. GENERAL INFORMATION 1ENGINE SERIAL NUMBER ---- 1-0 DINK 200 SPECIFICATION ----------------- 1-1 TOOLS-----------------------------1-11 LUBRICATION POINTS --------1-12 SERVICE PRECAUTIONS ------ 1-2 WIRING DIAGRAM--------------1-14 TORQUE VALUES--------------- 1-9 CABLE & HARNESS ROUTING- 1-19 1 TROUBLESHOOTING-----------1-20 ENGINE SERIAL NUMBER Location of Engine Serial Number 1-0
DINK 200 1. GENERAL INFORMATION SPECIFICATIONS Name & Model No. Motorcycle Name & Type Overall length Overall width Overall height Wheel base Engine type 0° 0.1 0.1 1700rpm Forced pressure & wet sump Inner/outer rotor type Full-flow filtration 1.1 liters Spark plug gap Battery Capacity Clutch Type NGK DPR7EA-9 0.7mm 12V8AH CVT Type Non-stage transmission Operation Automatic centrifugal type Reduction Gear 1-1 15.2/7250 1.
1. GENERAL INFORMATION DINK 200 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.
1. GENERAL INFORMATION 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.
DINK 200 1. GENERAL INFORMATION If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. Confirm 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.
1. GENERAL INFORMATION 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.
1. GENERAL INFORMATION DINK 200 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.
DINK 200 1. GENERAL INFORMATION Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! 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.
DINK 200 1. GENERAL INFORMATION 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. Do you understand the instrument? Be careful not to drop any parts.
1. GENERAL INFORMATION Symbols: The following symbols represent the servicing methods and cautions included in this service manual. Engine Oil Grease Gear Oil Special ＊ : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) : Apply grease for lubrication. : Transmission Gear Oil (90#) : Use special tool.
DINK 200 1. GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES Item 5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut Torque (kg-m) 0.5 1.0 2.2 3.5 5.5 Item 5mm screw 6mm screw, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut Torque (kg-m) 0.4 0.9 1.2 2.7 4.0 Torque specifications listed below are for important fasteners.
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DINK 200 1. GENERAL INFORMATION 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.
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1. GENERAL INFORMATION Oil Vapor Recovery Tube DINK 200 Fuel Tube Auto Bystarter Wire Thermostat Carburetor Overflow Tube Air Cut-off Valve (A.C.V.
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DINK 200 1. GENERAL INFORMATION POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Correct timing Incorrect timing Correctly adjusted Incorrectly adjusted Faulty CDI unit Faulty A.C.
DINK 200 1. GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Faulty A.C.
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DINK 200 1. GENERAL INFORMATION STARTER MOTOR 1.
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DINK 200 1. GENERAL INFORMATION FUEL GAUGE 1.
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