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DINK 200i
KYMCO DINK 200i Service Manual
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FRONT BRAKE PAD
BRAKE PAD REP
LACEMENT
Remove the two pad pins (1).
Remove the two caliper mounting bolts (2),
then remove the caliper.
Remove the brake pads.
Always replace the brake
pads in pairs to
ensure even disc pressur
e.
Ï
312
314
Table of Contents
Preface
2
Table of Contents
2
General Information
3
Serial Number
4
General Information
4
SPECIFICATION (DINK 200I)
5
Specification (Dink 125)
6
Torque Values
11
Special Tools
14
Lubrication Points
16
Cable & Harness Routing
18
General Information Dink
21
Inspection/Adjustment
34
TROUBLESHOOTING (DINK 200I)
34
Troubleshooting (Dink 125)
45
2. Exhaust Muffler/Frame Covers
56
Schematic Drawing
57
Service Information
58
Troubleshooting
58
Fastener Removal and Reinstallation
59
Frame Covers Removal/Installation
60
Exhaust Muffler
71
3. Inspection/Adjustment
73
Service Information
74
Maintenance Schedule
75
Fuel Line/Fuel Filter
77
Throttle Operation
77
Engine Oil
79
Transmission Oil
85
Air Cleaner
86
Secondary Air Supply System
87
Spark Plug
88
Valve Clearance
89
Idle Speed
90
Cylinder Compression
91
Drive Belt
91
Clutch Shoe Wear
92
Headlight Aim
92
Coolant
93
Brake Fluid
95
Brake Pad Wear
95
Nuts/Bolts/Fasteners
96
Wheels/Tires
96
Steering Handlebar
97
Suspension
97
Side Stand
98
4. Lubrication System
99
Lubrication System
99
Lubrication System
100
Lubrication System Diagram
100
Service Information
101
Troubleshooting
101
Oil Pump
102
Engine Removal/Installation
106
6 Cylinder Head/Valves
116
Cylinder Head/Valves
117
Schematic Drawing
117
Service Information
118
Troubleshooting
119
Cylinder Head Cover
120
Camshaft Holder
121
Camshaft
124
Cylinder Head
128
7. Cylinder/Piston
133
Cylinder/Piston
133
Cylinder/Piston
134
Schematic Drawing
134
Service Information
135
Troubleshooting
136
Cylinder and Piston
137
8. Drive and Driven Pulleys/
144
Drive and Driven Pulleys/Kick Starter
144
Drive and Driven Pulleys/ Kick Starter
145
Schematic Drawing
145
Service Information
146
Troubleshooting
147
Left Crankcase Cover
148
Drive Pulley, Drive Belt and Driven Pulley
152
9. Final Reduction
164
Final Reduction
164
Final Reduction
165
Schematic Drawing
165
Service Information
166
Troubleshooting
166
Final Reduction
166
Bearing Replacement
171
10. A.C. Generator/Starter Clutch
173
Generator/Starter Clutch
173
Generator/Starter Clutch
174
Schematic Drawing
174
Service Information
175
Troubleshooting
175
Alternator Stator
176
Starter Clutch
179
11. Crankcase/Crankshaft
183
Crankcase/Crankshaft
183
Crankcase/Crankshaft
184
Schematic Drawing
184
Service Information
185
Troubleshooting
185
Crankcase Separation
186
Crankshaft Inspection
187
Crankcase Assembly
188
12. Cooling System
191
Cooling System
191
Cooling System
192
Schematic Drawing
192
Dink
192
Service Information
193
Troubleshooting
193
Cooling System Testing
195
Coolant Replacement
196
Radiator
199
Fan Motor
201
Fan Motor Switch
202
Water Pump
203
Water Temperature Sensor
209
Thermostat
211
Dink 125:Fuel System/Carburetor/ Fuel Pump/Fuel Tank
214
Fuel System
215
Dink 125:Fuel System/Carburetor/ Fuel Pump/Fuel Tank
215
Schematic Drawing
216
Service Information
217
Fuel Pump Construction
218
Troubleshooting
219
Carburetor
220
Auto Choke
231
Carburetor Heater
234
Fuel Pump
235
Fuel Strainer
238
Fuel Tank
239
Air Cleaner
241
14 Dink 200 I: Fuel System (Auto Control Fuel Injection System) 14
242
DINK 200 I: FUEL SYSTEM (Auto Control Fuel Injection System)
244
System Location
244
Service Information
247
Troubleshooting
248
Check Engine Lamp (Celp)
249
Self-Diagnosis Procedures Without Dignostic Tool
250
Celp Failure Codes Chart
253
Diagnostic Tool (Pda)
259
Maintenance Menu (Using Diagnostic Tool)
266
Throttle Position Sensor Initial Procedure
268
Reset the Air by Pass Valve
269
Adapt Air Flow Per Cycle (Apc)
270
Apc Adaption Procedure
271
Spark Plug Anti-Flood
272
Engine Control Unit (Ecu)
273
Pressure Sensor (T-Map)
275
Temperature/Manifold Absolute
275
Throttle Body/Throttle Position Sensor
277
Water Temperature Sensor (Wts)
283
Fuel Injector
284
Fuel Pump
287
Fuel Tank
287
Fuel Pump Relay
288
O2/O2 Ht Sensor
293
Angle Detect Sensor
295
Air Cleaner
296
Handlebar/Front Wheel/Front Brake/ Front Shock Absorber/Steering Stem
297
Handlebar/Front Wheel/Front Brake/Front Shock
297
Troubleshooting
300
Handlebar
301
Front Wheel
305
Front Brake Fluid
309
Front Brake Pad
313
Brake Disc Inspection
315
Brake Master Cylinder
316
Front Brake Caliper
321
Front Shock Absorber
325
Steering Stem
326
Rear Brake/Rear Fork/Rear Wheel/ Rear Shock Absorber
329
Rear Brake/Rear Fork/Rear
329
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
330
Schematic Drawing
330
Service Information
331
Troubleshooting
332
Rear Brake Fluid
333
Rear Brake Pad
337
Brake Disc Inspection
339
Brake Master Cylinder
340
Rear Brake Caliper
345
Rear Wheel/Rear Fork
349
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
329
17. Battery/Charging System
355
Battery/Charging System
355
Troubleshooting
358
Battery
359
Charging System
361
Alternator Charging Coil
363
Regulator/Rectifier
364
Ignition System
367
Starting System
377
20. Lights/Meters/Switches
383
5
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KYMCO DINK 200i Specifications
General
Brand
KYMCO
Model
DINK 200i
Category
Scooter
Language
English
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