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5. ENGINE REMOVAL/INSTALLATION

5-3

DINK 200

ENGINE REMOVAL

Disconnect the battery negative cable.

Remove the frame body cover. (



2-3)

Disconnect the engine negative cable.

Disconnect all of the A.C. generator, auto

bystarter, spark plug, thermosensor wire

couplers and connectors.

Disconnect the engine fuel tube.

Drain the coolant. (



3-9)

Disconnect the water hose.

Disconnect the starter motor wire that goes to

the starter relay.

Disconnect the fuel tube and vacuum tube

that go to the carburetor from the fuel pump.

Disconnect the vacuum tube from the air

injection cut-off valve (AICV).

Disconnect the throttle cable from the

carburetor.

Remove the brake fluid tube bolt of the rear

brake caliper.

Remove the rear brake caliper bolt and the

rear brake caliper.

Starter Relay

Wire Connectors

Fuel Tube

Throttle Cable

Fuel Pump Vacuum Tube

Brake Fluid Tube

Rear Brake Caliper

Содержание DINK 200

Страница 1: ...ystem Most sections start with an assembly or system illustration and troubleshooting for the section The subsequent pages give detailed procedures for the section KWANG YANG MOTOR CO LTD OVERSEAS SAL...

Страница 2: ...INE SERIAL NUMBER 1 Location of Engine Serial Number ENGINE SERIAL NUMBER 1 0 TOOLS 1 11 SPECIFICATION 1 1 LUBRICATION POINTS 1 12 SERVICE PRECAUTIONS 1 2 WIRING DIAGRAM 1 14 TORQUE VALUES 1 9 CABLE H...

Страница 3: ...lose 0 Valve Intake 0 1 clearance cold Exhaust 0 1 Idle speed rpm 1700rpm Lubrication type Forced pressure wet sump Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capaci...

Страница 4: ...tening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally Use genuine parts and lubricants When servicing the motorcycle be sure t...

Страница 5: ...mutual working safety Disconnect the battery negative terminal before operation When using a spanner or other tools make sure not to damage the motorcycle surface After operation check all connecting...

Страница 6: ...cified capacity After operation terminal caps shall be installed securely When taking out the connector the lock on the connector shall be released before operation Hold the connector body when connec...

Страница 7: ...d terminal cover or loose negative terminal Check the double connector cover for proper coverage and installation Insert the terminal completely Check the terminal cover for proper coverage Do not mak...

Страница 8: ...ke sure that it is not interfering with any moving or sliding parts When fixing the wire harnesses do not make it contact the parts which will generate high heat Route wire harnesses to avoid sharp ed...

Страница 9: ...tact a sharp edge or corner When rubber protecting cover is used to protect the wire harnesses it shall be installed securely Do not break the sheath of wire If a wire or harness is with a broken shea...

Страница 10: ...n all steering positions When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions Be careful not to drop any parts Whe...

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

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

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

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

Страница 15: ...ly clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle Seat Lock Rear Wheel Bearing Grease Speedometer Cable T...

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

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

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

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

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

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

Страница 22: ...n rings Blown cylinder head gasket Flaws in cylinder head Seized valve Improper valve timing Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot...

Страница 23: ...too early Air in cooling system Excessive carbon build up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too early Start engine and accelerate lightly for obs...

Страница 24: ...lty ignition coil Broken or shorted high tension wire Faulty ignition switch Damaged air cut off valve diaphragm Damaged air cut off valve spring Remove spark plug and install it into spark plug cap t...

Страница 25: ...lean and unclog Cam timing gear aligning marks not aligned Faulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor jets for clogging Check fuel pump for fuel...

Страница 26: ...xcessive carbon build up in combustion chamber Damaged cam chain tensioner Worn cam gear teeth Worn or damaged cam chain Extended cam chain Faulty crankshaft bearing Worn crank pin bearing Worn or dam...

Страница 27: ...ngs Weak driven face spring Worn or seized driven pulley bearings Worn or slipping drive belt Worn weight rollers Worn or seized driven pulley bearings Oil or grease fouled drive belt Worn drive belt...

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

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

Страница 30: ...r rectifier Broken or poorly connected regulator rectifier black wire Limit voltage too high Start engine and test limit voltage of battery terminals Measure battery limit voltage with an electric tes...

Страница 31: ...Remove fuel unit and check operation of pointer by moving float up and down Remove fuel unit and check operation of pointer by moving float up and down Signals operate properly Signals dim remain on o...

Страница 32: ...stem nut POOR BRAKE PERFORMANCE Worn brake linings Foreign matter on brake linings Rough brake drum contacting area Worn brake linings Foreign matter on brake linings Rough brake drum contacting area...

Страница 33: ..._______________________________________________ __________________________________________________________________________________ _____________________________________________________________________...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 59: ...______________________________________________________________ __________________________________________________________________________________ ______________________________________________________...

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

Страница 61: ...g the engine After the engine is installed fill the cooling system with coolant and be sure to bleed air from the water jacket Start the engine to check for coolant leaks Before removing the engine th...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 77: ..._____________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLI...

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

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

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

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

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

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

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

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

Страница 86: ..._______________________________ __________________________________________________________________________________ __________________________________________________________________________________ DR...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 104: ...____________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 120: ...________________________________________ __________________________________________________________________________________ ____________________________________________________________________________...

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

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

Страница 123: ...g bolts Remove the five left crankcase bolts Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase Remove the gasket and dowel pins Remove the cranksh...

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

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

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

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

Страница 128: ...__________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING...

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

Страница 130: ...coolant with fresh water as soon as possible After servicing the system check for leaks with a cooling system tester SPECIAL TOOL Mechanical seal driver TORQUE VALUES Water pump impeller 1 0_ 1 4kg m...

Страница 131: ...1 063 1 062 1 060 1 058 1 056 1 054 1 052 1 049 1 046 1 043 1 040 40 1 072 1 070 1 068 1 066 1 064 1 062 1 059 1 056 1 053 1 050 1 047 45 1 080 1 078 1 076 1 074 1 072 1 069 1 056 1 063 1 062 1 057 1...

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

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

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

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

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

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

Страница 138: ...pins Remove the water pump impeller Inspect the mechanical water seal and seal washer for wear or damage Impeller Left Hand Threads Mechanical Seal Seal Washer Porcelain Water Pump Cover Bolts The im...

Страница 139: ...r pump assembly Remove the water pump assembly gasket and dowel pins Remove the water pump bearing snap ring from the water pump assembly Remove the water pump shaft and shaft inner bearing Remove the...

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

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

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

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

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

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

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

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

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

Страница 149: ...p which utilizes the positive and negative pulsating pressures produced by the engine crankcase to control the oil pump diaphragms and deliver fuel from the fuel tank to the carburetor through the suc...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 165: ..._____________________ __________________________________________________________________________________ __________________________________________________________________________________ STEERING HAN...

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

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

Страница 168: ...or does not track straight Improperly tightened axle nut Uneven front shock absorbers Soft front shock absorber Bent front fork Weak shock springs Bent front axle or uneven tire Insufficient damper o...

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

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

Страница 171: ...ove the side collar and dust seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearing...

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

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

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

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

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

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

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

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

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

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

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

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

Страница 184: ..._______________________________________ __________________________________________________________________________________ _____________________________________________________________________________...

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

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

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

Страница 188: ...your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the...

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

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

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

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

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

Страница 194: ...ction Disconnected battery cable Loose charging system connection Fuse burned out Loose connection or short circuit in Faulty ignition switch ignition system Low power Charging system failure Weak bat...

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

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

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

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

Страница 199: ...____________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYST...

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

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

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

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

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

Страница 205: ..._______________________________ __________________________________________________________________________________ __________________________________________________________________________________ ST...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 221: ...__________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUSTEMISSIONCONTROLS...

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

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

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

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

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