KYMCO G-Dink 125i User manual

1. E xt e r na l Com p one nt s G- Dink 125i
1
E x t e r n a l C o m pon e n t s
This chapter covers the location and servicing 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 57-61
• Rear Carrier 62-64
• Rear Fender 65-68
• Stands 69-74
• Handlebar Cover 75-80
• Under Cover 81-84

1. External components > E xha us t S ys t e m
G- Dink 125i
2
E x h a u s t S ys t e m
S A FETY FIRST : P r o t e c t i v e g l o v e s a nd e y e w ea r a r e r e c o mm e nd e d
a t t h i s po i n t .
Ge n e r a l I n s t r u c t i on s
• When removing frame covers, use care not to pull them by force because the cover joint
claws may be damaged.
• Make sure to route cables and harnesses according to the Cable & Harness Routing.
T r oub l e s hoo t i ng
N o i sy e x h a u s t m u ff l e r
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
L a ck o f po w e r
• Caved exhaust muffler
• Clogged exhaust muffler
• Exhaust muffler air leaks
Re m o v a l
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 Rear Carrier topic for more
information.
Remove the body cover. See the Body Cover topic for more information.

1. External components > E xha us t S ys t e m
G- Dink 125i
3
Remove the two exhaust pipe joint nuts with a 12 mm deep well socket.
Unplug the O
2 sensor connector.
Remove the three muffler mounting bolts with a 14 mm socket.

1. External components > E xha us t S ys t e m
G- Dink 125i
4
Remove the exhaust system.
Remove the exhaust pipe gasket and discard it.

1. External components > E xha us t S ys t e m
G- Dink 125i
5
O
2 Se
n s o r
R e m oval
Remove the O
2 sensor with a 17 mm wrench. Use care not to pinch the
wires.
The O
2 sensor issues signal to ECU when the temperature is over 350°
C while the engine is running.
Test the O
2 sensor at room temperature.
Use a digital multimeter set to ohms of resistance to inspect the O
2
sensor.

1. External components > E xha us t S ys t e m
G- Dink 125i
6
Measure the resistance between the white wire terminals of the O
2
sensor connector. Replace the O
2 sensor if the reading is out of
specification.
I T E M SP EC I F I C A T I O N S
O
2
h ea t e r s e n s o r r e s i s t a nc e ( a t 20 ° C / 68 ° F )
6.7 - 9.5 $ ( e ng i n e w a r m i ng cond i t i on )
Hea t S h i e l d s

1. External components > E xha us t S ys t e m
G- Dink 125i
7
Remove the four muffler heat shield bolts with a #2
screwdriver if needed.
Remove the heat shield.

1. External components > E xha us t S ys t e m
G- Dink 125i
8
To remove the heat shield on the exhaust 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 separate the muffler and the head pipe. Inspect the
exhaust gasket and replace it as needed.

1. External components > E xha us t S ys t e m
G- Dink 125i
9
I n s t a ll a t i on
Hea t S h i e l d s
Install the heat shields and tighten the bolts securely.
O
2 Se
n s o r
Apply anti-seize compound to the threads of the O
2 sensor. Install the
O
2 sensor and tighten it to specification with a 17 mm wrench. Use care
not to pinch the wires.
T or qu e
I t e mN-m
l b- ft
O
2
S e ns or 25 18

1. External components > E xha us t S ys t e m
G- Dink 125i
10
E x h a u s t S ys t e m
Insert a new exhaust pipe gasket into the exhaust port.
Fit the exhaust system into place

1. External components > E xha us t S ys t e m
G- Dink 125i
11
Install the two exhaust pipe joint nuts with a 12 mm deep well socket. Do
not tighten.
Install the three muffler mounting bolts and tighten to specification with a
socket.
I t e m
T or qu e
N-m k gf -m
M uf f l e r M ount i ng Bolt s 20 2
Tighten the two exhaust pipe joint nuts to specification with a 12 mm
deep well socket.
T or qu e
I t e mN-m
k gf -m
E xha us t P i p e J oi nt N ut s 35 3.5

1. External components > E xha us t S ys t e m
G- Dink 125i
12
If the exhaust pipe and muffler were separated tighten the muffler clamp
securely.
Plug in the O
2
sensor.
Install the luggage box. See the Luggage Box topic for more information.
Install the seat. See the Seat topic for more information.

1. E xt e r na l Com p one nt s > S ea t G-Dink 125i
13
Sea t
S A FETY FIRST : P r o t e c t i v e g l o v e s a nd e y e w ea r a r e r e c o mm e nd e d
a t t h i s po i n t .
Re m o v a l
Insert the key and turn it counterclockwise .
Remove the two luggage box hinge nuts with a 10 mm socket.

1. E xt e r na l Com p one nt s > S ea t G-Dink 125i
14
Remove the two seat hinge nuts with a 10 mm socket.
Remove the seat with the piston pivot.
Sea t L a t c h Ca b l e
The seat latch cable runs from the ignition switch to the seat latches.
The cable must be adjusted periodically so that the latches will open
correctly.
Open the seat.

1. E xt e r na l Com p one nt s > S ea t G-Dink 125i
15
I n s t a ll a t i on
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 socket.
Push down the back of the seat to lock closed.

1. E xt e r na l Com p one nt s > L ugga ge B ox
G-Dink 125i
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Lugg a g e B o x
S A FETY FIRST : P r o t e c t i v e g l o v e s a nd e y e w ea r a r e r e c o mm e nd e d
a t t h i s po i n t .
Re m o v a l
Remove the seat. See the Seat topic for more information.
Remove the two luggage nuts with a 10 mm socket.

1. E xt e r na l Com p one nt s > L ugga ge B ox
G-Dink 125i
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.
I n s t a ll a t i on
Plug in the luggage box light connector.
Install the luggage box.

1. E xt e r na l Com p one nt s > L ugga ge B ox
G-Dink 125i
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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 topic for more information.

1. E xt e r na l Com p one nt s > B ody C ove r G-Dink 125i
19
B od y C o v e r
S A FETY FIRST : P r o t e c t i v e g l o v e s a nd e y e w ea r a r e r e c o mm e nd e d
a t t h i s po i n t .
Re m o v a l
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 Rear Carrier topic for more
information.
Remove the two rear center cover screws with a #2 Phillips.

1. E xt e r na l Com p one nt s > B ody C ove r G-Dink 125i
20
Remove the rear center cover.
Remove the upper body cover bolt with a 10 mm socket.