KYMCO DINK 125 (01) PDF Document

Before operating your KYMCO DINK 125, it is important to understand the special messages used in the owner’s manual to emphasize safety information.

WARNING: Indicates a strong possibility that serious injury or death may result if instructions are not followed.

CAUTION: Indicates a possibility that equipment or property damage could result if instructions are not followed.

NOTE: Gives helpful information.

This scooter is designed to be used only on the road.

For your safety, it is strongly recommended that you always wear an approved scooter helmet, eye protection, boots, gloves, long pants, and a long-sleeved shirt or jacket whenever you ride your KYMCO DINK 125.

Helmets and protection: Your helmet is the most important piece of riding gear as it offers the best protection against head injuries. A helmet should fit your head comfortably and securely. Always wear a face shield or goggles to protect your eyes and help your vision.

Additional riding gear:

• Sturdy boots with non-slip soles to help protect your feet and ankles.

• Leather gloves to keep your hands warm and help prevent blisters, cuts, burns, and bruises.

• A scooter riding suit or jacket for comfort and protection. Bright-colored and reflective clothing can help make you more noticeable in traffic. Avoid loose clothes that could get caught on any part of your scooter.

Following the load limits and guidelines for your KYMCO DINK 125 is crucial for maintaining stability and safe handling.

Load Limits:

• Maximum weight capacity (includes rider, passenger, all cargo, and accessories): 163 kg (358 lbs)

• Maximum cargo weight: 18 kg (40 lbs)

Individual Compartment Weight Limits:

• In center compartment: 10 kg (22 lbs)

• On rear carrier: 5 kg (11 lbs)

• On helmet hook: 3 kg (6 lbs)

Loading Guidelines:

• Check that both tires are properly inflated.

• To prevent loose items from creating a hazard, make sure all cargo is securely tied down before you ride.

• Place cargo weight as close to the center of the scooter as possible.

• Balance cargo weight evenly on both sides.

• Ride at reduced speeds when carrying cargo and allow for greater braking distance.

The ignition switch on your KYMCO DINK 125 has several positions for different functions:

• “OFF” (symbol) Position: All electrical circuits are cut off. The engine will not start.

• “ON” (symbol) Position: The ignition circuit is completed, and the engine can now be started. The key cannot be removed from the ignition switch in this position.

• “LOCK” (symbol) Position: To lock the steering, turn the handlebar all the way to the left. Push down and turn the key to the “LOCK” position and remove the key. All electrical circuits are cut off.

• “FUEL CAP OPEN” (symbol) Position: To open the fuel fill cap, turn the key to this position. Make sure the key is in the “ON” position when starting the engine.

The multi-function display on your KYMCO DINK 125 includes a speedometer, odometer, trip meter, oil service meter, fuel gauge, and digital clock.

Speedometer: Shows riding speed. Press and hold the Mode button for more than 2 seconds to select between mph or Km/h.

Odometer/Tripmeter/Oil service meter:

• To select between these modes, press and hold the Adjust button for more than 2 seconds.

• The Odometer shows accumulated mileage.

• The Tripmeter shows mileage per trip.

• The Oil service meter shows mileage for the oil service frequency.

To reset the tripmeter:

1. Press and hold the Adjust button for more than 2 seconds to select TRIP.

2. Press and hold both the Mode button and Adjust button at the same time until the tripmeter is reset to 0.0.

To reset the oil service meter:

1. Press and hold the Adjust button for more than 2 seconds to select the oil service meter.

2. Press and hold both the Mode button and Adjust button at the same time until the oil service meter is reset.

To adjust the digital clock on your KYMCO DINK 125, follow these steps. Note that the clock can only be adjusted in ODO mode.

1. Turn the ignition switch ON.

2. Press and hold the Adjust button for more than 2 seconds to select ODO mode.

3. Press and hold both the Mode button and Adjust button at the same time for more than 2 seconds. The clock will enter adjust mode with the hour display flashing.

4. To set the hour, press the Adjust button until the desired hour is shown.

5. Press the Mode button. The minute display will start flashing.

6. To set the minute, press the Adjust button until the desired minute is shown.

7. To end the adjustment, press both the Mode and Adjust buttons at the same time. The display will stop flashing automatically if no button is pressed for about 10 seconds.

The instrument panel on your KYMCO DINK 125 has several indicators to keep you informed:

• Tachometer: Shows engine revolutions per minute (rpm). When the ignition is turned ON, the needle will sweep from zero to the maximum limit and back to zero to confirm proper function.

• Turn Signal Indicators: Flash when the respective left or right turn signal is operating.

• High Beam Indicator: Lights up when the headlight high beam is turned on.

• Oil Service Indicator: If this indicator comes on while driving, it means the engine oil should be changed at the next maintenance interval. The indicator comes on when the ignition is turned on and must go off when the engine is running.

• Seat Unlock Indicator (“MET-IN”): Lights up when the seat is not fully locked.

• Overheating Indicator: Comes on when the coolant temperature is too high. If this occurs, stop the engine, check the coolant level, and do not ride until the problem is corrected. The indicator also comes on when the ignition is turned on and must go off when the engine is running.

Right Handlebar Switches:

• Headlight switch: Has three positions. One turns the headlight, position light, and taillight off. The middle position turns on the position light and taillight. The third position turns on the headlight and taillight.

• Engine stop switch: The “RUN” position allows the engine to start and run. The “OFF” position cuts the ignition circuit, preventing the engine from starting or running.

• Electric starter button: Push this button to start the engine. The starter motor will not operate if a brake lever is not squeezed or if the side stand is down.

Left Handlebar Switches:

• Turn signal switch: Move the switch left or right to activate the turn signals. Push the switch in to cancel.

• Horn button: Press to sound the horn.

• Dimmer switch: Toggles the headlight between low beam and high beam.

• Passing light control switch: Press this switch to flash the headlight to signal other drivers.

To open the fuel fill cap:

1. Insert the ignition key into the ignition switch and turn it to the “FUEL CAP OPEN” position (the key cannot be removed).

2. Rotate the key clockwise to the designated position to open the fuel fill cap.

Refueling:

• Use unleaded petrol with a research octane number of 91 or higher.

• Do not overfill the tank. There should be no fuel in the filler neck.

To lock the fuel fill cap:

1. Push the fuel fill cap down into place until it locks firmly.

2. Turn the ignition key from the “FUEL CAP OPEN” position back to the “OFF” or “ON” position.

To unlock the seat “SEAT OPEN”:

• If the engine is running (key in “ON” position): Push the key in and turn it counterclockwise from “ON” to the “SEAT OPEN” position.

• If the engine is stopped (key in “OFF” position): Turn the key counterclockwise from “OFF” to the “SEAT OPEN” position.

After unlocking, pull the seat up to lift it.

To lock the seat:

Lower and push down on the reverse side of the hooks of the seat until it locks. Ensure the seat is secure before riding. The “MET-IN” indicator light will be on if the seat is not locked properly.

Always follow the proper starting procedure for your KYMCO DINK 125. This scooter is equipped with a side stand ignition cut-off system and will not start if the side stand is down.

1. Place the scooter on its center stand and make sure the side stand is fully up.

2. Make sure the engine stop switch is in the “RUN” position.

3. Turn the ignition switch to the “ON” position.

4. Squeeze the rear brake lever.

5. With the throttle closed, push the starter button. Release the starter button as soon as the engine starts.

6. Keep the throttle closed and allow the engine to warm up before riding.

To restart a warm engine that fails to start:

1. Place the scooter on its center stand and squeeze the rear brake lever.

2. Open the throttle 1/8 to 1/4 turn while pressing the starter button.

Proper break-in during the first 1600 km (1000 miles) is crucial for the life and performance of your KYMCO DINK 125.

Vary the engine speed: Do not hold the engine at a constant speed. Varying the speed allows parts to be loaded and unloaded, aiding the mating process.

Avoid constant low speed: Operating at a constant low speed can cause parts to glaze and not seat properly. Allow the engine to accelerate freely through the gears without exceeding the maximum recommended throttle limits.

Maximum throttle operation recommendation:

• Initial 800 km (500 miles): Use less than 1/2 throttle.

• Up to 1600 km (1000 miles): Use less than 3/4 throttle. Do not use full throttle during the first 1600 km.

Breaking in new tires: New tires need a break-in period of about 160 km (100 miles). Gradually increase your cornering lean angles and avoid hard acceleration, hard cornering, and hard braking during this period.

First service: The 1000 km (600 miles) service is the most critical. During this service, adjustments will be made, fasteners tightened, and the dirty oil replaced to ensure optimum service life.

For your safety, perform the following pre-ride inspection before each ride on your KYMCO DINK 125:

1. Engine oil level: Add engine oil if required. Check for leaks.

2. Fuel level: Fill the fuel tank when necessary. Check for leaks.

3. Coolant level: Add coolant if required. Check for leaks.

4. Front and rear brakes: Check operation and ensure there is no brake fluid leakage.

5. Tires: Check condition and pressure.

6. Throttle: Check for smooth opening and full closing in all steering positions.

7. Lights and horn: Check that the headlight, tail/brake light, turn signals, indicators, and horn function properly.

8. Engine stop switch: Check for proper function.

9. Side stand ignition cut-off system: Check for proper function.

10. Steering: Check for proper condition and smoothness.

Regularly checking and changing the engine oil is vital for your KYMCO DINK 125’s engine life.

Engine Oil Recommendation: Use a premium quality 4-stroke motor oil rated SG under the API service classification. The recommended viscosity is SAE 10W-30.

Checking the Oil Level:

1. Start the engine and let it idle for a few minutes.

2. Stop the engine and put the scooter on its center stand on level ground.

3. After a few minutes, remove the oil filler cap/dipstick, wipe it clean, and reinsert it without screwing it in.

4. Remove the dipstick again. The oil level should be between the upper and lower marks.

5. If required, add the specified oil up to the upper-level mark. Do not overfill.

6. Reinstall the oil filler cap/dipstick securely.

Changing the Engine Oil and Filter:

1. Warm up the engine and place the scooter on its center stand.

2. Place a drain pan under the engine. Remove the oil filler cap/dipstick.

3. Remove the oil drain plug to drain the oil.

4. Clean the oil strainer screen: remove the screen cap, spring, and screen. Clean the screen and check seals for damage before reinstalling. Torque for screen cap: 15 N-m.

5. Change the oil filter: Remove the three bolts on the oil filter cap. Remove the old filter, spring, and O-ring. Install a new filter, the spring, a new O-ring, and the cap. Torque for cap bolts: 12 N-m.

6. Reinstall the main oil drain plug. Torque: 25 N-m.

7. Fill the crankcase with 0.9 liter of recommended oil.

8. Start the engine and let it idle for 2-3 minutes. Stop the engine and re-check the oil level, adding more if necessary. Check for leaks.

To change the transmission oil on your KYMCO DINK 125, follow these steps:

1. Place the scooter on its center stand.

2. Place a drain pan under the drain bolt.

3. Remove the transmission oil drain bolt to drain the oil.

4. Remove the transmission oil filler bolt to allow the oil to drain completely.

5. After the oil has drained, install the drain bolt with a new sealing washer and tighten it. Torque: 13 N-m (9.5 lbf-ft).

6. Fill the transmission case with the recommended oil.

• Recommended transmission oil: SAE 90

• Oil capacity (at draining): 0.18 liter (0.2 US qt)

7. Install the transmission oil filler bolt with a new sealing washer and tighten it. Torque: 13 N-m (9.5 lbf-ft).

The air cleaner on your KYMCO DINK 125 should be serviced at regular intervals, more frequently in wet or dusty conditions.

1. Remove the band.

2. Remove a bolt from the crankcase and six screws from the air cleaner cover, then remove the air cleaner cover.

3. Remove the six screws holding the air cleaner element, then remove and discard the old element.

4. Install a new air cleaner element. Always use a genuine KYMCO element or a specified equivalent to prevent premature engine wear.

5. Reinstall the components in the reverse order of removal.

Proper tire maintenance is critical for the safety and performance of your KYMCO DINK 125.

Tire Pressure: Check pressure when the tires are cold. Insufficient pressure affects stability and increases wear, while overinflation reduces contact with the road.

Cold Inflation Tire Pressure Table:

Tire Tread Condition: Replace tires if they show visual damage like cracks or cuts, or if the tread depth is less than 1.6 mm (0.06 in) for the front tire, or 2 mm (0.08 in) for the rear tire.

Tire Replacement: Use only the specified tire sizes. An improperly repaired, installed, or balanced tire can cause loss of control.

Specified Tire Sizes:

Always keep the ignition switch OFF when working on the battery of your KYMCO DINK 125.

Battery Removal:

1. Open the seat.

2. The battery is in the battery box below the seat. Remove the two screws and the battery cover.

3. Remove the four screws holding the battery retainer and then remove the retainer.

4. Pull the battery out to expose the terminal leads.

5. Disconnect the negative (-) terminal lead first.

6. Disconnect the positive (+) terminal lead.

7. Remove the battery from the battery box.

Battery Installation:

Installation is the reverse order of removal. When reinstalling, connect the positive (+) cable first, and then connect the negative (-) cable to avoid a short circuit.

The fuse box on your KYMCO DINK 125 is located under the battery in the battery box.

1. Open the seat.

2. Open the battery cover.

3. Open the fuse box cover.

4. Pull out the old fuse and install a new fuse of the same rating. A spare fuse is located in the battery retainer.

5. Close the fuse box cover and reinstall the battery cover and seat.

Fuse List:

• 20A (Yellow) CHARGE fuse: Protects the battery charging system.

• 15A (Blue) MAIN fuse: Protects all electrical circuits.

• 15A (Blue) RELAY fuse: Protects the starter motor relay.

• 10A (Red) FAN fuse: Protects the cooling fan motor.

Regular cleaning will protect the surface finishes of your KYMCO DINK 125.

Washing the scooter:

1. Allow the engine and exhaust to cool down before washing.

2. Rinse the scooter thoroughly with cool water to remove loose dirt.

3. Clean the scooter with a sponge or soft cloth using cool water. Avoid directing water to muffler outlets and electrical parts.

4. Clean plastic parts with a cloth or sponge dampened with a mild detergent and water solution. Keep brake fluid and chemical solvents off plastic and painted surfaces.

5. After cleaning, rinse thoroughly with clean water to remove all detergent residue.

6. Dry the scooter, then start the engine and let it run for several minutes.

7. Test the brakes before riding, as braking efficiency may be temporarily reduced after washing.

Finishing Touches: After washing, consider using a commercially-available spray cleaner/polish or quality liquid or paste wax made for scooters or automobiles to protect the finish.

Cleaning the Windshield: Use plenty of water and a soft cloth or sponge. For a dirtier windshield, use a diluted neutral detergent and rinse thoroughly. Do not let battery electrolyte, brake fluid, or other acid chemicals get on the windshield as they will damage the plastic.

To prepare your KYMCO DINK 125 for extended storage (e.g., for winter), follow these steps:

1. Change the engine oil and filter.

2. Ensure the cooling system is filled with a 50/50% antifreeze solution.

3. Drain the carburetor and empty the fuel tank into an approved petrol container. Spray the inside of the tank with an aerosol rust-inhibiting oil and reinstall the fuel cap.

4. To prevent rusting in the cylinders:

• Remove the spark plugs. Pour a tablespoon (15-20 cc) of clean engine oil into each cylinder.

• Cover the spark plug holes with a cloth and crank the engine several times to distribute the oil.

• Reinstall the spark plugs and spark plug caps.

5. Remove the battery. Store it in an area protected from freezing temperatures and direct sunlight. Slow charge the battery once a month.

6. Wash and dry the scooter. Wax all painted surfaces and coat chrome with a rust-inhibiting oil.

7. Inflate the tires to their recommended pressures. Place the scooter on blocks to raise both tires off the ground.

8. Cover the scooter (do not use plastic or other coated materials) and store it in an unheated, dry area with minimal daily temperature variation, away from direct sunlight.

When removing your KYMCO DINK 125 from storage, follow these steps:

1. Uncover and clean the scooter.

2. Change the engine oil if the scooter has been in storage for more than one month.

3. Charge the battery as required and install it.

4. Drain any excess aerosol rust-inhibiting oil from the fuel tank. Fill the fuel tank with fresh petrol.

5. Perform all pre-ride inspection checks. Test ride the scooter at low speeds in a safe area away from traffic to ensure all components are working correctly.