Kymco Dink 125 User Manual

DINK 125

OWNER'S MANUAL

KWANG YANG MOTOR CO.,LTD.

Issued: JUN.30.2006

FOREWORD

Thank you for purchasing this KYMCO scooter and welcome to the family of KYMCO scooter riders.

Please read this owner's manual carefully before riding so that you will be thoroughly familiar with the proper operation of your scooter controls, its features, capabilities, and limitations.

To ensure a long, trouble-free life for your scooter, give it the proper care and maintenance described in this manual.

For replacement parts and accessories, we recommend genuine KYMCO products. They've been specially designed for your vehicle and manufactured to meet KYMCO's demanding standards.

Keep this owner's manual aboard your scooter at all time so that you can refer to it whenever you need information. This manual should be considered a permanent part of the scooter and should remain with the scooter when it is sold.

All information, illustrations, photographs and specifications contained in this manual are based on the latest product information available at the time of publication. Due to improvements or other changes, there may be some discrepancies in this manual. KYMCO reserves the right to make changes at any time without notice and without incurring any obligation.

READ THIS MANUAL CAREFULLY

Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this scooter should carefully read and understand the contents of this manual before riding the scooter.

SPECIAL MESSAGES

Please read this manual and follow its instructions carefully. To emphasize special information the words , and carry special meanings and should be carefully reviewed.

WARNING CAUTION Note

WARNING

CAUTION

NOTE:

The Owner's Manual should be considered a permanent part of your scooter. It should remain with the vehicle at all times and stay with the scooter if it is sold.

Indicates a strong possibility that serious injury or death may

result if instructions are not followed.

Indicates a possibility that equipment or property damage

could result if instructions are not followed.

Gives helpful information

ON-ROAD USE

This scooter is designed to be used only on the road.

CONTENTS

Page Page

SCOOTER SAFETY........................1

IMPORTANT SAFETY

INFORMATION................................1

PROTECTIVE APPAREL...................3

LOAD LIMITS AND GUIDELINES.......5

PARTS LOCATION..........................8

FRAME NUMBER............................12

ENGINE NUMBER...........................13

KEY NUMBER.................................14

CONTROLS..................................15

KEYS.............................................15

IGNITION SWITCH..........................15

INSTRUMENT AND INDICATORS....16

RIGHT HANDLEBAR SWITCH..........24

LEFT HANDLEBAR SWITCH............27

BRAKES.........................................29

FUEL FILL CAP................................30

SEAT..............................................32

CENTER COMPARTMENT/CENTER

COMPARTMENT LIGHT...................33

HELMET HOLDERS.........................34

CENTER HOOK ...............................35

PASSENGER FOOTPEG ..................36

STAND...........................................37

SUSPENSION.................................39

PRE-RIDE INSPECTION...............40

OPERATION.................................41

STARTING THE ENGINE.................41

RIDING...........................................45

(Cont'd)

Page Page

PARKING........................................49

BREAK-IN (RUNNING IN)................51

INSPECTION AND

MAINTENANCE............................53

THE IMPORTANCE OF

MAINTENANCE..............................53

MAINTENANCE SCHEDULE............54

TOOL KIT........................................57

CRANKCASE BREATHER...............57

ENGINE OIL...................................58

TRANSMISSION OIL.......................66

AIR CLEANER................................67

THROTTLE OPERATION.................68

IDLE SPEED...................................69

SPARK PLUG..................................70

COOLANT.......................................71

FRONT AND REAR SUSPENSION

INSPECTION..................................73

SIDE STAND...................................74

BRAKE FLUID................................75

BRAKE PAD WEAR........................76

BATTERY........................................77

FUSE REPLACEMENT....................80

TIRES............................................82

CLEANING...................................86

STORAGE GUIDE.........................91

SPECIFICATIONS.........................94

SCOOTER SAFETY

IMPORTANT SAFETY INFORMATION

Your scooter can provide many years of service and pleasure, if you take responsibility for your own safety and understand the challenges that you can meet on the road. There is much that you can do to protect yourself when you ride. You will find many helpful recommendations throughout this manual. Following are a few that we consider most important.

Wear a helmet

Scooter safety equipment starts with a quality helmet. One of the most serious injuries that can happen is a head injury. Always wear a properly approved helmet. You should also wear suitable eye protection.

Make yourself easy to see

To make yourself more visible, wear bright reflective clothing, position yourself so other drivers can see you, signal before turning or changing lanes, and use your horn when it will help others notice you.

Know your limits

Ride within the boundaries of your own skill at all times. Knowing these limits and staying within them will help you to avoid accidents.

Keep your scooter in safe condition

For safe riding, it's important to inspect your scooter before every ride and perform all recommended maintenance. Never exceed load limits, and only use accessories that have been approved by KYMCO for this scooter.

Inspection before riding

Do not forget to perform an entire safety inspection to ensure the safety of the rider.

Be extra safety conscious on bad weather days

Riding on bad weather days, especially wet ones, requires extra caution. Braking distance double on a rainy day. Stay off of the painted surface marks, manhole covers and greasy appearing areas as they can be especially slippery. Use extreme caution at railway crossings and on metal gratings and bridges. Whenever in doubt about road conditions, slow down.

Modification

Modification of the scooter, or removal of original equipment may render the vehicle unsafe or illegal. Obey all applicable equipment regulations in your area.

PROTECTIVE APPAREL

For your safety, we strongly recommend that you always wear an approved scooter helmet, eye protection, boots, gloves, long pants, and a long-sleeved shirt or jacket whenever you ride.

Helmets and protection

Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. A helmet should fit your head comfortably and securely. Always wear a face shield or goggles to protect your eyes and help your vision.

Additional riding gear

In addition to a helmet and eye protection, we also recommend:

Sturdy boots with non-slip soles to help protect your feet and ankles.

Leather gloves to keep your hands warm and help prevent blisters, cuts, burns and

bruises. A scooter riding suit or jacket for comfort as well as protection. Bright-colored and reflective clothing can help make you more noticeable in traffic. Be sure to avoid loose clothes that could get caught on any part of your scooter.

(1) (2)

(5)

(3)

(4)

(1)Wear gloves. (2)Clothes should be close-fitting. (3)Always wear an helmet. You

should also wear a face shield or goggles.

(4)Wear bright or reflective

clothing.

(5)Shoes should be close-fitting,

have low heels and offer ankle protection.

WARNING

Not wearing a helmet increases the chance of serious injury or death in a crash.

Be sure you and your passenger always wear an approved motorcycle helmet that fits properly. You should also wear eye protection and other protective apparel when you ride.

LOAD LIMITS AND GUIDELINES

These general guidelines may help you decide whether or how to equip your scooter and how to load it safely.

Center compartment weight limit:10 kg (22 lbs)

Load limits

Following are the load limits for your scooter:

Maximum weight capacity (Includes the weight of the rider, passenger, all cargo and All accessories.): 163 kg (358 lbs)

Maximum cargo weight: 18 kg (40 lbs)

Overloading the individual storage compartments can also affect stability and handling. So be sure to stay within the limits given below:

Maximum weight: In center compartment 10 kg (22 lbs) On rear carrier 5 kg (11 lbs) On helmet hook 3 kg (6 lbs)

Rear carrier weight limit:5 kg (11 lbs)

Helmet hook weight limit:3 kg (6 lbs)

Loading guidelines

Improperly loading your scooter can affect its stability and handling. You should ride at reduced speeds whenever carrying cargo. Follow these guidelines whenever you carry a passenger or cargo:

Check that both tires are properly inflated.



To prevent loose items from creating a hazard, make sure that all cargo is securely tied down before you ride away Place cargo weight as close to the center of the scooter as possible.



Balance cargo weight evenly on both sides.



WARNING

Overloading or improper loading can cause changes in vehicle handling, stability and braking which could lead to an accident.

Never exceed the stated load capacity for this scooter.

Cargo should be properly distributed and securely attached.

Reduce speed when carrying cargo. Allow greater distance for braking.

Accessories and Modification

There are great variety of accessories available to KYMCO owners. KYMCO cannot have direct control over the quality or suitability of accessories you may wish to purchase. The addition of unsuitable accessories can lead to unsafe operating conditions. It is not possible for KYMCO to test each accessory on the market or combinations of all the available accessories; however, your dealer can assist you in selecting quality accessories and installing them correctly. Use extreme caution when selecting and installing the accessories for your scooter.

WARNING

Improper accessories or modifications can make your scooter unsafe and can lead to an accident.

Never modify this scooter through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine KYMCO or equivalent components designed for use on this scooter and should be installed and used according to instruction. If you have question, consult an authorized KYMCO dealer.

No modifications

We strongly advise you not to remove any original equipment or modify your scooter in any way that would change its design or operation.

PARTS LOCATION

(02)

(03)

(04)

(01)

(07)

(01) Right rearview mirror (02) Instruments/Indicators

Left rearview mirror

(03)

Passing light control switch/

(04)

Headlight dimmer switch/ Turn signal switch/ Horn button Left rear suspension spring

(05)

preload adjuster Right rear suspension spring

(06)

preload adjuster Engine stop switch/Headlight

(07)

switch/Start button

(05)

(06)

(14)

(08)

Front brake lever

(09)

Throttle grip

(10)

Front brake fluid reservoir

(11)

Ignition switch (12) Fuel fill cap (13)

Rear brake fluid reservoir

(14)

Rear brake lever

(13)

(12)

(11)

(10)

(09)

(18)

(17)

(15)(16)

(15) Battery/Fuse box/

Spare fuse

(16)

Center compartment

(17)

Helmet holder

(18)

Coolant fill cap

(19) Coolant level (20) Side stand (21) Center stand (22) Left passenger footpeg (23) Air cleaner

(19)

(20)

(21)

(22)

(23)

(25)

(24)

(26) (27)

(24) Helmet hook (25) Seat (26) Right passenger footpeg (27) Oil filler cap/Dipstick

FRAME NUMBER

The read frame number (1), please remove the cover on inner cover with a flat head screwdriver. Always check that the frame number stamped on your scooter is the same written in document and warranty scooter is the same written in document and warranty card. Please write down your frame number in place below.

FRAME NUMBER:

(1)

ENGINE NUMBER

The engine number is stamped on left engine case. Please write down your engine number in place below.

ENGINE NUMBER:

KEY NUMBER

The key number (1) will be needed when you order replacement part. Record the number for your reference.

IGNITION KEY NUMBER:

(1)

CONTROLS

KEYS

This scooter has two ignition switch keys and shutter keys.

IGNITION SWITCH

Function

“ ” Position: All electrical circuits are cut off. The engine will not start.

" ” Position: The ignition circuit is completed and engine can now be started. The key cannot be removed from the ignition switch.

“ ” Position: To lock the steering, turn the handlebar all the way to the left. Push down and turn the key to the " ” position and remove the key. All electrical circuits are cut off.

“ ” Position: To open the fuel fill cap, turn the key to the " ” position. Make sure that the key is at the " ” position when starting the engine.

INSTRUMENT AND INDICATORS

(1)

(2) (3) (4)

(5)

(10)

(9)

TRIP ODO

mph

Km/h

(6)

(7)

(8)

(1) Multi-function display (2) Tachometer (3) Left turn signal indicator (4) Right turn signal indicator (5) High beam indicator (6) Oil service indicator (7) Met-in indicator (8) Overheating indicator (9) Adjust button (10) Mode button

(1) Multi-fuction display

The display includes the following functions:

(1)

Initial display

When the ignition switch is turned ON, the multi-function display will temporarily show all the modes so that you can make sure the liquid crystal display functioning properly.

(4)

mph

Km/h

TRIP ODO

(2)

(1) Speedometer (2)

Odometer/Trip meter/Oil service meter Fuel gauge

(3) (4) Digital clock

(3)

Speedometer

Shows riding speed.

Press and hold the Mode button for more than 2 seconds to select mph or Km/h.

mph

Km/h

Odometer/Tripmeter/Oil service meter

Press and hold the Mode button for more than 2 seconds to

select mph or Km/h for speedometer and mile or km for odometer/tripmeter/oil service meter.

mph

To select Odometer/Tripmeter/Oil service meter: Press and hold Adjust button for more than 2 seconds to select Odometer/Tripmeter/Oil service meter.

Km/h

Odometer Shows accumulated mileage.

Tripmeter Shows mileage per trip.

Oil service meter Shows mileage for oil service frequency.

Odometer

ODO

Tripmeter

TRIP

Oil service meter

To reset the tripmeter:

1. Press and hold Adjust button for more than 2

seconds to select TRIP.

TRIP

2. Press and hold both the Mode button and

Adjust button in the same time until the tripmeter is reset.

TRIP

To reset the oil service meter:

1. Press and hold Adjust button for more than 2 seconds to select oil service meter.

2. Press and hold both the Mode button and Adjust button in the same time until the oil service meter is reset.

Fuel gauge

Digital clock

The fuel gauge shows the approximate fuel supply available in a graduated display. The normal operating fuel range is with the section between the segment F and segment E. When the segment E or the fuel indicator flashes, fuel will be low and you should refill the tank as soon as possible.

(3)

(1)

(2)

(1) Segment E (2) Segment F (3) Fuel indicator

Show the time (hours and minutes) while the ignition is ON. To adjust the time manually, proceed as follows:

1. Turn the ignition switch ON.

2. Press and hold Adjust button for more than 2

seconds to select ODO mode.

Note:

Digital clock can be adjust in ODO mode only, never select tripmeter or oil service meter mode when you want to adjust your digital clock.

3. Press and hold both the Mode button and

Adjust button in the same time for more than 2 seconds. The clock will be set in the adjust mode with the hour display flashing.

4. To set the hour, press the Adjust button until the desired hour.

6. To set the minute, press the Adjust button until the desired minute.

5. Press the Mode button. The minute display will start flashing.

7. To end the adjustment, press both the Mode and Adjust buttons in the same time. The display will stop flashing automatically and the adjustment will be cancelled if the button is not pressed for about 10 seconds.

(2) Tachometer

(5) High beam indicator “ ”

Shows engine revolutions per minute (rpm).

Initial display

When the ignition switch is turned ON, the indicator of tachometer will run from zero to maxi limit then zero

so that you can make sure

the tachometer properly.

(3) Left turn signal indicator “ “

Flashes when the left turn signal operates.

(4) Right turn signal indicator “ “

Flashes when the right turn signal operates.

Lights when the headlight high beam is turned on.

(6) Oil service indicator “ ”

If the oil service indicator comes on while driving, this indicates that the engine oil should be changed at each maintenance interval.

NOTE:

The oil service indicator comes on when the vehicle's ignition is turned on and must come off when the engine is running.

To reset oil service indicator: Refer to the

page 19

(7) Seat unlock indicator "MET-IN"

Lights when the seat is not locked fully.

(8) Overheating indicator “ ”

When the coolant is over specified temperature, the overheating indicator comes on. If this occurs, stop the engine and check the reserve tank coolant level. Read and to not ride the vehicle until the problem has been corrected.

NOTE:

1. The overheating indicator comes on when the vehicle's ignition is turned on and must come off when the engine is running.

2. Restart after making sure that the indicator is out. Continuous use while the indicator is lighting may cause damage to the engine.

page 71

RIGHT HANDLEBAR SWITCH

Headlight switch (1)

“”

position

The headlight and taillight turn on.

position

"” The position light and taillight turn on.

position

""

The headlight, position and taillight turn off.

ENGINE

STOP

(1)

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