks Installation Guide the fender between the forks...

Page 60: ...xternal Components Front Fender G Dink 125i 60 Install the left forward front fender bolt and tighten securely with a 6 mm Allen Install the left rear fender bolt and tighten securely with a 10 mm soc...

Page 61: ...ternal Components Front Fender G Dink 125i 61 Install the right forward front fender bolt and tighten securely with a 6 mm Allen Install the right rear fender bolt and tighten securely with a 10 mm so...

Page 62: ...1 ExternalComponents Rear Carrier G Dink 125i 62 Rear Carrier Removal SAFETY FIRST Protective gloves and eyewear are recommended at this point...

Page 63: ...1 ExternalComponents Rear Carrier G Dink 125i 63 Remove the four carrier bolts with a 6 mm Allen Remove the carrier Installation...

Page 64: ...1 ExternalComponents Rear Carrier G Dink 125i 64 Install the carrier Install the two upper carrier bolts with a 6 mm Allen Install the two carrier bolts on each side with a 6 mm Allen...

Page 65: ...External Components Rear Fender G Dink 125i 65 Rear Fender SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Remove the airbox See the Airbox topic for more information...

Page 66: ...66 Remove the two fender mounting bolts with a 8 mm socket on the right side Remove the airbox Remove the left fender mounting bolts with a 10 mm socket on the back side Remove the left fender mounti...

Page 67: ...1 External Components Rear Fender G Dink 125i 67 Remove the rear fender Installation Install the rear fender...

Page 68: ...bolts with a 10 mm socket on the back side Install the left fender mounting bolts with a 8 mm socket on the front side Install the two right fender mounting bolts and tighten securely with a 8 mm sock...

Page 69: ...Protective gloves and eyewear are recommended at this point Side stand Removal Remove the luggage box See the LuggageBox topic for more information Remove the foot skirt See the FootSkirt topic for mo...

Page 70: ...1 ExternalComponents Stands G Dink 125i 70 Remove the side stand spring with a spring puller Remove the side stand bolt switch and side stand Installation...

Page 71: ...xternalComponents Stands G Dink 125i 71 Install the side stand switch and bolt Make sure to fit the switch into place correctly Tighten the bot securely Install the side stand spring with a spring pul...

Page 72: ...in the side stand switch connector Install the foot skirt See the Foot Skirt topic for more information Install the luggage box See the Luggage Box topic for more information Center Stand Removal Remo...

Page 73: ...1 ExternalComponents Stands G Dink 125i 73 Remove the two center stand nuts and bolts Remove the center stand Installation Install the nuts and bolts Tighten them securely...

Page 74: ...1 ExternalComponents Stands G Dink 125i 74 Install the center stand spring with a spring puller...

Page 75: ...ternalComponents Handlebar Cover G Dink 125i 75 Handlebar Covers SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Upper Cover Remove the four cover screws with a 2 Phil...

Page 76: ...Carefully free the tabs and remove the upper handlebar cover Lower Cover Remove the luggage box See the Luggage Box topic for more information Remove the throttle cables from the throttle body See th...

Page 77: ...1 ExternalComponents Handlebar Cover G Dink 125i 77 Route the throttle cables out of the handlebar cover...

Page 78: ...1 ExternalComponents Handlebar Cover G Dink 125i 78 Remove the lower cover Installation...

Page 79: ...1 ExternalComponents Handlebar Cover G Dink 125i 79 Place the lower cover onto the handlebar...

Page 80: ...1 ExternalComponents Handlebar Cover G Dink 125i 80 Route the throttle cables into the handlebar cover See the Throttle Cable topic for more information...

Page 81: ...Under Cover SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Remove the right and left foot skirts See the Foot Skirt topic for more information Remove the two under c...

Page 82: ...1 External Components Under Cover G Dink 125i 82 Remove the two under cover bolts on the left side with a 10 mm socket Remove the under cover...

Page 83: ...1 External Components Under Cover G Dink 125i 83 Installation Install the under cover...

Page 84: ...e two under cover bolts on the left side and tighten securely with a 10 mm socket Install the two under cover bolts on the right side and tighten securely with a 10 mm socket Install the right and lef...

Page 85: ...100 102 GENERAL INSTRUCTIONS Lubrication System The maintenance of lubrication system can be performed with the engine installed in the frame Use care when removing and installing the oil pump not to...

Page 86: ...ne oil passages Clean and unclog the oil passages before assembling the cylinder head After disassembly clean the removed parts and dry them with compressed air before inspection After removal mark an...

Page 87: ...d with the engine installed in the frame After disassembly clean the removed parts and dry them with compressed air before inspection If replacing the piston or cylinder they must be changed as a pair...

Page 88: ...move the following components Seat Luggage Box Center Cover Rear Carrier Body Cover Front Cover Front Lower Cover Foot Skirt Drain engine oil and remove the oil filter See the Engine Oil topic for mor...

Page 89: ...free the coolant hose from the water pump Allow any remaining coolant to drain into a suitable container Loosen the right crankcase coolant hose clamp with a 2 Phillips screwdriver Slide up the clamp...

Page 90: ...2 Engine Generator G Dink 125i 6 Remove the 9 generator cover bolts with an 8 mm socket Note the upper most bolt holds a wire stay Utilize the pry points and remove the generator cover...

Page 91: ...2 Engine Generator G Dink 125i 7 Remove the generator cover gasket Remove the two dowel pins...

Page 92: ...Coil Crank Position Sensor Free the rubber wire grommet from the right crankcase cover Remove the three stator mounting bolts and the two crank position sensor bolts with an 8 mm socket Remove the sta...

Page 93: ...2 Engine Generator G Dink 125i 9 To remove the fly wheel two special tools are needed ITEM TOOL NO UNIVERSAL HOLDER A120E00021 ITEM TOOL NO FLYWHEEL PULLER A120E00003...

Page 94: ...2 Engine Generator G Dink 125i 10 Hold the flywheel with the universal holder and loosen the nut with a 19 mm socket Remove the flywheel nut and washer...

Page 95: ...the threads of the flywheel puller tool before using it Thread the puller onto the flywheel Hold the tool with a large wrench and turn in the bolt until the pressure separates the flywheel from the c...

Page 96: ...2 Engine Generator G Dink 125i 12 Slide the starter driven gear off of the crankshaft Remove the woodruff key from the crankshaft Starter Clutch...

Page 97: ...er idle gear and shaft for wear and damage Replace the idle gear and shaft as needed Inspect the starter driven gear for wear and damage Measure the inside and outside diameter of the starter driven g...

Page 98: ...llows turning both ways or will not let the driven gear rotate smoothly in one direction the starter clutch must be replaced Remove the three starter clutch mounting bolts with a 6 mm Allen socket Ins...

Page 99: ...ing bolts to specification with a 6 mm Allen socket Torque Item Qty Thread size mm kgf m lb ft Oneway clutch bolt 3 8 1 8 2 2 13 02 15 91 Lubricate the starter idle gear shaft with fresh engine oil In...

Page 100: ...shaft Lubricate the inside of the starter driven gear with fresh engine oil Slide the starter driven gear onto the flywheel as shown Clean off the tapered end of the crankshaft where the flywheel will...

Page 101: ...Dink 125i 17 Line up the groove in the flywheel with the key and fit the flywheel onto the crankshaft Guide the starter driven gear into the starter clutch on the back of the flywheel Install the was...

Page 102: ...heel with the universal holder and torque the flywheel nut to specification with a 19 mm socket Torque Item Qty Thread size mm kgf m lb ft ACG flywheel nut 1 14 5 0 6 0 36 0 43 2 ITEM TOOL NO UNIVERSA...

Page 103: ...ng bolts and the three stator mounting bolts Tighten the bolts securely with an 8 mm socket Coat the rubber grommet in silicone sealant where it contacts the generator cover Fit the rubber wire gromme...

Page 104: ...2 Engine Generator G Dink 125i 20 Fit the generator cover into place Make sure the water pump shaft engages correctly with the oil pump shaft...

Page 105: ...r bolts Note the upper most bolt holds a wire stay Tighten the bolts securely in a with an 8 mm socket Fit the coolant hose to the right crankcase cover pipe Secure the hose with the clamp and tighten...

Page 106: ...Engine Generator G Dink 125i 22 Connect the coolant hose to the water pump Move the clamp into place and tighten it securely with a 2 Phillips screwdriver Plug in the regulator rectifier 3 pin connect...

Page 107: ...See the Engine Oil topic for more information Install the exhaust system See the Exhaust System topic for more information Fill the coolant and bleed the coolant See the Coolant topic for more informa...

Page 108: ...Dink 125i 24 Crankshaft SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Split the crankcases See the Crankcase topic for more information Lift the crankshaft out of th...

Page 109: ...rod with a feeler gauge Item Standard mm Service Limit mm Crankshaft Connecting rod big end side clearance 0 15 0 35 0 6 Grip the small end of the connecting rod and try and push the rod down towards...

Page 110: ...allation Lubricate the connecting rod big end and crankshaft shaft bearings with fresh engine oil Fit the crankshaft into the left crankcase bearing Take care to avoid damaging the new oil seal Join t...

Page 111: ...ion Remove the camshaft sprocket See the Camshaft topic for more information Remove the cylinder head See the Cylinder Head topic for more information Remove the generator cover flywheel starter idle...

Page 112: ...2 Engine Crankcase G Dink 125i 28 Remove the upper cam chain guide Inspect the cam chain guides for damage and excessive wear Replace the guides as needed...

Page 113: ...ve the cam chain from the crankshaft and crankcase Inspect the cam chain for wear and damage Replace the cam chain as needed Remove the oil filter cover with an 8 mm socket Remove the oil filter It sh...

Page 114: ...ere are 4 crankcase bolts attaching the left side There are 2 crankcase bolts attaching the right side Loosen the 6 crankcase bolts in a crisscross pattern with an 8 mm socket Remove the crankcase bol...

Page 115: ...t side Separate the halves of the crankcase If needed gently tap the reinforced areas of the right crankcase half with a rubber mallet Lift the right crankcase off of the left Remove the two dowel pin...

Page 116: ...2 Engine Crankcase G Dink 125i 32 To remove the crankshaft see the Crankshaft topic Replace the left crankshaft seal if the crankcases are separated Remove the seal with a seal pick...

Page 117: ...the left crankcase from the outside with a suitable driver The driver should have the same outside diameter as the seal Lubricate the new crankshaft seal lips with fresh engine oil Assembly Thoroughl...

Page 118: ...e half down on top of the left Install the engine mount spacer Insert the 5 crankcase bolts onto the left crankcase Insert the 2 crankcase bolts onto the right crankcase Tighten the bolts securely and...

Page 119: ...25i 35 Install the cam chain around the timing sprocket teeth on the crankshaft Fit the upper cam chain guide into place Insert the upper cam chain guide mounting bolt and tighten it to specification...

Page 120: ...ore information Install the CVT pulleys and belt See the CVT Installation topic for more information Install the cylinder and piston See the CylinderandPiston topic for more information Install the cy...

Page 121: ...int Removal Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Remove the spark plug See the Spark Plug topic for more inform...

Page 122: ...h an 10 mm socket Free the fuel hose stay from the cylinder head cover Loosen the four cylinder head cover bolts with a 10 mm socket Remove the cylinder head cover bolts Remove the cylinder head cover...

Page 123: ...the cylinder head cover gasket onto the cylinder head Make sure the projection fits into the groove Install the cylinder head cover over the gasket Make sure the ridge on the gasket fits into the groo...

Page 124: ...2 Engine Cylinder Head Cover G Dink 125i 40 Insert the cylinder head cover bolts Tighten the cylinder head cover bolts securely in two steps and in a crisscross pattern with an 10 mm socket...

Page 125: ...y with an 10 mm socket Install the breather hose to the cylinder head cover Secure the hose with the clamp Install the spark plug See the SparkPlug topic for more information Install the luggage box S...

Page 126: ...the spark plug See the Spark Plug topic for more information Remove the cylinder head cover See the Cylinder Head Cover topic for more information Remove the crankshaft cap on the right side of the e...

Page 127: ...ink 125i 43 The crankshaft must be rotate clockwise until the piston is at top dead center TDC on the compression stroke Turn crankshaft clockwise until the T mark aligns with the index notch in the t...

Page 128: ...ke sure that it is on the compression stroke by checking that there is some slack in the rocker arms If the rocker arms are rigid rotate the crankshaft 360 clockwise until the T mark is once again ali...

Page 129: ...25i 45 Remove the cam chain tensioner cap bolt with a 10 mm socket Loosen the cam chain tensioner mounting bolts evenly with an 8 mm socket Lift the cam chain tensioner out of the cylinder Remove the...

Page 130: ...e Camshaft G Dink 125i 46 Remove four cam chain holder bolts with a 12 mm socket Remove the cam chain holder Remove the camshaft sprocket as shown Support the chain so it does not fall into the cylind...

Page 131: ...Camshaft G Dink 125i 47 Remove the rocker arm shafts and pull the shafts out with a large flat blade screwdriver Lift out the rocker arms as the shafts are removed Remove the camshaft from the cylind...

Page 132: ...heights for the intake and exhaust lobes Inspect the camshaft bearings for excessive play or roughness Replace the entire camshaft assembly if the bearings are rough or have excessive play Inspect th...

Page 133: ...2 Engine Camshaft G Dink 125i 49 Inspect the rocker arm inner diameter for the intake and exhaust valves Inspect the camshaft bearing journals for scoring or scratches...

Page 134: ...d oil passages are free of clogs NOTE Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else Position the piston at top dead center as above The T...

Page 135: ...cate the inside diameter of the rocker arms and the roller with fresh engine oil Position the rocker arms to accept the rocker arm shafts Wipe the rocker arm shafts clean Insert the rocker arm shafts...

Page 136: ...e camshaft sprocket with the top edge of the cylinder head as shown Fit the camchain over the camshaft sprocket For correct engine timing the marks on the camshaft sprocket must be even with the cylin...

Page 137: ...a new gasket Insert the mounting bolts and tighten them evenly to specification with an 8 mm socket Torque Item Qty Thread size mm kgf m lb ft Cam chain tensioner bolt 2 6 1 0 1 4 7 23 10 13 Rotate th...

Page 138: ...aft and timing plugs are in good condition Replace them as needed Install the timing inspection and crankshaft caps to the right side of the engine Tighten the caps securely but not overly with a larg...

Page 139: ...c for more information Remove the cylinder head See the Cylinder Head topic for more information IMPORTANT Record the position of all parts so they can be returned to their proper place during reassem...

Page 140: ...2 Engine Valves G Dink 125i 56 Remove the spring retainer Remove the valve springs...

Page 141: ...he valve from the combustion chamber side of the cylinder head Rotate the valve as it is removed Remove the valve seal from the valve guide The valve seals should be replaced if they are removed or yo...

Page 142: ...2 Engine Valves G Dink 125i 58 Inspect the valve springs for fatigue and damage Replace the valve springs as needed or if the valve is also to be replaced...

Page 143: ...e seat should be centered on the valve face If the seat is pitted worn out or fits poorly on the valve face the valve seat must be resurfaced Item Standard mm IN 0 55 0 85 Valve seat width EX 1 15 1 4...

Page 144: ...ash point solvent and compressed air Return the components to their original locations NOTE Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else...

Page 145: ...uide and through the seal Turn the valve slowly as it is inserted If you are installing a new valve you must ream the valve guide first Make sure the valve will move smoothly in the valve guide withou...

Page 146: ...ner on top of the spring Push down the valve springs with a valve spring compressor to allow enough room to install the split keepers The valve cotter installer tool can also be used to install the sp...

Page 147: ...alve stem Repeat this with the other keeper After the valves have been reassemble place a clean shop towel under the cylinder head in the combustion chamber area and gently tap each valve stem with a...

Page 148: ...e See the Engine Removal topic for more information Remove the cylinder head cover See the CylinderHead Cover topic for more information Remove the camshaft sprocket See the Camshaft topic for more in...

Page 149: ...Cylinders and Pistons G Dink 125i 65 Remove the two right side cylinder bolts with an 8 mm socket Loosen the cylinder coolant hose clamp with a 2 Phillips screwdriver Free the coolant hose from the c...

Page 150: ...nd do not allow if to fall into the crankcase Remove the cylinder Remove the two cylinder dowel pins from the left studs Place a clean shop towel under and around the base of the piston to prevent any...

Page 151: ...n pin and the piston Clean off the cylinder mating surface but take care to keep debris from falling into the crankcase Spread the piston rings and lift them off opposite the gap Spread the rings the...

Page 152: ...8 The two upper rings are each a single piece of metal The oil ring consists of an expander ring and two side rails Clean the carbon build up off of the piston with a stiff bristled plastic brush or r...

Page 153: ...Cylinders and Pistons G Dink 125i 69 Also clean out the ring grooves You can use an old ring to scrape out any carbon build up in the grooves Inspection Inspect the cylinder bore for damage and abnor...

Page 154: ...levels with a dial bore gauge Item Standard mm Cylinder I D 52 405 52 415 Calculate the cylinder taper The taper is the maximum difference between either yellow and brown or blue and green Item Limit...

Page 155: ...f the cylinder to calculate the piston to cylinder clearance Replace the piston and cylinder as needed to achieve a correct piston to cylinder clearance Item Standard mm Piston to cylinder clearance 0...

Page 156: ...small end of the connecting rod with vernier calipers Item Standard mm Connecting rod small end I D Bore 15 016 15 034 Measure the ring groove width and the ring to groove clearance with feeler gauges...

Page 157: ...op ring in the cylinder about an inch Use the piston to push in the ring to keep it square with the cylinder Measure the ring gap with a feeler gauge Repeat this procedure with second ring and the oil...

Page 158: ...G Dink 125i 74 Check the oil way for clogs Assembly Clean the piston ring grooves and apply fresh engine oil to the piston rings Spread the rings the minimum amount possible to install them Do not tr...

Page 159: ...t no ring end gaps line up with the piston pin or perpendicular to the piston pin The rings should turn easily on the piston without sticking or roughness Install the oil expander ring so that the end...

Page 160: ...IN mark should face the intake side rear of the engine Place the piston over the connecting rod Insert the piston pin into the piston and rod Install new piston pin clips securely into their grooves T...

Page 161: ...he new base gasket onto the crankcase Coat the inside of the cylinder piston rings and piston in fresh engine oil Lower the cylinder over the studs and guide the piston into the cylinder while you are...

Page 162: ...ly with a 2 Phillips screwdriver Insert the lower cam chain guide and make sure it is seated correctly Install the cylinder head See the Cylinder Head topic Install the camshaft See the Camshaft topic...

Page 163: ...the oil pump The oil pump must be replaced as a set when it reaches its service limit After the oil pump is installed check each part for oil leaks TROUBLESHOOTING Oil level too low 1 Natural oil cons...

Page 164: ...2 Engine Oil Pump G Dink 125i 80 The oil pump is driven by a chain off of the crankshaft Loosen the oil pump cover bolt with an 8 mm socket Remove the oil pump cover bolt and the oil pump cover...

Page 165: ...25i 81 Remove the snap ring on the oil pump shaft with snap ring pliers Remove the oil pump drive chain and driven sprocket Inspect the oil pump drive chain and sprocket for signs of wear and damage R...

Page 166: ...2 Engine Oil Pump G Dink 125i 82 Remove the two oil pump screws with an 10 mm socket Remove the oil pump...

Page 167: ...turns smoothly If the oil pump shaft will not rotate smoothly the oil pump should be replaced with a new unit Oil Pump Installation Fit the oil pump into place so that the arrow is pointing up Insert...

Page 168: ...mp driven sprocket into the drive chain Install the gear onto the oil pump shaft and fit the chain onto its teeth on the crankshaft Install a new snap ring into its groove with snap ring pliers Instal...

Page 169: ...125i 85 Tighten the oil pump cover bolt securely with an 8 mm socket Install the starter driven gear flywheel and the generator cover See the Generator topic Fill the engine oil See the Engine Oil to...

Page 170: ...ver Front Cover Front Lower Cover Foot Skirt Rear Carrier Body Cover Under Cover Disconnect the cables from the battery terminals See the Battery topic for more information Remove the spark plug cap S...

Page 171: ...Removal G Dink 125i 87 The regulator rectifier is located on the left side of the vehicle Disconnect the generator 3 pin connector Disconnect the crank position sensor wire coupler Unplug the water te...

Page 172: ...thermosensor unit and thermo unit ground connectors Pull back the rubber starter motor lead cover Remove the starter motor lead nut with a 2 Phillips screwdriver Free the cable lead from the starter m...

Page 173: ...and free the coolant hose from the water pump Allow any remaining coolant to drain into a suitable container Loosen the thermostat hose clamp with a 2 Phillips screwdriver Slide up the clamp and free...

Page 174: ...t with an 8 mm socket Remove the bolt and free the engine ground from the right side of the engine Free the starter motor lead from the stay Support the engine with a suitable jack or stand Remove the...

Page 175: ...ocket Remove the nut and washer Hold the engine mounting bolts with a 14 mm wrench and loosen the nuts with a 19 mm socket Remove the engine mounting nuts and bolts from both sides Loosen the engine m...

Page 176: ...engine mounting bracket damper bolt and nut Remove the engine mounting bracket Remove the engine mounting bracket damper assembly Carefully move the engine back and separate it from the chassis To ins...

Page 177: ...e recommended at this point Before the engine is returned to the install the rear wheel See the Rear Wheel topic for more information Set the chassis on its center stand Use a jack to support the engi...

Page 178: ...two engine mounting bracket to frame mounting bolts and nuts Insert the bolts from the outside of the frame Insert the engine mounting bracket and damper bolt from the right side Thread on the nut In...

Page 179: ...m socket Torque Item Qty Thread size mm kgf m lb ft Remarks Engine hanger Frame side 2 14 6 0 7 0 43 20 50 40 U nut Tighten the engine mounting bracket damper bolt and nut with a 19 mm wrench for the...

Page 180: ...ll the rear shock absorbers See the Shock Absorbers topic for more information Route the starter motor lead to the starter motor and secure it in the stay Fit the starter motor cable lead onto the ter...

Page 181: ...25i 97 Fit the rubber starter motor lead cover into place Install the main engine ground to the right side of the engine Tighten the main engine ground bolt securely with an 8 mm socket Install air bl...

Page 182: ...e and tighten it securely with a 2 Phillips screwdriver Connect the coolant hose to the water pump Move the clamp into place and tighten it securely with a 2 Phillips screwdriver Fit the fuel stay int...

Page 183: ...2 Engine Engine Installation G Dink 125i 99 Plug in the water temperature sensor connector Connect the generator 3 pin connector for regulator rectifier...

Page 184: ...e stem O D IN 4 99 4 975 EX 4 97 4 955 Valve stem to guide IN 0 01 0 037 clearance EX 0 03 0 057 Valve seat width IN 1 2 EX 1 2 Engine Item Standard mm Cylinder I D 52 4 52 41 2 096 2 0964 Ring to gro...

Page 185: ...O D 32 006 32 009 Drive belt width 19 Clutch lining thickness 3 963 4 037 Clutch outer I D 130 130 2 Driven face spring free length 88 3 Driven face O D 33 965 33 985 Movable driven face I D 34 34 02...

Page 186: ...OLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EFFECTS Freezing Point Mixing Rate Coolant Concentrate Distilled Water 9 C 20 260 cc 1040 cc 15 C 30 390 cc 910 cc 25 C 40 520 cc 780 cc 37 C 50 650 cc 6...

Page 187: ...ley can be serviced with the engine installed Avoid getting grease and oil on the drive belt and pulley faces Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley...

Page 188: ...FIRST Protective gloves and eyewear are recommended at this point Removal Remove the following components Seat Luggage Box Center Cover Rear Carrier Body Cover Front Cover Front Lower Cover Foot Skirt...

Page 189: ...CVT Transmission Belt Case G Dink 125i 3 Remove the belt case plastic cover bolts with an 8 mm socket Remove the belt case cover bolts with an 8 mm socket Use the pry points to free the belt case cove...

Page 190: ...3 CVT Transmission Belt Case G Dink 125i 4 Remove the belt case cover and gasket Remove the two dowel pins Inspection Inspect the drive belt for cracks or excessive wear...

Page 191: ...3 CVT Transmission Belt Case G Dink 125i 5 Installation Install the two dowel pins into the belt case Install a new gasket with the belt case cover...

Page 192: ...3 CVT Transmission Belt Case G Dink 125i 6 Install the belt case cover bolts and tighten them securely with an 8 mm socket Insert the plastic cover bolts and tighten them securely with an 8 mm socket...

Page 193: ...ion Belt Case G Dink 125i 7 Fit the drain hose to the plastic belt case cover as shown Install the following components Foot Skirt Front Lower Cover Front Cover Body Cover Rear Carrier Center Cover Lu...

Page 194: ...gloves and eyewear are recommended at this point Remove the belt case See the Belt Case topic for more information Pulleys and Belt Hold the drive pulley with a universal holder tool and loosen the nu...

Page 195: ...3 CVT Transmission CVT Removal G Dink 125i 9 Remove the left face of the drive pulley Loosen the driven pulley nut with a 17 mm socket Remove the driven pulley nut...

Page 196: ...3 CVT Transmission CVT Removal G Dink 125i 10 Slide the driven pulley off of the shaft Remove the belt from the driven pulley...

Page 197: ...drive belt for cracks or excessive wear Remove the right movable face of the drive pulley from the crankshaft Slide the bushing out of the movable drive face Drive Pulley Disassembly Inspect the faces...

Page 198: ...CVT Removal G Dink 125i 12 Lift the ramp plate out of the back of the left drive pulley face Remove the rubber damper pieces from the ramp There are six weight rollers in the back of the right face o...

Page 199: ...the outside diameter of the rollers Replace the weight rollers as needed Item Standard mm Service Limit mm Weight roller O D Drive Pulley 15 9 0 3 g 15 0 Inspect the movable drive face and bushing fo...

Page 200: ...Standard mm Service Limit mm Clutch outer I D 130 0 130 2 130 2 Inspect the clutch shoe lining thickness Replace the shoes if the wear is below the service limit Item Standard mm Service Limit mm Clut...

Page 201: ...itting tool into the clutch spring compressor tool Use the clutch spring compressor tool to compress the spring in the driven pulley assembly Loosen the clutch drive plate nut with the special socket...

Page 202: ...nk 125i 16 Inspect the left side bearing by turning it with a finger If the bearing is rough turning or noisy it should be replaced Remove the clutch spring compressor tool Lift off the centrifugal cl...

Page 203: ...moval G Dink 125i 17 Measure the free length of the clutch spring Replace the spring if the measurement fails to meet the service limit Remove the three circlips from the clutch pivot pins with a smal...

Page 204: ...3 CVT Transmission CVT Removal G Dink 125i 18 Lift off the plate Slide the clutch shoes off of the pivots on the drive plate Inspect the clutch shoe bumpers and replace them as needed...

Page 205: ...Transmission CVT Removal G Dink 125i 19 Driven Pulley Disassembly Remove the clutch as shown above Remove the four guide rollers with guide roller pins Separate the left and right faces of the driven...

Page 206: ...0 Inspect the faces of the driven pulley Clean away any grease from the faces where the belt rides Remove the seals from the left face of the driven pulley Drive in the new seals with a suitable drive...

Page 207: ...Clean the left face and roller pins with a high flash point solvent and compressed air NOTE Always wear safety glasses when using compressed air and never point it directly at yourself or anyone else...

Page 208: ...uitable puller Remove the collar snap ring and bearing from the right face of the driven pulley Clean the right face with a high flash point solvent and compressed air NOTE Always wear safety glasses...

Page 209: ...rds the clutch Install the snap ring into the groove Install the collar and drive in the new needle bearing so that its markings face out Drive in the bearings with a suitable driver with the same out...

Page 210: ...allation SAFETY FIRST Protective gloves and eyewear are recommended at this point Driven Pulley Lubricate the bearings in the right face of the driven pulley with grease Drive in the new seals with a...

Page 211: ...essure because the boiling coolant may cause danger Avoid spilling coolant on painted surfaces because the coolant will corrode the painted surfaces Wash off any spilled coolant with fresh water as so...

Page 212: ...ents To check the coolant level see the Coolant Level Check topic for more information Draining SAFETY FIRST Antifreeze is highly toxic and can kill pets and animals if drank Do not leave coolant wher...

Page 213: ...cap in two stages Allow any built up pressure to vent and then open the cap all the way and remove it The water pump is located on the right side of the engine Ready a drain pan under the water pump d...

Page 214: ...e coolant lid screw with a 2 Phillips Remove the engine coolant lid Open the coolant reserve tank lid Siphon the coolant out of the reserve tank with an appropriate suction device If a suction device...

Page 215: ...mixing rate of 520cc coolant concentrate is 40 780cc distilled water is 60 Do not mix coolant concentrate of different brands Do not drink the coolant which is poisonous The freezing point of coolant...

Page 216: ...the bottom of the filler neck as shown Add coolant to the reserve tank until it reaches the upper level mark Gently rock the vehicle side to side to release any air bubbles trapped in the cooling sys...

Page 217: ...e and recheck the coolant level add coolant if necessary Check the reserve tank and add coolant if needed Wet the seal of the radiator cap and install Install the coolant reserve tank lid Install the...

Page 218: ...olant G Dink 125i 8 Install the radiator cap access panel Install the radiator coolant panel screws and tighten securely with a 2 Phillips screwdriver Install the windshield See the Windshield topic f...

Page 219: ...point Warning Allow the engine sufficient time to cool before handling or working on the cooling system components Pressure Testing Remove the windshield See the Windshield topic for more information...

Page 220: ...iller neck Pump the tester up until the gauge reads 0 84 kg cm2 or 12 psi The cooling system should hold this pressure for at least 6 seconds If it does not you will need to inspect the entire system...

Page 221: ...ator cover See the RadiatorCover topic for more information Drain the coolant See the Coolant topic for more information Unplug the thermostatic switch connectors Unplug the cooling fan motor connecto...

Page 222: ...tor G Dink 125i 12 Loosen the coolant hose clamps with a 2 Phillips screwdriver Free the filler neck coolant hose from the stay and remove it from the radiator Remove the water pump and thermostat hos...

Page 223: ...Cooling System Radiator G Dink 125i 13 Remove the two radiator mounting bolts with a 10 mm socket Slide the radiator to the left and free the grommet from the post above the right side of the radiato...

Page 224: ...e frame Coolant Reserve Tank The coolant reserve tank is mounting to the frame with a bolt There are two hoses that connect to the reserve tank The top hose is a dump hose that hangs over the other si...

Page 225: ...a suitable container below the reserve tank Pull back the clamp and free the overflow hose from the bottom of the reserve tank Allow the coolant in the reserve tank to drain into the container Remove...

Page 226: ...16 Remove the reserve tank from the frame Inspection Inspect the radiator fins for damage and clogging To remove the fan take out the three mounting bolts with a 10 mm socket Clean out the fins with...

Page 227: ...air and never point it directly at yourself or anyone else Check the radiator for any bent or damaged fins Use a small flat blade screwdriver to straighten them out but be careful not to puncture the...

Page 228: ...Dink 125i 18 If the thermostatic switch needs to be removed use a 22 mm wrench The thermostatic switch should be off below 85 C 185 F and on above 90 C 194 F Installation Coolant Reserve Tank Fit the...

Page 229: ...Dink 125i 19 Insert the reserve tank mounting bolt and tighten them securely with a 10 mm socket Connect the dump hose to the top of the reserve tank and the overflow hose to the bottom Secure the hos...

Page 230: ...r G Dink 125i 20 Fit the radiator into place so that the post on the frame fits into the rubber grommet on the right side of the radiator Install the two radiator mounting bolts and tighten them secur...

Page 231: ...de to the top right of the radiator Connect the coolant hose from the thermostat on the cylinder head to the top left of the radiator Connect the coolant hose from the water pump to the bottom right o...

Page 232: ...connectors Fill and bleed the coolant See the Coolant topic for more information Install the radiator cover See the RadiatorCovertopic for more information Install the right and left front lower cover...

Page 233: ...SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Remove the right and left front lower covers See the Front Lower Cover topic for information Remove the four bolts fro...

Page 234: ...Cooling system Radiator Cover G Dink 125i 24 Installation Install the radiator cover Install the four bolts Install the right and left front lower covers See the Front Lower Cover topic for informatio...

Page 235: ...Coolant topic for more information Remove the seat See the Seat topic for more information Remove the luggage box See the Luggage Box topic for more information Remove the rear carrier See the RearCa...

Page 236: ...stem Thermostat G Dink 125i 26 Remove the thermosensor unit with a 12 mm deep well socket Water Temperature Sensor WTS Unplug the water temperature sensor Use a 17 mm wrench to remove the water temper...

Page 237: ...with a new item Thermostat Loosen the thermostat hose clamp with a 2 Phillips screwdriver Slide up the clamp and free the coolant hose from the thermostat Squeeze the air bleed hose clamp with needle...

Page 238: ...System Thermostat G Dink 125i 28 Remove the two thermostat mounting bolts with an impact 3 Phillips screwdriver Lift off the thermostat cover Lift out the thermostat Remove the thermostat O ring and d...

Page 239: ...mosensor or the thermometer to contact the sides of the pan At 50 C 122 F 154 At 80 C 176 F 52 At 100 C 212 F 27 Thermosensor resistance At 120 C 248 F 16 Water Temperature Sensor Inspect the WTS in a...

Page 240: ...d check the operation of the thermostat The valve should begin to open around 71 C 160 F The valve should lift 3 5 4 5 mm 0 14 0 18 in at 80 C 176 F After the thermostat has been open for around 5 min...

Page 241: ...G Dink 125i 31 Plug in the thermosensor unit and ground connectors Water Temperature Sensor Install the WTS with a new O ring Tighten the WTS to specification with a 17 mm wrench Plug in the water te...

Page 242: ...ostat Make sure the thermostat seal is in good condition Replace the thermostat if needed Apply a light coat of waterproof grease to the thermostat seal Insert the thermostat into its cavity in the cy...

Page 243: ...at Move the clamp into place and tighten it securely with a 2 Phillips screwdriver Fill the coolant and check for leaks See the Coolant topic for more information Install the body cover See the Body C...

Page 244: ...spect the telltale hole in the generator cover below the water pump for signs of coolant leaking If there is coolant coming from this hole the mechanical seal is compromised and must be replaced Remov...

Page 245: ...ation Loosen the water pump hose clamp with a 2 Phillips screwdriver Slide up the clamp and free the coolant hose from the water pump Allow any remaining coolant to drain into a suitable container Loo...

Page 246: ...owel pins and the water pump cover gasket Impeller and Shaft Remove the generator cover See the Generator topic for more information Hold the water pump shaft and loosen the impeller with a 12 mm sock...

Page 247: ...e back of the impeller Inspect the impeller blades and seal Replace the seal washer if the mechanical seal is to be replaced Remove the water pump shaft from the generator cover To replace the mechani...

Page 248: ...lips of the new oil seal in fresh engine oil and drive it in with a suitable drive that is the same outside diameter as the oil seal Apply silicone sealant to the outside of the mechanical seal Press...

Page 249: ...new snap ring onto the water pump shaft if the snap ring was removed Lubricate the water pump shaft with fresh engine oil where it will ride in the case Insert the water pump shaft into the generator...

Page 250: ...with a 12 mm socket Remember the impeller has left hand threads Torque Item Qty Thread size mm kgf m lb ft Water pump impeller 1 7 1 0 1 4 7 23 10 13 Install the generator cover See the Generator top...

Page 251: ...e four bolts Tighten the water pump cover bolts to specification with an 8 mm socket Connect the coolant hose to the water pump Move the clamp into place and tighten it securely with a 2 Phillips scre...

Page 252: ...ingSystem Water Pump G Dink 125i 42 Fill the coolant and bleed the coolant See the Coolant topic for more information Foot Skirt FrontLowerCover FrontCover BodyCover RearCarrier CenterCover Luggage Bo...

Page 253: ...NS The servicing operations of this section can be made with the engine installed When replacing the drive shaft use a special tool to hold the bearing inner race for this operation TROUBLESHOOTING En...

Page 254: ...recommended at this point Place the scooter on level ground and up on its center stand The oil drain bolt and oil filler bolt are located on the transmission Gear oil type SAE 90 Gear oil capacity At...

Page 255: ...mm socket Item Qty Thread size mm Torque kgf m lb ft Final Drive oil check bolt 1 8 0 8 1 2 5 79 8 68 If the level is too high allow the oil to flow out of the check hole until the level is even with...

Page 256: ...Place a suitable container under the drain plug to capture the final drive oil Loosen the oil drain plug with a 12 mm socket Remove the drain plug and slowly rotate the rear wheel to drain the transm...

Page 257: ...ghten to specification Torque Item Qty Thread size mm kgf m lb ft Final drive oil drain bolt 1 8 0 8 1 2 5 79 8 68 Filling Fill the final drive oil with a syringe until oil begins to flow from the lev...

Page 258: ...G Dink 125i 6 Thread in the final drive oil level check bolt Install the oil check plug and torque it to specification with a 12 mm socket Item Qty Thread size mm Torque kgf m lb ft Final drive oil ch...

Page 259: ...eel 7 15 Wheel Inspection 16 17 Bearing Replacement 18 21 Troubleshooting Front wheel wobbling Bent rim Loose front axle Bent spoke plate Faulty tire Improperly tightened axle nut Rear wheel wobbling...

Page 260: ...Wheel SAFETY FIRST Protective gloves and eyewear are recommended at this point Removal Loosen the front axle with an 8 mm socket Lift the front end of the vehicle with a suitable stand or jack so that...

Page 261: ...pport the front wheel and slide the front axle out from the left side Guide the front wheel out from the fork legs and the brake disc out from between the pads Do not squeeze the brake lever while the...

Page 262: ...re information Inspect the wheel bearings by turning them in the hub If the bearings have play in them or are rough replace all the bearings for that wheel See the Bearing Replacement topic for more i...

Page 263: ...t Slide the front wheel into the fork Fit the brake disc between the brake pads in the front caliper Apply a light coat of grease to the front axle Insert the axle from the left side Set the front whe...

Page 264: ...Allen Thread Torque Item Qty size mm kgf m lb ft Front axle 1 14 1 5 2 5 10 84 18 08 Pump the front brake lever to establish pressure and to seat the pads against the disc If the Brakes do not pump u...

Page 265: ...muffler must be cold to avoid scalding During servicing keep oil or grease off the brake pads and brake disk Removal Remove the muffler See the Exhaust System topic for more information Remove the air...

Page 266: ...k out of the way Hold the rear brake to keep the rear wheel from turning Remove the rear axle nut with a 24 mm socket Remove the rear brake caliper See the Rear Brake Caliper topic for more informatio...

Page 267: ...5 Wheels Rear Wheel G Dink 125i 9 Slide the rear fork out and remove it from the right side of the vehicle Remove the rear axle washer from the right side of the rear axle...

Page 268: ...h a 12 mm socket Free the shock absorber from the frame Slide the rear wheel to the right and off of the rear axle Inspect the wheel bearings by turning them with a finger If the bearings have play in...

Page 269: ...le Slide the rear wheel on to the axle so that the brake disc sits on the right side Install the right shock absorber if it was removed Install the upper mounting bolt and tighten it to specification...

Page 270: ...5 Wheels Rear Wheel G Dink 125i 12 Fit the rear fork into place Install the two rear fork mounting bolts and tighten them securely with a 14 mm socket...

Page 271: ...e nut and tighten it to specification with a 24 mm socket Fit the shock absorber into place Make sure the preload arrow indicator faces out from the lower mount Torque Item Qty Thread size mm kgf m lb...

Page 272: ...5 Wheels Rear Wheel G Dink 125i 14 Install the upper shock absorber mounting bolt and torque it to specification with a 12 mm socket Torque Item kgf m lb ft shock absorber mounting bolt 4 28 93...

Page 273: ...the rear brake caliper See the Rear Brake Caliper topic for more information Install the rear fender See the Rear Fender topic for more information Install the airbox See the Airbox topic for more in...

Page 274: ...so 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 hub See the Bearing Replacement topic for more informati...

Page 275: ...hop The service limit is 2 0 mm 0 08 in or less Check the front axle runout The axle runout specification is half of the total indicator reading Replace the axle if the measurement exceeds 0 2 mm or 0...

Page 276: ...ore you plan to install them Do not let the wheel rest on its brake disc To remove the Brake discs see the Brake Disc topic Front Wheel Remove the dust seal from the right side of the front wheel usin...

Page 277: ...G Dink 125i 19 Remove one of the bearings with a bearing puller Special Tools Bearing Puller E00037 Remove the distance collar Repeat the procedure and remove the other bearing and seal The seal shoul...

Page 278: ...ake the bearing out of the freezer and install it You can use a bearing installer tool or a socket with the same outside diameter as the bearing Make sure the bearing is fully seated and the marked si...

Page 279: ...in the other bearing The bearing should fit against the distance collar Do not continue to force the bearing in or the distance collar will begin to push the right bearing back out Apply grease to th...

Page 280: ...tem and Bearing Removal 2 7 Steering Stem and Bearing Installation 8 12 Handlebar 13 21 TROUBLESHOOTING Hard steering heavy Excessively tightened steering stem top cone race Broken steering balls Insu...

Page 281: ...he steering stem adjusting nut may need to be adjusted The KYMCO G Dink 125i uses ball bearings in the steering Always replace the races at the same time as the bearings Remove the handlebar covers Se...

Page 282: ...125i 3 A special lock nut wrench is needed to loosen the steering stem lock nut Special Tool Lock Nut Wrench A120F00002 Slide the special tool over the steering stem and loosen the lock nut Remove th...

Page 283: ...7 Steering Removal G Dink 125i 4 Slide off the lock washer Support the steering stem and loosen the steering stem adjusting nut with a pin spanner Remove the steering stem adjusting nut...

Page 284: ...7 Steering Removal G Dink 125i 5 Remove the dust cover and grease seal Lower the steering stem out of the frame Remove the upper bearing inner race...

Page 285: ...r ball bearings Slide the lower ball bearings up and off of the steering stem Inspect the bearings and races for wear and damage Replace them as needed Use a chisel to remove the bottom bearing inner...

Page 286: ...rive out the bearing races in the steering head Have the drift set against the lip of the race and work around the race evenly to drive it out Repeat the process with the remaining bearing race To ins...

Page 287: ...his point Coat the new dust seal in grease and slide it down the steering stem Drive the new lower bearing inner race onto the steering stem with a pipe with the same outside diameter as the bearing r...

Page 288: ...lation G Dink 125i 9 Lubricate the upper bearing with grease and set it into place Lubricate the new lower bearing with grease and place it on the steering stem Set the upper bearing inner race into t...

Page 289: ...G Dink 125i 10 Guide the steering stem into the steering head of the frame Lubricate the grease seal with grease Set the grease seal and dust cover into place over the steering stem Thread on the stee...

Page 290: ...2 half turn Adjust the nut so the steering moves correctly The adjusting nut should be tight enough so that the steering doesn t flop back and forth and vertical movement is eliminated However it shou...

Page 291: ...ch A120F00002 Install the front fork See the Front Fork topic for more information Install the front wheel See the Front Wheel topic for more information Install the front fender See the Front Fender...

Page 292: ...ndlebar Covers topic for more information Remove the front cover See the Front Cover topic for more information Bar Ends Remove the bar ends with a 6 mm Allen To remove the brake master cylinders see...

Page 293: ...parate the switch housing from the handlebar Disconnect the throttle cables and free the right switch housing from the handlebar Slide off the throttle grip Remove the two left switch housing mounting...

Page 294: ...7 Steering Handlebar G Dink 125i 15 Disconnect the switch Separate the left switch housing from the handlebar Handlebar Route the cables and lines from the handlebar cable guide...

Page 295: ...7 Steering Handlebar G Dink 125i 16 Hold the handlebar lock bolt with a 14 mm wrench and loosen the nut with a 17 mm socket Remove the handlebar lock nut and bolt Remove the handlebar...

Page 296: ...between the angle of the grip and the throttle tube so that the new grip can be installed with the correct angle NOTE Always wear safety glasses when using compressed air and never point it directly...

Page 297: ...ar onto the steering stem and align the holes Install the handlebar lock bolt and thread on the nut Hold the handlebar lock bolt with a 14 mm wrench and tighten the nut to specification with a 17 mm s...

Page 298: ...cables and lines through the handlebar cable guide Switch Housings and Throttle Align the left switch housing and install on the handlebar Insert the two housing screws and tighten them securely with...

Page 299: ...e grip onto the right side of the handlebar Install the right switch and throttle housing The post on the housing should fit into the hole in the bar Lubricate the end of the throttle in grease Fit th...

Page 300: ...all the brake master cylinders See the Master Cylinders topic for more information Bar Ends Install the bar ends with a 6 mm Allen Install the front cover See the Front Cover topic for more informatio...

Page 301: ...s Brakes 19 25 Brake Pad Replacement 26 35 GENERAL INSTRUCTIONS During servicing keep oil or grease off the brake pads and brake disk TROUBLESHOOTING Poor brake performance Worn brake pads Contaminate...

Page 302: ...e paints and some plastics Avoid contact with skin Removal The master cylinders for the front and rear brakes are essentially the same Remove the handlebar covers See the Handlebar topic for more info...

Page 303: ...rakes Master Cylinders G Dink 125i 3 Unplug the brake light switch connector Remove the two master cylinder mounting bolts with an 8 mm socket Remove the master cylinder clamp Remove the master cylind...

Page 304: ...Dink 125i 4 Remove the two master cylinder cover screws with a 2 Phillips head screwdriver Remove the master cylinder cover plastic piece and rubber accordion diaphragm Pour out any remaining brake fl...

Page 305: ...8 Brakes Master Cylinders G Dink 125i 5 Loosen the brake lever pivot nut with a 10 mm socket and the pivot bolt with a flat blade screwdriver Remove the pivot nut and bolt...

Page 306: ...8 Brakes Master Cylinders G Dink 125i 6 Remove the brake lever Brake Light Switch Remove the brake light switch mounting bolt with a 2 Phillips screwdriver Remove the brake light switch...

Page 307: ...8 Brakes Master Cylinders G Dink 125i 7 Brake Light Switch Install the brake light switch Tighten the mounting screw securely with a 2 Phillips screwdriver Brake Levers Install the brake lever...

Page 308: ...at of grease to brake lever pivot bolt Insert the pivot bolt from above and thread on the nut Tighten the brake lever bolt with a flat blade screwdriver and then tighten the nut with a 10 mm socket In...

Page 309: ...Install the master cylinder clamp Be sure to insert the pin on the clamp into the hole on the handlebar Install the two master cylinder mounting bolts and tighten them securely with an 8 mm socket Pl...

Page 310: ...sealing washers Tighten the banjo bolt to specification with a 12 mm socket Item Torque N m lb ft Banjo bolt 35 25 8 Fill the master cylinder reservoir s with brake fluid and bleed the system See the...

Page 311: ...otective gloves and eyewear are recommended at this point Removal Loosen the brake pad pin with a 5 mm Allen Drain the brake fluid if the caliper is to be disassembled See the Brake Fluid topic for mo...

Page 312: ...nder the banjo bolt to catch any remaining brake fluid Remove the banjo bolt that holds the brake hose to the caliper using a 12 mm socket Discard the two sealing washers Replace the brake hose banjo...

Page 313: ...Brakes Front Brake Caliper G Dink 125i 13 Brake Pad Removal Remove the brake pad pin Remove the brake pads Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven...

Page 314: ...inside surface of the brake caliper Blow compressed air into the banjo bolt opening to remove the caliper pistons The pistons are a tight fit in the brake caliper and will pop out with a lot of force...

Page 315: ...and can damage paints and some plastics Avoid contact with skin Install the pad retainer clip onto the caliper bracket Install the brake pad spring as shown Note the long middle tab on the spring poi...

Page 316: ...t Brake Caliper G Dink 125i 16 Fit the ends of the pads into the pad retainer as shown Apply a light coat of waterproof grease to the brake pad pin Push the pads against the pad spring and insert the...

Page 317: ...tween the pads Line up the caliper bracket mounts with the fork Install the two caliper bracket mounting bolts Tighten the mounting bolts to specification Item Torque N m lb ft Front Rear caliper bolt...

Page 318: ...25 8 Tighten the brake pad pin securely with a 5 mm Allen Refill and bleed the brake fluid See the Brake Fluid topic for more information Pump the brake lever to seat the caliper pistons against the...

Page 319: ...SAFETY FIRST Protective gloves and eyewear are recommended at this point Inspection Measure the thickness of the brake rotor with a Vernire caliper or micrometer ITEM STANDARD SERVICE LIMIT Brake dis...

Page 320: ...vice limit Measure the runout of the brake disc with a dial gauge If the reading is out of specification remove the disc from the wheel and recheck Item Standard mm Rear brake disk runout max 0 4 Fron...

Page 321: ...8 Brakes Brake Disc G Dink 125i 21 Remove the five brake disc mounting bolts with an Allen wrench Remove the front brake disc...

Page 322: ...r wear and damage Replace the parts as needed Set the front brake disc in place on the front wheel Installation Coat the threads of the disc bolts in a non permanent thread locking agent Thread in the...

Page 323: ...ront brake disc mounting bolts Tighten the bolts to specification with an Allen socket Item Qty Thread size mm Torque kgf m lb ft Disk bolt 5 8 3 2 3 8 23 15 27 48 Install the front wheel See the Fron...

Page 324: ...8 Brakes Brake Disc G Dink 125i 24 Remove the five brake disc mounting bolts with an Allen wrench Lift the brake disc off of the rear wheel...

Page 325: ...and torque them to specification with an Allen socket Set the rear brake disc in place as shown Insert the five rear brake disc mounting bolts and tighten them to specification with an Allen socket It...

Page 326: ...i 26 Brake Pad Replacement SAFETY FIRST Protective gloves and eyewear are recommended at this point Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven Front L...

Page 327: ...8 Brakes Brake Pad Replacement G Dink 125i 27 Remove the two caliper mounting bolts with a 12 mm socket Remove the front caliper Remove the brake pad pin...

Page 328: ...cement G Dink 125i 28 Remove the brake pads Replace the pads if the brake wear exceeds the wear indicator lines or if the wear is uneven Insert new brake pads as needed Fit the ends of the pads into t...

Page 329: ...s against the pad spring and insert the brake pad pin It may be necessary to spread the pads and force the pistons back into the caliper in order to allow room for the brake disc to fit between the ne...

Page 330: ...Tighten the mounting bolts to specification Item Torque N m lb ft Front Rear caliper bolt 35 25 8 Tighten the brake pad pin securely with a 5 mm Allen Pump the brake lever to seat the caliper pistons...

Page 331: ...e Exhaust System topic for more information If the caliper is to be disassembled the brake hose must be removed Drain the rear brake fluid See the Brake Fluid topic for more information Remove the rea...

Page 332: ...ear caliper mounting bolts with a 12 mm socket Remove the rear caliper from the swingarm One at a time move the brake pads to the center gap in the pad retainers and lift the pad out If needed use the...

Page 333: ...the wear indicator lines or if the wear is uneven One at a time fit the brake pads into the center gap in the pad retainers and then move the pad into the retainer If needed use the piston side pad t...

Page 334: ...8 Brakes Brake Pad Replacement G Dink 125i 34 Install the two caliper bracket mounting bolts Tighten the mounting bolts to specification Item Torque N m lb ft Front Rear caliper bolt 35 25 8...

Page 335: ...ly with a 8mm socket Fill the rear brake system with fresh brake fluid and bleed out the air See the Brake Fluid topic for more information Pump the brake lever to seat the caliper pistons against the...

Page 336: ...he front fork components for the KYMCO G Dink 125i Front Fork Removal and Installation 2 5 Fork Disassembly 6 15 Fork Assembly 16 22 TROUBLESHOOTING Soft front shock absorber Weak shock springs Insuff...

Page 337: ...are recommended at this point Removal Remove the front cover See the Front Cover topic for more information Remove the front fender See the Front Fender topic for more information Remove the front br...

Page 338: ...5i 3 Loosen the fork clamp pinch bolts with a 12 mm socket The top bolts must be removed Slide the forks legs down and out of the fork clamp using a twisting motion To disassemble the forks see the Fr...

Page 339: ...al G Dink 125i 4 Installation Slide the fork legs up into fork clamp using a twisting motion Install the fork legs so that the upper fork clamp bolt hole lines up with the groove on the inner fork tub...

Page 340: ...12 mm socket Install the front wheel See the Front Wheel topic for more information Install the front brake caliper See the Front Caliper topic for more information Install the front fender See the Fr...

Page 341: ...FETY FIRST Protective gloves and eyewear are recommended at this point Remove the front forks See the Front Fork Removal and Installation topic for more information Clean the outside of the forks befo...

Page 342: ...9 Front Suspension Fork Disassembly G Dink 125i 7 Remove the rubber fork cap Place the fork leg in a soft jawed vice Push down on the top plug and remove the snap ring...

Page 343: ...i 8 Remove the top plug Lift out the fork spring Dump the fork oil into a suitable container Pump the fork through its stroke several times to free as much oil as possible Hold the fork inverted for s...

Page 344: ...lat blade screwdriver to pop the dust seal out of the fork slider Take care to avoid scratching the fork tube Use a small flat blade screwdriver to pry out the fork oil seal stopper ring Take care to...

Page 345: ...e holder of the outer fork tube in a soft jawed Insert an 8 mm Allen socket into the damper rod Hold the damper rod and loosen the fork bottom bolt with an 8 mm Allen wrench Remove the fork bottom bol...

Page 346: ...te the inner and outer fork tubes by pulling them apart using a slide hammer motion Remove the oil lock piece The oil lock piece may come out with the damper rod in the inner fork tube or it may be le...

Page 347: ...Fork Disassembly G Dink 125i 12 Inspect the oil seal and the bushing in the fork slider Place a rag across the top of the fork slider and pry our the oil seal as shown Remove the oil seal and spacer f...

Page 348: ...9 Front Suspension Fork Disassembly G Dink 125i 13 Inspection Inspect the top plug O ring O ring and replace it if needed Insect the slider bushing and replace it as needed...

Page 349: ...pension Fork Disassembly G Dink 125i 14 Inspect the fork springs for signs of fatigue Replace the fork springs if they vary dramatically in length Inspect the damper rod and seal Replace the component...

Page 350: ...9 Front Suspension Fork Disassembly G Dink 125i 15 Inspect the inner fork tube for bends and damage Replace it as needed For assembly see the Fork Assembly topic...

Page 351: ...free cloth Coat the bushing and seals with fork oil before installation Drive the fork slider bushing into the slider with a suitable driver with the same outside diameter as the bushing Insert the da...

Page 352: ...9 Front Suspension Fork Assembly G Dink 125i 17 Place the spacer into the fork slider Insert the inner fork tube into the inner fork tube...

Page 353: ...olt Insert the fork bottom bolt into the bottom the fork slider and thread it into the damper rod Place the axle holder of the outer fork tube in a soft jawed Insert an 8 mm Allen socket into the damp...

Page 354: ...9 Front Suspension Fork Assembly G Dink 125i 19 Drive in the fork oil seal with the fork seal driver Insert the stopper ring into its groove...

Page 355: ...he dust seal securely into the outer fork tube Compress the fork tube all the way Fill the fork tube with the specified quantity of fork oil 145 1 cc Use fork oil type SS 8 10W Pump the fork slowly th...

Page 356: ...d end facing down towards the axle Lubricate the top plug O ring with fresh fork oil and insert the plug into the top of the inner fork tube as shown Push the top plug down against the spring and inst...

Page 357: ...ion Fork Assembly G Dink 125i 22 Install the rubber fork cap Fit the fork protectors into place so that they face forward Install the front fork See the Front Fork Removal and Installation topic for m...

Page 358: ...uspension Rear Suspension This chapter provides information on the rear suspension components of the KYMCO G Dink 125i Shock Absorbers 2 8 Swingarm 9 13 TROUBLESHOOTING Soft rear shock absorber Weak s...

Page 359: ...ring preload for stiffer rear suspension and can be used when the scooters heavily loaded Be certain to adjust both shock absorbers to the same spring preload positions Use a pin spanner to adjust the...

Page 360: ...e seat See the Seat topic for more information Remove the rear carrier See the Rear Carrier topic for more information Remove the body cover to access the upper shock absorber mounts See the Body Cove...

Page 361: ...Suspension Shock Absorbers G Dink 125i 4 Remove the two Swingarm mounting bolt with a 12 mm socket Remove the upper shock absorber mounting bolt with a 14 mm 17mm socket Free the shock absorber from t...

Page 362: ...ck absorbers for wear and damage Replace the shock absorbers as needed Check over the shock absorber for damage and oil leaks Replace the shock absorber if needed Do not attempt to disassemble the sho...

Page 363: ...uspension Shock Absorbers G Dink 125i 6 Install the upper shock absorber mounting bolt nut and torque it to specification with a 14 mm 17 mm socket Item Torque kgf m lb ft Shock absorber mounting bolt...

Page 364: ...s G Dink 125i 7 Install the lower shock absorber mounting bolt nut and torque it to specification with a 12 mm socket Item Torque kgf m lb ft Shock absorber mounting bolt 2 7 19 44 Install the other s...

Page 365: ...Absorbers G Dink 125i 8 Install the rear carrier See the Rear Carrier topic for more information Install the luggage box See the Luggage Box topic for more information Install the seat See the Seat to...

Page 366: ...yewear are recommended at this point Removal Place the vehicle on its center stand Remove the muffler See the Exhaust System topic for more information Remove the rear fender See the Rear Fender topic...

Page 367: ...the rear axle nut with a 24 mm socket Remove the rear brake caliper See the Rear Brake Caliper topic for more information Remove the two rear fork bolts with a 12 mm socket Slide the rear fork out an...

Page 368: ...10 Rear Suspension Swingarm G Dink 125i 11 Installation Fit the rear fork into place Install the two rear fork mounting bolts and tighten them securely with a 12 mm socket...

Page 369: ...10 Rear Suspension Swingarm G Dink 125i 12 Install the rear axle nut and tighten it to specification with a 24 mm socket Item Qty Thread size mm Torque kgf m lb ft Remarks...

Page 370: ...Caliper topic for more information Install the rear fender See the Rear Fender topic for more information Install the lower shock absorber mounting bolt and torque it to specification with a 12 mm so...

Page 371: ...age decreases suddenly and then increases when a load is added When a battery is overcharged some symptoms can be found If there is a short circuit inside the battery no voltage is produced on the bat...

Page 372: ...termittent power Loose battery cable connection Loose charging system connection Loose connection or short circuit in the ignition system Low power Weak battery Loose battery connection Charging syste...

Page 373: ...e spark plug Use a spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine TROUBLESHOOTING No peak voltage Short circuit in engine stop switch or ignit...

Page 374: ...LIGHTS SWITCHES AND FUEL PUMP GENERAL INSTRUCTIONS Note the following when replacing the halogen headlight bulb 1 Wear clean gloves while replacing the bulb Do not put finger prints on the headlight b...

Page 375: ...ed broken or shorted wire Temperature gauge does not register correctly Faulty temperature gauge Faulty thermosensor Broken or shorted wire between the temperature gauge and thermosensor Fuel gauge do...

Page 376: ...cid is poisonous and may seriously damage the skin and eyes Avoid contact with skin eyes or clothing In case of contact flush with water and get prompt medical attention Removal Remove the seat See th...

Page 377: ...back of the vehicle Remove the negative battery cable bolt with a 10 mm socket or 3 Phillips screwdriver Free the negative cable from the battery Remove the positive battery cable bolt with a 10 mm s...

Page 378: ...tery voltage with a multi meter Place the positive probe onto the positive battery terminal and the negative probe to the negative battery terminal If the battery reads under 12 3 V it is undercharged...

Page 379: ...Fit the battery into the battery tray Connect the positive battery cable and install the bolt with a 10 mm socket or 3 Phillips screwdriver Connect the negative battery cable and install the bolt wit...

Page 380: ...t the charger leads to their appropriate battery terminals Keep open flames away from a charging battery Standard Charge 0 9 Amps 5 10 Hours Note For battery charging do not exceed the charging curren...

Page 381: ...making charging system checks Start the engine and warm it up to the operating temperature stop the engine Connect the multimeter between the positive and negative terminals of the battery To prevent...

Page 382: ...m the following checks Before performing any tests make sure the electrical connections are not loose or corroded Spark Test Check the spark plug to see if it is the correct type and gapped properly I...

Page 383: ...switch to ON lift the side stand hold in one of the brake levers and push the engine start button The plug should spark Caution Do not touch the spark plug or spark plug wire while cranking or running...

Page 384: ...tion System G Dink 125i 14 Remove the ignition coil leads Remove the two ignition coil mounting bolts with an 8 mm socket Remove the ignition coil Ignition Coil Resistance Primary Set the multimeter t...

Page 385: ...resistance Ignition Coil Primary Resistance 0 55 0 75 AC Generator Inspection Crank Position Sensor Inspection Note This test is performed with the stator installed in the engine Disconnect the crank...

Page 386: ...Protective gloves and eyewear are recommended at this point You will need a digital multimeter to inspect the starting system Starter Relay Inspection Remove the body cover See the Body Cover topic fo...

Page 387: ...ect the starter relay wire connector Check for continuity between the yellow red wire and green yellow wire There should be continuity when the starter button is depressed If there is no continuity ch...

Page 388: ...Test Remove the battery cover See the Battery topic for more information Turn the ignition switch to OFF Remove the negative battery cable bolt with a 10 mm socket or 3 Phillips screwdriver Free the n...

Page 389: ...rting System G Dink 125i 19 Remove the nuts that hold the starter motor lead and battery lead wires to the starter relay with a 10 mm socket Remove the leads from the starter relay Disconnect the star...

Page 390: ...and the starter motor cable Connect a fully charged battery across the starter relay yellow red and green yellow wire terminals Check for continuity between the starter relay large terminals The rela...

Page 391: ...emoval Remove the battery cover See the Battery topic for more information Turn the ignition switch to OFF Remove the negative battery cable bolt with a 10 mm socket or 3 Phillips screwdriver Free the...

Page 392: ...ses SAFETY FIRST Protective gloves and eyewear are recommended at this point Fuse Box Remove the seat and the luggage box See the Seat topic for more information The fuse box is located on top of the...

Page 393: ...ignition control module or ECU maybe damaged if dropped or the connector is disconnected when the key is ON The excessive voltage may damage the ignition control module or ECU Always turn off the igni...

Page 394: ...11 Electrical System ECU Removal G Dink 125i 24 Loose two nuts attaching to the holder intake pipe Remove the ECU Inspection...

Page 395: ...ntinuity at all times Check for continuity between each pin B1 and D1 of the ECU side connector There should be continuity at all times Check for continuity between pin D1 and H4 of the ECU side conne...

Page 396: ...tter when the CELP illuminated while riding condition should find out the cause of the problem as soon as possible The check engine lamp CELP or Fi indicator is located in the center of meter If the E...

Page 397: ...ill be lighting for two seconds and then off If the engine has problem the CELP will blink to show the failure codes There re 23 failure codes for the Synerjet system If the vehicle gets more failure...

Page 398: ...120 Throttle Position Sensor TPS Fault 2 1 Use KYMCO AFI Diagnostic Tool to reset code Ensure TPS is within specs With throttle plate closed 0 68 volts 0 03 volts 2 Check TPS wiring and connections 3...

Page 399: ...r supply If getting more than three faults ECU could be faulty 15 P0700 Engine RPM CVT Fault 2 1 If engine exceeds 3250 rpm at idle ECU will lower engine idle speed or shut engine down 2 When start th...

Page 400: ...r excluding trouble how the DTC can be cleared Confirm the failure is excluded Turn on the ignition switch but the engine not stated and keep the CELP light up for four times If it is off automaticall...

Page 401: ...do the TPI ABV initialization process If the throttle cable is being moved when the throttle body is installed it can cause a hard to start engine or incorrect idling speed ABV controls air bypass val...

Page 402: ...t this point Remove the front cover See the Front Cover for more information Disconnect the horn connectors from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds w...

Page 403: ...ion and troubleshooting for the lights see the Electrical Systems chapter landing page Headlight Bulb Replacement Make sure the machine has been off for several minutes before removing the headlight b...

Page 404: ...the bulb with your bare hands if you plan to reuse it Do not touch your new bulb with your bare hand The oils on your hand can cause an early failure of the headlight bulb If you do touch the bulb wi...

Page 405: ...11 Electrical System Lights G Dink 125i 35 Fit the rubber cover into place Make sure the rubber covers are secured in place Aim Turn the screws to adjust the head light aim as needed...

Page 406: ...the Front Cover topic for more information Turn the turn signal bulb socket counterclockwise and free it from the lamp Push in on the bulb and rotate it clockwise to remove if from the socket Insert...

Page 407: ...urn the socket clockwise to lock it into place Taillights Bulb Replacement Lift the seat See the Seat topic for more information Remove the turn signal sockets with bulbs from the turn signal lamps Re...

Page 408: ...ghts G Dink 125i 38 Replace the bulbs as needed Push in and turn the bulbs counterclockwise to remove the and clockwise to install them Install the taillight socket into the lamp and turn it clockwise...

Page 409: ...als Remove the rear cover See the Body Cover topic for more information Turn the socket counterclockwise and remove it from the lamp Push in the bulb and turn it counterclockwise Remove the bulb Inser...

Page 410: ...g light from the mud flap See the Body Cover topic for more information Pull the rubber tag light socket out of its housing Pull the bulb straight out and insert a new one Insert the rubber socket int...

Page 411: ...loves and eyewear are recommended at this point Starter Relay See the Starting System topic for more information High Low Beam Relays Remove the front cover See the Front Cover for more information Re...

Page 412: ...a digital multimeter to inspect the fuel cut off relay Set the multimeter to read ohms of resistance Connect the multimeter to the fuel cut off relay connector terminals Connection Black Red Red Black...

Page 413: ...ove the front cover See the Front Cover for more information The ECU relay is located in the front under the dash panel to the left of the start relay Remove and disconnect the ECU relay Disconnect th...

Page 414: ...will need a digital multimeter to inspect the switches Ignition Switch Remove the front cover See the Front Cover topic for more information Unplug the white six pin ignition switch connector Use a d...

Page 415: ...Dink 125i 45 Removal Remove the front cover See the Front Cover topic for more information Remove the front center cover See the Front Center Cover topic for more information Remove the dash See the...

Page 416: ...stem Switches G Dink 125i 46 Remove the seat latch cable cover Loosen the seat latch cable screw with a 2 Phillips screwdriver Remove the seat latch cable screw and free the seat latch cable from the...

Page 417: ...o strike the bolts so that they rotate loose Turn the bolts clockwise to loosen them Installation Install new anti tamper bolts and tighten them securely Fit the end of the seat latch cable into the i...

Page 418: ...the front center cover See the Front Center Cover topic for more information Support the scooter level surface Put the side stand up and engine stop switch on RUN Turn the ignition switch to OFF Note...

Page 419: ...Terminal Standard Violet Red Green Pink 5 V ECU voltage Black Blue Green Pink 0 4 1 4 V less Incline the tilt switch 65 10 degrees to the left or right at the ignition switch ON Measure the voltage a...

Page 420: ...he tilt switch Handlebar Switches Remove the front cover See the Front Cover topic for more information To remove the handle bar switches see the Handlebar topic Unplug the green connector for the rig...

Page 421: ...lectrical System Switches G Dink 125i 51 Right Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches Continuity should exist between the wires as indica...

Page 422: ...Electrical System Switches G Dink 125i 52 Left Handlebar Switches Use a digital multimeter to check for continuity to inspect the handlebar switches Continuity should exist between the wires as indica...

Page 423: ...ical System Switches G Dink 125i 53 Luggage Box Switch Remove the luggage box See the Luggage Box topic for more information Unplug the two pin luggage box light switch connector with green and green...

Page 424: ...nk 125i 54 Side Stand Switch Remove the luggage box See the Luggage Box topic for more information Place the vehicle on the center stand Unplug the three pin side stand switch connector Use a digital...

Page 425: ...stand extended there should be continuity between the yellow black wire and the green wire terminals To remove the side stand switch see the Stands topic Brake Light Switches Test the front and rear...

Page 426: ...or continuity between the brake light switch connectors There should be continuity when the lever is pulled and none when released To remove the brake light switch see the Master Cylinder topic Remove...

Page 427: ...ater resistance two white wires 6 7 9 5 Air Fuel 14 7 Rich 0 80V O2 Sensor Voltage Air Fuel 14 7 Lean 0 18V Crank position sensor Pulser resistance 20 C 68 F 96 144 Inductive ignition coil resistance...

Page 428: ...IGNITION SYSTEM G DINK 125i G 58...

Page 429: ...LIGHTING SYSTEM G DINK 125i G 59...

Page 430: ...STARTING SYSTEM G DINK 125i G 60...

Page 431: ...TDC ABVAngDurMech 140 O2 sensor voltage V 0 1 V O2 sensor heater OFF ON ON O2 sensor correct 20 IDLE CO 0 4 1 5 Ign Dwell duration ms 1 5 2 5ms EngineSpeed IDLE rpm 1800 100 rpm Engine Temp C C Air Te...

Page 432: ...chnical specifications and information for KYMCO G Dink 125i models G Dink 125i Specifications ____________________________________ 1 3 Component Location 4 6 Special Tools 7 9 Torque Specifications _...

Page 433: ...oke Length Width Height mm 813 8 418 5 313 2 Dry weight kg 29 6 Valve train OHC CENTER PIVOT Bore Stroke mm 54 54 5 Actual displacment cc 124 8 Cylinder arrangement Single cylinder 2V Cooling system L...

Page 434: ...Ignition type ECU STARTER MOTOR Capacity 0 6 KW BATTERY Type MF Capacity 12V 8AH Charge Time A HRS 1 2A 5 10hr Fuse STD A 30A 15A 10A Generator Generator power 250W 5000rpm DRIVE TRANSMISSION Type CV...

Page 435: ...Capacity type 1100 cc 15W40 Exchanging capacity 900 cc Oil filter type Filter GEAR OIL Capacity type 0 23L 90 Exchanging capacity 0 18L LIGHT HEAD LIGHT Type High Low 12V 60W 55W LICENCE LIGHT Type 12...

Page 436: ...12 Quick Reference Component Location G Dink 125i 4 Component Location Winker Relay Turn Signal Relay Horn DC Power Socket Instrument Cluster Ignition Switch Radiator Cap...

Page 437: ...12 Quick Reference Component Location G Dink 125i 5 Fuel Pump Relay Tilt Switch ECU Relay High Beam Relay Low Beam Relay Start Relay Throttle Body ECU Fuel Injector WTS...

Page 438: ...12 Quick Reference Component Location G Dink 125i 6 Regulator Rectifier Ignition Coil Starter Relay Oxygen Sensor O2 sensor Stator and Crank Pulse Coolant Reserve Tank Sensor Pulser Coil...

Page 439: ...ion Tool No Photo Flywheel puller A120E00003 Oil seal and bearing installer A120E00014 Universal holder A120E00017 Flywheel holder A120E00021 Clutch spring compressor A120E00034 Valve adjuster A120E00...

Page 440: ...age A120E00048 INJECTOR CLEANER for Synerjet A120E00075 Wires Injector Connector A120E00090 Lock nut wrench A120F00002 Lower Upper Race Remover Installer A120F00008 Steering Stem Top Thread Wrench sho...

Page 441: ...12 Quick Reference Special Tools G Dink 125i 9 Description Tool No Photo Electric Repair Kit A120F00032...

Page 442: ...12 Quick Reference Torque Specifications G Dink 125i 10 Torque Specifications Engine Torque Specifications General Torque Specifications...

Page 443: ...12 Quick Reference Torque Specifications G Dink 125i 11 Frame Torque Specifications...

Page 444: ...12 Quick Reference Torque Specifications G Dink 125i 12 General Torque Specifications...

Page 445: ...any failure lamp light up on dashboard See the Self Diagnosis topic for more information 4 Is the Idle screw of Throttle Valve being changed or loose 5 Has the vehicle under regular service Is the ga...

Page 446: ...ECU Good spark Broken or shorted spark plug wire Faulty ignition switch Faulty ignition pulse generator Loose or disconnected spark plug wire 5 Test cylinder compression Low compression Valve stuck o...

Page 447: ...ner dirty not increase Restricted fuel flow Clogged muffler Engine speed increase Pinched fuel tank breather 4 Check ignition timing Incorrect Faulty ECU Faulty ignition pulse generator Correct 5 Test...

Page 448: ...orifice Valve train lubricated properly 11 Check for engine overheating Overheating Fan motor not working Excessive carbon build up in combustion chamber Use of poor quality fuel Not overheating Wron...

Page 449: ...ator Normal 3 Inspect the fuel injector Abnormal Faulty injector Normal 4 Check for leaks in the intake pipe Leaking Loose insulator clamp Damage insulator No leak 5 Perform spark test Weak or intermi...

Page 450: ...haft not installed properly Correct 5 Check valve spring Weak Faulty valve spring Not weak POOR HANDLING Possible cause 1 If steering is heavy Steering stem adjusting nut too tight Damaged steering he...

Page 451: ...ference VIN and Engine Number Location G Dink 125i 19 VIN and Engine Number Location The VIN is stamped on the body frame under the luggage box The engine serial number is stamped on bottom of the lef...

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