KYMCO 125 DINK - User manual

1. GENERAL INFORMATION
1-0
DINK 50/125
1
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GENERAL INFORMATION
_________________________________________________________________________________________
SERIAL NUMBER-----------------------------------------------------------1 - 1
SPECIFICATION (DINK 50)-----------------------------------------------1 - 2
SPECIFICATION (DINK 125) ---------------------------------------------1 - 3
SERVICE PRECAUTIONS-------------------------------------------------1 - 4
TORQUE VALUES ----------------------------------------------------------1 - 8
SPECIAL TOOLS ------------------------------------------------------------1-11
LUBRICATION POINTS ---------------------------------------------------1-13
CABLE&HARNESSROUTING (DINK 125) ----------------------------1-15
CABLE&HARNESSROUTING (DINK 50)------------------------------1-30
TROUBLESHOOTING------------------------------------------------------1-35
1

1. GENERAL INFORMATION
1-1
DINK50/125
SERIAL NUMBER
Location of Engine Serial Numbe
r
(1) Location of Frame Serial Numbe
r
DINK 50 DINK 125

1. GENERAL INFORMATION
1-2
DINK 50/125
SPECIFICATIONS(DINK 50)
Overall length 2030 mm (81.2 in)
Overall width 780 mm (31.2in)
Overall height 1255 mm (50.2 in)
Wheel base 1390 mm (55.6 in)
Engine type Air cooled 4-stroke,
OHC engine
Displacement 49.5cc (2.97 cu-in)
Fuel Used 92↑nonleaded
gasoline
Front wheel 47 kg (103.4 lb)
Rear wheel 64 kg (140.8 lb)
Dry weight
Total 111 (244.2 lb)
Front wheel 52 kg (114.4lb)
Rear wheel 69 kg (151.8lb)
Curb weight
Total 121 kg (266.2 lb)
Front wheel 120/70-13
Tire Rear wheel 130/70-12
Ground clearance 140 mm (308 in)
Braking distance 7 m/30 km/hr
Min. turning radius 2350 mm (94 in)
Starting system Starting motor/Kick
starter
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Triple-sphere
Valve arrangement O.H.C.
Bore x stroke 39.0×41.6 mm
(1.56×1.66 in)
Compression ratio 11:1
Compression pressure 18 kgf/cm2(1800
kPa, 256 psi)-Max
Open 3°(BTDC)
Intake Close 11°(ABDC)
Open -9°(BBDC)
Exhaust Close 19°(ATDC)
Intake 0.05 mm (0.002 in)Valve
clearance
(cold) Exhaust 0.05 mm (0.02 in)
Idle speed (rpm) 2000~2200rpm
Lubrication type Forced pressure &
Wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 0.85 L (0.748 lmp qt,
0.901 US qt))
Lubrication System
Oil exchanging
capacity 0.7L (0.616 lmp qt, 0.742 US qt)
ENGINE
Cooling Type Air cooling
Air cleaner type & No Paper element, wet
Fuel capacity 7 L (1.47 lmp gal,
1.82 US gal)
Type LFA1
Main jet No. #100(speed limited:#90)
Venturi dia. φ17mm (φ0.68 in)
Fuel System
Carburetor
Throttle type piston
Type CDI
Ignition timing 13°/2100 rpm
28°/4000r
pm
Spark plug NGK
CR7HSA
Ignition System
Spark plug gap 0.7 mm (0.028 in)
Electrical Equipment
Battery Capacity 12V4AH
Clutch type C.V.T
Type Non-stage transmission
Transmission
Gear
Operation Automatic centrifugal
Type
Type C.V.T
1st 0.75~2.47
Power Drive System
Reduction Gear
Reduction
ratio Final 13.67
Front 1.75 kgf/cm2(175 kPa,
24.85 psi)
Tire pressure
(1 person)
Rear 2 kgf/cm2(200 kPa,
28.4 psi)
Turning Left 42.5°
Moving Device
angle Right 42.5°
Fron
t
Disk brake
Brake system
type Rear Drum brake
Sus
p
ension Fron
t
Telescope
type Rear Double swing
Shock absorbe
r
Front Telescope
Damping
Device
type Rear Double swing
Frame type Under bone

1. GENERAL INFORMATION
1-3
DINK50/125
SPECIFICATIONS (DINK 125)
Overall length 2030 mm (81.2 in)
Overall width 760 mm (30.4 in)
Overall height 1255 mm (50.2 in)
Wheel base 1390 mm (55.6 in)
Engine type Watercooled 4-stroke,
OHC engine
Displacement 124.6 cc (7.6 cu-in)
Fuel Used 92# nonleaded
gasoline
Front wheel 53 kg (116.6 lb)
Rear wheel 85 kg (187 lb)
Dry weight
Total 138 (303.6 lb)
Front wheel 60 kg (132 lb)
Rear wheel 92 kg (202.4 lb)
Curb weight
Total 152 kg (334.4 lb)
Front wheel 120/70-13
Tire Rear wheel 140/70-12
Ground clearance 140 mm (308 in)
Min. turning radius 2350 mm (94 in)
Starting system Starting motor/Kick
starter
Type Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C.
Bore x stroke 52.4×57.8 mm
(2.096×2.312 in)
Compression ratio 10:1
Compression pressure 15 kgf/cm2(1500
kPa, 213 psi)
Open 12°(BTDC)
Intake Close 35°(ABDC)
Open 28°(BBDC)
Exhaust Close 0°(ATDC)
Intake 0.1 mm (0.004 in)Valve
clearance
(cold) Exhaust 0.1 mm (0.004 in)
Idle speed (rpm) 1700±150rpm
Lubrication type Forced pressure &
Wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 1.1 L (0.968 lmp qt,
1.166 US qt))
Lubrication System
Oil exchanging
capacity 0.9 L (0.792 lmp qt, 0.954 US qt)
ENGINE
Cooling Type Liquid cooled
Air cleaner type Paper element, wet
Fuel capacity 11 L (2.31 lmp gal,
2.86 US gal)
Type LEA5
Piston dia. φ21.8 mm (φ0.872 in)
Venturi dia. φ24 mm (φ0.96 in)
Fuel System
Carburetor
Throttle type Butterfly type
Type CDI
Ignition timing 10°±1.5°/1000 rpm
Spark plug NGK
DPR7EA-9
Ignition System
Spark plug gap 0.9 mm (0.036 in)
Electrical Equipment
Battery Capacity 12V8AH
Clutch type Dry multi-disc clutch
Type Non-stage transmission
Transmission
Gear
Operation Automatic centrifugal
Type
Type Two-stage reduction
1st 2.8~1
Power Drive System
Reduction Gear
Reduction
ratio Final 8.82
Front 1.75 kgf/cm2(175 kPa,
24.85 psi)
Tire pressure
Rear 2 kgf/cm2(200 kPa,
28.4 psi)
Turning Left 42.5°
Moving Device
angle Right 42.5°
Fron
t
Disk brake
Brake system
type Rear Disk brake
Sus
p
ension Fron
t
Telescope
type Rear Double swing
Shock absorbe
r
Front Telescope
Damping
Device
type Rear Double swing
Frame type Under bone

1. GENERAL INFORMATION
1-4
DINK 50/125
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.
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
DINK50/125
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.
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.
Confir
m
Capacity

1. GENERAL INFORMATION
1-6
DINK 50/125
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.
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！
N
o Contac
t
Do not press or
squeeze the wire

1. GENERAL INFORMATION
1-7
DINK50/125
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.
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#)
: Caution
: Warning
Engine Oil
Grease
Gear Oil
＊
Remove Rust！
Do you understand
the instrument？

1. GENERAL INFORMATION
1-8
DINK 50/125
TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque
kgf-m (N-m, lbf-ft) Item Torque kgf-m (N-m, lbf-ft)
5mm bolt and nut
6mm bolt and nut
8mm bolt and nut
10mm bolt and nut
12mm bolt and nut
14mm bolt and nut
0.5 (5, 3.6)
1 (10, 7.2)
2.2 (22, 16)
3.5 (35, 25)
5.5 (55, 40)
7 (70, 50)
4mm screw
5mm screw
6mm screw, SH bolt
6mm flange bolt and nut
8mm flange bolt and nut
10mm flange bolt and nut
0.3 (3, 2.2)
0.4 (4, 2.9)
0.9 (9, 6.5)
1.2 (12, 9)
2.7 (27, 20)
4 (40, 29)
Torque specifications listed below are for important fasteners.
ENGINE
Item Q‘ty Thread dia.
(mm)
Torque
k
g
f-
m
(
N-m,
lbf-ft) Remarks
MAINTENANCE:
Spark plug
Tappet ADJ nut
Engine oil strainer screen cap
Engine oil filter cap bolt
Engine oil drain plug
Transmission gear oil drain bolt
Transmission gear oil fill bolt
LUBRICATION SYSTEM:
Oil pump screw
COOLING SYSTEM:
Fan motor bolt
Fan motor switch
Water pump impeller
CYLINDER HEAD:
Cylinder head cover
Cylinder head nut (DINK 50)
Cylinder head nut (DINK 125)
Tensioner sealing bolt
Cam chain tensioner mounting bolt
Cylinder head bolt
1
2
1
3
1
1
1
1
3
1
1
4
4
1
2
2
10
5
30
6
12
10
10
3
5
16
8
6
6
8
6
6
6
1.2 (12, 8.6)
0.9 (9, 6.5)
1.5 (15, 11)
1.2 (12, 8.6)
2.5 (25, 18)
1.3 (13, 9)
1.3 (13, 9)
0.2 (2, 1.5)
0.53 (5, 2.8)
1.8 (17, 13)
1.2 (12, 9)
1.2 (12, 8.6)
0.7-1.1(10, 7.2)
2 (20, 14)
0.6 (6, 4)
1.2 (12, 8.6)
1 (10, 7.2)
Apply oil
Apply oil
Left hand threads
Apply oil
Apply oil
(Cont’d)

1. GENERAL INFORMATION
1-9
DINK50/125
Item Q‘ty Thread dia.
(mm) Torque kgf-m (N-m, lbf-ft) Remarks
CYLINDER:
Cylinder bolt
DRIVE/DRIVEN PULLEY:
L crankcase cover
Drive pulley nut (DINK 50)
Drive pulley nut (DINK 125)
Clutch outer nut
Driven pulley assembly plate nut
STARTER SYSTEM:
Flywheel nut
TRANSMISSION:
Transmission case cover bolt
2
8
1
1
1
1
1
9
6
6
10
10
12
28
14
6
1 (10, 7.2)
1.2 (12, 8.6)
5.5 (55, 40)
5.5 (55, 40)
5.5 (55, 40)
5.5 (55, 40)
5.5 (55, 40)
1.2 (12, 8.6)
FRAME
Item Q‘ty Thread dia.
(mm) Torque k
g
f-
m
(
N-m, lbf-ft
)
Remarks
EXHAUST MUFFLER:
Exhaust muffler mounting bolt
Exhaust pipe mounting nut
ENGINE ASSEMBLY:
Engine hanger mounting bolt
Engine mounting bolt/nut
STEERING SYSTEM:
Steering stem lock nut
Handlebar lock nut
Steering stem pinch bolt
WHEEL:
Front wheel axle nut
Rear wheel axle nut
3
2
1
1
1
1
4
1
1
10
8
12
10
27
10
8
12
16
3.3 (33, 24)
2 (20, 14)
5 (50, 36)
5 (50, 36)
8 (80, 58)
4.5 (45, 32)
3.2 (32, 23)
6 (60, 43)
12 (120, 86)
(Cont’d)

1. GENERAL INFORMATION
1-10
DINK 50/125
Item Q‘ty Thread dia.
(mm) Torque k
g
f-
m
(
N-m, lbf-ft
)
Remarks
SUSPENSION:
Rear shock absorber upper mount bolt
Rear shock absorber lower mount bolt
Rear fork
BRAKE:
Front caliper
Rear caliper
Brake hose oil bolt
Master cylinder holder bolt
Master cylinder reservoir cover screw
Brake caliper bleeder
OTHERS:
Start relay nut
Rear spoiler
2
2
2
2
2
4
4
4
2
2
3
10
8
8
8
8
10
6
4
5
6
8
4 (40, 29)
2.7 (27, 19)
2.7 (27, 19)
2.7 (27, 19)
2.7 (27, 19)
3.5 (35, 25)
1.2 (12, 9)
0.16 (1.6, 1)
0.6 (6, 4))
0.3 (3, 2)
1.2 (12, 9)

1. GENERAL INFORMATION
1-11
DINK50/125
SPECIAL TOOLS
Tool Name Tool No.
Illustration
(Note: the special tools may differ
slightly from those shown in the
figure of this manual.)
Flywheel puller
(Refer to the “STARTER
CLUTCH” section in the chapter
10.)
A120E00003
Oil seal and bearing
installer A120E00014
Universal holder
(Refer to the “DRIVE PULLEY,
DRIVE BELT AND DRIVEN
PULLEY” section in the chapter
8.)
A120E00017
Flywheel holder
(Refer to the “STARTER
CLUTCH” section in the chapter
10.)
A120E00021
Clutch spring compressor
(Refer to the “DRIVE PULLEY,
DRIVE BELT AND DRIVEN
PULLEY” section in the chapter
8.)
A120E00034
Valve adjuster
(Refer to the “VALVE
CLEARANCE” section in the
chapter 3.)
A120E00036
(Cont’d)

1. GENERAL INFORMATION
1-12
DINK 50/125
Tool Name Tool No.
Illustration
(Note: the special tools may differ
slightly from those shown in the
figure of this manual.)
Bearing puller A120E00037
Valve spring compressor
(Refer to the “CYLINDER
HEAD” section in the chapter 6.) A120E00040
Lock nut wrench
(Refer to the “STEERING
STEM” section in the chapter 15.) A120F00002

1. GENERAL INFORMATION
1-13
DINK50/125
LUBRICATION POINTS
ENGINE Lubrication Points Lubricant
Valve guide/valve stem movable part
Camshaft protruding surface
Valve rocker arm friction surface
Camshaft drive 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
Cranksahft one-way clutch movable part
Oil pump drive chain
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 (SAE 10W-
30)
•API SG Egnine Oil
Transmission gear SAE 90
Kick starter part
Friction sprin
g
movable part/shaft movable part
Final gear shaft grooved part High-temperature resistant grease
Starter one-way clutch threads Thread locking agent
A.C. generator connector
Transmission case breather tube Adhesive

1. GENERAL INFORMATION
1-14
DINK 50/125
FRAME
The following is the lubrication points for the frame.
Use 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.
Seat Lock Grease
Engine Oil
Grease
Brake Lever Pivot
Speedometer Gear
/
Front Wheel Bearing
Grease
Rear Fork Bearing
Grease
Throttle Cable

1. GENERAL INFORMATION
1-15
DINK50/125
CABLE & HARNESS ROUTING
(1) Brake light switch (Front brake) (2) Front brake hose (3) Throttle cable (Note)
(4) Left handlebar switch (5) Brake light switch (Rear brake)
(6) Rear brake hose (7) Right handlebar switch
(A) Pass the front brake hose, rear brake hose, throttle cable, right handlebar switch and left handlebar
switch through the guide.
Note: Pass the throttle cable through the lower handlebar cover.

1. GENERAL INFORMATION
1-16
DINK 50/125
(1) Seat lock cable (2) Rear brake hose (3) Speedometer cable
(4) Instrument connectors (5) Fuel fill cap ground wire connector
(6) Fuel cap lock cable (7) Radiator bleed hose (8) Flashing relay
(9) Coolant fill hose (10) Radiator bleed hose (11) Siphon hose
(A) Pass the radiator bleed hose through the guide.

1. GENERAL INFORMATION
1-17
DINK50/125
(1) Low beam relay (2) Speedometer cable (3) Resistor
(4) Fuel tank breather hose (5) Right handlebar switch (6) Left handlebar switch
(7) Harness wire (8) Fuel fill hose (9) Throttle cable
(10) Seat lock cable (11) Siphon hose
(12) Left turn signal light connector (13) Headlight connector (14) Horn
(15) High beam relay (16) Fan EMI filter
(A) Pass the harness wire through the guide.
(B) Pass the seat lock cable through the guide pipe.

1. GENERAL INFORMATION
1-18
DINK 50/125
(1) Throttle cable (2) Harness wire (3) Seat lock cable
(4) Speedometer cable
(A) Pass the harness wire and throttle cable through the guide.
(B) Pass the seat lock cable through the guide pipe.

1. GENERAL INFORMATION
1-19
DINK50/125
(1) Throttle cable (2) Harness wire (3) Seat lock cable
(4) Siphon hose (5) Fuel tank breather hose (6) Fuel fill hose
(A) Pass the harness wire through the guide.
(B) Pass the harness wire and throttle cable through the guide.
(C) Pass the seat lock cable through the guide pipe.