KYMCO DINK 200 User Manual

PREFACE

This Service Manual describes the
technical features and servicing
procedures for the KYMCO DINK

CLASSIC 200.

Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.

Section 2 is the removal/installation
procedures for the frame covers which
are subject to higher removal/installation
frequency during maintenance and
servicing operations.

Section 3 describes the inspection/
adjustment procedures, safety rules and
service information for each part, starting
from periodic maintenance.

Sections 5 through 13 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 14 is the
removal/ installation of chassis. Section
16 states the testing and measuring
methods of electrical equipment. Section
20 provides the maintenance instructions
of the exhaust emission control system.

Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

TABLE OF CONTENTS

GENERAL INFORMATION

1

EXHAUST MUFFLER/FRAME COVERS

2

INSPECTION/ADJUSTMENT

3

LUBRICATION SYSTEM

4

ENGINE REMOVAL/INSTALLATION

5

CYLINDER HEAD/VALVES

6

CYLINDER/PISTON

7

DRIVE AND DRIVEN PULLEYS/KICK
STARTER

8

FINAL REDUCTION

9

A.C. GENERATOR/STARTER CLUTCH

10

CRANKCASE/CRANKSHAFT

11

COOLING SYSTEM

12

FUEL SYSTEM/CARBURETOR/FUEL
PUMP

13

STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK

14

REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`

15

BATTERY/CHARGING SYSTEM

16

IGNITION SYSTEM

17

STARTING SYSTEM

18

SWITCHES/HORN/FUEL UNIT/
T HERMO-STATIC
SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS

19

E/M

EXHAUST EMISSION CONT ROL SYST EM

20

The information and contents included in
this manual may be different from the
motorcycle in case specifications are
changed.

CHASSIS

EQUIPMENT

ENGINE

1. GENERAL INFORMATION

1-0

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1

ENGINE SERIAL NUMBER

1

Location of Engine Serial Number

ENGINE SERIAL NUMBER

----

1-0 TOOLS

-----------------------------

1-11

SPECIFICATION

-----------------

1-1 LUBRICATION POINTS

--------

1-12

SERVICE PRECAUTIONS

------

1-2 WIRING DIAGRAM

--------------

1-14

TORQUE VALUES

---------------

1-9 CABLE & HARNESS ROUTING-1-19

TROUBLESHOOTING

-----------

1-20

1. GENERAL INFORMATION

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SPECIFICATIONS

Name & Model No.

SH40AA

Motorcycle Name & Type

Dink Classic 200

Overall length

1907mm

Overall width

750mm

Overall height

1170mm

Wheel base

1390mm

Engine type

Water cooled 4-stroke,
OHC engine

Displacement

176cc

Fuel Used

92# nonleaded gasoline

Front wheel

53

Net weight (kg)

Rear wheel

77

Total

130

Front wheel

58

Gross weight(kg)

Rear wheel

85

Total

143

Front wheel

120/70-12

Rear wheel

130/70-12

Ground clearance

155mm

Perform

-

Braking distance (m)

7.9m(40km/hr)

ance

Min. turning radius

2350mm

Starting system

Starting motor &

Kick starter

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber t ype

Semi-sphere

Valve arrangement

O.H.C.& Center

Pivot

Bore x stroke (mm)

62 x 58.2

Compression ratio

10.9:1
Compression pressure
(kg/cm_-rpm)

15

Max. output (ps/rpm)

15.2/7250

Max. torque (kg-m/rpm)

1.4/6500

Intake

Open

BTDC 12°

Port

(1mm)

Close

ATDC 35°

timin
g

Exhaust

Open

BDDC 28°

(1mm)

Close

0°

Valve

Intake

0.1

clearance (cold)

Exhaust

0.1

Idle speed (rpm)

1700rpm

Lubrication type

Forced pressure &

wet sump

Oil pump type

Inner/outer rotor

type

Oil filter type

Full-flow filtration

Oil capacity

1.1 liters

Cooling Type

Water cooling

Air cleaner type & No

Paper element, wet

Fuel capacity

10 liters

Type

VE

Piston dia.

26

Venturi dia.

22equivalent

Throttle type

Butterfly type

Type

CDI

Ignition timing

Repeatedly

Contact breaker

Non-contact point

type

Spark plug

NGK

DPR7EA-9

Spark plug gap

0.7mm

Battery

Capacity

12V8AH

Clutch

Type

CVT

Type

Non-stage transmission

Operation

Automatic
centrifugal

type

Type

Two-stage reduction

Reduction

1st

2.8-1.0

ratio

2nd

(46/16)x(46/15)=8.8

2

Front

Caster angle

Axle

Connecting rod

Tire pressure

Front

1.75

(kg/cm_)

Rear

2.0~2.25

Turning

Left

42.5°

angle

Right

42.5°

Front

Disk brake

Brake system
type

Rear

Disk brake

Front

Telescope

Suspension
type

Rear

Double swing

Shock absorber

Front

Telescope

type

Rear

Double swing

Frame type

Under bone

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Damping

Device

1. GENERAL INFORMATION

1-2

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SERVICE PRECAUTIONS

 Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when
reassembling.

 When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.

 Use genuine parts and lubricants.

 When servicing the motorcycle, be sure to

use special tools for removal and
installation.

 After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil
before reassembly.

1. GENERAL INFORMATION

1-3

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 Apply or add designated greases and

lubricants to the specified lubrication
points.

 After reassembly, check all parts for

proper tightening and operation.

 When two persons work together, pay

attention to the mutual working safety.

 Disconnect the battery negative (-) terminal

before operation.

 When using a spanner or other tools, make

sure not to damage the motorcycle surface.

 After operation, check all connecting

points, fasteners, and lines for proper
connection and installation.

 When connecting the battery, the positive

(+) terminal must be connected first.

 After connection, apply grease to the

battery terminals.

 Terminal caps shall be installed securely.

1. GENERAL INFORMATION

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 If the fuse is burned out, find the cause and

repair it. Replace it with a new one
according to the specified capacity.

 After operation, terminal caps shall be

installed securely.

 When taking out the connector, the lock on

the connector shall be released before
operation.

 Hold the connector body when connecting

or disconnecting it.

 Do not pull the connector wire.

 Check if any connector terminal is bending,

protruding or loose.

Confirm
Capacity

1. GENERAL INFORMATION

1-5

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 The connector shall be inserted

completely.

 If the double connector has a lock, lock

it at the correct position.

 Check if there is any loose wire.

 Before connecting a terminal, check for

damaged terminal cover or loose negative
terminal.

 Check the double connector cover for

proper coverage and installation.

 Insert the terminal completely.
 Check the terminal cover for proper

coverage.

 Do not make the terminal cover opening

face up.

 Secure wire harnesses to the frame with

their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.

Snapping!

1. GENERAL INFORMATION

1-6

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 After clamping, check each wire to make

sure it is secure.

 Do not squeeze wires against the weld or

its clamp.

 After clamping, check each harness to make

sure that it is not interfering with any
moving or sliding parts.

 When fixing the wire harnesses, do not

make it contact the parts which will
generate high heat.

 Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of
bolts and screws.

 Route wire harnesses passing through the

side of bolts and screws. Avoid the
projected ends of bolts and screws.

No Contact !

1. GENERAL INFORMATION

1-7

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 Route harnesses so they are neither

pulled tight nor have excessive slack.

 Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or
corner.

 When rubber protecting cover is used to

protect the wire harnesses, it shall be
installed securely.

 Do not break the sheath of wire.
 If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape
or replace it.

 When installing other parts, do not press or

squeeze the wires.

Do not pull too
tight!

Do not press or
squeeze the wire.

1. GENERAL INFORMATION

1-8

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 After routing, check that the wire harnesses

are not twisted or kinked.

 Wire harnesses routed along with handlebar

should not be pulled tight, have excessive
slack or interfere with adjacent or
surrounding parts in all steering positions.

 When a testing device is used, make sure to

understand the operating methods
thoroughly and operate according to the
operating instructions.

 Be careful not to drop any parts.

 When rust is found on a terminal, remove

the rust with sand paper or equivalent
before connecting.

 Do not bend or twist control cables.

Damaged control cables will not operate
smoothly and may stick or bind.

Do you understand
the instrument?

Remove Rust!

1. GENERAL INFORMATION

1-9

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 Symbols:

The following symbols represent the
servicing methods and cautions included in
this service manual.

: Apply engine oil to the

specified points. (Use
designated engine oil for
lubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

Special

Engine Oil
Grease

Gear Oil

＊

1. GENERAL INFORMATION

1-10

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TORQUE VALUES

STANDARD TORQUE VALUES

Item

Torque (kg-m)

Item

Torque (kg-m)

5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut

0.5

1.0

2.2

3.5

5.5

5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut

0.4

0.9

1.2

2.7

4.0

Torque specifications listed below are for important fasteners.

ENGINE

Item

Q‘ty

Thread dia.(mm)

Torque (kg-m)

Remarks

Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Exhaust muffler joint lock nut
Cylinder head cap nut
Valve adjusting lock nut

Cam chain tensioner slipper bolt

Oil bolt
Clutch outer nut
Clutch drive plate nut
Flywheel nut
Oil pump bolt
Cylinder head cover bolt
Spark plug
Cam chain tensioner bolt
Water pump impeller

2
2
1
2
4
2
1
1
1
1
1
2
4
1
1
1

8
8

30

8
8
5

6
12
12
12
14

5

6
10

6

8

2.2

2.2

1.5

0.9

2.2

0.9

0.9

1.3

5.5

5.5

5.5

0.4

1.2

1.2

0.9

1.4

Double end bolt
Double end bolt
Apply oil to
threads

Left hand threads

FRAME

Item

Q‘ty

Thread dia.(mm)

Torque (kg-m)

Remarks

Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upp er bolt
Rear shock absorber lower bolt
Front shock absorber lock bolt
Engine hanger bolt

1
1
1
2
2
4
1

10
12
14
10

8
10
12

4.5

6.0

9.0

3.0

3.0

2.5

5.5

U-nut
U-nut
U-nut

1. GENERAL INFORMATION

1-11

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SPECIAL TOOLS

Tool Name

Tool No.

Remarks

Ref. Page

Valve guide driver

Valve guide removal/installation

Valve guide reamer

Valve guide grinding

Valve spring compressor

Valve removal

Lock nut wrench, 39mm

Clutch disassembly

Bearing driver

Bearing removal

Bearing remover, 12mm

Bearing removal

Remover shaft

Bearing removal

Remover weight

Bearing removal

Bearing remover, 15mm

Bearing removal

Bearing driver

Bearing removal

Clutch spring compressor

Clutch disassembly

Ball race remover extension

Ball race removal

Ball race remover

Ball race removal

Spring compressor

Spring removal

Mechanical seal driver

Water pump mechanical seal
removal/installation

Kick starter spring remover

Kick starter spring removal

Gear remover

Starter gear removal

Valve adjuster

Tapper adjustment

Float level gauge

Carburetor fuel level check

Valve seat cutter 45°

Valve seat refacing

Valve seat cutter 32°

Valve seat refacing

Valve seat cutter 60°

Valve seat refacing
Cutter clip, 5mm
Universal holder

Holding clutch for removal
Bearing driver (32x35mm)

Bearing installation
Pilot, 12mm

Bearing installation
Pilot, 15mm

Bearing installation
Pilot, 17mm

Bearing installation
Flywheel puller

A.C. generator flywheel removal
Rear shock absorber compressor

Rear shock absorber disassembly
Steering head bearing remover

Steering head bearing removal
Kick starter spring remover

Kick starter spring installation
Flywheel holder

A.C. generator flywheel holding
Reamer clip
Fuel unit wrench

Fuel unit removal

1. GENERAL INFORMATION

1-12

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LUBRICATION POINTS

ENGINE

Lubrication Points

Lubricant

Valve guide/valve stem movable part

Camshaft protruding surface

Valve rocker arm friction surface

Camshaft drive chain

Cylinder lock bolt and nut

Piston surroundings and piston ring grooves

Piston pin surroundings

Cylinder inside wall

Connecting rod/piston pin hole

Connecting rod big end

Crankshaft

Crankshaft one-way clutch movable part

Oil pump drive chain

Starter reduction gear engaging part

Countershaft gear engaging part

Final gear engaging part

Bearing movable part

O-ring face

Oil seal lip

•Genuine KYMCO Engine Oil (SAE15W-40)

•API SE, SF or SG Engine Oil

Starter idle gear

Friction sp ring movable part/shaft movable p art

Shaft movable grooved part

Starter spindle movable part

High-temperature resistant grease

Starter one-way clutch threads

Thread locking agent

A.C. generator connector

Transmission case breather tube

Adhesive

1. GENERAL INFORMATION

1-13

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FRAME

The following is the lubrication points for the frame.
Use general purpose grease for parts not listed.
Apply clean engine oil or grease to cables and movable parts not specified. This will avoid
abnormal noise and rise the durability of the motorcycle.

Seat Lock

Rear Wheel Bearing

Grease

Speedometer Cable
Throttle Cable

Main Stand Pivot
Side Stand Pivot

Speedometer Gear/
Front Wheel Bearing

Engine Oil

Grease

Grease

Grease

Grease

Front Brake Lever Pivot

1. GENERAL INFORMATION

1-14

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CABLE & HARNESS ROUTING

Front Stop Switch

Rear Stop Switch

Throttle Cable

Fuel Vapor
Recovery Tube

Wire Connectors
Radiator

Front Brake Fluid Tube

Rear Brake Fluid Tube

Speedometer Cable

Horn

Water Hose

Fuel Vapor
Recovery Tube

Pressure Type
Radiator Cap

1. GENERAL INFORMATION

1-15

DINK 20 0

Fuel Vapor
Recovery Tube

Radiator Air Vent Tube

Front Brake Fluid Tube

Rear Brake Fluid Tube

Fuel Tank
Inlet Tube

Water Hose

Ignition Switch

Fuel Filler

Water Hoses

Thermostatic
Switch

Fuel Tank
Breather Tube

1. GENERAL INFORMATION

1-16

DINK 20 0

Throttle Cable
Speedometer Cable

Fuel Vapor
Recovery Tube

Rear Brake Fluid
Tube

Fuel Tank Inlet
Tube

Water Hose
Fuel Filler

Fuel Tank
Breather Tube

Throttle Cable

Front Stop
Switch

Wire Harness

Fuel Unit

1. GENERAL INFORMATION

1-17

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Starter Relay

Oil Vapor
Recovery Tube

Carburetor

Fuel Tube

Ignition Coil

Auto Bystarter Wire

Thermostat

Carburetor
Overflow Tube

Air Cut-off
Valve (A.C.V.)

1. GENERAL INFORMATION

1-18

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Starter Relay

Fuel Tube

Battery

Ignition Coil

Thermostat

Air Injection Air
Cleaner

Fuel Tube

CDI Unit

Auto Bystarter

Spark Plug Cap

Battery

Fuel Pump

Fuel Tube

Wire Harness

Spark Plug Cap

Throttle Cable

Positive Crankcase
Ventilation (PCV)

Vacuum Tee

Vacuum Tee

Fuel Pump

Ground Wire

Fuel Pump Vacuum Tube

Fuel Filter

Air Injection
Air Cleaner

Ignition Coil

Reed Valve

1. GENERAL INFORMATION

1-19

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WIRING DIAGRAM

1. GENERAL INFORMATION

1-20

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TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Empty fuel tank
Clogged carburetor fuel inlet

tube, vacuum tube or fuel tube

Clogged auto fuel valve
Clogged float oil passage
Clogged fuel tank cap

breather hole

Clogged fuel strainer
Clogged fuel filter
Faulty fuel pump

Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Broken or shorted ignit ion coil
Broken or shorted exciter

coil

Faulty ignition switch

Starter motor idles but

crankshaft does not rotate

Valve clearance too small
Improper valve and seat

contact

Worn cylinder and piston rings
Blown cylinder head gasket
Flaws in cylinder head
Seized valve
Improper valve timing

Faulty auto bystarter
Air leaking through intake

pipe

Incorrect ignition timing
Incorrectly adjusted pilot

screw

Flooded carburetor
Faulty auto bystarter
Throttle valve excessively

open

Check if fuel reaches
carburetor by
loosening drain screw

Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground

Inspection/Adjustment

Probable Cause

Spark jumps

Normal
compression

Engine does not
fire

Weak or no spark

Low or no
compression

Engine fires but
does not start

Test cylinder
compression

Start engine by follow­ing normal starting
procedure

Remove spark plug and
inspect again

Symptom

Fuel reaches
carburetor

Fuel does not
reach carburetor

Wet spark plug

Dry spark plug

1. GENERAL INFORMATION

1-21

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ENGINE LACKS POWER

Clogged air cleaner
Restricted fuel flow
Clogged fuel line between fuel

tank and carburetor

Clogged exhaust muffler
Faulty auto bystarter
Split carburetor vacuum piston

diaphragm

Faulty CDI unit
Faulty A.C. generator

Improper valve clearance

adjustment

Worn valve seat (valve stem too

protruding

Improper valve and seat contact
Worn cylinder and piston rings
Blown cylinder head gasket
Flaws in cylinder head
Improper valve timing

Clogged carburetor jets

Fouled spark plug
Incorrect heat range plug

Oil level too high
Oil level too low
Oil not changed

Clogged oil pipe
Faulty oil pump

Insufficient coolant
Faulty thermostat
Worn cylinder and piston rings
Mixture too lean
Poor quality fuel
Excessive carbon buildup in

combustion chamber

Ignition timing too early
Air in cooling system

Excessive carbon build-up in

combustion chamber

Poor quality fuel
Clutch slipping
Mixture too lean
 Ignition timing too early

Start engine and accelerate
lightly for observation

Inspection/Adjustment

Symptom

Probable Cause

Engine speed
increases

Correct timing

Engine speed does
not increase
sufficiently

Incorrect timing

Check ignition timing
(using a timing light)

Test cylinder compression

Check carburetor for
clogging

Rapidly accelerate or run
at high speed

Remove spark plug and
inspect

Check if engine overheats
Check valve clearance

Correct

Incorrect

Normal

compression

Abnormal
compression

Not Clogged

Clogged

Remove oil dipstick and
check oil level and condition

Remove cylinder head oil
pipe bolt and inspect

Engine overheats

Engine does not
overheats

Plug not fouled or
discolored

Plug fouled or
discolored

Correct and not
contaminated

Incorrect or
contaminated

Valve train lubricated
properly

Valve train not
lubricated properly

Engine does not knock

Engine knocks

1. GENERAL INFORMATION

1-22

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POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Faulty CDI unit
Faulty A.C. generator

Mixture too rich (turn screw

out)

Mixture too lean (turn screw

in)

Damaged insulator rubber
Carburetor not securely

tightened

Faulty intake manifold

gasket

Deformed carburetor O-ring

Faulty or fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Broken or shorted high

tension wire

Faulty ignition switch

Damaged air cut-off valve

diaphragm

Damaged air cut-off valve

spring

Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing

Check carburetor air
cut-off valve

Check carburetor
gasket for air leaks

Check carburetor pilot
screw adjustment

Correct timing

Incorrect timing

Correctly adjusted

No air leak

Air leaks

Good spark

Weak or inter­ mittent spark

Good

Faulty

Incorrectly adjusted

1. GENERAL INFORMATION

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POOR PERFORMANCE (AT HIGH SPEED)

Faulty CDI unit
Faulty A.C. generator

Improperly adjusted valve

clearance

Worn valve seat

Empty fuel tank
Clogged fuel tube or filter
Faulty fuel pump
Cracked fuel pump vacuum

tube

Clean and unclog

Cam timing gear aligning

marks not aligned

Faulty spring

Inspection/Adjustment

Symptom

Probable Cause

Check ignition timing

Check carburetor jets
for clogging

Check fuel pump for
fuel supply

Correct timing

Incorrect timing

Check valve spring
tension

Check valve clearance

Fuel flows freely

Fuel flow rest ricted

Correct

Incorrect

Not clogged

Clogged

Correctly adjusted

Incorrectly adjusted

Not weakened

Weak spring

Check valve timing

1. GENERAL INFORMATION

1-24

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ENGINE NOISE

Valve clearance too large

Worn camshaft lobe

Worn piston rings

Worn piston pin and connecting rod

small end

Excessive carbon build-up in combustion

chamber

Damaged cam chain tensioner
Worn cam gear teeth
Worn or damaged cam chain
Extended cam chain

Faulty crankshaft bearing

Worn crank pin bearing

Worn or damaged final reduction gears

Worn final reduction gear shaft splines

Valve noise

Symptom

Probable Cause

Crankshaft noise

Gear noise

Piston noise

Cam chain noise

1. GENERAL INFORMATION

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CLUTCH, DRIVE AND DRIVEN PULLEYS

Worn or slipping drive belt
Broken ramp plate
Broken drive face spring
Separated clutch lining
Damaged driven pulley shaft splines
Damaged final gear
Seized final gear

Broken shoe spring

Clutch outer and clutch weight stuck

Seized pivot

Worn or slipping drive belt
Worn weight rollers
Seized drive pulley bearings
Weak driven face spring
Worn or seized driven pulley bearings

Worn or slipping drive belt
Worn weight rollers
Worn or seized driven pulley bearings

Oil or grease fouled drive belt
Worn drive belt
Weak driven face spring
Worn or seized driven pulley bearings

Engine starts but
motor-cycle does not
move

Engine lacks power at
start of a grade(poor
slope performance)

Symptom

Probable Cause

Engine lacks power at
high speed

There is abnormal
noise
or smell while running

Motorcycle creeps or
engine starts but soon
stops or seems to rush
out (Rear wheel
rotates when engine
idles)

1. GENERAL INFORMATION

1-26

DINK 20 0

STARTER MOTOR

1. Starter motor won‘t turn

Burned out fuse
Weak or dead battery
Faulty stop switch
Loose or disconnected

connectors

Broken or shorted ignition

switch wire

Faulty or weak battery

Poor starter button

connection

Open or shorted starter relay
Loose or disconnected

connectors

Worn brushes
Open or shorted wires or

rotor

Open starter motor cable
Loose connectors

Open wire harness

2. Starter motor turns slowly or idles

Weak or dead battery

Loose connector or terminal
Poor contact in starter relay
Faulty starter clutch

Seized cylinder

Broken or shorted starter

motor cable

3. Starter motor does not stop turning

Faulty starter pinion

Starter relay shorted or stuck

Inspection/Adjustment

Inspection/Adjustment

Inspection/Adjustment

Symptom

Symptom

Symptom

Check operation of
stop switch by
applying brake

Stoplight does not
come on

Stoplight comes

Check battery
circuit by operating
turn signals

Check battery
circuit by operating
turn signals

Turn ignition
switch
OFF

Probable Cause

Probable Cause

Probable Cause

Signals operate
properly

Signals dim, remain
on or don‘t
operate

Check operation of
starter relay by
depressing starter
button

Connect starter
motor directly to
battery

Connect starter
motor directly to
battery

Starter motor
turns slowly

Starter motor
turns normally

Signals operate
properly

Signals dim, remain
on or don‘t operate

Not stopped

Stopped

Rotate crankshaft

Starter motor

turns

St arter does not

turn

Relay operates
properly

Relay does not
operate

Turns easily

Hard to turn

1. GENERAL INFORMATION

1-27

DINK 20 0

closed

NO SPARK AT SPARK PLUG

Faulty spark plug

Faulty spark plug

Poorly connected coupler

Faulty ignition switch
Faulty exciter coil
Faulty pulser coil
Faulty ignition coil

Broken wire harness
Poorly connected coupler

Faulty CDI unit

Faulty ignition coil

Replace with a new
spark plug and inspect
again

Check CDI unit
coupler for looseness

Inspection/Adjustment

Symptom

Probable Cause

Normal

Abnormal

Normal

Abnormal

Normal

Abnormal

Abnormal

Measure resistance
between terminals of
CDI unit coupler

Check related parts

Check ignition coil
with a CDI unit tester

Weak or no spark

Not loose

Good spark

Loose

Good

Good

Check spark plug cap
and high-tension wire
for looseness

Check CDI unit with a
CDI unit tester

1. GENERAL INFORMATION

1-28

DINK 20 0

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging

Faulty AC generator
Faulty regulator/rectifier
Faulty battery

Shorted AC generator coil
Open circuit between AC

generator 3 yellow wires

Faulty regulator/rectifier
Faulty AC generator
Loose regulator/rectifier

coupler

Limit voltage too high

Overcharging

Faulty battery
Faulty regulator/rectifier
Broken or poorly

connected

regulat or/rectifier black wire

Limit voltage too high

Start engine and test
limit voltage of
battery terminals

Measure battery limit
voltage with an
electric tester

Test output voltage of
regulator/rectifier
coupler red wire

Inspection/Adjustment

Inspection/Adjustment

Symptom

Symptom

Probable Cause

Probable Cause

Normal voltage

Normal

Normal

Voltage does not

increase

Abnormal

Resistance too

low

Normal voltage

No voltage

Measure resistance
between AC generator
coil terminals

Check resistance
between regulator/
rectifier terminals

Normal

Abnormal

1. GENERAL INFORMATION

1-29

DINK 20 0

FUEL GAUGE

1. Pointer does not register correctly (Ignition switch ON)

Burned out fuse
Weak or dead battery
Faulty ignition switch
Loose or disconnected

connectors

Broken wire harness

Faulty float

Broken or shorted fuel

unit wire

Disconnected connector
Incorrectly connected

connector

Broken or shorted wire in

fuel gauge

2. Pointer fluctuates or swings (Ignition switch ON)

Burned out fuse
Weak or dead battery
Faulty ignition switch
Loose or disconnected

connector

Broken wire harness

Poor contact in fuel unit

Insufficient damping oil in

fuel gauge

Loose or disconnected

connector

Broken or shorted wire in

fuel gauge

Inspection/Adjustment

Inspection/Adjustment

Symptom

Symptom

Remove fuel unit and
check operation of
pointer by moving
float up and down

Remove fuel unit and
check operation of
pointer by moving
float up and down

Signals operate
properly

Signals dim, remain
on or don‘t
operate

Signals operate
properly

Signals dim,
remain

Check battery circuit
by operating turn
signals

Check battery circuit
by operating turn
signals and horn

Probable Cause

Probable Cause

Pointer does not
move

Pointer moves

Pointer moves

Pointer does not
move

Check operation of
pointer by opening and
shorting fuel unit
terminal on wire
harness side

Move float up and
down rapidly (1 round
/sec.) to check the
operation of pointer

Pointer does not
move

Pointer moves

Pointer does not
move in accord­ance with float

Pointer moves in
accordance with
float

Good

Faulty

Check connectors for
proper connection

Check connectors for
proper connection.

Good

Faulty

Float up: Full
Float down: Empty

1. GENERAL INFORMATION

1-30

DINK 20 0

STEERING HANDLEBAR DOES NOT TRACK STRAIGHT

(Front and rear tire pressures are normal)

Steering stem nut too tight
Broken steering steel balls

Excessive wheel bearing play
Bent rim
Loose axle nut

Misaligned front and rear wheels
Bent front fork

POOR SUSPENSION PERFORMANCE

(Front and rear tire pressures are normal)

Weak shock spring
Excessive load
Shock damper oil leaking

Bent fork tube or shock rod

Fork tube and slider binding
Fork spring and slider binding
Damaged shock stopper rubber
Loose steering stem nut

POOR BRAKE PERFORMANCE

Worn brake linings
Foreign matter on brake linings
Rough brake drum contacting area

Worn brake linings
Foreign matter on brake linings
Rough brake drum contacting area

Worn brake linings
Worn brake cam contacting area on

Worn brake linings
Foreign matter on brake linings

Sluggish or elongated brake cables
Brake shoes improperly contact
Water and mud in brake system
Oil or grease on brake linings

Steering is heavy

Suspension is too soft

Soft brake lever

Hard brake lever

Poor brake
performance

Front or rear wheel is
wobbling

Symptom

Symptom

Symptom

Probable Cause

Probable Cause

Probable Cause

St eering handlebar pulls
to one side

Suspension is too hard

Suspension is noisy

Brake squeaks
Hard to brake

2. EXHAUST MUFFLER/FRAME COVERS

2-0

DINK 20 0

2

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

EXHAUST MUFFLER/FRAME COVERS

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 2-1

SERVICE INFORMATION -------------------------------------------- 2-2

TROUBLESHOOTING ------------------------------------------------- 2-2

FRAME COVERS REMOVAL----------------------------------------- 2-3

EXHAUST MUFFLER REMOVAL ----------------------------------- 2-6

2

2. EXHAUST MUFFLER/FRAME COVERS

2-1

DINK 20 0

SCHEMATIC DRAWING

2. EXHAUST MUFFLER/FRAME COVERS

2-2

DINK 20 0

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• When removing frame covers, use care not to pull them by force because the cover joint claws

may be damaged.

• Make sure to route cables and harnesses according to the Cable & Harness Routing.

TORQUE VALUES

Exhaust muffler lock bolt 3.5kg-m
Exhaust muffler joint lock nut 1.2kg-m

TROUBLESHOOTING

Noisy exhaust muffler

• Damaged exhaust muffler

• Exhaust muffler joint air leaks

Lack of power

• Caved exhaust muffler

• Clogged exhaust muffler

• Exhaust muffler air leaks

2. EXHAUST MUFFLER/FRAME COVERS

2-3

DINK 20 0

FRAME COVERS REMOVAL

REAR CARRIER & HAND RAIL
REMOVAL

Remove the met-in box:
First remove the two bolts and two nuts
attaching the met-in box.
Remove the bolt attaching the center cover.
Remove the met-in box.

Remove the hand rail right and left lock bolts.
Remove the two hex bolts and one stay bolt
attaching the rear carrier.
Disconnect the third stoplight wire connector
on the rear carrier.
Remove the rear carrier and hand rail.

FRAME BODY COVER REMOVAL

Remove the two screws on the bottom of the
center cover.
Remove the center cover.
Remove the two screws attaching the front
part of the frame body cover.

Remove the two screws attaching the rear
protective cover.
Remove the rear protective cover.
Remove the two screws attaching the rear
ends of the right and left side rails.

Center Cover Bolt

Screws

Screws

Bolts/Nuts
Hex Bolts

Lock Bolts
Frame Body Cover

Center Cover

Rear Protective Cover
Screws

Screws

2. EXHAUST MUFFLER/FRAME COVERS

2-4

DINK 20 0

Remove the screws attaching the right and left
side covers.
Remove the right and left side covers by
pulling them backward.

Remove the right and left screws on the rear
part of the frame body cover.
Disconnect the seat lock wire.
Remove the frame body cover.

FLOOR BOARD REMOVAL

Remove the floor mat.
Remove the center cover. (2-3)
Remove the eight screws and two bolts
attaching the front right and left side covers.
Remove the two bottom cover adjusting
screws.
Remove the front right and left side covers.

Remove the six bolts attaching the floor
board.
Remove the floor board .
The installation sequence is the reverse of
removal.

Screws

Side Cover

Seat Lock Wire

Screws

Floor Board

Bolts

2. EXHAUST MUFFLER/FRAME COVERS

2-5

DINK 20 0

FRONT UPPER COVER REMOVAL

Remove the right and left rearview mirrors.
Remove the two screws on the back of the
front upper cover.
Remove the two bolts on the front of the
front upper cover.
Disconnect the headlight wire connector.
Remove the front upper cover.
The installation sequence is the reverse of
removal.

FRONT LOWER COVER REMOVAL

First remove the front upper cover.
Remove the two screws attaching the front
lower cover.
Remove the four screws on the back of the
front lower cover.
Disconnect the right/left turn signal light wire
connectors.
Remove the front lower cover
The installation sequence is the reverse of
removal.

LEG SHIELD REMOVAL

Remove the front upper cover.
Remove the front lower cover.
Remove the four screws attaching the leg
shield and instruments and remove the fuse
box.
Remove the nut attaching the leg shield.
Remove the adjusting screw which combines
the leg shield with instruments.

Remove the leg shield.
The installation sequence is the reverse of
removal.

Screws

Screws

Screws

Adjusting Screw

Screws

Bolts

2. EXHAUST MUFFLER/FRAME COVERS

2-6

DINK 20 0

HANDLEBAR COVER REMOVAL

First remove the four screws attaching the
handlebar front cover.
Remove the handlebar front cover.
Remove the two screws and one bolt
attaching the handlebar rear cover.
Remove the handlebar rear cover.
The installation sequence is the reverse of
removal.

BOTTOM COVER REMOVAL

Remove the side stand.
Remove the four bolts attaching the bottom
cover.
Remove the bottom cover.

FRONT INNER FENDER A/B REMOVAL

Remove the front upper cover. (2-5)
Remove the front lower cover. (2-5)
Remove the screws which combines inner
fender A with inner fender B.
Remove the two bolts attaching the inner
fender A.
Separate inner fenders A and B.

The installation sequence is the reverse of
removal.

EXHAUST MUFFLER REMOVAL

Remove the two exhaust muffler joint lock
nuts.
Remove the two exhaust muffler lock bolts to
remove the exhaust muffler.
Remove the exhaust muffler joint packing
collar.
The installation sequence is the reverse of
removal.

Torque:

Exhaust muffler joint lock nut: 1.2kg-m
Exhaust muffler lock bolt: 3.5kg-m

Screws

Screws

Screws

Bolt

Lock Bolts

Bolts

Bolt

Bottom Cover
Joint Lock Nut

3. INSPECTION/ADJUSTMENT

3-0

DINK 20 0

3

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

INSPECTION/ADJUSTMENT

__________________________________________________________________________________

SERVICE INFORMATION -------------------------------------------- 3- 1
MAINTENANCE SCHEDULE ---------------------------------------- 3- 2
FUEL LINE/FUEL FILTER ------------------------------------------- 3- 2
THROTTLE OPERATION --------------------------------------------- 3- 2
ENGINE OIL ------------------------------------------------------------ 3- 4
AIR CLEANER ---------------------------------------------------------- 3- 5
SPARK PLUG ----------------------------------------------------------- 3- 5
VALVE CLEARANCE ------------------------------------------------- 3- 6
CARBURETOR IDLE SPEED ----------------------------------------- 3- 6
IGNITION TIMING----------------------------------------------------- 3- 7
CYLINDER COMPRESSION ------------------------------------------ 3- 7
FINAL REDUCTION GEAR OIL ------------------------------------- 3- 8
DRIVE BELT ------------------------------------------------------------ 3- 8
HEADLIGHT AIM ------------------------------------------------------ 3- 9
CLUTCH SHOE WEAR ------------------------------------------------ 3-10
COOLING SYSTEM ---------------------------------------------------- 3-10
BRAKE SYSTEM ------------------------------------------------------- 3-10
NUTS/BOLTS/FASTENERS------------------------------------------- 3-11
WHEELS/TIRES -------------------------------------------------------- 3-11
STEERING HANDLEBAR--------------------------------------------- 3-11
SUSPENSION ----------------------------------------------------------- 3-11

3

3. INSPECTION/ADJUSTMENT

3-1

DINK 20 0

SERVICE INFORMATION

GENERAL

°I WARNING

•Before running the engine, make sure that the working area is well-ventilated.

Never run the engine in a closed area. The exhaust contains poisonous carbon
monoxide gas which may cause death to people.

•Gasoline is extremely flammable and is explosive under some conditions. The

working area must be well-ventilated and do not smoke or allow flames or
sparks near the working area or fuel storage area.

SPECIFICATIONS

ENGINE
Throttle grip free play : 2_ 6mm
Spark plug : NGK: DP7EA9
Spark plug gap : 0.8_ 1.0mm
Valve clearance : IN: 0.1mm EX: 0.1mm

Idle speed : 1500±100rpm

(SH25AA: 1700±100rpm)

Engine oil capacity: Cylinder compression : 15±2kg/cm_
At disassembly : 1.1 liter Ignition timing : BTDC 10°±3°/1500rpm
At change : 0.8 liter Coolant capacity : 1165cc
Gear oil capacity : Radiator capacity : 825cc
At disassembly : 0.2 liter Reserve tank capacity : 340cc
At change : 0.195 liter

CHASSIS
Front/rear brake free play: 20_ 30mm

TIRE

1 Rider

2 Riders

Front

1.75kg/cm_

1.75kg/cm_

Rear

2.00kg/cm_

2.25kg/cm_

TIRE SPECIFICATION:
Front : 100/90–10
Rear : 120/70–10

TORQUE VALUES

Front axle nut : 5.0_ 7.0kg-m
Rear axle nut : 11.0_ 13.0kg-m

3. INSPECTION/ADJUSTMENT

3-2

DINK 20 0

MAINTENANCE SCHEDULE

Perform the periodic maintenance at each scheduled maintenance period.
I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary.
A: Adjust C: Clean R: Replace T : Tighten

Regular Service Mileage (km)

Frequency

Item

comes
first





1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

11000

12000

Engine oil

R

New

motorcycle

300km

RRRRRRRRRRR

Engine oil filter screen

C

C

Fuel filter screen

R

Gear oil

Note 3

R

New

motorcycle

300km

R

R

Valve clearance

AAA

A

Carburetor

I

I

Air Cleaner

Note 2,3

IRR

Spark plug

Clean at every 3000km and replace if necessary

Brake system

IIIIIIIIIII

I

Drive belt

I

Suspension

III

Nut, bolt, fastener

I

TireII

I

Steering head bearing

III

I

Brake fluid

Perform pre-ride inspection daily

Radiator coolant

Replace every year or at every 10000km (R)

Radiator core

I

I

Radiator cap

I

I

Brake lever

I

I

Brake shoe wear

I

I

Shock absorber

I

I

• In the interest of safety, we recommend these items be serviced only by an authorized

KYMCO motorcycle dealer.

Note: 1. For higher odometer readings, repeat at the frequency interval established here.

2. Service more frequently when riding in dusty or rainy areas.

3. Service more frequently when riding in rain or at full throttle.

Whichever

3. INSPECTION/ADJUSTMENT

3-3

DINK 20 0

FUEL LINE/FUEL FILTER

Remove the center cover.
Check the fuel tube replace any parts which
show signs of deterioration, damage or
leakage.
Check for dirty or clogged fuel filter and
replace with a new one if it is clogged.

THROTTLE OPERATION

Check the throttle grip for smooth movement.
Measure the throttle grip free play.

Free Play: 2_ 6mm

Major adjustment of the throttle grip free
play is made with the adjusting nut at the
carburetor side. Adjust by loosening the lock
nut and turning the adjusting nut.

Minor adjustment is made with the adjusting
nut at the throttle grip side.
Slide the rubber cover out and adjust by
loosening the lock nut and turning the
adjusting nut.

Lock Nut

Adjusting Nut

Fuel Filter

• Do not smoke or allow flames or

sparks in your working area.

°Ø

Fuel Tube

Lock Nut

Adjusting Nut

3. INSPECTION/ADJUSTMENT

3-4

DINK 20 0

ENGINE OIL

OIL LEVEL INSPECTION

Stop the engine and support the motorcycle
upright on level ground.
Wait for 2_ 3 minutes and check the oil level
with the dipstick. Do not screw in the
dipstick when making this check.

OIL CHANGE

Remove the oil drain bolt to drain the engine
oil.
Install the aluminum washer and tighten the
oil drain bolt.
Torque: 1.5kg-m

Pour the recommended oil through the oil
filler hole.

Oil Capacity:

At disassembly: 1.1 liter
At change: 0.8 liter

Recommended Oil:

SAE: 15W40#
API: SG/CD
Start the engine and check for oil leaks.

Stop the engine and recheck the oil level.

OIL FILTER SCREEN INSPECTION

Drain the engine oil.
Remove the oil filter screen and spring.
Clean the oil filter screen.
Install the oil filter screen, spring, and filter
screen cap.
Fill the engine with recommended engine oil.

• Drain the oil while the engine is warm.

°Ø

• Replace the aluminum washer with a

new one if it is deformed or damaged.

°Ø

Oil Dipstick

Oil Filter Screen Cap

Spring

Oil Filter Screen

3. INSPECTION/ADJUSTMENT

3-5

DINK 20 0

AIR CLEANER

Remove the seven air cleaner case cover
screws and the cover.

Remove the air cleaner element.
Check the element and replace it if it is
excessively dirty or damaged.

CHANGE INTERVAL

More frequent replacement is required when
riding in unusually dusty or rainy areas.

SPARK PLUG

Remove the frame center cover.
Remove the spark plug cap and spark plug.
Check the spark plug for wear and fouling
deposits.
Clean any fouling deposits with a spark plug
cleaner or a wire brush.

Specified Spark Plug: NGK: DP7EA9
Measure the spark plug gap.

Spark Plug Gap: 0.8_ 1.0mm

Torque: 0.8_ 1.0kg-m

Spark Plug

Screws

Air Cleaner Case Cover

Air Cleaner Element

°b

Gap
Wear
Fouling
Deposits

Cracks
Damage

Deformation

0.9mm

• The air cleaner element has a

viscous type paper element. Do not
clean it with compressed air.

• Be sure to install the air cleaner

element and cover securely.

°Ø

• When installing, first screw in the spark

plug by hand and then tighten it with a
spark plug wrench.

°Ø

3. INSPECTION/ADJUSTMENT

3-6

DINK 20 0

VALVE CLEARANCE

Remove the center cover and the secondary
air inlet tube bolt.
Remove the cylinder head cover.

Turn the A.C. generator flywheel to the top
dead center (TDC) on the compression stroke
so that the “T” mark on the flywheel aligns
with the index mark on the left crankcase
cover.

Inspect and adjust valve clearance.
Valve Clearance: IN: 0.1mm

EX: 0.1mm

Loosen the lock nut and adjust by turning the
adjusting nut

Valve Wrench

CARBURETOR IDLE SPEED

Lift up the seat and remove the inspection
cover.
Warm up the engine before this operation.
Start the engine and connect a tachometer.
Turn the throttle stop screw to obtain the
specified idle speed.
Idle Speed: 1500±100rpm

When the engine misses or run erratic, adjust
the pilot screw.

Throttle Stop Screw

Pilot Screw

Feeler Gauge

• Inspect and adjust valve clearance while

the engine is cold (below 35¢J).

°Ø

• Check the valve clearance again after

the lock nut is tightened.

°Ø

• The engine must be warm for accurate

idle speed inspection and adjustment.

°Ø

Cylinder Head Cover

Bolts

“T” Mark

Top Dead Center

Special

3. INSPECTION/ADJUSTMENT

3-7

DINK 20 0

IGNITION TIMING

Remove the timing hole cap.

Check the ignition timing with a timing light.
When the engine is running at the specified
idle speed, the ignition timing is correct if the
“F” mark on the flywheel aligns with the
index mark on the crankcase cover.
Also use a timing light to check the advance.
Raise the engine speed to 4,000rpm.
The index mark should be between the
advance marks.

CYLINDER COMPRESSION

Warm up the engine before compression test.
Remove the center cover and spark plug cap.
Remove the spark plug .
Insert a compression gauge.
Open the throttle valve fully and push the
starter button to test the compression.

Compression: 15±2kg/cm_
If the compression is low, check for the

following:

_Leaky valves
_Valve clearance to small
_Leaking cylinder head gasket
_Worn pistons
_Worn piston/cylinder

If the compression is high, it indicates that
carbon deposits have accumulated on the
combustion chamber and the piston head.

Compression Gauge

Timing Light

• The CDI unit is not adjustable.

• If the ignition timing is incorrect, check

the ignition system,

°Ø

Timing Hole Cap

“F” Mark

3. INSPECTION/ADJUSTMENT

3-8

DINK 20 0

FINAL REDUCTION GEAR OIL

Stop the engine and remove the oil check bolt.
The oil level shall be at the oil check bolt hole.
If the oil level is low, add the recommended
oil SAE90# to the proper level.

Install the oil check bolt.

OIL CHANGE

Remove the oil check bolt.
Remove the oil drain bolt and drain the oil
thoroughly.
Install the oil drain bolt.
Torque: 1.0kg-m

Fill the final reduction with the recommended
oil SAE90#.

Gear Oil Capacity:
At disassembly : 200cc
At change : 195cc
Reinstall the oil check bolt and check for oil

leaks.

DRIVE BELT

Remove the left crankcase cover.
Inspect the drive belt for cracks or excessive
wear.
Replace the drive belt with a new one if
necessary and in accordance with the
Maintenance Schedule.

Drive Belt

Oil Check Bolt Hole/Oil Filler

• Place the motorcycle on its main stand

on level ground.

°Ø

Oil Drain Bolt/Sealing Washer

• Make sure that the sealing washer is in

good condition.

°Ø

• Make sure that the sealing washer is in

good condition.

°Ø

3. INSPECTION/ADJUSTMENT

3-9

DINK 20 0

HEADLIGHT AIM

Turn the ignition switch ON.
Turn on the headlight switch.
Adjust the headlight aim by turning the
headlight aim adjusting bolt.

CLUTCH SHOE WEAR

Start the engine and check the clutch
operation by increasing the engine speed
gradually.
If the motorcycle tends to creep, or the engine
stalls, check the clutch shoes for wear and
replace if necessary.

COOLING SYSTEM

COOLANT LEVEL INSPECTION

Place the motorcycle on its main stand on
level ground.
Check the coolant level of the reserve tank
and the level should be between the upper
and lower level lines.
If necessary, fill the reserve tank with
recommended coolant to the “F” level line.

Recommended Coolant: SIGMA Coolant
(Standard Concentration 30%)

COOLANT REPLACEMENT

Remove the front cover.
Remove the radiator cap.
Remove the drain bolt to drain the coolant
and tilt the motorcycle to the right and the
coolant will drain more easily.
Drain the coolant in the reserve tank.
Reinstall the drain bolt.
Fill the radiator with the specified coolant.

Lower Line

Headlight Aim Adjusting Bolt

Upper Line

Radiator Cap

• The coolant level does not change no

matter the engine is warm or cold. Fill
to the “F” (upper) line.

°Ø

• The coolant freezing point should be

5¢J lower than the temperature of the
riding area.

°Ø

• Perform this operation when the engine

is cold.

°Ø

Reserve Tank

3. INSPECTION/ADJUSTMENT

3-10

DINK 20 0

Coolant capacity : 1165cc
Radiator capacity : 825cc
Reserve tank capacity :340cc
Start the engine and check if there is no

bubbles in the coolant and the coolant level is
stable. Reinstall the radiator cap.
If there are bubbles in the coolant, bleed air
from the system.
Fill the reserve tank with the recommended
coolant up to the upper line.

BRAKE SYSTEM

BRAKE LEVER

Measure the front and rear brake lever free
plays.

BRAKE FLUID

Turn the steering handlebar upright and check
if the front/rear brake fluid level is at the
upper limit. If the brake fluid is insufficient,
fill to the upper limit.

Specified Brake Fluid: DOT-3

BRAKE DISK/BRAKE PAD

Check the brake disk surface for scratches,
unevenness or abnormal wear.
Check if the brake disk runout is within the
specified service limit.
Check if the brake pad wear exceeds the wear
indicator line.

Drain Bolt

Rear Brake Reservoir

Brake Disk

Front Brake Reservoir

• The brake fluid level will decrease if the

brake pads are worn.

°Ø

• Keep grease or oil off the brake disk to

avoid brake failure.

°Ø

3. INSPECTION/ADJUSTMENT

3-11

DINK 20 0

NUTS/BOLTS/FASTENERS

Check all important chassis nuts and bolts for
looseness.
Tighten them to their specified torque values
if any looseness is found.

WHEELS/TIRES

Check the tires for cuts, imbedded nails or
other damages.
Check the tire pressure.

Tire Pressure

1 Rider

2 Riders

Front

1.75kg/cm_

1.75kg/cm_

Rear

2.00kg/cm_

2.25kg/cm_

STEERING HANDLEBAR

Raise the front wheel off the ground and
check that the steering handlebar rotates
freely.
If the handlebar moves unevenly, binds, or
has vertical movement, adjust the steering
head bearing.

SUSPENSION

Check the action of the front/rear shock
absorbers by compressing them several times.
Check the entire shock absorber assembly for
oil leaks, looseness or damage.
Jack the rear wheel off the ground and move
the rear wheel sideways with force to see if
the engine hanger bushings are worn.
Replace the engine hanger bushings if there is
any looseness.

• Tire pressure should be checked when

tires are cold.

°Ø

Pressure Gauge

4. LUBRICATION SYSTEM

4-0

DINK 20 0

4

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

LUBRICATION SYSTEM

__________________________________________________________________________________

LUBRICATION SYSTEM DIAGRAM-------------------------------- 4-1

SERVICE INFORMATION -------------------------------------------- 4-2

TROUBLESHOOTING ------------------------------------------------- 4-2

ENGINE OIL/OIL FILTER -------------------------------------------- 4-3

OIL PUMP REMOVAL------------------------------------------------- 4-4

OIL PUMP DISASSEMBLY ------------------------------------------- 4-4

OIL PUMP INSPECTION ---------------------------------------------- 4-5

OIL PUMP ASSEMBLY------------------------------------------------ 4-6

OIL PUMP INSTALLATION------------------------------------------ 4-6

4

4. LUBRICATION SYSTEM

4-1

DINK 20 0

LUBRICATION SYSTEM

Oil Pump

Oil Filter Screen

Crankshaft

Rocker Arm Shaft

4. LUBRICATION SYSTEM

4-2

DINK 20 0

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The maintenance of lubrication system can be performed with the engine installed in the frame.

• Drain the coolant before starting any operations.

• Use care when removing and installing the oil pump not to allow dust and foreign matters to enter

the engine and oil line.

• Do not attempt to disassemble the oil pump. The oil pump must be replaced as a set when it

reaches its service limit.

• After the oil pump is installed, check each part for oil leaks.

SPECIFICATIONS

OIL PUMP

Standard (mm)

Service Limit (mm)

Inner rotor-to-outer rotor clearance

0.15

0.20

Outer rotor-to-pump body clearance

0.15_ 0.20

0.25

Rotor end-to-pump body clearance

0.04_ 0.09

0.12

ENGINE OIL

Engine Oil Capacity

At disassembly: 1.1 liter At change: 0.9 liter

Recommended Oil

SAE15W40# API: SG/CD

TROUBLESHOOTING

Oil level too low Poor lubrication pressure

• Natural oil consumption • Oil level too low

• Oil leaks • Clogged oil filter or oil passage

• Worn piston rings • Faulty oil pump

• Worn valve guide

• Worn valve guide seal

Oil contamination

• Oil not changed often enough

• Faulty cylinder head gasket

• Loose cylinder head bolts

4. LUBRICATION SYSTEM

4-3

DINK 20 0

ENGINE OIL/OIL FILTER

Remove the oil dipstick and check the oil
level with the oil dipstick.
If the level is near the lower level, fill to the
upper level with the recommended engine oil.

OIL CHANGE

Remove the oil drain bolt located at the left
side of the engine to drain the engine oil.
After the oil has been completely drained,
install the aluminum washer and tighten the
oil drain bolt.
Torque: 14.7N-m
Pour the recommended oil through the oil
filler hole.

OIL FILTER SCREEN

Drain the engine oil.
Remove the oil filter screen cap.
Remove the oil filter screen and spring.
Check the oil filter screen for clogging or
damage and replace if necessary. Check the
filter screen O-ring for damage and replace if
necessary.
Install the oil filter screen, spring, O-ring and
filter screen cap.
Torque: 14.7N-m

Recommended Oil: SAE15W40# API: SG/CD
Oil Capacity:

At disassembly: 1.1 liter
At change: 0.9 liter
Start the engine and check for oil leaks. Start

the engine and let it idle for few minutes, then
recheck the oil level.

Oil Dipstick

Oil Drain Bolt

Oil Filter Screen Cap

• Place the motorcycle upright on

level ground for engine oil level check.

• Run the engine for 2_ 3 minutes

and check the oil level after the engine is
stopped for 2_ 3 minutes.

°Ø

• The engine oil will drain more

easily while the engine is warm.

°Ø

4. LUBRICATION SYSTEM

4-4

DINK 20 0

Circlip

Bolts

Oil Pump Driven Gear

Oil Separator

OIL PUMP REMOVAL

First drain the coolant.
Remove the right crankcase cover. (10-3)
Remove the A.C. generator starter driven
gear. (10-4)
Remove the attaching bolt and oil separator
cover.

Pry the circlip off and remove the oil pump
driven gear, then remove the oil pump drive
chain.

Remove the two oil separator bolts to remove
the oil pump.

OIL PUMP DISASSEMBLY

Remove the screw and disassemble the oil
pump as shown.

Oil Separator Cover
Oil Pump

4. LUBRICATION SYSTEM

4-5

DINK 20 0

Outer Rotor

Inner Rotor

Outer Rotor

Outer Rotor
Inner Rotor

Dowel Pin

Pump Body

Rotor End

Pump Body

Pump Shaft

OIL PUMP INSPECTION

Measure the pump body-to-outer rotor
clearance.

Service Limit: 0.25mm replace if over

Measure the inner rotor-to-outer rotor
clearance.

Service Limit: 0.20mm replace if over

Measure the rotor end-to-pump body
clearance.

Service Limit: 0.12mm replace if over

OIL PUMP ASSEMBLY

Install the outer rotor, inner rotor and pump
shaft into the pump body.

There is one mark on the surface of the inner
rotor and outer rotor.

The mark is upside.

Insert the pump shaft by aligning the flat
on the shaft with the flat in the inner
rotor. Install the dowel pin.

°Ø

Pump Body

4. LUBRICATION SYSTEM

4-6

DINK 20 0

Screw

Bolts

Oil Separator Cover

Pump Driven Gear

Bolt

Install the pump cover by aligning the hole in
the cover with the dowel pin.
Tighten the screw to secure the pump cover.
Make sure that the pump shaft rotates freely
without binding.

OIL PUMP INSTALLATION

Install the oil pump and oil separator and
tighten the two bolts.
Make sure that the pump shaft rotates freely.
The arrow of oil pump is upside.

Install the pump drive chain and driven gear,
then set the circlip securely on the pump
shaft.

Install the oil separator cover properly.

Install the A.C. generator starter driven gear.
(10-5)

Circlip

Fit the tab of the separator cover into the
slit in the separator.

°Ø

Oil Separator

Pump Drive Chain

Arrow Mark

5. ENGINE REMOVAL/INSTALLATION

5-0

DINK 20 0

5

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

ENGINE REMOVAL/INSTALLATION

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 5-1
SERVICE INFORMATION -------------------------------------------- 5-2
ENGINE REMOVAL --------------------------------------------------- 5-3
ENGINE INSTALLATION -------------------------------------------- 5-5

5

5. ENGINE REMOVAL/INSTALLATION

5-1

DINK 20 0

SCHEMATIC DRAWING

3.0kg-m

5.0kg-m

4.0kg-m

5. ENGINE REMOVAL/INSTALLATION

5-2

DINK 20 0

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• A floor jack or other adjustable support is required to support and maneuver the engine. Be

careful not to damage the motorcycle body, cables and wires during engine removal.

• Use shop towels to protect the motorcycle body during engine removal.

• Drain the coolant before removing the engine.

• After the engine is installed, fill the cooling system with coolant and be sure to bleed air from the

water jacket. Start the engine to check for coolant leaks.

• Before removing the engine, the rear brake caliper must be removed first. Be careful not to bend

or twist the brake fluid tube.

SPECIFICATIONS

Engine dry weight: 30kg
Engine oil capacity: at disassembly: 1.1 liter
Coolant capacity:

Total capacity : 1165cc
Radiator capacity : 825cc
Reserve tank capacity : 340cc

TORQUE VALUES

Engine mounting bolt 5.0kg-m
Rear shock absorber upper mount bolt 4.0kg-m

5. ENGINE REMOVAL/INSTALLATION

5-3

DINK 20 0

ENGINE REMOVAL

Disconnect the battery negative cable.
Remove the frame body cover. (2-3)
Disconnect the engine negative cable.
Disconnect all of the A.C. generator, auto
bystarter, spark plug, thermosensor wire
couplers and connectors.
Disconnect the engine fuel tube.
Drain the coolant. (3-9)
Disconnect the water hose.

Disconnect the starter motor wire that goes to
the starter relay.

Disconnect the fuel tube and vacuum tube
that go to the carburetor from the fuel pump.
Disconnect the vacuum tube from the air
injection cut-off valve (AICV).
Disconnect the throttle cable from the
carburetor.

Remove the brake fluid tube bolt of the rear
brake caliper.
Remove the rear brake caliper bolt and the
rear brake caliper.

Starter Relay

Wire Connectors

Fuel Tube

Throttle Cable

Fuel Pump Vacuum Tube

Brake Fluid Tube

Rear Brake Caliper

5. ENGINE REMOVAL/INSTALLATION

5-4

DINK 20 0

Remove the right/left rear shock absorber
upper mount bolts.

Remove the two engine mounting bolts and
pull out the engine with the engine hanger
backward.

ENGINE HANGER REMOVAL

Remove the engine hanger bolts to remove the
engine hanger.

Inspect the engine hanger bushings and
stopper rubber for wear or damage.

Engine Mounting

Bushings

Rear Shock Absorber Upper Mount Bolts

Stopper Rubber

Bolt

Engine Hanger

5. ENGINE REMOVAL/INSTALLATION

5-5

DINK 20 0

ENGINE INSTALLATION

Install the engine in the reverse order of
removal.
Tighten the engine mounting bolts.

Torque: 5.0kg-m

Tighten the rear shock absorber upper mount
bolts.

Torque: 4.0kg-m
After installation, inspect and adjust the

following:

• Throttle grip free play (3-3)

• Fill the rear brake reservoir with brake fluid

and bleed air from the rear brake.

• Fill the cooling system with coolant and

start the engine to bleed air from the
system.

Engine Mounting Nuts

Engine Hanger Bolt

Rear Shock Absorber Upper Mount Bolts

6. CYLINDER HEAD/VALVES

6-0

DINK 20 0

6 .

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

CYLINDER HEAD/VALVES

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 6- 1

SERVICE INFORMATION -------------------------------------------- 6- 2

TROUBLESHOOTING ------------------------------------------------- 6- 3

CYLINDER HEAD COVER REMOVAL ----------------------------- 6- 4

CAMSHAFT REMOVAL----------------------------------------------- 6- 4

CYLINDER HEAD REMOVAL --------------------------------------- 6- 6

CYLINDER HEAD DISASSEMBLY --------------------------------- 6- 7

CYLINDER HEAD ASSEMBLY -------------------------------------- 6- 8

CYLINDER HEAD INSTALLATION -------------------------------- 6- 9

CAMSHAFT INSTALLATION---------------------------------------- 6-10

CYLINDER HEAD COVER INSTALLATION ---------------------- 6-11

6

6. CYLINDER HEAD/VALVES

6-1

DINK 20 0

SCHEMATIC DRAWING

6. CYLINDER HEAD/VALVES

6-2

DINK 20 0

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator

and water jacket must be drained first.

• When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable

parts and valve arm sliding surfaces for initial lubrication.

• The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages.

Clean and unclog the oil passages before assembling the cylinder head.

• After disassembly, clean the removed parts and dry them with compressed air before inspection.

• After removal, mark and arrange the removed parts in order. When assembling, install them in the

reverse order of removal.

SPECIFICATIONS

Standard (mm)

Service Limit (mm)

Item

SH40AA

SH40AA

IN

0.10

EX0.10



Cylinder head compression pressure

15kg/cm_



Cylinder head warpage



0.05IN30.8763

30.75EX30.4081

30.26IN10.00_ 10.018

10.10EX10.00_ 10.018

10.10

Valve rocker arm shaft

IN

9.972_ 9.987

9.9

O.D.

EX

9.972_ 9.987

9.9IN1.2

1.8EX1.2

1.8IN4.990_ 4.975

4.925EX4.970_ 4.955

4.915IN5.00_ 5.012

5.03EX5.00_ 5.012

5.03

Valve stem-to-guide

IN

0.010_ 0.037

0.08

clearanceEX0.030_ 0.057

0.10

TORQUE VALUES

Cylinder head cap nut 19.6N-m Apply engine oil to threads
Valve clearance adjusting nut 8.8N-m Apply engine oil to threads
Cylinder head cover bolt 7.8_ 11.8N-m

SPECIAL TOOLS

Valve spring compressor
Valve seat cutter, 24.5mm 45° IN-EX
Valve seat cutter, 25mm Plane cutter 37.5° EX
Valve seat cutter, 22mm Plane cutter 37.5° EX
Valve seat cutter, 26mm Plane cutter 63.5° IN/EX
Cutter clip
Valve guide driver
Valve guide reamer

Valve clearance (cold)

Camshaft cam height

Valve rocker arm I.D.

Valve seat width

Valve stem O.D.

Valve guide I.D.

6. CYLINDER HEAD/VALVES

6-3

DINK 20 0

TROUBLESHOOTING

• The poor cylinder head operation can be diagnosed by a compression test or by tracing engine

top-end noises.

Poor performance at idle speed White smoke from exhaust muffler

• Compression too low • Worn valve stem or valve guide

• Damaged valve stem oil seal

Compression too low

• Incorrect valve clearance adjustment Abnormal noise

• Burned or bend valves • Incorrect valve clearance adjustment

• Incorrect valve timing • Sticking valve or broken valve spring

• Broken valve spring • Damaged or worn camshaft

• Poor valve and seat contact • Worn cam chain tensioner

• Leaking cylinder head gasket • Worn camshaft and rocker arm

• Warped or cracked cylinder head

• Poorly installed spark plug

Compression too high

• Excessive carbon build-up in combustion

chamber

6. CYLINDER HEAD/VALVES

6-4

DINK 20 0

CYLINDER HEAD COVER
REMOVAL

Remove the center cover. (2-3)
Remove the met-in box. (2-3)
Remove the cylinder head cover four bolts
and then remove the cylinder head cover.

CAMSHAFT REMOVAL

Turn the A.C. generator flywheel so that the
“T” mark on the flywheel aligns with the
index mark on the crankcase.
Hold the round hole on the camshaft gear
facing up and the location is the top dead
center on the compression stroke.
Remove the two bolts attaching cam chain
tensioner and the tensioner.

First remove the two bolts between the
cylinder head and cylinder.
Then, remove the four cap nuts attaching the
cylinder head.

Remove the camshaft holder and dowel pins.

Cylinder Head Cover

Bolt

Cam Chain Tensioner

Round Hole

Camshaft Holder

Bolts

Camshaft Holder

Cap Nuts

• Diagonally loosen the cylinder head

cap nuts in 2 or 3 times.

°Ø

6. CYLINDER HEAD/VALVES

6-5

DINK 20 0

Remove the camshaft gear from the cam chain
to remove the camshaft.

CAMSHAFT INSPECTION

Check each cam lobe for wear or damage.
Measure the cam lobe height.

Service Limits:

SH40AA

IN: 30.75mm replace if below

Check each camshaft bearing for play or
damage. Replace the camshaft assembly with
a new one if the bearings are noisy or have
excessive play.

CAMSHAFT HOLDER DISASSEMBLY

Take out the valve rocker arm shafts using a
6mm bolt and screwdriver.
Remove the valve rocker arms.

Cam Chain

Camshaft Gear

Camshaft Bearings

Valve Rocker Arms

Rocker Arm Shafts

Screwdriver

6. CYLINDER HEAD/VALVES

6-6

DINK 20 0

CAMSHAFT HOLDER INSPECTION

Inspect the camshaft holder, valve rocker
arms and rocker arm shafts for wear or
damage.

Measure the I.D. of each valve rocker arm.
Service Limits: IN: 10.10mm replace if over

EX: 10.10mm replace if over
Measure each rocker arm shaft O.D.
Service Limits: IN: 9.90mm replace if below

EX: 9.90mm replace if below

CYLINDER HEAD REMOVAL

First drain the coolant from the radiator and
water jacket, then remove the thermostat
water hose.
Remove the camshaft. (6-4)
Remove the carburetor and intake manifold.
Remove the bolt attaching the thermostat
housing and the thermostat housing.
Remove the cylinder head.

Remove the dowel pins and cylinder head
gasket.
Remove the cam chain guide.
Remove all gasket material from the cylinder
head mating surface.

Intake Manifold

Cam Chain Tensioner Slipper

Camshaft Holder

If the valve rocker arm contact surface is
worn, check each cam lobe for wear or
damage.

°Ø

Rocker Arm Shafts

Cylinder

Cylinder Head Gasket

Be careful not to drop any gasket
material into the engine.

°Ø

6. CYLINDER HEAD/VALVES

6-7

DINK 20 0

CYLINDER HEAD DISASSEMBLY

Remove the valve spring cotters, retainers,
springs, spring seats and valve stem seals
using a valve spring compressor.

Remove carbon deposits from the exhaust
port and combustion chamber.

Valve Spring Compressor

Cylinder Head

• Be sure to compress the valve springs

with a valve spring compressor.

• Mark all disassembled parts to ensure

correct reassembly.

°Ø

Exhaust Port

Combustion Chamber

Be careful not to damage the cylinder
head mating surface.

°Ø

6. CYLINDER HEAD/VALVES

6-8

DINK 20 0

INSPECTION

CYLINDER HEAD
Check the spark plug hole and valve areas for

cracks.
Check the cylinder head for warpage with a
straight edge and feeler gauge.

Service Limit: 0.05mm repair or replace if

over

VALVE SPRING FREE LENGTH
Measure the free length of the inner and outer

valve springs.
Service Limits:

Inner (IN, EX) : 29.3mm replace if below
Outer (IN, EX): 32.0mm replace if below

VALVE /VALVE GUIDE
Inspect each valve for bending, burning,

scratches or abnormal stem wear.
Check valve movement in the guide.

Measure each valve stem O.D.
Service Limits: IN: 4.925mm replace if

below
EX: 4.915mm replace if
below

CYLINDER HEAD ASSEMBLY

Install the valve spring seats and stem seals.
Lubricate each valve stem with engine oil and

insert the valves into the valve guides.
Be sure to install new valve stem seals.

Straight Edge

Feeler Gauge

Valve Spring Compressor

6. CYLINDER HEAD/VALVES

6-9

DINK 20 0

Tap the valve stems gently with a plastic
hammer to firmly seat the cotters.

CYLINDER HEAD INSTALLATION

Install the cam chain guide.
Install the dowel pins and a new cylinder
head gasket.

Install the cylinder head and take out the cam
chain

Assemble the camshaft holder.
First install the intake and exhaust valve
rocker arms; then install the rocker arm shafts.

Gasket

Cam Chain Guide

Valve Rocker Arms

Plastic Hammer

Cam Chain

Cylinder Head

Camshaft Holder

Be careful not to damage the valves.

°Ø

Dowel Pins

• Install the exhaust valve rocker arm

shaft on the “EX” side of the camshaft
holder and the exhaust rocker arm shaft
is shorter.

• Clean the intake valve rocker arm shaft

off any grease before installation.

• Align the cutout on the exhaust valve

rocker arm shaft with the bolt of the
camshaft holder.

°Ø

6. CYLINDER HEAD/VALVES

6-10

DINK 20 0

CAMSHAFT INSTALLATION

Turn the A.C. generator flywheel so that the
“T” mark on the flywheel aligns with the
index mark on the crankcase.
Keep the round hole on the camshaft gear
facing up and align the punch marks on the
camshaft gear with the cylinder head surface
(Position the intake and exhaust cam lobes
down.) and install the cam chain over the
camshaft gear.

Install the dowel pins.

Install the camshaft holder, washers and nuts
on the cylinder head.
Tighten the four cylinder head nuts and the
two bolts between the cylinder head and
cylinder.

Torque: Cylinder head cap nut: 19.6N-m

Cylinder & cylinder head bolt:

7.8_ 11.8N-m

Dowel Pins

Nut

Washer

Punch Marks

Bolts

Cam Chain

Round Hole

• Apply engine oil to the threads of the

cylinder head cap nuts.

• Diagonally tighten the cylinder head

cap nuts in 2_ 3 times.

• First tighten the cylinder head cap nuts

and then tighten the bolts between the
cylinder and cylinder head to avoid
cracks.

°Ø

6. CYLINDER HEAD/VALVES

6-11

DINK 20 0

Install a new cam chain tensioner gasket.
Release the lock pawl and push the push rod
all the way in.

Install the cam chain tensioner and tighten the
two bolts.
Install the tensioner spring and tighten the
sealing bolt.

Torque: 2.9_ 5.8N-m

CYLINDER HEAD COVER
INSTALLATION

Adjust the valve clearance. (3-6)
Install a new cylinder head cover O-ring and
install the cylinder head cover.

Install and tighten the cylinder head cover
bolts.

Torque: 7.8_ 11.8N-m

Cam Chain Tensioner

Sealing Bolt

Bolt

Lock Pawl

Push Rod

Gasket

Cam Chain Tensioner

Spring

Cylinder Head Cover

O-ring

Be sure to install the O-ring into the
groove properly.

°Ø

7. CYLINDER/PISTON

7-0

DINK 20 0

7

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

CYLINDER/PISTON

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 7-1

SERVICE INFORMATION -------------------------------------------- 7-2

TROUBLESHOOTING ------------------------------------------------- 7-2

CYLINDER REMOVAL------------------------------------------------ 7-3

PISTON REMOVAL ---------------------------------------------------- 7-3

PISTON INSTALLATION --------------------------------------------- 7-7

CYLINDER INSTALLATION----------------------------------------- 7-7

7

7. CYLINDER/PISTON

7-1

DINK 20 0

SCHEMATIC DRAWING

7. CYLINDER/PISTON

7-2

DINK 20 0

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

Standard (mm)

Service Limit (mm)

Item

SH40AA

SH40AA

I.D.

62.005_ 62.015

62.10

Warpage

0.01

0.05

Cylindricity

0.01

0.05

True roundness

0.01

0.05

Ring-to-groove

top

0.015_ 0.050

0.09

clearance

Second

0.015_ 0.050

0.09

top

0.15_ 0.30

0.50

Piston,

Ring end gap

Second

0.15_ 0.30

0.50

piston ring

Oil side rail

0.2_ 0.9



Piston O.D.

61.993_ 61.995

61.90

Piston O.D. measuring position

9mm from bottom of skirt

.

Piston-to-cylinder clearance

0.010_ 0.040

0.01

Piston pin hole I.D.

15.002_ 15.008

15.04

Piston pin O.D

14.994_ 15.000

14.96

Piston-to-piston pin clearance

0.002_ 0.014

0.02

Connecting rod small end I.D. bore

15.016_ 15.034

15.06

TROUBLESHOOTING

• When hard starting or poor performance at low speed occurs, check the crankcase breather for

white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.

Compression too low or uneven
compression Excessive smoke from exhaust muffler

• Worn or damaged cylinder and piston rings • Worn or damaged piston rings

• Worn, stuck or broken piston rings • Worn or damaged cylinder and piston

Compression too high Abnormal noisy piston

• Excessive carbon build-up in combustion • Worn cylinder, piston and piston rings

chamber or on piston head • Worn piston pin hole and piston pin

• Incorrectly installed piston

Cylinder

7. CYLINDER/PISTON

7-3

DINK 20 0

CYLINDER REMOVAL

Remove the cylinder head. (6-7)
Remove the water hose from the cylinder.
Remove the cylinder base bolt.

Remove the cam chain guide.
Remove the cylinder.
Remove the cam chain tensioner.

Remove the cylinder gasket and dowel pins.
Clean any gasket material from the cylinder
surface.

PISTON REMOVAL

Remove the piston pin clip.
Press the piston pin out of the piston.

Cylinder Base Bolt

Water Hose

Dowel Pins

Cam Chain Guide

Gasket

Shop Towel

Cylinder

Piston Pin

Piston

Piston Rings

Cam Chain Tensioner

Place a clean shop towel in the crankcase
to keep the piston pin clip from falling
into the crankcase.

＊

7. CYLINDER/PISTON

7-4

DINK 20 0

Inspect the piston, piston pin and piston
rings.
Remove the piston rings.

Clean carbon deposits from the piston ring
grooves.

Install the piston rings onto the piston and
measure the piston ring-to-groove clearance.

Service Limits:

Top: 0.09mm replace if over
2nd: 0.09mm replace if over

Remove the piston rings and insert each
piston ring into the cylinder bottom.

Measure the piston ring end gap.
Service Limit: 0.5mm replace if over

Measure the piston pin hole I.D.
Service Limit: 15.04mm replace if over

• Take care not to damage or break the

piston rings during removal.

＊

• Use the piston head to push each

piston ring into the cylinder.

＊

7. CYLINDER/PISTON

7-5

DINK 20 0

Measure the piston pin O.D.

Service Limit: 14.96mm replace if below

Measure the piston O.D.

Service Limit: 61.90mm replace if below

Measure the piston-to-piston pin clearance.

Service Limit: 0.02mm replace if over

CYLINDER INSPECTION

Inspect the cylinder bore for wear or damage.
Measure the cylinder I.D. at three levels of
top, middle and bottom at 90° to the piston
pin (in both X and Y directions).

Service Limit: 62.10mm repair or replace if

below

Measure the cylinder-to-piston clearance.
Service Limit: 0.1mm repair or replace if

over

The true roundness is the difference between
the values measured in X and Y directions.
The cylindricity (difference between the
values measured at the three levels) is subject
to the maximum value calculated.

Service Limits:
True Roundness:0.05mm repair or replace

if over

Cylindricity: 0.05mm repair or replace if over

• Take measurement at 9mm from the
bottom and 90° to the piston pin hole.

＊

Middle

Bottom

Top

7. CYLINDER/PISTON

7-6

DINK 20 0

Inspect the top of the cylinder for warpage.
Service Limit: 0.05mm repair or replace if over

Measure the connecting rod small end I.D.

Service Limit: 15.06mm replace if over

PISTON RING INSTALLATION

Install the piston rings onto the piston.
Apply engine oil to each piston ring.

Second

Side Rail

Top

• Be careful not to damage the piston and

piston rings during assembly.

• All rings should be installed with the

markings facing up.

• After installing the rings, they should

rotate freely without sticking.

• Stagger the ring end gaps as the figure

shown.

＊

Second

Top

Side Rail

Oil Ring

7. CYLINDER/PISTON

7-7

DINK 20 0

PISTON INSTALLATION

Remove any gasket material from the
crankcase surface.

Install the piston, piston pin and a new
piston pin clip.

CYLINDER INSTALLATION

Install the dowel pins and a new cylinder
gasket on the crankcase.

Coat the cylinder bore, piston and piston
rings with clean engine oil.
Carefully lower the cylinder over the piston
by compressing the piston rings.

Gasket

Cylinder

Dowel Pin

• Be careful not to drop foreign matters
into the crankcase.

＊

Piston

Piston Pin Clip

Piston Pin

• Be careful not to damage or break the

piston rings.

• The piston ring end gaps should not be

parallel with or at 90° to the piston pin.

＊

• Position the piston “IN” mark on the

intake valve side.

• Place a clean shop towel in the

crankcase to keep the piston pin clip
from falling into the crankcase.

＊

7. CYLINDER/PISTON

7-8

DINK 20 0

Tighten the cylinder base bolt.

Install the cam chain guide.

Connect the water hose to the cylinder.
Install the cylinder head. (6-9)
Tighten the cylinder base bolt.

• Insert the tab on the cam chain guide
into the cylinder groove.

＊

Cylinder Base Bolt

Cam Chain Guide

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

DINK 20 0

8

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

DRIVE AND DRIVEN PULLEYS/

KICK STARTER

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 8- 1

SERVICE INFORMATION -------------------------------------------- 8- 2

TROUBLESHOOTING ------------------------------------------------- 8- 2

LEFT CRANKCASE COVER ------------------------------------------ 8- 3

DRIVE PULLEY -------------------------------------------------------- 8- 4

CLUTCH/DRIVEN PULLEY ------------------------------------------ 8- 8

KICK STARTER -------------------------------------------------------- 8-15

8

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

DINK 20 0

SCHEMATIC DRAWING

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

DINK 20 0

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The drive pulley, clutch and driven pulley can be serviced with the engine installed.

• Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from

them to minimize the slipping of drive belt and drive pulley.

SPECIFICATIONS

Item

Standard (mm)

Service Limit (mm)

Movable drive face bushing I.D.

33.000_ 33.025

33.06

Drive face collar O.D.

32.006_ 32.009

31.90

Drive belt width

19.0

17.5

Clutch lining thickness

3.963_ 4.037

2.0

Clutch outer I.D.

130.0_ 130.2

130.5

Driven face spring free length

88.3

83.2

Driven face O.D.

33.965_ 33.985

33.94

Movable driven face I.D.

34.00_ 34.025

34.06

Weight roller O.D.

16.99_ 17.00

16.00

TORQUE VALUES

Drive face nut 49.0_ 58.8N-m
Clutch outer nut 49.0_ 58.8N-m
Clutch drive plate nut 49.0_ 58.8N-m

SPECIAL TOOLS

Universal holder Clutch spring compressor
Bearing driver Lock nut wrench, 39mm

Kick starter spring remover

TROUBLESHOOTING

Engine starts but motorcycle won‘t move Lack of power

• Worn drive belt • Worn drive belt

• Broken ramp plate • Weak driven face spring

• Worn or damaged clutch lining • Worn weight roller

• Broken driven face spring • Faulty driven face

Engine stalls or motorcycle creeps

• Broken clutch weight spring

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

DINK 20 0

LEFT CRANKCASE COVER

REMOVAL

Remove two bolts on the air cleaner.
Remove the air cleaner.

Remove the left crankcase cover bolts and left
crankcase cover.
Remove the seal rubber and dowel pins.

INSTALLATION

Install the dowel pins and the seal rubber.

Install the left crankcase cover.

Install the cable clamp to the specified
location. Install and tighten the left crankcase
cover bolts.

Kick Lever

Left Crankcase Cover
Air Cleaner

Bolts

Dowel Pins

Left Crankcase Cover

Bolts

Bolts

• Do not pull out the kick starter spindle.
Press in the kick starter spindle when
installing the left crankcase cover.

＊

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

DINK 20 0

Install the air cleaner and tighten the bolts.

DRIVE PULLEY

REMOVAL

Remove the left crankcase cover.
Hold the drive pulley using an universal
holder and remove the drive face nut.
Remove the drive pulley face.

Universal Holder

Remove the drive belt from the movable drive
face.

INSPECTION

Check the drive belt for cracks, separation or
abnormal or excessive wear.
Measure the drive belt width.

Service Limit: 17.5mm replace if below

Drive Pulley Face

Universal Holder

Movable Drive Face

Drive Belt

Bolts

• Use specified genuine parts for

replace-ment.

＊

Special

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

DINK 20 0

Remove the movable drive face assembly.
Remove the drive pulley collar.

DISASSEMBLY

Remove the ramp plate.

Remove the weight rollers.

INSPECTION

Check each weight roller for wear or damage.
Measure each weight roller O.D.

Service Limit: 16.00mm replace if below

Drive Pulley Collar

Ramp Plate

Weight Roller

Movable Drive Face Assembly

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

DINK 20 0

Measure the movable drive face bushing
assemblyy I.D.

Service Limit: 27.20mm replace if over

Check the drive pulley collar for wear or
damage.
Measure the O.D. of the drive pulley collar
sliding surface.

Service Limit: 26.90mm replace if below

ASSEMBLY

Install the weight rollers into the movable
drive face.

Weight Roller

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-7

DINK 20 0

Install the ramp plate.

Insert the drive pulley collar into the movable
drive face.

INSTALLATION

Install the movable drive face onto the
crankshaft.

Lay the drive belt on the driven pulley.
Set the drive belt on the drive pulley collar.

Drive Pulley Collar

Ramp Plate

Driven Pulley

Movable Drive Face Assembly

Drive Pulley Collar

Drive Belt

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-8

DINK 20 0

Install the drive pulley face and drive face
nut.

Hold the drive pulley with the universal
holder and tighten the drive face nut.

Torque: 49.0_ 58.5N-m

Universal Holder

CLUTCH/DRIVEN PULLEY

Remove the left crankcase cover. (8-3)
Remove the drive pulley and drive belt. (8-

4)
Hold the clutch outer with the universal
holder and remove the clutch outer nut.

Universal Holder
Remove the clutch outer.

INSPECTION

Inspect the clutch outer for wear or damage.
Measure the clutch outer I.D.

Service Limit: 130.5mm replace if over

Drive Pulley Face

Special

• Do not get oil or grease on the

drive belt or drive pulley faces.

＊

Clutch Outer

Drive Face Nut

Drive Pulley

Universal Holder

Universal Holder

Special

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-9

DINK 20 0

Check the clutch shoes for wear or damage.
Measure the clutch lining thickness.

Service Limit: 2.0mm replace if below

CLUTCH/DRIVEN PULLEY
DISASSEMBLY

Hold the clutch/driven pulley assembly with
the clutch spring compressor.

Clutch Spring Compressor
Set the tool in a vise and remove the clutch

drive plate nut.

Lock Nut Wrench, 39mm
Loosen the clutch spring compressor and

disassemble the clutch/driven pulley
assembly.
Remove the seal collar.

Clutch/Driven Pulley

Special

Special

Clutch Spring Compressor

• Be sure to use a clutch spring

compressor to avoid spring damage.

＊

Lock Nut Wrench

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-10

DINK 20 0

Pull out the guide roller pins and guide rollers.
Remove the movable driven face from the
driven face.

Remove the oil seal from the movable driven
face.

INSPECTION

Measure the driven face spring free length.
Service Limit: 83.2mm replace if below

Check the driven face assembly for wear or
damage.
Measure the driven face O.D.

Service Limit: 33.94mm replace if below

Movable Driven Face

Guide Roller Pin

Guide Roller

Oil Seal

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-11

DINK 20 0

Check the movable driven face for wear or
damage.
Measure the movable driven face I.D.

Service Limit: 34.06mm replace if over

DRIVEN PULLEY FACE BEARING
REPLACEMENT

Check the bearings for play and replace them
if they have excessive play.
Drive the inner needle bearing out of the
driven pulley face.

Remove the snap ring and drive the outer
bearing out of the driven face.

Apply grease to the outer bearing.
Drive a new outer bearing into the driven face
with the sealed end facing up.

Bearing Driver

Seat the snap ring in its groove.
Apply grease to the driven face bore areas.

Snap Ring

Inner Bearing

Outer Bearing

• Discard the removed bearing and

replace with a new one.

＊

• Discard the removed bearing and

replace with a new one.

＊

Special

Pack all bearing cavities with 9_ 9.5g
grease.

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-12

DINK 20 0

Press a new needle bearing into the driven
face.

Bearing Driver

CLUTCH DISASSEMBLY

Remove the circlips and retainer plate to
disassemble the clutch.

Circlips

Retainer Plate

Special

• Keep grease off the clutch

linings.

＊

Clutch Lining

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-13

DINK 20 0

CLUTCH ASSEMBLY

Install the damper rubbers on the drive plate
pins.
Install the clutch weights/shoes and clutch
springs onto the drive plate.
Install the retainer plate and secure with the
circlips.

CLUTCH/DRIVEN PULLEY AS SEMBLY

Clean the pulley faces and remove any grease
from them.
Apply grease to the O-rings and install them
onto the moveable driven face.

Circlips

Drive Plate

Movable Driven Face

8. DRIVE AND DRIVEN PULLEYS/

KICK STARTER

8-14

DINK 20 0

Install the movable driven face onto the
driven face.
Apply grease to the guide rollers and guide
roller pins and then install them into the holes
of the driven face.

Install the seal collar.
Remove any excessive grease.

Set the driven pulley assembly, driven face
spring and clutch assembly onto the clutch
spring compressor.

Compress the tool and install the drive plate
nut.
Set the tool in a vise and tighten the drive
plate nut to the specified torque.

Torque: 49.0_ 58.8N-m

Clutch Spring Compressor
Outer Driver, 32x35mm

INSTALLATION

Install the clutch/driven pulley onto the drive
shaft.

• Be sure to clean the driven face

off any grease.

＊

• Align the flat surface of the driven

face with the flat on the clutch drive plate.

＊

• Keep grease off the drive shaft.

＊

Movable Driven Face

Guide Roller Pin

Seal Collar

Guide Roller

Clutch/Driven Pulley

Driven Face

Clutch Spring Compressor

Lock Nut Wrench

• Be sure to use a clutch spring

compressor to avoid spring damage.

＊

Special