Kymco dink 200i repair manual

Poor performance at idle speed White smoke from exhaust muffler Page Cylinder Head Cover. Be sure to install the O-ring into the groove properly. Page Camshaft Holder Tighten the four cylinder head nuts to the specified torque.

Torque: DINK i: 2. Remove the valve rocker arms. Service Limits: IN: Service Limits: IN: 9. Page Camshaft.

Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke. Measure the cam lobe height. Keep the round hole on the camshaft gear facing up and align the punch marks on the Install a new cam chain tensioner gasket. Gasket Sealing Bolt Cam Chain Tensioner Install the cam chain tensioner and tighten the two bolts to the specified torque. Page Cylinder Head.

Install two dowel pins. Install the new gasket. Install the intake manifold and tighten the two mounting nuts securely. Be careful not to damage the cylinder head mating surface. Check the cylinder head for warpage with a straight edge and feeler gauge. Page Troubleshooting. If white smoke is found, it means that the piston rings are worn, stuck or broken. Compression too low or uneven Page Cylinder And Piston.

Remove the cylinder. Remove the cylinder gasket 4 and dowel pins 3. Clean carbon deposits from the piston ring grooves. Take the maximum reading to determine the cylinder wear. Take a maximum reading to determine the clearance. Apply engine oil to the piston pin.

Apply engine oil to the connecting rod small end and piston pin hole. Pass the cam chain through the cylinder and install the cylinder over the piston. Be careful not to damage the piston rings and cylinder walls. Page Service Information Page Left Crankcase Cover. Remove the gasket and dowel pins. Remove the snap ring and washer from the kick starter spindle. Friction Spring Remove the plastic bushing and kick starter spindle bushing.

Use the special tool to hold the drive pulley, then remove the nut and ratchet. Page Check the drive belt for cracks, separation or abnormal or excessive wear.

Measure the drive belt width. Clutch out inspection Inspect the clutch outer for wear or damage. Page Install the drive pulley face and ratchet. Use the special tool to hold drive pulley face, then tighten the nut to the specified torque. Torque: DINK i: 5. Boss Ramp Plate Remove the ramp plate and four slide pieces.

Slide Pieces Remove the six weight rollers. Weight Roller Measure outside diameter. Service limit: Remove any excess grease. Install the weight rollers. The direction of all weight rollers is the same. Boss Be sure to use a clutch spring compressor to avoid spring damage. Remove the spring collar on the movable driven face.

Remove the needle bearing from driven face. Remove the snap ring, then remove the bearing from driven face. Page Check the spring for damage.

Measure the spring free length. Service limit: DINK i: mm 5. Measure the clutch shoe thickness. Apply grease Filling 12 g of grease to driven face inner side. Apply grease to lips of the new dust seals and install into the movable driven face. Page Final Reduction. Press the driveshaft out from the drive belt compartment. Countershaft Inspect the final gear and final gear shaft Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage.

Install new gasket. Install the two dowel pins. Dowel Pins Gasket Install the transmission case cover. Install and tighten the nine bolts to the specified torque in a crisscross pattern in 2 or 3 steps. Page Bearing Replacement. Remove the transmission case cover bearings by using the special tool. Special tool: Bearing puller AE Install the new bearings or new oil seal into the transmission case cover by using the special tool.

Perform this operation when the engine is cold. Page Alternator Stator. Disconnect the alternator stator connectors refer to the chapter Remove the nine bolts from the right crankcase cover and then remove the cover. Torque: 1 kgf-m 10 N-m, 7. Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 or 3 steps. Page Starter Clutch. Hold the flywheel with a special tool and remove the flywheel nut.

Special tool: Flywheel holder AE Check the operation of the sprag clutch by turning the driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should not turn counterclockwise. Shaft Reduction Gear Apply oil to the starter reduction gear shaft.

Install the starter reduction gear and shaft to the right crankcase. Torque: 5. The engine must be removed for this operation. Page Crankcase Separation. Remove the cam chain tensioner slipper and cam chain. Remove the two right crankcase attaching bolts. Bolt Cam Chain Bolts Remove the five left crankcase bolts. Page Crankshaft Inspection. Service Limit: Play Play Service Limits: Axial : 0. Gasket Dowel Pins Install the two dowel pins and a new gasket. Install the cam chain tensioner slipper.

Install and tighten the cam chain tensioner slipper bolt. Torque: 1. Page Cooling System. Other cooling system service can be done with the engine installed in the frame. Page Cooling System Testing. Always let the engine and radiator cool down before removing the radiator cap. Page Coolant Replacement. Therefore, for best performance change the coolant regularly as specified in he maintenance schedule. Remove the reserve tank cap 5 and drain the coolant from the reserve tank.

Reinstall and tighten the drain bolt securely. Place the scooter on its center stand on a flat, level surface. Bleed air from the system as follow: 1.

Page Radiator. Disconnect the siphon hose 1 and air bleed hose 2. Remove the bolt 3. Loosen the hose bands, then disconnect the upper radiator hose 4 and lower radiator hose 5 from the radiator. Page Fan Motor. Page Fan Motor Switch. Remove the fan motor switch 1. Page Water Pump. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal. Impeller Left Hand Threads Remove the water pump impeller. Remove the 3 bolts attaching the water pump assembly.

Remove the water pump assembly, gasket and dowel pins. Water Pump Assembly Install the snap ring to secure the inner bearing properly. Inner Bearing Water Pump Assembly Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover.

Dowel Pins Install the two dowel pins and a new gasket. Page Water Temperature Sensor. Disconnect the water temperature sensor connectors 1. Torque: 0. Page Thermostat. Thermostat Thermostat Remove the thermostat from the thermostat housing. Page Fuel System. When working with gasoline, keep sparks and flames away from the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area. Page Fuel Pump Construction.

Page Carburetor. Disconnect the auto choke connector 1. Disconnect the vacuum hose 2. Disconnect the fuel hose from the carburetor. Spring Spring Retainer Remove the spring retainer, jet needle. Jet Needle Float Chamber Remove the four screws and float chamber. Remove main jet. Remove the needle jet holder and needle jet. Remove the casting enrichment valve. Auto Choke Seat Then remove the O-ring. Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.

Clean all circuits of the carburetor thoroughly-not just the perceived problem area. Float Valve Float Pin Check the float valve and valve seat for foreign substance, clogging or damage. Check the tip of the float valve, where it contacts the valve seat, for stepped wear or contamination.

Top Cap Spring Check the diaphragm 1 of the coasting enrichment valve for tears. Check the spring 2 and cover 3 of the coasting enrichment for damage. If stick is found, replace the part with a new one. Check throttle valve for free movement. If stick is found, replace the part with a new carburetor.

When reassembling, carefully observe the following instructions. Assemble the parts taking consideration of their function. Before assembling, wash all of the parts in a clean petroleum based solvent. Page Auto Choke. Remove the two screws, then remove the auto choke and set plate. Page Carburetor Heater. If the heater is getting hot, means the heater without problem, otherwise the heater has to be changed. Page Fuel Pump. Disassemble the fuel pump. Inspect each gasket for damage.

Page Fuel Strainer. Page Fuel Tank. Remove the right fuel tank plate 9. Remove the two nuts 10 and then remove the left fuel tank plate Page Air Cleaner. Loosen the air cleaner clamp screw 1. Disconnect the crankcase breather hose 2 from the air cleaner. Page Troubleshooting Page Check Engine Lamp Celp This lamp test shall indicate to the operator that the lamp is functional and capable of signaling faults should they occur. Place the scooter on its main stand.

Page Celp Failure Codes Chart Park the car and Be immediately carry on maintaining a check immediately. The confirmation has the engine temperature Does confirming the TPS deal with contact, connect line and haven't moved and short circuit?

If still appear an abnormality, P TPI range fault depend on to change whether the new article process confirmation reduce expenses a valve body TPS Confirm Dai soon the air side whether valve electric resistance break the road or short circuit or not?

Does confirming the sensor know The confirmation light the front line turn electric resistance whether in the specification? Does the confirmation light the front line turn and deal with contact, connect line and haven't moved and break road? When the engine start turns soon over the rpms, in order to avoid hurtling suddenly and violently, the ECU will reduce engine to turn to even turn off soon. Confirm whether the output voltage of the sensor is within specification? Check whether the output pin position of the sensor is correct or open circuit occurs?

Replace with a new sensor We recommended the diagnostics program be installed in the SD card. They are not trouble indicators for AFI system and some data no definite range but you can compare normal with abnormal condition from current data. To adapt the APC plus or minus 0. Page Apc Adaption Procedure Page Spark Plug Anti-Flood Page Engine Control Unit Ecu Connect the battery terminals topsy- turvy may cause ECU damage.

Check for continuity between wire terminal 1 and 16 of the ECU side connector There should be continuity at all times. Coat O-ring with clean engine oil. Check and confirm the battery voltage above 12V by a voltmeter after replacement. Disconnect throttle position sensor connector. Disconnect the air by pass valve connector. If stick is found, replace the part with a new throttle body. Page Water Temperature Sensor Wts Install and tighten the WTS to the specified torque.

Page Fuel Injector Read the data: Engine Temp. Replace the new O-rings if it has damaged. O-ring Install fuel hose joint onto the fuel injection. Install the spring clip into the groove on the fuel injection. Install and tighten the bolt securely. Connect the connector. Standard: Page Fuel Tank Page Fuel Pump Relay Tighten the bolts using crisscross pattern.

Installation is in the reverse order of the removal. Connect the ohmmeter to the fuel pump relay connector terminals.

Read the data: O2 sensor voltage mV O2 sensor heater activation Page Angle Detect Sensor Disconnect the angle detect sensor connector. Page Air Cleaner Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down. Page Handlebar Remove the two bolts 1 and disconnect the brake light switch wire 2 , then remove the rear brake master cylinder.

Tighten the bolt to the specified torque. Torque: 4. Disconnect the throttle cable 2 from the throttle grip. Remove the right handlebar switch. Remove the two screws 3 and then remove the left handlebar switch. Align the pin on the left handlebar switch with the hole on the handlebar. Install and tighten the two screws securely. Install the right handlebar switch.

Align the pin on the right handlebar switch with the hole on the handlebar. Page Front Wheel Remove the nut 1 , then pull out the axle 2. Remove the front wheel and collar. Axle runoutn inspection Set the axle in V blocks and measure the runout using a dial gauge. Apply grease to the speedometer gear unit 2. Install the speedometer gear unit by aligning its retaining pawl with the hub cutout.

If not aligned, the retaining pawl will be deformed when the axle nut is tightened. Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly. Also check if the outer race fits tightly in the hub. Special tool: Bearing installer AE Install the distance collar. Page Front Brake Fluid Apply the brake lever several times. Fluid leakage Replace.

Remove the two screws 1. Remove the reservoir cover 2 , diaphragm plate 3 and diaphragm 4. Connect a bleed hose 5 to the bleed valve 6. Stop operating the brake when no more fluid flows out of the bleed valve. Pump up the system pressure with the brake lever until these are not air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt.

Page Front Brake Pad Remove the two caliper mounting bolts 2 , then remove the caliper. Remove the brake pads. Always replace the brake pads in pairs to ensure even disc pressure. Mi servirebbe il manuale officina x People Si abs anno dove lo potrei scaricare? David Hale Sunday, 28 February I am looking for a workshop manual so that I can fully maintain my Kymco x-town ct Can you help me? Kymco People Owner's Manual. Kymco Quannon Comments: 4. Kymco Activ Spare Parts Catalog.

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