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Dink 50
KYMCO Dink 50 User Manual
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8
.
DRIVE AND DRIVEN PULLEYS/
KICK STARTER
8-29
D
I
N
K
5
0
/
1
2
5
Remove the weight rollers.
MOVABLE DRIVE FACE INSPECTION
Check each weight roller for wear or damage.
Measure each roller O.D.
Service Limit
: 15.4mm replace if below
DRIVE PULLEY INSTALLATION
Install the drive pulley collar and movable
drive face onto the crankshaft.
Weight Rolle
r
Drive Pulley Colla
r
Movable Drive Face
191
193
Table of Contents
Table of Contents
1
General Information
1
Serial Number
2
Specifications (DINK 50)
3
Specifications (DINK 125)
4
Service Precautions
5
Symbols
8
Torque Values
9
Special Tools
12
Lubrication Points
14
Frame
15
Cable & Harness Routing (Dink 125)
16
Cable and Harness Routing (DINK 50)
31
Engine will Not Start or Is Hard to Start
36
Troubleshooting
36
Engine Lacks Power
37
Poor Performance (Especially at Idle and Low Speeds)
38
Poor Performance (at High Speeds)
39
Engine Noise
40
Clutch, Drive and Driven Pulleys
41
Starter Motor Does Not Stop Turning
42
Starter Motor Turns Slowly or Idles
42
Starter Motor Won‘t Turn
42
No Spark at Spark Plug
43
Poor Charging (Battery over Discharging or Overcharging)
44
Fuel Gauge Troubleshooting
45
Pointer Does Not Register Correctly (Ignition Switch ON)
45
Pointer Fluctuates or Swings (Ignition Switch ON)
45
Poor Brake Performance
46
Poor Suspension Performance
46
Steering Handlebar Does Not Track Straight
46
Exhaust Muffler/Frame Covers
47
Schematic Drawing
48
Exhaust Muffler/Frame Covers - Service Information
49
Troubleshooting
49
Fastener Removal and Installation
50
Frame Covers Removal/Installation
51
Luggage Box
51
Seat
51
Center Cover
52
Rear Spoiler/Rear Spoiler Stay
52
Upper/Lower Handlebar Cover
53
Windshield/Windshield Garnish
54
Front Cover
55
Front Meter Visor
55
Front Fender
56
Right/Left Foot Skirt
56
Body Cover
57
Front Lower Cover
57
Rear Fender
57
Floorboard
58
Rear Combination Light under Cover
58
Under Cover
59
Meter Panel
60
Inner Cover
61
Exhaust Muffler Removal/Installation
62
Inspection/Adjustment
63
Coolant Capacity
64
Inspection/Adjustment - Service Information
64
Inspection/Adjustment - Specifications
64
Tire Specifications
64
Maintenance Schedule
65
Fuel Line/Fuel Filter Check
67
Throttle Operation Check
67
Engine Oil Capacity
68
Engine Oil Recommendation
68
Engine Oil Level Check
69
Engine Oil Replacement
69
Oil Strainer Screen Clean
71
Oil Filter Replacement (DINK 125 Only)
72
Transmission Oil Change
74
Air Cleaner Element Replacement
75
Secondary Air Supply System Check
76
Spark Plug Check
77
Valve Clearance (DINK 125) Check
78
Valve Clearance (DINK 50) Check
79
Carburetor Idle Speed Check
80
Cylinder Compression Check
81
Drive Belt
81
Clutch Shoe Wear
82
Headlight Aim
82
Coolant (DINK 125 Only) Inspection
83
Coolant Recommendation
83
Brake Fluid Level Check
84
Brake Pad Wear Check
84
Nuts/Bolts/Fasteners Check
85
Tire Pressure
85
Wheels/Tires Check
85
Rear Suspension Adjustment
86
Steering Handlebar Check
86
Suspension Check
86
Side Stand Check
87
Lubrication System
88
Lubrication System (DINK 125) View
89
Lubrication System (DINK 50) View
90
Lubrication System - Service Information
91
Lubrication System Diagram
91
Lubrication System Specifications
91
Lubrication System Troubleshooting
91
Oil Pump (DINK 125) Removal
92
Oil Pump(125)
92
Oil Pump (DINK 125) Installation
93
Oil Pump (DINK 125) Disassembly
94
Oil Pump (DINK 125) Inspection
94
Oil Pump (DINK 125) Assembly
95
Oil Pump (DINK 50) Removal
96
Oil Pump (DINK 50) Disassembly
97
Oil Pump (DINK 50) Inspection
97
Oil Pump (DINK 50) Assembly
98
Oil Pump (DINK 50) Installation
99
Engine Removal/Installation
101
Engine Hanger
102
Engine Removal/Installation - Service Information
102
Engine Removal/Installation - Specifications
102
Engine Removal/Installation - Torque Values
102
Engine (DINK 125) Removal
103
Engine Removal/Installation(Dink 50)
103
Engine (DINK 125) Installation
107
Engine (DINK 125) Inspection
108
Engine Hanger Removal/Installation/Inspection
109
Engine (DINK 50) Removal
110
Engine Hanger Bracket Removal
113
Engine (DINK 50) Installation
114
Engine Hanger Bracket Inspection
114
Cylinder Head/Valves
115
Cylinder Head/Valves Schematic Drawing (DINK 125)
116
Cylinder Head/Valves Schematic Drawing (DINK 50)
117
Cylinder Head/Valves Service Information
118
Cylinder Head/Valves Specifications (DINK 125)
118
Cylinder Head/Valves Specifications (DINK 50)
119
Cylinder Head/Valves - Special Tools
120
Cylinder Head/Valves Torque Values (DINK 125)
120
Cylinder Head/Valves Troubleshooting
120
Cylinder Head Cover (DINK 125) Removal/Installation
121
Camshaft Holder Installation
122
Camshaft Holder Removal
122
Camshaft Holder Disassembly
123
Camshaft Holder Inspection
123
Camshaft Holder Assembly
124
Camshaft Removal
125
Cam Chain Tensioner Inspection
126
Camshaft Inspection
126
Camshaft Installation
127
Cylinder Head Removal
129
Cylinder Head Installation
130
Cylinder Head Disassembly
131
Cylinder Head Inspection
132
Valve Spring Check
132
Valve/Valve Guide Check
132
Cylinder Head Assembly
133
Cylinder Head Check
133
Camshaft/Camshaft Holder Removal
134
Cylinder Head Cover Installation
134
Cylinder Head Cover Removal
134
Camshaft
136
Camshaft Inspection/Installation
138
Valve/Valve Guide Inspection
141
Valve Spring Inspection
142
Valve Spring Compressor E040
143
Cylinder/Piston
145
Cylinder/Piston Schematic Drawing (DINK 125)
146
Cylinder/Piston Schematic Drawing (DINK 50)
147
Cylinder/Piston Service Information
148
Cylinder/Piston Specifications (DINK 125)
148
Cylinder/Piston Specifications (DINK 50)
149
Cylinder/Piston Troubleshooting
149
Cylinder/Piston (DINK 125) Removal
150
Piston Ring Inspection
151
Piston/Piston Pin Inspection
152
Cylinder Inspection
153
Piston Ring Installation
154
Cylinder/Piston (DINK 50) Removal
157
Cylinder/Piston (DINK 50) Inspection
158
Cylinder Inspection (DINK 50)
160
Piston Ring Installation (DINK 50)
161
Cylinder Installation (DINK 50)
162
Piston Installation (DINK 50)
162
Drive and Driven Pulleys/Kick Starter
163
Drive and Driven Pulleys/Kick Starter Schematic Drawing (DINK 125)
164
Drive and Driven Pulleys/Kick Starter Schematic Drawing (DINK 50)
165
Drive and Driven Pulleys/Kick - Service Information
166
Drive and Driven Pulleys/Kick Starter Specifications
166
Drive and Driven Pulleys/Kick Torque Values
167
Drive and Driven Pulleys/Kick Troubleshooting
167
Left Crankcase Cover (DINK 125) Removal/Installation
168
Left Crankcase Cover (DINK 125) Disassembly
170
Left Crankcase Cover (DINK 125) Inspection
171
Left Crankcase Cover (DINK 125) Assembly
172
Drive Pulley, Drive Belt and Driven Pulley Removal
173
Clutch out Inspection
174
Drive Belt Inspection
174
Drive Pulley, Drive Belt and Driven Pulley Installation
175
Drive Pulley Disassembly
177
Drive Pulley Inspection
178
Movable Drive Face/Slide Pieces/Drive Pulley Face Check
178
Weight Rollers Check
178
Drive Pulley Assembly
179
Driven Pulley Disassembly
181
Driven Pulley Inspection
183
Driven Pulley Assembly
184
Kick Starter (DINK 50) - Left Crankcase Cover Removal
185
Kick Starter Spindle Removal
185
Kick Starter Spindle Inspection
186
Kick Starter Installation
187
Left Crankcase Cover Installation
188
Drive Belt Inspection/Replacement
189
Drive Belt Installation
190
Drive Pulley Removal
191
Movable Drive Face Disassembly
191
Movable Drive Face Inspection
192
Starter Gear Removal/Inspection/Installation
193
Clutch/Driven Pulley Disassembly
194
Clutch/Driven Pulley Removal
194
Clutch/Driven Pulley Inspection
195
Clutch/Driven Pulley Assembly
197
Clutch/Driven Pulley Installation
198
Final Reduction
199
Final Reduction Schematic Drawing (DINK 125)
200
Final Reduction Schematic Drawing (DINK 50)
201
Schematic Drawing(Dink 50)
201
Final Reduction - Service Information
202
Final Reduction Specifications
202
Final Reduction Troubleshooting
202
Final Reduction(Dink 125)
202
Final Reduction Removal
203
Final Reduction Inspection
204
Final Reduction Installation
205
Bearing Replacement
207
Transmission Case
207
Transmission Case Cover
207
Driveshaft Bearing
208
Final Reduction Disassembly (DINK 50)
209
Final Reduction Inspection (DINK 50)
209
Bearing Replacement (Left Crankcase Cover)
211
Bearing Replacement (Transmission Case Cover)
211
Final Reduction Assembly
212
Generator/Starter Clutch
215
Generator/Starter Clutch Schematic Drawing (DINK 125)
216
Generator/Starter Clutch Schematic Drawing (DINK 50)
217
Schematic Drawing(Dink 50)-1
217
Schematic Drawing(Dink 50)-2
218
Generator/Starter Clutch - Service Information
219
Generator/Starter Clutch Specifications
219
Generator/Starter Clutch Troubleshooting
219
Alternator Stator (DINK 125) Removal
220
Alternator Stator (DINK 125) Inspection
221
Alternator Stator (DINK 125) Installation
221
Starter Clutch (DINK 125) Removal
223
Starter Clutch (DINK 125) Inspection
224
Starter Clutch (DINK 125) Installation
225
AC Generator (DINK 50) Removal
227
AC Generator Installation
228
Crankcase/Crankshaft
231
Crankcase/Crankshaft Schematic Drawing (DINK 125)
232
Crankcase/Crankshaft Schematic Drawing (DINK 50)
233
Crankcase/Crankshaft - Service Information
234
Crankcase/Crankshaft Specifications
234
Crankcase/Crankshaft Troubleshooting
234
Crankcase Separation (DINK 125)
235
Crankshaft Inspection
236
Crankcase Assembly
237
Crankcase/Crankshaft (DINK 50) Removal
240
Crankshaft Inspection (DINK 50)
242
Crankcase/Balancer Installation
243
Cooling System
244
Cooling System Schematic Drawing
245
Cooling System(Dink 125 Only)
245
Cooling System - Service Information
246
Cooling System Torque Values
246
Cooling System Troubleshooting
246
Coolant Mixture (with Anti-Rust and Anti-Freezing Effects)
247
Cooling System Specifications
247
Goolant Gravity
247
Cooling System Testing
248
Radiator Cap Inspection
248
Coolant Replacement/Air Bleeding
249
Radiator Removal
252
Radiator Installation
253
Fan Motor Inspection
254
Fan Motor Installation
254
Fan Motor Removal
254
Fan Motor Switch Inspection
255
Fan Motor Switch Installation
255
Fan Motor Switch Removal
255
Mechanical Seal (Water Seal) Inspection
256
Water Pump
256
Water Pump/Impeller Removal
256
Water Pump Shaft Removal
258
Mechanical Seal Replacement
259
Water Pump Shaft Installation
259
Water Pump/Impeller Installation
260
Water Temperature Sensor Inspection
262
Water Temperature Sensor Removal
262
Water Temperature Sensor Installation
263
Thermostat Installation
264
Thermostat Removal
264
Thermostat Disassembly
265
Thermostat Assembly
266
Thermostat Inspection
266
Thermostat Technical Data
266
Fuel System/Carburetor/Fuel Pump/Fuel Tank
267
Fuel System View (DINK 125)
268
Fuel System Schematic Drawing (DINK 125)
269
Fuel System Schematic Drawing (DINK 50)
270
Fuel System/Carburetor/Fuel Pump/Fuel Tank Service Information
271
Fuel System/Carburetor/Fuel Pump/Fuel Tank Specifications
271
Fuel Pump Construction
272
Fuel System/Carburetor/Fuel Pump/Fuel Tank Troubleshooting
273
Carburetor (DINK 125) Removal/Installation
274
Carburetor (DINK 125) Disassembly
276
Carburetor (DINK 125) Inspection
280
Carburetor Body/Jets Cleaning
280
Carburetor (DINK 125) Assembly
284
Auto Choke Inspection
285
Auto Choke Removal
285
Auto Choke Installation
286
Carburetor Heater Inspection/Replacement
288
Fuel Pump Removal/Installation
289
Fuel Pump Testing
289
Fuel Pump Disassembly
290
Fuel Pump Inspection
290
Fuel Pump Assembly
291
Fuel Strainer Inspection
292
Fuel Strainer Removal/Installation
292
Fuel Tank Removal/Installation
293
Air Cleaner Removal/Installation
295
Carburetor (DINK 50) Removal
296
Vacuum Chamber Disassembly
297
Float Chamber Disassembly
298
Vacuum Piston Inspection
298
Float Valve Inspection
299
Jets/Screws Removal
299
Auto Bystarter Inspection
301
Auto Bystarter Removal
301
Air Cut-Off Valve (ACV) Removal
302
Carburetor Body Cleaning
303
Accelerator Pump Disassembly/Inspection
304
Auto Bystarter Installation
304
Float Chamber Assembly
305
Float Level Inspection
306
Vacuum Chamber Assembly
306
Carburetor Installation
307
Fuel Pump Installation
309
Fuel Pump Removal
309
Fuel Strainer Installation
310
Fuel Strainer Removal
310
Fuel Tank Removal (DINK 50)
310
Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Steering Stem
311
Troubleshooting
314
Handlebar Removal
315
Handlebar Installation
316
Handlebar Disassembly
317
Handlebar Assembly
318
Axle Runout Inspection
319
Front Wheel Removal
319
Wheel Rim Inspection
319
Front Wheel Installation
320
Front Wheel Disassembly
321
Front Brake Fluid Check
323
Front Brake Fluid Replacement/Air Bleeding
323
Brake Fluid Draining
324
Brake Fluid Filling/Air Bleeding
325
Front Brake Pad Replacement
327
Brake Disc Inspection
329
Brake Master Cylinder Removal
330
Brake Master Cylinder Installation
331
Brake Master Cylinder Assembly
333
Brake Master Cylinder Disassembly
333
Brake Master Cylinder Inspection
334
Front Brake Caliper Disassembly
335
Front Brake Caliper Assembly
337
Front Brake Caliper Inspection
338
Front Shock Absorber Inspection
339
Front Shock Absorber Installation
339
Front Shock Absorber Removal
339
Steering Stem Removal
340
Steering Stem Installation
342
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber
343
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber Drawings
344
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber Specifications
346
Service Information
346
Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber Troubleshooting
347
Rear Brake Fluid (DINK 125 Only)
348
Brake Fluid Draining (Rear)
349
Brake Fluid Filling/Air Bleeding (Rear)
350
Rear Brake Pad (DINK 125) Replacement
352
Brake Disc Inspection (Rear)
354
Brake Master Cylinder Removal (Rear)
355
Brake Master Cylinder Installation (Rear)
356
Brake Master Cylinder Assembly (Rear)
358
Brake Master Cylinder Disassembly (Rear)
358
Brake Master Cylinder Inspection (Rear)
359
Rear Brake Caliper Disassembly
360
Rear Brake Caliper Assembly
362
Rear Brake Caliper Inspection
363
Rear Wheel/Rear Fork Removal
364
Rear Fork Bearing Replacement
365
Rear Wheel/Rear Fork Inspection
365
Rear Fork Bearing Installation
367
Rear Shock Absorber Removal/Inspection/Installation
369
Rear Wheel (DINK 50) Inspection
370
Rear Wheel (DINK 50) Installation
370
Rear Wheel (DINK 50) Removal
370
Rear Brake Check
371
Rear Brake Disassembly
371
Rear Brake Lining Inspection
371
Rear Brake Assembly
372
Rear Shock Absorber Installation
373
Rear Shock Absorber Removal
373
Battery/Charging System
374
Charging Circuit Diagram (DINK 125)
375
Charging System Layout (DINK 125)
375
Charging Circuit Diagram (DINK 50)
376
Charging System Layout (DINK 50)
376
Battery/Charging System Service Information
377
Battery/Charging System Specifications
378
Battery/Charging System Troubleshooting
379
Battery (DINK 125) Removal/Installation
380
Battery Charging
381
Voltage Inspection
381
Charging System Inspection
382
Current Leakage Test
382
Charging Voltage Inspection
383
Alternator Charging Coil Inspection
384
Battery Line Check
385
Ground Line Check
385
Regulator/Rectifier - Wire Harness Inspection
385
Charging Coil Line Check
386
Regulator/Rectifier Removal/Installation
386
Regulator/Rectifier Inspection (DINK 50)
387
Ignition System
388
Ignition Circuit Diagram (DINK 125)
389
Ignition System Layout (DINK 125)
389
Ignition System Layout (DINK 50)
390
Ignition System - Service Information
391
Ignition System Specifications
391
Ignition System Troubleshooting
391
Ignition Coil Inspection
392
Ignition Coil Primary Peak Voltage
392
Ignition Coil Removal/Installation
393
Ignition Pulse Generator Inspection
393
CDI Removal/Installation
394
CDI Resistance Inspection
394
CDI (DINK 50) Removal/Installation
396
CDI (DINK 50) Resistance Inspection
396
Starting System
397
Starting Circuit (DINK 125)
398
Starting System Layout (DINK 125)
398
Starting Circuit (DINK 50)
399
Starting System Layout (DINK 50)
399
Starting System Service Information
400
Starting System Specifications
400
Starting System Troubleshooting
400
Starter Motor Inspection
401
Starter Motor Removal
401
Starter Motor Installation
402
Starter Relay Inspection
403
Lights/Meters/Switches
407
Lights/Meters/Switches - Service Information
408
Position Light Bulb Replacement
409
Headlight Bulb Replacement
410
Front Turn Signal Light Bulb Replacement
411
Taillight/Brake Light/Rear Turn Signal Light Bulb Replacement
411
License Light Bulb Replacement
412
Rear Turn Signal Light Bulb Replacement
412
Taillight/Brake Light Bulb Replacement
412
Brake Light Switch
413
Ignition Switch Inspection
413
Right Handlebar Switch
414
Handlebar Switch Inspection
414
Left Handlebar Switch
415
Luggage Box Light Switch Inspection
416
Fuel Unit Removal
417
Fuel Unit Inspection
418
Fuel Unit Installation
419
Side Stand Switch (DINK 125 Only) Inspection
420
Side Stand Switch (DINK 125 Only) Removal
420
Side Stand Switch (DINK 125 Only) Installation
420
Horn Inspection
421
Horn Removal/Installation
421
Heater Controller Unit (DINK 125 Only) Inspection
422
Heater Controller Unit (DINK 125 Only) Removal/Installation
422
DINK 125 Wiring Diagram
423
DINK 50 Wiring Diagram
424
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KYMCO Dink 50 Specifications
General
Brand
KYMCO
Model
Dink 50
Category
Scooter
Language
English
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