KYMCO DINK50 User manual

PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO DINK50.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.
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 5 through 12 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 13 is the
removal/ installation of chassis. Section
16 states the testing and measuring
methods of 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.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
EXHAUST MUFFLER/FRAME COVERS
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/CYLINDER/PISTON
6
KICK STARTER/DRIVE
PULLEY/CLUTCH/DRIVEN PULLEY
7
FINAL REDUCTION
8
A.C. GENERATOR
9
CRANKCASE/CRANKSHAFT
10
COOLING SYSTEM
11
CARBURETOR/FUEL PUMP
12
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
13
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
14
FUEL TANK
15
BATTERY/CHARGING SYSTEM
16
IGNITION SYSTEM
17
STARTING SYSTEM
18
SWITCHES/HORN/FUEL UNIT /
T HERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
19
TIR
E
HIGH-SPEED TIRE (TUBELESS TIRE)
20
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
CHASSIS EQUIPMENT
ENGINE
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1. GENERAL INFORMATION
1-0
1
ENGINE SERIAL NUMBER
1
Location of Engine Serial Number
ENGINE SERIAL NUMBER
---
1- 0 TOOLS
----------------------------
1-14
SPECIFICATION
-----------------
1- 1 LUBRICATION POINTS
--------
1-16
SERVICE PRECAUTIONS
------
1- 3 WIRING DIAGRAM
--------------
1-17
TORQUE VALUES
---------------
1-13 CABLE &HARNESS ROUTING
-
1-22
TROUBLESHOOTING
-----------
1-24
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1. GENERAL INFORMATION
1-1
SPECIFICATIONS
Name & Model No.
SH10BA
Overall length
1950mm
Overall width
735mm
Overall height
1180mm
Wheel base
1350mm
Engine type
Air cooled 2-stroke
Displacement
49.4cc
Fuel Used
92# nonleaded gasoline
Front wheel
45
Net weight (kg)
Rear wheel
61.5
Total
106.5
Front wheel
80
Gross weight(kg)
Rear wheel
149
Total
229
Front wheel
110/70-12
Rear wheel
130/70-12
Ground clearance
155mm
Perform
-
Braking distance (m)
4.4m /30km/HV
ance
Min. turning radius
2150mm
Starting system
Starting motor &
kick starter
Type
Gasoline, 2-stroke
Cylinder arrangement
Single cylinder, flat
Combustion chamber type
Semi-sphere
Bore x stroke (mm)
39 x 41.4
Compression ratio
7.2:1
Compression pressure
(kg/cm_-rpm)
11.8
Max. output (ps/rpm)
5.2/7000
Max. torque (kg m/rpm)
0.56/6500
Intake
Open
Automatic controlled
Port
(1mm)
Close
Automatic controlled
timin
g
Exhaust
Open
(1mm)
Close
Valve
Intake
clearance (cold)
Exhaust
Idle speed (rpm)
2000±100rpm
Lubrication type
Separate type
Oil pump type
Plunger type
Oil filter type
Full-flow filtration
Oil capacity
1.1 liters
Cooling Type
Air cooling
Air cleaner type & No
Paper element, wet
Lubrication oil
capacity
1.5. liters
Fuel capacity
10. liters
Type
PB
Piston dia.
Venturi dia.
14 equivalent
Throttle type
Type
CDI
Ignition timing
13.5°/2000rpm
Contact breaker
Spark plug
NGK
BR8HSA
Spark plug gap
0.6_0.7mm
Battery
Capacity
12V4AH
Clutch
Type
Dry multi-disc clutch
Type
Non-stage transmission
Operation
Automatic centrifugal
type
Type
Two-stage reduction
Reduction
1st
ratio
2nd
Front
Caster angle
Axle
Connecting rod
Tire pressure
Front
1.75
(kg/cm_)
Rear
2.25
Turning
Left
42.5°
angle
Right
42.5°
Brake system
Front
Disk brake
type
Rear
Expanding
Suspension
Front
Telescope
type
Rear
Unit swing
Shock absorber
Front
Telescope
type
Rear
Double swing
Frame type
Under bone
Tires
Fuel System
Carburetor
Electrical
Ignition System
Power Drive System
Reduction Gear
Moving Device Damping
Device
Engine
System
Transmis- sion Gear
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1. GENERAL INFORMATION
1-2
SPECIFICATIONS
Name & Model No.
SH10AA
Overall length
1950mm
Overall width
735mm
Overall height
1180mm
Wheel base
1350mm
Engine type
Water cooled 2stroke
Displacement
49.4cc
Fuel Used
92# nonleaded gasoline
Front wheel
45
Net weight (kg)
Rear wheel
61..5
Total
106.5
Front wheel
80
Gross weight(kg)
Rear wheel
149
Total
229
Front wheel
110/70-12
Rear wheel
130/70-12
Ground clearance
155mm
Perform
-
Braking distance (m)
4.4m /30km/HV
ance
Min. turning radius
2150mm
Starting system
Starting motor &
kick starter
Type
Gasoline,2-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Bore x stroke (mm)
39 x 41.4
Compression ratio
7.2:1
Compression pressure
(kg/cm_-rpm)
11.8
Max. output (ps/rpm)
5.7/7000
Max. torque (kg m/rpm)
0.6/6500
Intake
Open
Automatic controlled
Port
(1mm)
Close
Automatic controlled
timin
g
Exhaust
Open
(1mm)
Close
Valve
Intake
clearance (cold)
Exhaust
Idle speed (rpm)
2000±100rpm
Lubrication type
Separate type
Oil pump type
Plunger type
Oil filter type
Full-flow filtration
Oil capacity
1.1 liters
Cooling Type
Water cooling
Air cleaner type & No
Paper element, wet
Lubrication oil
capacity
1.5 liters
Fuel capacity
10 liters
Type
ＰＢ
Piston dia.
Venturi dia.
14 equivalent
Type
CDI
Ignition timing
13.5°/2000rpm
Spark plug
NGK
BR6HSA
Spark plug gap
0.6_0.7mm
Battery
Capacity
12V4AH
Clutch
Type
Dry multi-disc clutch
Type
Non-stage transmission
Operation
Automatic
centrifugal
type
Type
Two-stage reduction
Reduction
1st
ratio
2nd
Front
Caster angle
Axle
Connecting rod
Tire pressure
Front
1.75
(kg/cm_)
Rear
2.25
Turning
Left
42.5°
angle
Right
42.5°
Brake system
Front
Disk brake
type
Rear
Expanding
Suspension
Front
Telescope
type
Rear
Unitswing
Shock absorber
Front
Telescope
type
Rear
Double swing
Frame type
Under bone
Tires
Engine
Fuel System
Carburetor
Electrical Power Drive System
Transmis- sion Gear Reduction
Gear
Moving Device Damping
Device
System
Ignition System
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1. GENERAL INFORMATION
1-3
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.
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1. GENERAL INFORMATION
1-4
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.
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1. GENERAL INFORMATION
1-5
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
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1. GENERAL INFORMATION
1-6
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!
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1. GENERAL INFORMATION
1-7
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 !
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1. GENERAL INFORMATION
1-8
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.
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1. GENERAL INFORMATION
1-9
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 !
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1. GENERAL INFORMATION
1-10
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
Special
Engine Oil
Grease
Gear Oil
＊
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1. GENERAL INFORMATION
1-11
SERVICE INFORMATION
ENGINE
Standard (mm)
Service Limit (mm)
Item
SH10BA
SH10AA
SH10BA
SH10AA
Cylinder head warpage


0.10
0.10
Piston O.D.(5mmfrombottom ofpiston
skirt)
38.970_38.9
55
38.970_38.9
55
38.90
38.90
Cylinder-to- piston clearance
0.03_0.07
0.10
0.10
Piston pin hole I.D.
12.002_12.0
08
12.002_12.0
08
12.03
12.03
Piston pin O.D.
11.994_12.0
11.994_12.0
11.98
11.98
Piston-to-piston pin clearance
0.002_0.014
←
0.03
←
Piston ring end gap (top/second)
0.10_0.25
0.10_0.25
0.40
0.40
Connecting rod small end I.D.
17.005_17.0
17
17.005_17.0
17
17.03
17.03
Cylinder bore
39.0_39.025
39.0_39.025
39.05
39.05
Drive belt width
18
18
17
17
Drive pulley collar O.D.
20.01_20.02
5
20.01_20.02
5
19.97
19.97
Movable drive face ID.
20.035_20.0
85
20.035_20.0
85
20.21
20.21
Weight roller O.D.
13.0
13.0
12.4
12.4
Clutch outer I.D.
107_107.2
107_107.2
107.5
107.5
Driven face spring free length
87.9
87.9
82.6
82.6
Driven face O.D.
33.965_33.9
85
←
33.94
←
Movable driven face I.D.
34.0_34.025
←
34.06
←
Connecting rod big end side clearance

←
0.60
←
Connecting rod big end radial clearance

←
0.04
←
Crankshaft runout A/B


L:0.15 R:0.10
←
CARBURETOR
SH10BA
SH10AA
Venturi dia.
14mm
14mm
Identification number
PB058
PB058
Float level
8.6mm
8.6mm
Main jet
#85
#85
Slow jet
#35
#35
Air screw opening
1_±_
1_±_
Idle speed
2000±100rpm
2000±100rpm
Throttle grip free play
2_6mm
2_6mm
Jet needle clip notch
1st notch
1st notch
A
A
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1. GENERAL INFORMATION
1-12
FRAME
Standard (mm)
Service Limit (mm)
Item
SH10BA
SH10AA
SH10BA
SH10AA
Axle shaft runout


0.2
0.2
Radial
Front wheel rim runout
Axial
Front shock absorber spring free length
200.0
200.0
182.8
182.8
Rear wheel rim runout
2.0
2.0
Brake drum I.D.
Front/rear
110
110
111
111
Brake lining thickness
Front/rear
4.0/4.0
4.0/4.0
2.0/2.0
2.0/2.0
Brake disk runout
Front/rear


0.30
0.30
Rear shock absorber spring free length
235.7
235.7
218.7
218.7
ELECTRICAL EQUIPMENT
SH10BA
SH10AA
Capacity
12V4AH
12V4AH
Voltage
13.0_13.2V
13.0_13.2V
Charging
Standard
0.4A/5H
0.4A/5H
Battery
current
Quick
4A/0.5H
4A/0.5H
Spark plug
(NGK)
BR8HSA
BR6HSA
Spark plug gap
0.6_0.7mm
0.6_0.7mm
Primary coil
0.153_0.187Ω
0.153_0.187Ω
Secondary coil
(with plug cap)
6.99_10.21KΩ
6.99_10.21KΩ
Ignition coil resistance
Secondary coil
(without plug cap)
3.24_3.96KΩ
3.24_3.96KΩ
Pulser coil resistance (20℃)
80_160Ω
80_160Ω
Ignition timing
13.5°±2°BTDC/2000rpm
13.5°±2°BTDC/2000rpm
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1. GENERAL INFORMATION
1-13
TORQUE VALUES
ENGINE
Item
Thread dia. (mm)
Torque (kg-m)
Remarks
Cylinder head bolt
Clutch drive plate nut
Clutch outer nut
Drive face nut
Oil check bolt
Engine mounting bolt
Engine hanger bracket bolt
Exhaust muffler joint lock nut
Exhaust muffler lock bolt
Spark plug
BF7x115
10
NH10
NH12
10
BF10x95
BF10x50
NC6mm
BF8x35
1.5_1.7
3.5_4.0
3.5_4.5
5.0_6.0
1.0_1.5
4.5_5.5
3.5_4.5
1.0_1.4
3.0_3.6
1.1_1.7
(cold)
(cold)
FRAME
Item
Thread dia. (mm)
Torque (kg-m)
Remarks
Handlebar lock nut
Steering stem lock nut
Steering top cone race
Front axle nut
Rear axle nut
Rear brake arm bolt
Front shock absorber:
upper mount bolt
lower mount bolt
hex bolt
Front damper nut
Front pivot arm bolt
Rear shock absorber:
upper mount bolt
lower mount bolt
lower joint nut
10
25.4
25.4
12
16
8
8
10
8
8
4.5_5.0
8.0_12.0
0.5_1.3
5.0_7.0
11.0_13.0
3.3
3.3
1.5_3.0
1.5_3.0
3.5_4.5
2.4_3.0
1.5_2.5
Flange bolt/U-nut
Flange U-nut
Flange U-nut
Flange nut
Flange bolt/U-nut
Cross head
Apply locking agent
Flange screw/U-nut
Flange nut
Torque specifications listed above are for important fasteners. Others should be tightened to
standard torque values below.
STANDARD TORQUE VALUES SH bolt: 8mm Flange 6mm bolt
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
0.8_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
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1. GENERAL INFORMATION
1-14
SPECIAL TOOLS
Tool Name
Tool No.
Remarks
Universal bearing puller
Crankshaft bearing removal
Lock nut wrench, 39mm
Drive pulley disassembly/assembly
Lock nut socket wrench
Top cone race holding
Lock nut wrench,
Stem lock nut tightening
Crankcase puller
Crankcase disassembly
Bearing remover set, 12mm
(Spindle assy, 15mm)
(Remover weight)
Drive shaft bearing removal/installation
Bearing remover set, 15mm
(Spindle assy, 15mm)
(Remover head, 15mm)
(Remover shaft, 15mm)
Drive shaft bearing removal/installation
Bearing outer driver, 28x30mm
Bearing installation
Bearing remover
Driven pulley outer bearing installation
Clutch spring compressor
Driven pulley disassembly/assembly
Crankcase assembly collar
Driven shaft, crankshaft & crankcase
assembly
Crankcase assembly tool
Crankshaft & crankcase assembly
Rear shock absorber remover
Front shock absorber disassembly/
assembly
Ball race remover
Steering stem bearing races
Rear shock absorber compressor
Rear shock absorber disassembly/assembly
Float level gauge
Carburetor fuel level check
Lock nut socket wrench, 32mm
One-way clutch lock nut removal/
installation
Universal holder
Flywheel holding
Flywheel puller
Flywheel removal
Pilot, 12mm
Drive shaft bearing installation
Bearing outer driver, 32x35mm
Drive shaft bearing installation
Final shaft bearing installation
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1. GENERAL INFORMATION
1-15
Tool Name
Tool No.
Remarks
Bearing outer driver, 37x40mm
Drive shaft bearing installation Final shaft
bearing installation Crankshaft bearing
installation
Outer driver, 24x26mm
Driven pulley bearing installation
Pilot, 10mm
Front wheel bearing installation
Bearing driver pilot, 17mm
Drive shaft bearing installation
Snap ring pliers (close)
Circlip removal/installation
Bearing outer driver, 42x47mm
Crankshaft bearing installation
Pilot, 20mm
Crankshaft bearing installation
Bearing outer driver handle A
Bearing installation
Drive in ball race
Bearing puller head, 10mm
Front wheel bearing removal
Universal bearing puller
Crankshaft bearing removal
Bearing puller
Front wheel bearing removal
Pressure tester set
Cylinder compression gauge
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1. GENERAL INFORMATION
1-16
LUBRICATION POINTS
ENGINE
NO.
Lubrication Points
Lubricant
Remarks
1
Crankcase sliding & movable parts
JASO-FC or API-TC
2
Cylinder movable parts
3
Transmission gear (final gear)
SAE-90#
4
Kick starter spindle bushing
Grease
5
Drive pulley movable parts
Grease
6
Starter pinion movable parts
Grease
FRAME
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.
Front/Rear Brake Lever
Seat Lock
Throttle Cable
Main Stand Pivot
Grease
Engine Oil
Grease
Speedometer Gear/
Brake Cam/Front
Shock Absorber
Lower Mount
Bushings/Pivot
Grease
Grease
Grease
Grease
Engine Oil
Brake Cam/
Anchor Pin
Engine Oil
Speedometer Cable
Rear Wheel
Bearing
Rear Brake Cable
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1. GENERAL INFORMATION
1-17
Front Stop
Switch
Rear Stop
Switch
Throttle
Cable
Radiator
Brake Master
Cylinders
Speedometer
Cable
Horn
Fuel Tank
Breather Tube
Water Hose
Pressure Type
Radiator Cap
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1. GENERAL INFORMATION
1-18
Front Brake Fluid Tube
Water Hose
Ignition
Switch
Fuel
Filler
Water Hoses
Winker
Fuse Box
Fuel Tank Breather
Tube
Fuel Tank Inlet
Tube
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