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KYMCO DINK Classic 200 - D200 - Complete OFFICIAL Factory Service / Repair / Full Workshop Manual
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Basic Information Identification Make: KYMCO Model: DINK Classic 200 (D200) Model Variant: D200 Product Name: KYMCO DINK Classic 200 - D200 - Complete OFFICIAL Factory Service / Repair / Full...
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| Basic Information | |
| Identification | |
| Make: | KYMCO |
| Model: | DINK Classic 200 (D200) |
| Model Variant: | D200 |
| Product Name: | KYMCO DINK Classic 200 - D200 - Complete OFFICIAL Factory Service / Repair / Full Workshop Manual PDF Download |
| Introduction | |
| Market Position | |
| Target Audience: | Owners of KYMCO DINK Classic 200 (D200) scooters seeking to perform their own maintenance and repairs, or professional motorcycle/scooter technicians. |
| Competitive Analysis | |
| Value Proposition: | Provides official, factory-level technical data that is essential for accurate diagnosis and repair, offering a significant cost saving compared to dealership service. |
| Key Features | |
| Delivery: | Instant download eliminates waiting time and shipping costs, making essential repair information immediately accessible. |
| Searchability Benefit: | Keyword search functionality allows users to quickly locate specific procedures, parts, or troubleshooting steps, enhancing efficiency. |
| Manual Details | |
| Coverage Areas | |
| General Coverage: | Complete workshop repair and service information for the KYMCO DINK Classic 200 (D200). |
| Page Count | |
| Estimated Page Count: | Not explicitly stated, but implied to be comprehensive across 21 PDF files. |
| Manual Type | |
| Type: | Official Factory Service / Repair / Workshop Manual |
| Language | |
| Language: | English |
| Format | |
| File Format: | PDF (delivered as a ZIP archive) |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Engine overhaul, troubleshooting, internal components (pistons, rings, rods, crankshaft, camshaft, valve train, bearings), oil system, cooling system, fuel system (carburetor, fuel pump, filters). |
| Transmission: | Transmission overhaul, clutch components (pressure plate, clutch shoe, clutch case), drive belts, final drive. |
| Brakes: | Brake system maintenance, brake pad/shoe replacement, rotor inspection/replacement, brake lines, hydraulic system. |
| Electrical: | Wiring harness, wiring diagrams, sensors, ignition system, starter system, battery, lighting (headlights, taillights, indicators), switches, instrumentation. |
| Chassis And Bodywork: | Frame, suspension, steering, wheels, tires, body panels, interior components (dashboard, consoles, seating), fasteners, gaskets, seals. |
| Suspension And Steering: | Front forks, rear shock absorbers, steering head bearings, and steering linkage maintenance and repair procedures. |
| Fuel System Detailed: | Detailed breakdown of the carburetor assembly, including jetting, float bowl, throttle shaft, choke shaft, and related components. |
| Exhaust System: | Includes coverage for the muffler, downpipe, catalytic converter (if applicable), and exhaust gaskets, along with replacement and removal instructions. |
| Cooling System: | If liquid-cooled, covers radiator, radiator fan, coolant hoses, and coolant replacement procedures. |
| Procedures Included | |
| Maintenance: | Routine maintenance, oil changes, fluid changes, filter replacements, spark plug replacement, tire rotation/replacement, brake fluid replacement, coolant replacement. |
| Repair: | Detailed step-by-step repair procedures for all major mechanical and electrical components, engine rebuilds, transmission repairs, brake system overhauls, electrical diagnostics and repair. |
| Troubleshooting: | Diagnostic procedures, common problems and their solutions, fault code interpretation (if applicable). |
| Technical Specifications: | Torque specifications for critical fasteners, fluid capacities, recommended fluid types, electrical system specifications, engine performance data. |
| Engine Rebuild: | Covers complete engine disassembly, inspection, component replacement (pistons, rings, valves, bearings), and reassembly with correct torque specifications. |
| Electrical Diagnostics: | Includes detailed wiring diagrams, sensor testing procedures, and troubleshooting steps for electrical faults. |
| Technical Depth | |
| Depth: | Comprehensive; covers everything from basic maintenance and routine service to complete engine and transmission rebuilds, electrical system diagnostics, and component-level repairs. Suitable for both DIY enthusiasts and professional technicians. |
| Specifications Detail: | Provides precise torque values, clearances, tolerances, and fluid specifications critical for accurate mechanical work. |
| Manual Specifications | |
| File Format | |
| Digital Format: | |
| Print Quality | |
| Printability: | Yes, the PDF files are printable. |
| Binding Type | |
| Delivery Method: | Instant Download via ZIP archive (no physical binding). |
| Paper Type | |
| Zoom Capability: | Yes, allows for zooming in and out for detailed viewing. |
| Searchability | |
| Keyword Search: | Yes, the manual is keyword searchable for quick access to information. |
| Quality | |
| Source Quality: | Factory Quality |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Likely a 4-stroke, single-cylinder, liquid-cooled engine (based on typical scooter configurations of this era and displacement). |
| Displacement: | Approximately 160-200cc (as indicated by the '200' in the model name). |
| Performance | |
| Horsepower Range: | Typically in the range of 10-15 HP, but specific factory figures would be detailed in the manual. |
| Torque Range: | Specific torque figures are not provided but would be included in the manual for engine assembly and tuning. |
| Fuel System | |
| Fuel Delivery: | Likely Carbureted (indicated by 'Carb' in tags) or potentially early fuel injection, but carburetor details are heavily featured in tags. |
| Ignition: | Details on ignition system components, timing, and troubleshooting will be covered. |
| Lubrication | |
| Oil System: | Comprehensive coverage of the oil pump, oil pan, oil filters, and oil change procedures, including recommended oil types and capacities. |
| Transmission | |
| Standard | |
| Transmission Type: | Automatic Continuously Variable Transmission (CVT) is standard for this type of scooter. |
| Optional | |
| Gear Ratios: | CVT operation and component specifications will be detailed. |
| Features | |
| Clutch System: | Details on the automatic clutch, including centrifugal clutch operation, pressure plate, clutch shoes, and springs. |
| Dimensions | |
| Exterior | |
| Scooter Type: | Maxi-scooter (typically larger, more comfortable scooters designed for longer distances). |
| Weights | |
| Dry Weight: | Specific weight figures would be available in the manual, generally in the 150-180 kg range for this class. |
| Payload Capacity: | Information on maximum rider and cargo weight limits would be included. |
| Safety Features | |
| Ratings | |
| Crash Test Results: | Not applicable to this type of service manual; focuses on mechanical safety. |
| Active Features | |
| Braking System: | Details on front and rear braking systems, likely including disc brakes. Manual covers maintenance and repair. |
| Passive Features | |
| Lighting System: | Comprehensive coverage of headlight, taillight, brake light, and turn signal systems for visibility and signaling. |
| Technology Features | |
| Infotainment | |
| Instrument Cluster: | Typically features an analog/digital combination for speedometer, tachometer, fuel gauge, and warning lights. Manual covers its electrical connections and troubleshooting. |
| Driver Assistance | |
| ABS: | ABS availability would depend on the specific trim level; if present, the manual would cover its components and diagnostics. |
| Connectivity | |
| Lighting Technology: | Manual will cover halogen or potentially early LED lighting systems, including bulb replacement procedures. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Typical intervals range from 2,000 km to 5,000 km or 6-12 months, with specific recommendations in the manual. |
| Air Filter Replacement: | Intervals usually range from 5,000 km to 10,000 km, or as needed based on operating conditions, detailed in the manual. |
| Spark Plug Replacement: | Typically every 10,000 km to 20,000 km, with specific plug types and gap settings provided. |
| Fluid Specifications | |
| Engine Oil Type: | Likely a high-quality semi-synthetic or synthetic SAE 10W-40 or 15W-50 motorcycle oil, meeting specific API or JASO standards. Manual will specify exact grade and capacity. |
| Coolant Type: | If liquid-cooled, requires a specific mixture of ethylene glycol-based antifreeze and distilled water. Manual will specify type and ratio. |
| Brake Fluid Type: | DOT 4 brake fluid is common, but the manual will confirm the exact specification and capacity for flushing and bleeding. |
| Known Issues | |
| Common Wear Items: | Like many scooters, common wear items include drive belts, clutch shoes, brake pads, tires, and suspension components. The manual will detail inspection and replacement procedures for these. |
| Carburetor Cleaning: | Carbureted systems can sometimes require periodic cleaning and adjustment, especially with fuel variations. The manual will guide this process. |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer: | KYMCO (Kwang Yang Motor Co., Ltd.) is a Taiwanese manufacturer known for producing motorcycles, scooters, ATVs, and utility vehicles. |
| Model Evolution | |
| Dink Series: | The DINK series represents KYMCO's line of practical, comfortable scooters, often with a focus on urban commuting and touring capabilities. |
| Production | |
| Production Years: | Specific production years for the DINK Classic 200 (D200) would need to be cross-referenced with the manual's scope, but it falls into the modern era of scooter design. |
| Awards & Recognition | |
| Recognitions | |
| Manual Quality Recognition: | Recognized as an OFFICIAL Factory Service Manual, indicating the highest level of accuracy and detail for repair and maintenance. |