KYMCO Dink-R 150 User manual

Dink-R 150
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO Dink-R 150.
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section 2 is the removal/installation
procedures for the frame covers, which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.
Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.
Sections 6 through 17 give instructions
for disassembly, assembly and inspection
of engine, chassis frame and electrical
equipment.
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.
QUALITY TECHNOLOGY DEPARTMENT
EDUCATION SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
FRAMECOVERS/EXHAUST MUFFLER
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE
FUEL SYSTEM
5
ENGINE REMOVAL/INSTALLATION
6
CYLINDER HEAD/VALVES
7
CYLINDER/PISTON
8
DRIVE AND DRIVEN PULLEYS/KICK
STARTER
9
FINAL REDUCTION
10
CRANKCASE/CRANKSHAFT
11
COOLING SYSTEM
12
CHASSIS
FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
13
REAR WHEEL /REAR BRAKE /REAR
SUSPENSION
14
ELECTRICAL EQUIPMENT
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
15
IGNITION SYSTEM
16
STARTING SYSTEM
17
LIGHTS/INSTRUMENTS/SWITCHES
18
EVAPORATIVE EMISSION
CONTROL SYSTEM
19
ABS SYSTEM
20
Our company reserves the right to
make any alteration in the design.
The information and contents
included in this manual may be
different from the motorcycle in
case specifications are changed.

1. GENERAL INFORMATION
1-1
Dink-R 150
Location of Engine Serial Number
Location of Frame Serial Number
1
ENGINE SERIAL NUMBER
1
ENGINE SERIAL NUMBER ...................1- 1 LUBRICATION POINTS........................1-15
SPECIFICATIONS....................................1- 2 CABLE & HARNESS ROUTING.............1-17
SERVICE PRECAUTIONS......................1- 3 TROUBLESHOOTUNG...........................1-20
TORQUE VALUES ..................................1-11
SPECIAL TOOLS .....................................1-12

1. GENERAL INFORMATION
1-2
Dink-R 150
SPECIFICATIONS
Name & Model
Dink-R 150
Overall length (mm)
1970
Overall width (mm)
780
Overall height (mm)
1305
Wheel base (mm)
1370
Engine type
Liquid cooled 4-stroke
Fuel Used
92# nonleaded gasoline
Displacement (cc)
150cc
Front wheel
63
Net weight (kg)
Rear wheel
85
Total
148
Front wheel
99
Max weight
Capacity (kg)
Rear wheel
199
Total
298
Tires
Front wheel
120/70-13
Rear wheel
130/70-13
Ground clearance (mm)
125
Min. turning radius (mm)R/L
2180
Starting system
Starting motor
Fuel type
Gasoline, 4-stroke
motor oil
Cylinder arrangement
Single cylinder, flat
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C.
Bore x stroke (mm)
9X 54.5
Compression ratio
11.3
Compression pressure
(kg/cm²rpm)
15kg/cm²
Max. output
10.9kw/8000rpm
Max. torque (NM/rpm)
13.7 N.M/6500rpm
Port
timing
Intake
Open
3
Close
34
Exhaust
Open
8
Close
32
Valve clearance
Intake
0.10mm
Exhaust
0.10mm
Idle speed (rpm)
1800
Lubrication type
centrifugal type
Lubrication oil capacity (liter)
1.2L
Exchanging capacity
1.0L
Air cleaner type & No.
Wet, single
Gear Oil capacity
0.13L
Exchanging capacity
0.12L
Fuel capacity (liter)
6.8L
Type

Carburetor
Piston dia. (mm)

Venturi dia. (mm)

Ignition system type
ECU
Ignition timing F mark

Spark
NGK
CPR7EA-9
plug
Spark plug gap (mm)
0.8～0.9
Battery capacity
12V 8.6AH
Power to transmission gear
Power-transmission
gear-clutch
Reduction ratio of power to
transmission

Clutch type
Dry multi-disc clutch
Transmission gear operation type
Automatic centrifugal
type
Transmission ratio
1 speed

Reduction
Type
Two-stage reduction
gear
1st reduction ratio
0.82—2.64
2nd reduction ratio
10.56
Transmission gear type
Non-stage transmission
Tire pressure
Front wheel
2.0/2.0 kg/cm²
(kg/cm²)
Rear wheel
2.0/2.25 kg/cm²
Turning angle
Right43& left 43
Brake system
Front wheel
Disk
type
Rear wheel
Disk
Suspension
Front wheel
Telescope
type
Rear wheel
Unit swing
Shock absorber
Front wheel
Telescope
type
Rear wheel
Unit swing
Frame type
Pipe under bone

1. GENERAL INFORMATION
1-3
Dink-R 150
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
When tightening 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 to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.

1. GENERAL INFORMATION
1-4
Dink-R 150
Apply or add designated greases and
lubricants to the specified lubrication
points.
After reassembly, check all parts for proper
tightening and operation.
When two persons work together, pay
attention to the 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 points,
fasteners, and lines for proper connection
and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.

1. GENERAL INFORMATION
1-5
Dink-R 150
If the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified 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 connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
protruding or loose.
Confirm
Capacity

1. GENERAL INFORMATION
1-6
Dink-R 150
The connector shall be inserted
completely.
If the double connector has a lock, lock
it at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check for
damaged 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 make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.
Snapping!

1. GENERAL INFORMATION
1-7
Dink-R 150
After clamping, check each wire to make
sure it is secure.
.
Do not squeeze wires against the weld or
its clamp
After clamping, check each harness to
make 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 edges
or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
No Contact !

1. GENERAL INFORMATION
1-8
Dink-R 150
Route harnesses so they are neither
pulled tight nor have excessive slack.
.
Protect wires and harnesses with electrical
tape or tube if they contact 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 sheath,
repair by wrapping it with protective tape
or replace it.
When installing other parts, do not press or
squeeze the wires.
Do not pull
too tight!
Do not press or
squeeze the wire.

1. GENERAL INFORMATION
1-9
Dink-R 150
After routing, check that the wire harnesses
are not twisted or kinked.
Wire harnesses routed along with handlebar
should not be pulled tight, have excessive
slack or interfere with adjacent or
surrounding parts in 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.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do not bend or twist control cables.
Damaged control cables will not operate
smoothly and may stick or bind.
Do you understand
the instrument? Is
the instrument set
correctly?
Remove Rust !

1. GENERAL INFORMATION
1-10
Dink-R 150
Symbols:
The following symbols represent 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 Oil (90#)
: Use special tool.
: Caution
: Warning
Engine Oil
Grease
Gear Oil
Special
＊

1. GENERAL INFORMATION
Dink-R 150
1-11
TORQUE VALUES
STANDARD TORQUE VALUES
Item
Torque (kg-m)
Item
Torque (kg-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.45-0.6
0.6-1.2
1.8-2.5
3.0-4.0
5.0-6.0
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.35-0.5
0.7-1.1
1.0-1.4
2.4-3.0
3.5-4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item
Q‘ty
Thread dia.(mm)
Torque (kg-m)
Remarks
Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Exhaust muffler lock bolt
Cylinder head flange nut
Valve adjusting lock nut
Cam chain tensioner slipper bolt
Oil bolt
Clutch outer nut
Clutch drive plate nut
Starter motor mounting bolt
Oil pump bolt
Drive face nut
Spark plug
A.C. generator stator bolt
Cam chain tensioner bolt
2
4
1
2
4
2
1
1
1
1
2
3
1
1
2
1
6
6
30
6
7
3
8
8
10
28
6
4
10
10
6
6
0.7-1.1
0.7-1.1
1.0-2.0
0.7-1.1
1.2-1.6
0.07-0.09
0.4-0.7
1.1-1.5
3.5-4.5
5.0-6.0
0.8-1.2
0.1-0.3
5.5-6.5
1.0-1.4
0.8-1.2
0.8-1.2
Double end bolt
Double end bolt
Apply oil to
threads
FRAME
Item
Q‘ty
Thread dia.(mm)
Torque (kg-m)
Remarks
Steering stem lock nut
Steering handle post nut
Front axle nut
Rear axle nut
Rear shock absorber upper bolt
Rearshock absorberlowerbolt
Muffler Bracket/ Rear Fork
Rear Fork/Engine Case
Engine Hanger---Frame side
Engine Hanger---Engine side
1
1
1
1
1
1
1
1
2
2
BC1
10
12
16
10
8
8
8
10
10
6.0-8.0
4.0-5.0
5.0-7.0
11.0-13.0
3.5-4.5
2.4-3.0
3.0-3.6
2.4-3.0
4.5–5.5
4.5–5.5
U-nut
U-nut
U-nut
U-nut
Flangebolt
U-nut

1. GENERAL INFORMATION
Dink-R 150
1-12
SPECIAL TOOLS
Description
Tool No.
Photo
Flywheel puller
A120E00003
Oil seal and bearing installer
A120E00014
Universal holder
A120E00017
Flywheel holder
A120E00021
Clutch spring compressor
A120E00034
Valve adjuster
A120E00036
Bearing puller
A120E00037
Cylinder Compression Gauage
A120E00039

1. GENERAL INFORMATION
Dink-R 150
1-13
Description
Tool No.
Photo
Valve spring compressor
A120E00040
Fuel Pressure Gauage
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
(shoter type)
A120F00024
Steering Stem Top Thread Wrench
A120F00029
Band Remover/Installer
A120F00030

1. GENERAL INFORMATION
Dink-R 150
1-14
Description
Tool No.
Photo
Pliers Fuel Pipe
A120F00031
Electric Repair Kit
A120F00032

1. GENERAL INFORMATION
Dink-R 150
1-15
LUBRICATION POINTS
ENGINE
Lubrication Points
Lubricant
Valve guide/valve stem movable part
Cam lobes
Valve rocker arm friction surface
Cam chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft R/L side oil seal
Starter reduction gear engaging part
Countershaft gear engaging part
Final gear engaging part
Bearing movable part
O-ring face
Oil seal lip
Genuine KYMCO Engine Oil (SAE15W-40)
APISL Engine Oil
Starter idle gear
Friction spring movable part/shaft movable part
Shaft movable grooved part
Kick starter spindle movable part
High-temperature resistant grease
A.C. generator connector
Transmission case breather tube
Adhesive

1. GENERAL INFORMATION
Dink-R 150
1-16
FRAME
The following is the lubrication points for the frame.
Use a general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified.
This will avoid abnormal noise and rise the durability of the motorcycle.
Rear Wheel axle
Bearings & nut
Main Stand Pivot
&Side stand pivot
Front Wheel Bearings
axle &nut
Grease
Grease
Grease
Grease
Brake Lever Pivot
Front Brake Cable/
Speedometer Cable/
Throttle Cable
Grease

1. GENERAL INFORMATION
Dink-R 150
1-17
CABLE & HARNESS ROUTING
Long-distance
antenna
ABS ECU/Pump
Fuel tank vent pipe
Fuel Pump Relay
ECU Relay
Headlight
controller
ABS ECU/Pump
Tank cap pull wire
Headlight
controller
Fuel Pump Relay
ECU Relay
Keyless controller
Radiator Filler Cap
USB controller
short-distance
antenna
Instrument
Keyless controller
short-distance
antenna

1. GENERAL INFORMATION
Dink-R 150
1-18
Long-distance
antenna
USB controller
ABS ECU/Pump
Ignition Switch
Fuel Pump Relay
ECU Relay
Keyless controller
ECU/Throttle
WTS
Ignition Coil
Fuel Injector
Fuel Pump
Crank Breather
Tube
Fuel Tank
Fuel tube
Spark plug cap

1. GENERAL INFORMATION
Dink-R 150
1-19
Ignition Coil
Fuel Pump
Fuel Injector
Front Wheel Speed
Sensor Connector
Starter
Relay②
Horn
Ignition Switch
USB controller
Regulator/Rectifier
O2sensor
Connector
Charcoal Canister/
Purge Control Valve
CPS Connector
Crank Breather
Tube
Fan
Relay
Start
Relay
①
Start
Relay②
Headlight
controller
EMI filter
Radiator Filler Cap
Coolant radiator
Tilt Switch