User Guide

ManualsBrandsKymco ManualsOtherMO D200

5. ENGINE REMOVAL/INSTALLATION

5-0

DINK 20 0

__________________________________________________________________________________

ENGINE REMOVAL/INSTALLATION

__________________________________________________________________________________

SCHEMATIC DRAWING ---------------------------------------------- 5-1

SERVICE INFORMATION -------------------------------------------- 5-2

ENGINE REMOVAL --------------------------------------------------- 5-3

ENGINE INSTALLATION -------------------------------------------- 5-5

Summary of content (6 pages)

PAGE 1
5.
PAGE 2
5. ENGINE REMOVAL/INSTALLATION SCHEMATIC DRAWING 4.0kg-m 3.0kg-m 5.
PAGE 3
5. ENGINE REMOVAL/INSTALLATION DINK 200 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.
PAGE 4
5. ENGINE REMOVAL/INSTALLATION DINK 200 Wire Connectors 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.
PAGE 5
. ENGINE REMOVAL/INSTALLATION DINK 200 Rear Shock Absorber Upper Mount Bolts 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 Mounting Bolt ENGINE HANGER REMOVAL Remove the engine hanger bolts to remove the engine hanger. Engine Hanger Bolt Inspect the engine hanger bushings and stopper rubber for wear or damage.
PAGE 6
5. ENGINE REMOVAL/INSTALLATION DINK 200 ENGINE INSTALLATION Install the engine in the reverse order of removal. Tighten the engine mounting bolts. Torque: 5.0kg-m Engine Hanger Bolt 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.