KYMCO DINK 200 User manual

PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO DINK
CLASSIC 200.
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 13 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 14 is the
removal/ installation of chassis. Section
16 states the testing and measuring
methods of electrical equipment. Section
20 provides the maintenance instructions
of the exhaust emission control system.
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/VALVES
6
CYLINDER/PISTON
7
DRIVE AND DRIVEN PULLEYS/KICK
STARTER
8
FINAL REDUCTION
9
A.C. GENERATOR/STARTER CLUTCH
10
CRANKCASE/CRANKSHAFT
11
COOLING SYSTEM
12
FUEL SYSTEM/CARBURETOR/FUEL
PUMP
13
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
14
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
15
BATTERY/CHARGING SYSTEM
16
IGNITION SYSTEM
17
STARTING SYSTEM
18
SWITCHES/HORN/FUEL UNIT /
T HERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS
19
E/M
EXHAUST EMISSION CONT ROL SYST EM
20
The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.
CHASSIS EQUIPMENT
ENGINE

1. GENERAL INFORMATION
1-0
DINK 200
1
ENGINE 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 &HARNESS ROUTING
-
1-19
TROUBLESHOOTING
-----------
1-20

1. GENERAL INFORMATION
1-1
DINK 200
SPECIFICATIONS
Name & Model No.
SH40AA
Motorcycle Name & Type
Dink Classic 200
Overall length
1907mm
Overall width
750mm
Overall height
1170mm
Wheel base
1390mm
Engine type
Water cooled 4-stroke,
OHC engine
Displacement
176cc
Fuel Used
92# nonleaded gasoline
Front wheel
53
Net weight (kg)
Rear wheel
77
Total
130
Front wheel
58
Gross weight(kg)
Rear wheel
85
Total
143
Front wheel
120/70-12
Rear wheel
130/70-12
Ground clearance
155mm
Perform
-
Braking distance (m)
7.9m(40km/hr)
ance
Min. turning radius
2350mm
Starting system
Starting motor &
Kick starter
Type
Gasoline, 4-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C.& Center
Pivot
Bore x stroke (mm)
62 x 58.2
Compression ratio
10.9:1
Compression pressure
(kg/cm_-rpm)
15
Max. output (ps/rpm)
15.2/7250
Max. torque (kg-m/rpm)
1.4/6500
Intake
Open
BTDC 12°
Port
(1mm)
Close
ATDC 35°
timin
g
Exhaust
Open
BDDC 28°
(1mm)
Close
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 capacity
1.1 liters
Cooling Type
Water cooling
Air cleaner type & No
Paper element, wet
Fuel capacity
10 liters
Type
VE
Piston dia.
26
Venturi dia.
22equivalent
Throttle type
Butterfly type
Type
CDI
Ignition timing
Repeatedly
Contact breaker
Non-contact point
type
Spark plug
NGK
DPR7EA-9
Spark plug gap
0.7mm
Battery
Capacity
12V8AH
Clutch
Type
CVT
Type
Non-stage transmission
Operation
Automatic
centrifugal
type
Type
Two-stage reduction
Reduction
1st
2.8-1.0
ratio
2nd
(46/16)x(46/15)=8.8
2
Front
Caster angle
Axle
Connecting rod
Tire pressure
Front
1.75
(kg/cm_)
Rear
2.0~2.25
Turning
Left
42.5°
angle
Right
42.5°
Front
Disk brake
Brake system
type
Rear
Disk brake
Front
Telescope
Suspension
type
Rear
Double swing
Shock absorber
Front
Telescope
type
Rear
Double swing
Frame type
Under bone
Tires
Engine
System
Fuel System
Carburetor
Electrical
Ignition System
Power Drive System
Transmis- sion Gear Reduction
Gear
Moving Device Damping
Device

1. GENERAL INFORMATION
1-2
DINK 200
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
1-3
DINK 200
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
1-4
DINK 200
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
1-5
DINK 200
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
1-6
DINK 200
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
1-7
DINK 200
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
1-8
DINK 200
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?
Remove Rust!