KYMCO DINK 200i Service Manual

7. CYLINDER/PISTON
7-2
DINK 200i/125
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
Unit: mm (in)
Ite
m
Standar
d
Service Limit
DINK 200i 62Д62.015 (2.48Д2.4806) 62.1 (2.484)
I.D.
DINK 125 52.4Д52.41 (2.096Д2.0964) 52.5 (2.1)
Warpage
!
0.05 (0.002)
Cylindricity
!
0.05 (0.002)
Cylinder
True roundness
!
0.05 (0.002)
Ring-to-groove Top
0.015Д0.05 (0.006Д0.002) 0.09 (0.0036)
clearance
Second
0.015Д0.05 (0.006Д0.002) 0.09 (0.0036)
Top
0.15Д0.3 (0.006Д0.012) 0.5 (0.02)
Ring end gap Second
0.15Д0.3 (0.006Д0.012) 0.5 (0.02)
Oil side rail
0.2Д0.9 (0.008Д0.036)
!
DINK 200i
61.995Д61.975 (2.4878Д2.479) 61.9 (2.476)
Piston O.D.
DINK 125
52.37Д52.39 (2.0948Д2.0956) 52.3 (2.092)
DINK 200i
5 mm (0.2 in) from bottom of skirt !
Piston O.D.
measuring
position
DINK 125
9 mm (0.36 in) from bottom of skirt !
Piston-to-cylinder clearance
0.01Д0.04 (0.0004Д0.0016) 0.1 (0.004)
Piston,
piston ring
Piston pin hole I.D.
15.002Д15.008 (0.60008Д0.6
0032) 15.04 (0.6016)
Piston pin O.D
14.994Д15 (0.59976Д0.6) 14.96 (0.5984)
Piston-to-piston pin clearance
0.002Д0.014 (0.00008Д0.00056) 0.02 (0.0008)
Connecting rod small end I.D. bore
15.016Д15.034 (0.60064Д0.60136) 15.06 (0.6024)

KYMCO DINK 200i Specifications

General

Displacement	175.1 cc
Cooling System	Liquid cooled
Transmission	CVT
Front Suspension	Telescopic fork
Front Brake	Disc
Rear Brake	Disc
Seat Height	780 mm
Dry Weight	148 kg
Front Tire	120/70-12
Rear Tire	130/70-12
Starter	Electric
Length	2050 mm
Engine Type	Single cylinder, 4-stroke
Fuel System	Electronic Fuel Injection