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

EXHAUST MUFFLER/FRAME COVERS

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE AND DRIVEN PULLEYS/KICK STARTER

FINAL REDUCTION

A.C. GENERATOR/STARTER CLUTCH

CRANKCASE/CRANKSHAFT

COOLING SYSTEM

FUEL SYSTEM/CARBURETOR/FUEL PUMP

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

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

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

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

E/M

EXHAUST EMISSION CONT ROL SYST EM

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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ENGINE SERIAL NUMBER

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

1-1

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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

Net weight (kg)

Rear wheel

Total

130

Front wheel

Gross weight(kg)

Rear wheel

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)

Max. output (ps/rpm)

15.2/7250

Max. torque (kg-m/rpm)

1.4/6500

Intake

Open

BTDC 12°

Port

(1mm)

ATDC 35°

timin g

Exhaust

Open

BDDC 28°

(1mm)

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

Piston dia.

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

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

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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

8 8 5

6 12 12 12 14

6 10

2.2

1.5

0.9

2.2

0.9

1.3

5.5

0.4

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

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

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

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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

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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

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

1-23

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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

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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

Symptom

Check operation of stop switch by applying brake

Stoplight does not come on

Stoplight comes

Check battery circuit by operating turn signals

Turn ignition switch OFF

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

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

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closed

NO SPARK AT 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

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

Check spark plug cap and high-tension wire for looseness

Check CDI unit with a CDI unit tester

1. GENERAL INFORMATION

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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

Symptom

Probable Cause

Normal voltage

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

+ 195 hidden pages

KYMCO DINK 200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual