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!

1. GENERAL INFORMATION
1-9
DINK 200
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
＊

1. GENERAL INFORMATION
1-10
DINK 200
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
0.5
1.0
2.2
3.5
5.5
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.4
0.9
1.2
2.7
4.0
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 joint lock nut
Cylinder head cap nut
Valve adjusting lock nut
Cam chain tensioner slipper bolt
Oil bolt
Clutch outer nut
Clutch drive plate nut
Flywheel nut
Oil pump bolt
Cylinder head cover bolt
Spark plug
Cam chain tensioner bolt
Water pump impeller
2
2
1
2
4
2
1
1
1
1
1
2
4
1
1
1
8
8
30
8
8
5
6
12
12
12
14
5
6
10
6
8
2.2
2.2
1.5
0.9
2.2
0.9
0.9
1.3
5.5
5.5
5.5
0.4
1.2
1.2
0.9
1.4
Double end bolt
Double end bolt
Apply oil to
threads
Left hand threads
FRAME
Item
Q‘ty
Thread dia.(mm)
Torque (kg-m)
Remarks
Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper bolt
Rear shock absorber lower bolt
Front shock absorber lock bolt
Engine hanger bolt
1
1
1
2
2
4
1
10
12
14
10
8
10
12
4.5
6.0
9.0
3.0
3.0
2.5
5.5
U-nut
U-nut
U-nut

1. GENERAL INFORMATION
1-11
DINK 200
SPECIAL TOOLS
Tool Name
Tool No.
Remarks
Ref. Page
Valve guide driver
Valve guide removal/installation
Valve guide reamer
Valve guide grinding
Valve spring compressor
Valve removal
Lock nut wrench, 39mm
Clutch disassembly
Bearing driver
Bearing removal
Bearing remover, 12mm
Bearing removal
Remover shaft
Bearing removal
Remover weight
Bearing removal
Bearing remover, 15mm
Bearing removal
Bearing driver
Bearing removal
Clutch spring compressor
Clutch disassembly
Ball race remover extension
Ball race removal
Ball race remover
Ball race removal
Spring compressor
Spring removal
Mechanical seal driver
Water pump mechanical seal
removal/installation
Kick starter spring remover
Kick starter spring removal
Gear remover
Starter gear removal
Valve adjuster
Tapper adjustment
Float level gauge
Carburetor fuel level check
Valve seat cutter 45°
Valve seat refacing
Valve seat cutter 32°
Valve seat refacing
Valve seat cutter 60°
Valve seat refacing
Cutter clip, 5mm
Universal holder
Holding clutch for removal
Bearing driver (32x35mm)
Bearing installation
Pilot, 12mm
Bearing installation
Pilot, 15mm
Bearing installation
Pilot, 17mm
Bearing installation
Flywheel puller
A.C. generator flywheel removal
Rear shock absorber compressor
Rear shock absorber disassembly
Steering head bearing remover
Steering head bearing removal
Kick starter spring remover
Kick starter spring installation
Flywheel holder
A.C. generator flywheel holding
Reamer clip
Fuel unit wrench
Fuel unit removal

1. GENERAL INFORMATION
1-12
DINK 200
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
Crankshaft 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 KYM CO Engine Oil (SAE15W-40)
•API SE, SF or SG Engine Oil
Starter idle gear
Friction springmovable part/shaft movable part
Shaft movable grooved part
Starter spindle movable 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
1-13
DINK 200
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
Rear Wheel Bearing
Grease
Speedometer Cable
Throttle Cable
Main Stand Pivot
Side Stand Pivot
Speedometer Gear/
Front Wheel Bearing
Engine Oil
Grease
Grease
Grease
Grease
Front Brake Lever Pivot

1. GENERAL INFORMATION
1-14
DINK 200
CABLE & HARNESS ROUTING
Front Stop Switch
Rear Stop Switch
Throttle Cable
Fuel Vapor
Recovery Tube
Wire Connectors
Radiator
Front Brake Fluid Tube
Rear Brake Fluid Tube
Speedometer Cable
Horn
Water Hose
Fuel Vapor
Recovery Tube
Pressure Type
Radiator Cap

1. GENERAL INFORMATION
1-15
DINK 200
Fuel Vapor
Recovery Tube
Radiator Air Vent Tube
Front Brake Fluid Tube
Rear Brake Fluid Tube
Fuel Tank
Inlet Tube
Water Hose
Ignition Switch
Fuel Filler
Water Hoses
Thermostatic
Switch
Fuel Tank
Breather Tube

1. GENERAL INFORMATION
1-16
DINK 200
Throttle Cable
Speedometer Cable
Fuel Vapor
Recovery Tube
Rear Brake Fluid
Tube
Fuel Tank Inlet
Tube
Water Hose
Fuel Filler
Fuel Tank
Breather Tube
Throttle Cable
Front Stop
Switch
Wire Harness
Fuel Unit

1. GENERAL INFORMATION
1-17
DINK 200
Starter Relay
Oil Vapor
Recovery Tube
Carburetor
Fuel Tube
Ignition Coil
Auto Bystarter Wire
Thermostat
Carburetor
Overflow Tube
Air Cut-off
Valve (A.C.V.)

1. GENERAL INFORMATION
1-18
DINK 200
Starter Relay
Fuel Tube
Battery
Ignition Coil
Thermostat
Air Injection Air
Cleaner
Fuel Tube
CDI Unit
Auto Bystarter
Spark Plug Cap
Battery
Fuel Pump
Fuel Tube
Wire Harness
Spark Plug Cap
Throttle Cable
Positive Crankcase
Ventilation (PCV)
Vacuum Tee
Vacuum Tee
Fuel Pump
Ground Wire
Fuel Pump Vacuum Tube
Fuel Filter
Air Injection
Air Cleaner
Ignition Coil
Reed Valve