KYMCO DINK 200 User Manual

7. CYLINDER/PISTON
7-2
DINK 200
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• The cylinder and piston can be serviced with the engine installed in the frame.
• When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are
correctly installed.
• After disassembly, clean the removed parts and dry them with compressed air before inspection.
SPECIFICATIONS
Standard (mm)
Service Limit (mm)
Item
SH40AA
SH40AA
I.D.
62.005_ 62.015
62.10
Warpage
0.01
0.05
Cylindricity
0.01
0.05
True roundness
0.01
0.05
Ring-to-groove
top
0.015_ 0.050
0.09
clearance
Second
0.015_ 0.050
0.09
top
0.15_ 0.30
0.50
Piston,
Ring end gap
Second
0.15_ 0.30
0.50
piston ring
Oil side rail
0.2_ 0.9

Piston O.D.
61.993_ 61.995
61.90
Piston O.D. measuring position
9mm from bottom of skirt
.
Piston-to-cylinder clearance
0.010_ 0.040
0.01
Piston pin hole I.D.
15.002_ 15.008
15.04
Piston pin O.D
14.994_ 15.000
14.96
Piston-to-piston pin clearance
0.002_ 0.014
0.02
Connecting rod small end I.D. bore
15.016_ 15.034
15.06
TROUBLESHOOTING
• When hard starting or poor performance at low speed occurs, check the crankcase breather for
white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.
Compression too low or uneven
compression Excessive smoke from exhaust muffler
• Worn or damaged cylinder and piston rings • Worn or damaged piston rings
• Worn, stuck or broken piston rings • Worn or damaged cylinder and piston
Compression too high Abnormal noisy piston
• Excessive carbon build-up in combustion • Worn cylinder, piston and piston rings
chamber or on piston head • Worn piston pin hole and piston pin
• Incorrectly installed piston
Cylinder

KYMCO DINK 200 Specifications

General

Brand	KYMCO
Model	DINK 200
Category	Scooter
Language	English