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KYMCO DINK 200i Service Manual

KYMCO DINK 200i
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14. DINK 200 i: FUEL SYSTEM (Auto Control Fuel Injection System)
14-36
TPS INSPECTION
(Using a commercially available
multimeter)
Input voltage
Turn ignition switch to ON with the engine
stop switch in the run position and put the
side stand up.
Disconnect throttle position sensor connector.
Connect the multimeter (+) probe to the
violet/red wire and the multimeter (-) probe
to the violet/green wire to measure the
voltage from the ECU input to throttle
position sensor.
Standard (20°C/68°F): 5±0.25 V
Resistance
Measure the resistance between the throttle
position sensor violet/red and violet/green
wire terminals.
Standard: 5K±30% " (20°C/68°F)
Be sure that the battery is in goo
d
condition before performing this
measurement.
Ï 

Table of Contents

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KYMCO DINK 200i Specifications

General IconGeneral
Displacement175.1 cc
Cooling SystemLiquid cooled
TransmissionCVT
Front SuspensionTelescopic fork
Front BrakeDisc
Rear BrakeDisc
Seat Height780 mm
Dry Weight148 kg
Front Tire120/70-12
Rear Tire130/70-12
StarterElectric
Length2050 mm
Engine TypeSingle cylinder, 4-stroke
Fuel SystemElectronic Fuel Injection

Summary

General Information

Specifications (DINK 200i)

Detailed technical specifications for the DINK 200i model, covering dimensions, engine, fuel system, and more.

Specifications (DINK 125)

Detailed technical specifications for the DINK 125 model, covering dimensions, engine, fuel system, and more.

Service Precautions

Essential safety and handling guidelines for servicing the vehicle.

Torque Values

Specific torque settings for critical fasteners across various engine and frame components.

Troubleshooting

Diagnostic guides for common engine performance issues and noises.

Exhaust Muffler/Frame Covers

Frame Covers Removal/Installation

Step-by-step instructions for removing and installing various frame body panels and covers.

Exhaust Muffler

Procedures for the removal and installation of the exhaust muffler system.

Inspection/Adjustment

Maintenance Schedule

Recommended intervals for routine inspection, cleaning, adjustment, and replacement of parts.

Spark Plug

Procedures for inspecting, cleaning, and checking the spark plug gap and condition.

Valve Clearance

Instructions for inspecting and adjusting valve clearance while the engine is cold.

Engine Oil

Guidance on engine oil selection, capacity, and checking the oil level.

Brake Fluid

Checks for brake fluid level, hose condition, and replacement/bleeding procedures.

Brake Pad Wear

Procedures for inspecting front and rear brake pad wear and replacement guidelines.

Lubrication System

Troubleshooting

Common issues related to lubrication system problems like low oil level or poor pressure.

Oil Pump

Detailed instructions for the removal, installation, and inspection of the engine oil pump.

Engine Removal/Installation

Torque Values

Specified torque values for engine mounting and hanger bolts during installation.

Removal

Step-by-step procedure for safely removing the engine from the vehicle frame.

Installation

Procedure for reinstalling the engine, including torque specifications and system checks.

Engine Hanger

Inspection and replacement of engine hanger bushings and stopper rubber for wear.

Cylinder Head/Valves

Specifications

Key specifications for cylinder head, camshaft, and valve components, including service limits.

Troubleshooting

Diagnosing issues related to poor cylinder head operation and engine noises.

Cylinder Head Cover

Procedure for removing and installing the cylinder head cover, including O-ring.

Camshaft Holder

Instructions for removing, installing, and adjusting camshaft holder and cylinder head nuts.

Camshaft

Steps for camshaft removal, inspection of lobes, and measurement of cam height.

Cylinder/Piston

Troubleshooting

Diagnosing issues related to cylinder compression and piston performance.

Cylinder and Piston

Procedures for removing the cylinder and piston, including inspection of rings and bore.

Drive and Driven Pulleys/Kick Starter

Troubleshooting

Common issues with the drive clutch and driven pulleys affecting engine operation.

Left Crankcase Cover

Steps for removing and installing the left crankcase cover, gasket, and dowel pins.

Drive Pulley, Drive Belt and Driven Pulley

Procedures for removing, inspecting, and installing the drive pulley, belt, and driven pulley assembly.

Final Reduction

Troubleshooting

Diagnosing issues with the final reduction gears, such as abnormal noise or transmission failure.

Final Reduction

Detailed steps for removing and inspecting the final reduction gears and components.

Bearing Replacement

Procedures for replacing bearings in the transmission case cover and transmission case.

A.C. Generator/Starter Clutch

Troubleshooting

Common issues with the starter motor, including failure to start or incorrect rotation.

Alternator Stator

Steps for removing, inspecting, and installing the alternator stator and pulse coil.

Starter Clutch

Procedure for removing, inspecting, and installing the starter clutch assembly.

Crankcase/Crankshaft

Troubleshooting

Diagnosing excessive engine noise, bearing play, or worn piston components.

Crankcase Separation

Detailed steps for separating the crankcase halves for crankshaft access.

Crankshaft Inspection

Procedures for inspecting crankshaft connecting rod clearance, small end ID, and runout.

Cooling System

Troubleshooting

Diagnosing issues like high engine temperature, coolant leaks, and gauge inaccuracies.

Coolant Replacement

Steps for preparing, draining, refilling, and bleeding air from the cooling system.

Radiator

Procedure for removing and installing the radiator, including hose and connector disconnections.

Water Pump

Inspection of the mechanical seal and removal/installation of the water pump and impeller.

DINK 125: Fuel System/Carburetor/Fuel Pump/ Fuel Tank

Specifications

Key specifications for the DINK 125 carburetor, including bore size, float level, and jet settings.

Troubleshooting

Common fuel system issues for the DINK 125, such as engine not starting or rough idling.

Carburetor

Detailed instructions for carburetor removal, installation, and disassembly.

Fuel Pump

Procedures for fuel pump removal, installation, testing, and disassembly for inspection.

DINK 200 i: Fuel System (Auto Control Fuel Injection System)

Troubleshooting

Diagnostic guides for common DINK 200i fuel system issues, including engine stalls and poor performance.

Check Engine Lamp (CELP)

Explanation of the CELP function and how it signals various fault conditions.

Self-Diagnostic Procedures without Diagnostic Tool

Steps for accessing and interpreting diagnostic codes using the ignition switch and throttle.

Self-Diagnosis Reset (Clear Failure Codes) Procedure

Instructions for clearing stored diagnostic trouble codes (DTCs) from the ECU memory.

Throttle Position Sensor Initial Procedure

Procedure to reset the throttle position sensor after throttle body replacement.

Engine Control Unit (ECU)

Guidelines for ECU removal, installation, inspection, and pin functions.

Temperature/Manifold Absolute Pressure Sensor (T-MAP)

Procedures for T-MAP sensor removal, installation, and inspection of input voltage and resistance.

Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Steering Stem

Troubleshooting

Common issues related to steering, suspension, and front brake performance.

Handlebar

Procedure for removing and installing the handlebar, switches, and master cylinders.

Front Wheel

Steps for removing, inspecting, and installing the front wheel, including runout checks.

Front Brake Fluid

Checks for fluid level and hose condition, and procedures for fluid replacement and air bleeding.

Front Brake Pad

Instructions for replacing the front brake pads and caliper mounting.

Brake Master Cylinder

Procedure for removing, disassembling, inspecting, and assembling the front brake master cylinder.

Front Brake Caliper

Steps for caliper disassembly, piston removal, and caliper assembly with new seals.

Front Shock Absorber

Procedure for removing, inspecting, and installing the front shock absorbers.

Steering Stem

Instructions for removing, inspecting, and installing the steering stem and bearings.

Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber

Troubleshooting

Diagnosing issues related to rear wheel wobble, poor brake performance, and suspension.

Rear Brake Fluid

Checks for rear brake fluid level and hose condition, and procedures for replacement and bleeding.

Rear Brake Pad

Instructions for replacing the rear brake pads and caliper mounting.

Brake Master Cylinder

Procedure for removing, disassembling, inspecting, and assembling the rear brake master cylinder.

Rear Brake Caliper

Steps for caliper disassembly, piston removal, and caliper assembly with new seals.

Rear Wheel/Rear Fork

Procedures for removing and installing the rear wheel, fork, and bearings.

Rear Shock Absorber

Procedure for removing, inspecting, and installing the rear shock absorbers.

Battery/Charging System

Troubleshooting

Diagnosing issues related to battery power, charging system failure, and intermittent power.

Battery

Procedure for battery removal, installation, voltage inspection, and charging.

Charging System

Tests for current leakage and charging voltage to diagnose charging system faults.

Alternator Charging Coil

Inspection of alternator charging coil resistance and continuity to ground.

Regulator/Rectifier

Inspection of wire harness, battery line, ground line, and charging coil line.

Ignition System

Specifications

Key specifications for spark plug, gap, ignition timing, and system types (ECU/CDI).

Troubleshooting

Diagnosing issues related to low peak voltage, no peak voltage, and no spark at the plug.

Ignition Coil Inspection

Procedure for checking primary peak voltage and ignition pulse generator resistance.

Starting System

Troubleshooting

Diagnosing issues with the starter motor, including failure to turn or rotating without starting.

Start Motor

Procedure for inspecting, removing, and installing the starter motor assembly.

Lights/Meters/Switches

Bulb Replacement

Instructions for replacing position light and headlight bulbs.

Headlight

Procedure for removing and installing headlight bulbs, dust cover, and connectors.

Handlebar Switch

Inspection of right and left handlebar switches for continuity.

Fuel Unit

Procedure for removing and installing the fuel unit, including float and meter checks.

Side Stand Switch

Inspection, removal, and installation of the side stand switch for proper operation.

Wiring Diagrams

DINK 200i

Complete wiring diagram for the DINK 200i model, illustrating electrical system layout.

DINK 125

Complete wiring diagram for the DINK 125 model, illustrating electrical system layout.

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