KYMCO K-XCT 125i Service Manual
  1. Manuals
  2. Brands
  3. KYMCO Manuals
  4. Motorcycle
  5. K-XCT 125i
  6. Service manual

KYMCO K-XCT 125i Service Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
Table of Contents

Advertisement

Quick Links

Download this manual
K-XCT 125i
By KWANG YANG Motor Co., Ltd.
1st Edition, Aug. 2012
All rights reserved. Any reproduction or
unauthorized use without the written
permission of KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T100-LKG5-A1

Advertisement

Table of Contents
loading

Related Manuals for KYMCO K-XCT 125i

Summary of Contents for KYMCO K-XCT 125i

  • Page 1 K-XCT 125i By KWANG YANG Motor Co., Ltd. 1st Edition, Aug. 2012 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T100-LKG5-A1...

  • Page 2: Table Of Contents

    PREFACE TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION technical features servicing EXHAUST MUFFLER/FRAME procedures for the KYMCO K-XCT 125i. COVERS INSPECTION/ADJUSTMENT Section 1 contains the precautions for all operations stated in this manual. LUBRICATION SYSTEM Read them...

  • Page 3: General Information

    1. GENERAL INFORMATION K-XCT 125i ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION ________________________________________________________________________________ SERIAL NUMBER ------------------------------------------------------------------------------------ 1-1 SPECIFICATION ------------------------------------------------------------------------------------- 1-2 SERVICE PRECAUTIONS ------------------------------------------------------------------------- 1-3 TORQUE VALUES ----------------------------------------------------------------------------------- 1-8 SPECIAL TOOLS ----------------------------------------------------------------------------------- 1-10 LUBRICATION POINTS -------------------------------------------------------------------------- 1-12 TROUBLESHOOTING ---------------------------------------------------------------------------- 1-14...
  • Page 4 1. GENERAL INFORMATION K-XCT 125i Identification Numbers Record...

  • Page 5: Specification

    1. GENERAL INFORMATION K-XCT 125i SPECIFICATIONS Name K-XCT 125i Oil filter type Full-flow filtration Model No. SK25BA Oil capacity 1.2 liter Exchanging capacity 1.0 liter Overall length 2120 mm Fi injection system Overall width 785 mm Air cleaner type & No...

  • Page 6: Service Precautions

    1. GENERAL INFORMATION K-XCT 125i  Apply or add designated greases and SERVICE PRECAUTIONS lubricants to the specified lubrication  Make sure to install new gaskets, O-rings, points. circlips, cotter pins, etc. when reassembling.  When tightening bolts or nuts, begin with ...
  • Page 7 1. GENERAL INFORMATION K-XCT 125i  Before connecting a terminal, check for damaged terminal cover or loose negative  After operation, terminal caps shall be terminal. installed securely. Confirm Capacity  Check the double connector cover for  When taking out the connector, the lock on proper coverage and installation.
  • Page 8 1. GENERAL INFORMATION K-XCT 125i  Protect wires and harnesses with electrical  Do not squeeze wires against the weld or tape or tube if they contact a sharp edge or its clamp. corner. Do not pull too tight！  After clamping, check each harness to ...
  • Page 9 1. GENERAL INFORMATION K-XCT 125i  Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent surrounding parts steering positions.  When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions.
  • Page 10 1. GENERAL INFORMATION K-XCT 125i  Symbols: following symbols represent servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for Engine Oil lubrication.) : Apply grease for lubrication.

  • Page 11: Torque Values

    1. GENERAL INFORMATION K-XCT 125i TORQUE VALUES Item Thread dia.(mm) Torque (kgf-m) Remarks Cylinder head bolt A 0.7~1.1 0.7~1.1 Cylinder head bolt B Oil filter screen cap 2.0~3.0 0.7~1.1 O2 sensor Cylinder head cover 0.8~0.9 1.0~2.0 Tappet adjusting hole cap Cam chain set plate 1.0~1.4...
  • Page 12 1. GENERAL INFORMATION K-XCT 125i TORQUE VALUES FRAME...

  • Page 13: Special Tools

    1. GENERAL INFORMATION K-XCT 125i SPECIAL TOOLS 1-10...
  • Page 14 1. GENERAL INFORMATION K-XCT 125i 1-11...

  • Page 15: Lubrication Points

    1. GENERAL INFORMATION K-XCT 125i LUBRICATION POINTS FRAME The following is the lubrication points for the frame. Use grease for parts not listed. Apply engine oil or grease to cables and movable parts not specified. It will avoid abnormal noise and damage the durability of the motorcycle.
  • Page 16 1. GENERAL INFORMATION K-XCT 125i ENGINE 1-13...

  • Page 17: Troubleshooting

    1. GENERAL INFORMATION K-XCT 125i TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Possible cause 1. Check for operation of the fuel pump Abnormal  Faulty fuel pump Normal 2. Inspect the fuel flow Abnormal  Faulty pressure regulator Normal 3.
  • Page 18 1. GENERAL INFORMATION K-XCT 125i ENGINE LACKS POWER Possible cause 1. Raise wheel off the ground Wheels do not  Brake dragging and spin by hand spin freely  Worn or damaged wheel bearing Wheel spins freely 2. Check tire pressure Pressure low ...
  • Page 19 1. GENERAL INFORMATION K-XCT 125i Possible cause 9. Check oil level and condition Incorrect  Oil level too high  Oil level too low  Contaminated oil Correct 10. Remove cylinder head cover Valve train not  Clogged oil and inspect lubrication lubricated properly ...
  • Page 20 1. GENERAL INFORMATION K-XCT 125i POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause 1. Check ignition timing Incorrect  Improper ignition timing Correct 2. Inspect the fuel flow Abnormal  Faulty pressure regulator Normal 3. Inspect the fuel injector Abnormal ...
  • Page 21 1. GENERAL INFORMATION K-XCT 125i POOR PERFORMANCE AT HIGH SPEED Possible cause 1. Check ignition timing Incorrect  Faulty ECU Correct 2. Inspect the fuel flow Abnormal  Faulty pressure regulator Normal 3. Inspect the fuel injector Abnormal  Faulty injector Normal 4.

  • Page 22: Exhaust Muffler/Frame Covers

    . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ • Exhaust System ...............1-2~1-13 • Luggage Box..............1-14~1-16 • Seat................1-17~1-19 • Rear Carrier ..............1-20~1-22 • Body Cover ..............1-23~1-32 • Windshield ..............1-33~1-36 • Front Cover Meter ............1-37~1-38 •...
  • Page 23 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i SERVICE INFORMATION GENERAL INSTRUCTIONS  When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged.  Make sure to route cables and harnesses according to the Cable & Harness Routing.
  • Page 24 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i...
  • Page 25 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i ...
  • Page 26 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i...
  • Page 27 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i...
  • Page 28 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i...
  • Page 29 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i Remove the muffler heat shield bolts.
  • Page 30 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i...
  • Page 31 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i...
  • Page 32 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-10...
  • Page 33 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-11...
  • Page 34 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-12...
  • Page 35 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-13...
  • Page 36 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-14...
  • Page 37 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-15...
  • Page 38 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-16...
  • Page 39 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-17...
  • Page 40 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-18...
  • Page 41 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-19...
  • Page 42 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-20...
  • Page 43 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-21...
  • Page 44 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-22...
  • Page 45 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-23...
  • Page 46 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-24...
  • Page 47 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-25...
  • Page 48 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-26...
  • Page 49 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-27...
  • Page 50 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-28...
  • Page 51 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-29...
  • Page 52 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-30...
  • Page 53 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-31...
  • Page 54 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-32...
  • Page 55 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-33...
  • Page 56 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-34...
  • Page 57 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-35...
  • Page 58 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-36...
  • Page 59 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-37...
  • Page 60 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-38...
  • Page 61 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-39...
  • Page 62 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-40...
  • Page 63 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-41...
  • Page 64 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-42...
  • Page 65 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-43...
  • Page 66 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-44...
  • Page 67 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-45...
  • Page 68 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-46...
  • Page 69 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-47...
  • Page 70 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-48...
  • Page 71 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-49...
  • Page 72 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-50...
  • Page 73 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-51...
  • Page 74 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-52...
  • Page 75 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-53...
  • Page 76 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-54...
  • Page 77 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-55...
  • Page 78 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-56...
  • Page 79 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-57...
  • Page 80 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-58...
  • Page 81 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-59...
  • Page 82 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-60...
  • Page 83 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-61...
  • Page 84 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-62...
  • Page 85 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-63...
  • Page 86 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-64...
  • Page 87 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-65...
  • Page 88 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-66...
  • Page 89 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-67...
  • Page 90 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-68...
  • Page 91 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-69...
  • Page 92 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-70...
  • Page 93 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-71...
  • Page 94 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-72...
  • Page 95 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-73...
  • Page 96 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-74...
  • Page 97 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-75...
  • Page 98 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-76...
  • Page 99 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-77...
  • Page 100 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-78...
  • Page 101 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-79...
  • Page 102 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-80...
  • Page 103 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-81...
  • Page 104 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-82...
  • Page 105 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-83...
  • Page 106 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-84...
  • Page 107 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-85...
  • Page 108 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-86...
  • Page 109 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-87...
  • Page 110 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-88...
  • Page 111 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-89...
  • Page 112 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-90...
  • Page 113 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-91...
  • Page 114 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-92...
  • Page 115 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-93...
  • Page 116 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-94...
  • Page 117 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-95...
  • Page 118 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-96...
  • Page 119 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-97...
  • Page 120 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-98...
  • Page 121 . EXHAUST MUFFLER/FRAME COVERS K-XCT 125i 2-99...

  • Page 122: Inspection/Adjustment

    . INSPECTION/ADJUSTMENT K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ INSPECTION/ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 3- 1 MAINTENANCE SCHEDULE -------------------------------------------- 3- 2 FUEL LINE ------------------------------------------------------------------- 3- 4 THROTTLE OPERATION ------------------------------------------------- 3- 4 ENGINE OIL ----------------------------------------------------------------- 3- 5 TRANSMISSION OIL ------------------------------------------------------ 3-11 AIR CLEANER -------------------------------------------------------------- 3-12...

  • Page 123: Inspection/Adjustment

    K-XCT 125i . INSPECTION/ADJUSTMENT SERVICE INFORMATION GENERAL ！ WARNING Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people.

  • Page 124: Maintenance Schedule

    KYMCO by properly trained and equipped technicians. Your KYMCO dealer meets all of these requirements. ＊Should be serviced by your KYMCO dealer, unless the owner has the proper tools and service data and is mechanically qualified. ＊＊In the interest of safety, we recommend these items be serviced only by your KYMCO dealer.
  • Page 125 K-XCT 125i . INSPECTION/ADJUSTMENT MAINTENANCE SCHEDULE FREQUENCY WHICHEVER ODOMETER READING [NOTE (1)] COMES FIRST 10 15 20 25 30 X 1000 km REFER 0.6 3 12 15 18 X 1000 mi PAGE ITEM NOTE MONTH CLUTCH SHOE WEAR BRAKE FLUID...

  • Page 126: Fuel Line

    . INSPECTION/ADJUSTMENT K-XCT 125i FUEL LINE Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. THROTTLE OPERATION Check the throttle grip for smooth movement. Measure the throttle grip free play. Free Play: 2～6 mm...

  • Page 127: Engine Oil

    K-XCT 125i . INSPECTION/ADJUSTMENT Minor adjustment is made with the adjusting nut at the throttle grip side. Slide the rubber cover (1) out and adjust by loosening the lock nut (3) and turning the adjusting nut (2). (Chart) ENGINE OIL VISCOSITIES...
  • Page 128 . INSPECTION/ADJUSTMENT K-XCT 125i Engine oil replacement Engine oil quality is the chief factor affecting engine service life. Change the engine oil as specified in the maintenance schedule. When running in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule.
  • Page 129 K-XCT 125i . INSPECTION/ADJUSTMENT 1. Remove the oil filler cap/dipstick(1) from the right crankcase cover. 2. Place a container under the left crankcase. 3. Remove the oil drain plug (2) to drain the oil. 4. Reinstall the drain plug and tighten the drain plug to specification.
  • Page 130 . INSPECTION/ADJUSTMENT K-XCT 125i Oil strainer screen clean Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. ＊ Let the engine and exhaust system cool before working in those areas.
  • Page 131 K-XCT 125i . INSPECTION/ADJUSTMENT Oil filter replacement Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. ＊ Let the engine and exhaust system cool before working in those areas.
  • Page 132 . INSPECTION/ADJUSTMENT K-XCT 125i 5. Install the new oil filter. ＊ Make sure the rubber seal on the oil filter facing the left crankcase. Rubber Seal 6. Install the spring, O-ring and cap. Torque: 12 N-m (1.2 kgf-m) 7. Fill the crankcase with the recommended grade oil and install the oil filler cap.

  • Page 133: Transmission Oil

    K-XCT 125i . INSPECTION/ADJUSTMENT TRANSMISSION OIL Oil change 1. Place the scooter in its center stand. 2. Place a drain pan under the drain bolt (1). 3. Remove the transmission oil drain bolt. 4. Remove the transmission oil filler bolt (2), slowly turn the rear wheel and drain the oil.

  • Page 134: Air Cleaner

    Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model. Using the wrong KYMCO air cleaner element or a non-KYMCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems.

  • Page 135: Spark Plug

    K-XCT 125i . INSPECTION/ADJUSTMENT SPARK PLUG Remove the spark plug cap and spark plug Check the spark plug for wear and fouling deposits. Clean any fouling deposits with a spark plug cleaner or a wire brush. Specified Spark Plug: NGK CR7E...

  • Page 136: Valve Clearance

    . INSPECTION/ADJUSTMENT K-XCT 125i VALVE CLEARANCE ＊  Inspect and adjust valve clearance while the engine is cold (below 35℃). Remove the four bolts , then remove cylinder head cover. Timing hole cap Remove the timing hole cap and O-ring Remove the crankshaft hole cap and O-ring .

  • Page 137: Idle Speed

    K-XCT 125i . INSPECTION/ADJUSTMENT Adjust by loosening the valve adjusting screw lock-nut and turning the adjusting screw until there is a slight drag on the thickness gauge . Valve Clearance: IN: 0.1 mm EX:0.1 mm Apply oil to the valve adjusting screw lock-nut threads and seating surface.

  • Page 138: Cylinder Compression

    . INSPECTION/ADJUSTMENT K-XCT 125i CYLINDER COMPRESSION Warm up the engine before compression test. Remove the center cover and spark plug cap. Remove the spark plug . Insert a compression gauge. Open the throttle valve fully and push the starter button to test the compression.

  • Page 139: Clutch Shoe Wear

    K-XCT 125i . INSPECTION/ADJUSTMENT CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually. If the scooter tends to creep, or the engine stalls, check the clutch shoes for wear and replace if necessary (refer to the “DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY”...
  • Page 140 . INSPECTION/ADJUSTMENT K-XCT 125i 3-18...
  • Page 141 K-XCT 125i . INSPECTION/ADJUSTMENT 3-19...

  • Page 142: Nuts/Bolts/Fasteners

    . INSPECTION/ADJUSTMENT K-XCT 125i NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Tire pressure Insufficient air pressure in the tires not only hastens tire wear but also seriously affects the stability of the scooter.

  • Page 143: Suspension

    K-XCT 125i . INSPECTION/ADJUSTMENT SUSPENSION Check the action of the front/rear shock absorbers by compressing them several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn.
  • Page 144 . INSPECTION/ADJUSTMENT K-XCT 125i 3-22...

  • Page 145: Lubrication System

    . LUBRICATION SYSTEM K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM ---------------------------------- 4-1 SERVICE INFORMATION ------------------------------------------------ 4-2 TROUBLESHOOTING ----------------------------------------------------- 4-2 OIL PUMP ------------------------------------------------------------------ 4-3...

  • Page 146: Lubrication System

    . LUBRICATION SYSTEM K-XCT 125i LUBRICATION SYSTEM DIAGRAM Rocker Arm Shaft Crankshaft Oil Strainer Screen Oil Pump Oil Filter Screen...

  • Page 147: Service Information

    . LUBRICATION SYSTEM K-XCT 125i SERVICE INFORMATION GENERAL INSTRUCTIONS  The maintenance of lubrication system can be performed with the engine installed in the frame.  Drain the coolant before starting any operations.  Be careful when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.

  • Page 148: Oil Pump

    . LUBRICATION SYSTEM K-XCT 125i OIL PUMP Bolts REMOVAL Remove the flywheel and driven gear (refer to the “STARTER CLUTCH” section in the chapter 10). Remove the bolt and then oil separator cover. ＊ When removing and installing the oil pump, be careful not to allow dust or dirt to enter the engine.
  • Page 149 . LUBRICATION SYSTEM K-XCT 125i Arrow Mark INSTALLATION Install the oil pump and oil separator and tighten the two bolts. The arrow mark must be keep upward. ＊ Make sure the pump shaft rotates freely and arrow on the oil pump is upside.
  • Page 150 . LUBRICATION SYSTEM K-XCT 125i DISASSEMBLY Remove the screw and disassemble the oil pump as shown. Pump Cover Outer Rotor Inner Rotor Pump Body Screw Dowel Pin Pump Shaft ASSEMBLY Pump Body Dowel Pin Install the outer rotor, inner rotor and pump shaft into the pump body.

  • Page 151: Engine Removal/Installation

    . ENGINE REMOVAL/INSTALLATION K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 5-1 ENGINE REMOVAL/INSTALLATION --------------------------------- 5-2 ENGINE HANGER --------------------------------------------------------- 5-8...
  • Page 152 5. ENGINE REMOVAL/INSTALLATION K-XCT 125i 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 scooter body, cables and wires during engine removal.  Use shop towels to protect the scooter body during engine removal.
  • Page 153 . ENGINE REMOVAL/INSTALLATION K-XCT 125i ENGINE REMOVAL/INSTALLATION REMOVAL ＊ Remove the air cleaner Disconnect the ECU connector (A) Disconnect the O2 heater/O2 sensor connector Disconnect the throttle cable(B) ＊ Remove a bolt from fuel hose guide (C). Disconnect the fuel hose (D) from fuel injector.
  • Page 154 5. ENGINE REMOVAL/INSTALLATION K-XCT 125i Loosen the rear axle nut. Support the scooter securely on its main stand. Remove bolts attaching to rear brake hose clamps. Remove two bolts, then remove the rear brake caliper. Disconnect the alternator connector. Disconnect the ignition pulse generator connector.
  • Page 155 . ENGINE REMOVAL/INSTALLATION K-XCT 125i Remove the bolts and engine ground cable. Remove the two nuts (7), then remove the intake manifold from cylinder head. Remove the bolt (8), then remove the thermostat from cylinder head. Remove the spark plug cap .
  • Page 156 5. ENGINE REMOVAL/INSTALLATION K-XCT 125i Disconnect the lower radiator hose from lower radiator pipe. Remove the right and left rear shock absorber lower mount bolts .
  • Page 157 . ENGINE REMOVAL/INSTALLATION K-XCT 125i Remove the engine mount nut Pull out the engine mount bolt. Remove the engine from the frame. ＊ At removing the engine, be careful not to catch your hand or finger between the engine hanger and crankcase.
  • Page 158 5. ENGINE REMOVAL/INSTALLATION K-XCT 125i INSTALLATION Installation is in the reverse order of removal. Tighten the engine mounting bolt/nut to the specified torque. Torque: 5 kgf-m (50 N-m) Tighten the right and left rear shock absorber lower mount bolts to the specified torque.
  • Page 159 . ENGINE REMOVAL/INSTALLATION K-XCT 125i ENGINE HANGER REMOVAL Remove the engine mount nut . Pull the engine mount bolt out. ＊ Be careful to put the engine down. Remove the left engine hanger mount bolt . Remove the right engine hanger mount bolt and collar .

  • Page 160: Cylinder Head/Valves

    K-XCT 125i . CYLINDER HEAD/VALVES __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD/VALVES __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 6- 1 SERVICE INFORMATION ------------------------------------------------ 6- 2 TROUBLESHOOTING ----------------------------------------------------- 6- 3 CYLINDER HEAD COVER ----------------------------------------------- 6- 4 CAMSHAFT HOLDER ----------------------------------------------------- 6- 5 CAMSHAFT ----------------------------------------------------------------- 6- 8...

  • Page 161: Cylinder Head/Valves

    K-XCT 125i . CYLINDER HEAD/VALVES SCHEMATIC DRAWING...

  • Page 162: Service Information

    K-XCT 125i . CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL INSTRUCTIONS  The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first.  When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.

  • Page 163: Troubleshooting

    K-XCT 125i . CYLINDER HEAD/VALVES SPECIAL TOOLS Valve spring compressor A120E00040 TROUBLESHOOTING  The poor cylinder head operation can be diagnosed by a compression test or by tracing engine Poor performance at idle speed White smoke from exhaust muffler  Compression too low ...

  • Page 164: Cylinder Head Cover

    K-XCT 125i . CYLINDER HEAD/VALVES CYLINDER HEAD COVER REMOVAL Remove four bolts then remove the cylinder head cover. INSTALLATION Install a new cylinder head cover O-ring and install the cylinder head cover. ＊ Be sure to install the O-ring into the groove properly.

  • Page 165: Camshaft Holder

    K-XCT 125i . CYLINDER HEAD/VALVES CAMSHAFT HOLDER REMOVAL Turn the A.C. generator flywheel so that the T mark on the flywheel aligns with the index mark on the crankcase. Hold the round hole on the camshaft gear facing up and location is the top dead center on the compression stroke.
  • Page 166 K-XCT 125i . CYLINDER HEAD/VALVES DISASSEMBLY Take out the valve rocker arm shafts Remove the valve rocker arms. Rocker Arm Shafts INSPECTION Camshaft Holder Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage. ＊...
  • Page 167 K-XCT 125i . CYLINDER HEAD/VALVES ASSEMBLY Rocker Arm Shafts Apply engine oil to the rocker arms and rocker arm shafts. Install the rocker arms and shafts into the camshaft holder. ＊  Install the exhaust valve rocker arm shaft on the “EX” side of the camshaft holder ...

  • Page 168: Camshaft

    K-XCT 125i . CYLINDER HEAD/VALVES Tensioner Sealing Bolt CAMSHAFT REMOVAL Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke.
  • Page 169 K-XCT 125i . CYLINDER HEAD/VALVES INSPECTION Camshaft Inspect camshaft lobes for pitting/scratches/blue discoloration. If any defects are found, replace the camshaft with a new one, then inspect lubrication Camshaft Bearings system. Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play.
  • Page 170 K-XCT 125i . CYLINDER HEAD/VALVES INSTALLATION Punch Marks Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear facing up and align the punch marks on the...
  • Page 171 K-XCT 125i . CYLINDER HEAD/VALVES Valve Spring Compressor DISASSEMBLY Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor. ＊  Be sure to compress the valve springs with a valve spring compressor.
  • Page 172 K-XCT 125i . CYLINDER HEAD/VALVES INSPECTION Remove carbon deposits from the exhaust Combustion Chamber port and combustion chamber. ＊ Be careful not to damage the cylinder head mating surface. Exhaust Port Valve /Valve guide Inspect each valve for bending, burning, scratches or abnormal stem wear.

  • Page 173: Cylinder Head

    K-XCT 125i . CYLINDER HEAD/VALVES Cylinder head Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. Service Limit: 0.05 mm Valve Spring Compressor ASSEMBLY Install the valve spring seats and oil seal.

  • Page 174: Cylinder/Piston

    . CYLINDER/PISTON K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER/PISTON __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 7-1 SERVICE INFORMATION ------------------------------------------------ 7-2 TROUBLESHOOTING ----------------------------------------------------- 7-3 CYLINDER AND PISTON ------------------------------------------------ 7-4...

  • Page 175: Cylinder/Piston

    K-XCT 125i . CYLINDER/PISTON SCHEMATIC DRAWING...

  • Page 176: Service Information

    . CYLINDER/PISTON K-XCT 125i SERVICE INFORMATION GENERAL INSTRUCTIONS  When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.  After disassembly, clean the removed parts and dry them with compressed air before inspection.

  • Page 177: Troubleshooting

    K-XCT 125i . CYLINDER/PISTON TROUBLESHOOTING  When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken. Compression too low or uneven...

  • Page 178: Cylinder And Piston

    . CYLINDER/PISTON K-XCT 125i CYLINDER AND PISTON REMOVAL Remove the cylinder head (refer to “CYLINDER HEAD” section in the chapter Remove the water hose attached the cylinder. Remove the two cylinder bolts/washers (2). Remove the cylinder. Remove the cylinder gasket (4) and dowel pins (3).
  • Page 179 K-XCT 125i . CYLINDER/PISTON Spread each piston ring and remove it by lifting up at a point opposite the gap ＊ Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston ring grooves.
  • Page 180 . CYLINDER/PISTON K-XCT 125i Service Limit: 0.02 mm (0.0008 in) Piston/Piston pin Measure the piston O.D. at the point (A) from the bottom and 90° to the piston pin hole. 10 mm Service Limit: 15.04 mm (0.6016 in)
  • Page 181 K-XCT 125i . CYLINDER/PISTON Cylinder Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown. Check the cylinder wall for wear or damage. Measure and record the cylinder I.D. at three levels in an X and Y axis. Take the maximum reading to determine the cylinder wear.
  • Page 182 . CYLINDER/PISTON K-XCT 125i Intake Side Guide Inspect the exhaust side and intake side chain guides. Wear/Damage → Replace. Exhaust Side Guide INSTALLATION Piston ring Carefully install the piston rings into the piston ring grooves with the markings facing ＊...
  • Page 183 K-XCT 125i . CYLINDER/PISTON Cylinder/Piston Clean any gasket material attached the cylinder mating surfaces of the crankcase and oil passage. Apply engine oil to the piston pin. Apply engine oil to the connecting rod small end and piston pin hole.
  • Page 184 . CYLINDER/PISTON K-XCT 125i Apply engine oil to the cylinder wall, piston and piston ring outer surfaces. 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 185: Drive And Driven Pulleys

    . DRIVE AND DRIVEN PULLEYS K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 8- 1 SERVICE INFORMATION ------------------------------------------------ 8- 2 TROUBLESHOOTING ----------------------------------------------------- 8- 3 LEFT CRANKCASE COVER --------------------------------------------- 8- 4 DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY ---------- 8- 5...

  • Page 186: Schematic Drawing

    . DRIVE AND DRIVEN PULLEYS K-XCT 125i SCHEMATIC DRAWING...

  • Page 187: Service Information

    . DRIVE AND DRIVEN PULLEYS K-XCT 125i SERVICE INFORMATION GENERAL INSTRUCTIONS  The drive pulley, clutch and driven pulley can be serviced with the engine installed.  Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.

  • Page 188: Troubleshooting

    . DRIVE AND DRIVEN PULLEYS K-XCT 125i TROUBLESHOOTING Engine starts but motorcycle fail to move Lack of power  Worn drive belt  Worn drive belt  Broken ramp plate  Weak driven face spring  Worn or damaged clutch lining ...

  • Page 189: Left Crankcase Cover

    . DRIVE AND DRIVEN PULLEYS K-XCT 125i LEFT CRANKCASE COVER REMOVAL Remove ten left crankcase cover bolts and then remove the left crankcase cover. Remove the gasket and dowel pins. Dowel Pins INSTALLATION Install the dowel pins and gasket. Install the left crankcase cover.

  • Page 190: Drive Pulley, Drive Belt And Driven Pulley

    . DRIVE AND DRIVEN PULLEYS K-XCT 125i DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY Nut/Ratchet REMOVAL Remove the left crankcase cover Use the special tool to hold the drive pulley, then remove the nut and ratchet. Special tool: Universal holder...
  • Page 191 . DRIVE AND DRIVEN PULLEYS K-XCT 125i Remove the movable drive face assembly. Movable Drive Face Assembly Drive belt inspection Check the drive belt for cracks, separation or abnormal or excessive wear. Replace a new belt at every 20000KM ＊...
  • Page 192 . DRIVE AND DRIVEN PULLEYS K-XCT 125i Boss INSTALLATION Apply lubricant to the drive face boss inner surface, then install the movable drive face assembly. Movable Drive Face Assembly Clutch Outer/Driven Pulley Assembly Install the clutch outer onto the driven pulley assembly.
  • Page 193 . DRIVE AND DRIVEN PULLEYS K-XCT 125i Nut/Ratchet 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 200i: 5.8 kgf-m (58 N-m, 42 lbf-ft) 5.5~6.5 kgf-m (55~65 N-m)
  • Page 194 . DRIVE AND DRIVEN PULLEYS K-XCT 125i DRIVE PULLEY DISASSEMBLY Remove the drive face boss. Boss Ramp Plate Remove the ramp plate Take out six weight rollers. Weight Roller...
  • Page 195 . DRIVE AND DRIVEN PULLEYS K-XCT 125i DRIVE PULLEY INSPECTION Weight rollers Check each roller for wear or damage. Measure outside diameter. Service limit: 19.8 mm (0.792 in) Movable drive face/Slide pieces/Drive pulley face Ramp Plate Check the movable drive face splines for wear, cracks or damage.
  • Page 196 . DRIVE AND DRIVEN PULLEYS K-XCT 125i DRIVE PULLEY ASSEMBLY Clean the movable drive face, drive pulley face, weight rollers, slide pieces, ramp plate and drive face boss. ＊ Remove any excess grease. Install the weight rollers. ＊ The direction of all weight rollers is the same.
  • Page 197 . DRIVE AND DRIVEN PULLEYS K-XCT 125i Install the drive face boss. Boss 8-12...
  • Page 198 . DRIVE AND DRIVEN PULLEYS K-XCT 125i DRIVEN PULLEY DISASSEMBLY Lock Nut Wrench Hold the clutch/driven pulley assembly with the clutch spring compressor. ＊ Be sure to use a clutch spring compressor to avoid spring damage. Special tool: Clutch Spring Compressor...
  • Page 199 . DRIVE AND DRIVEN PULLEYS K-XCT 125i Remove the spring. Remove the spring collar on the movable driven face. Remove the three guide pins/rollers, then remove the movable driven face. Remove the needle bearing from driven face. Remove the snap ring, then remove the bearing from driven face.
  • Page 200 . DRIVE AND DRIVEN PULLEYS K-XCT 125i DRIVEN PULLEY INSPECTION Grooves Check the driven pulley for smooth operation. If any scratches or damage is found then replace as a set. Check guide pins and rollers for wear or damage. If any scratches or d amage is found then replace as a set.
  • Page 201 . DRIVE AND DRIVEN PULLEYS K-XCT 125i DRIVEN PULLEY ASSEMBLY Clean any oil from the drive belt sliding surfaces on the driven face. 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 202: Final Reduction

    K-XCT 125i . FINAL REDUCTION __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 9-1 SERVICE INFORMATION ------------------------------------------------ 9-2 TROUBLESHOOTING ----------------------------------------------------- 9-2 FINAL REDUCTION ------------------------------------------------------- 9-3 BEARING REPLACEMENT ---------------------------------------------- 9-7...

  • Page 203: Final Reduction

    . FINAL REDUCTION K-XCT 125i SCHEMATIC DRAWING...

  • Page 204: Service Information

    K-XCT 125i . FINAL REDUCTION SERVICE INFORMATION GENERAL INSTRUCTIONS  The servicing operations of this section can be made with the engine installed.  When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation.
  • Page 205 . FINAL REDUCTION K-XCT 125i FINAL REDUCTION REMOVAL Drain the transmission gear oil into a clean container (refer to the “TRANSMISSION OIL” section in the chapter 3). Remove the driven pulley (refer to the “DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY” section in the chapter...
  • Page 206 K-XCT 125i . FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage. Inspect the final gear and final gear shaft for wear, damage or seizure. Check the driveshaft for wear or damage. Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage.
  • Page 207 . FINAL REDUCTION K-XCT 125i Drive Shaft Bearing Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage. Countershaft Bearing Final Shaft Bearing Final Gear Shaft Bearing Drive Shaft Bearing...
  • Page 208 K-XCT 125i . FINAL REDUCTION Dowel pins Install new gasket. Install two dowel pins. Install the transmission case cover. Install and tighten the nine bolts to the specified torque in a crisscross pattern in 2 or 3 steps. Torque: 1.0~1.4kgf-m Fill the transmission case with the specified oil (refer to the “TRANSMISSION OIL”...

  • Page 209: Bearing Replacement

    . FINAL REDUCTION K-XCT 125i BEARING REPLACEMENT TRANSMISSION CASE COVER Remove the transmission case cover Remove the transmission case cover bearings by using the special tool. Special tool: Bearing puller A120E00037 Install the new bearings or new oil seal into the transmission case cover by using the special tool.
  • Page 210 K-XCT 125i . FINAL REDUCTION Install the new bearings or new oil seal into the transmission case by using the special tool. Special tool: Oil seal and bearing installer A120E00014 After installation, fill the transmission case with the specified oil.

  • Page 211: Generator/Starter Clutch

    . A.C. GENERATOR/STARTER CLUTCH K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 10-1 SERVICE INFORMATION ------------------------------------------------ 10-2 TROUBLESHOOTING ----------------------------------------------------- 10-2 ALTERNATOR STATOR-------------------------------------------------- 10-3 STARTER CLUTCH -------------------------------------------------------- 10-6 10-0...
  • Page 212 K-XCT 125i . A.C. GENERATOR/STARTER CLUTCH SCHEMATIC DRAWING 10-1...
  • Page 213 . A.C. GENERATOR/STARTER CLUTCH K-XCT 125i SERVICE INFORMATION GENERAL INSTRUCTIONS  All servicing operations and inspections in this section can be made with the engine installed.  Drain the coolant before removing the right crankcase cover.  Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.)
  • Page 214 K-XCT 125i . A.C. GENERATOR/STARTER CLUTCH A.C.GENERATOR REMOVAL Drain the engine oil (refer to the “ENGINE OIL” section in the chapter 3). Disconnect the generator connectors Remove ten bolts attached the right crankcase cover and then remove the cover. Dowel Pins Remove two dowel pins and gasket.
  • Page 215 . A.C. GENERATOR/STARTER CLUTCH K-XCT 125i INSPECTION Check the stator and pulse coil for damage. Stator INSTALLATION Install the stator and tighten the stator mount bolts to the specified torque. Torque: 1 kgf-m Apply sealant to the grommet seating surface and install it to the cover groove properly.
  • Page 216 K-XCT 125i . A.C. GENERATOR/STARTER CLUTCH Install the dowel pins and gasket. Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 or 3 steps. 10-5...
  • Page 217 . A.C. GENERATOR/STARTER CLUTCH K-XCT 125i STARTER CLUTCH REMVOAL Remove the right crankcase cover Hold the flywheel with a special tool and remove the flywheel nut. Special tool: Flywheel holder A120E00021 Flywheel Holder Flywheel Flywheel Puller Remove the flywheel by using the special tool.
  • Page 218 K-XCT 125i . A.C. GENERATOR/STARTER CLUTCH Starter Driven Gear Remove the starter driven gear. INSPECTION Install the driven gear into the flywheel. 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.
  • Page 219 . A.C. GENERATOR/STARTER CLUTCH K-XCT 125i INSTALLATION Starter Driven Gear Install the starter driven gear onto the crankshaft. Shaft Reduction Gear Apply oil to the starter reduction gear shaft. Install the starter reduction gear and shaft to the right crankcase.
  • Page 220 K-XCT 125i . A.C. GENERATOR/STARTER CLUTCH Hold the flywheel with the special tool and tighten the flywheel nut. Torque: 5.0~6.0 kgf-m Special tool: Flywheel holder A120E00021 Flywheel Flywheel Holder Install the dowel pins and gasket. Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 or 3 steps.

  • Page 221: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE/CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING ------------------------------------------------- 11-1 SERVICE INFORMATION ------------------------------------------------ 11-2 TROUBLESHOOTING ----------------------------------------------------- 11-2 CRANKCASE SEPARATION -------------------------------------------- 11-3 CRANKCASE ASSEMBLY ----------------------------------------------- 11-4 11-0...

  • Page 222: Crankcase/Crankshaft

    . CRANKCASE/CRANKSHAFT K-XCT 125i SCHEMATIC DRAWING 11-1...

  • Page 223: Service Information

    . CRANKCASE/CRANKSHAFT K-XCT 125i SERVICE INFORMATION GENERAL INSTRUCTIONS  This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation.  When separating the crankcase, never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces.

  • Page 224: Crankcase Separation

    . CRANKCASE/CRANKSHAFT K-XCT 125i CRANKCASE SEPARATION Remove the two right crankcase attaching bolts. Bolt Bolts Remove the left crankcase bolts. Left Crankcase Place the crankcase with the left crankcase Right Crankcase down and remove the right crankcase from the left crankcase.

  • Page 225: Crankcase Assembly

    . CRANKCASE/CRANKSHAFT K-XCT 125i Oil Seal Remove the oil seal from the left crankcase. Left Crankcase CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces. ＊ Avoid damaging the crankcase mating surfaces. Install a new oil seal into the left crankcase.
  • Page 226 . CRANKCASE/CRANKSHAFT K-XCT 125i Place the left crankcase down and install the crankshaft into the left crankcase. ＊  Avoid damaging the oil seal.  Apply grease to the lip of the oil seal. Change a new gasket. Bolts Place into the crankshaft and onto the left crankcase.
  • Page 227 . CRANKCASE/CRANKSHAFT K-XCT 125i Cam Chain Tensioner Slipper Install the cam chain. Install the cam chain tensioner slipper. Install and tighten the cam chain tensioner slipper bolt. Torque: 1.0kgf-m Bolt 11-6...

  • Page 228: Cooling System

    . COOLING SYSTEM K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 12- 1 TROUBLESHOOTING ----------------------------------------------------- 12- 1 COOLING SYSTEM TESTING ------------------------------------------- 12- 3 COOLANT REPLACEMENT --------------------------------------------- 12- 4 RADIATOR ------------------------------------------------------------------ 12- 7 FAN MOTOR ---------------------------------------------------------------- 12- 9...

  • Page 229: Cooling System

    . COOLING SYSTEM K-XCT 125i SERVICE INFORMATION GENERAL INSTRUCTIONS  The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame.  The engine must be cool before servicing the cooling system.
  • Page 230 1.095 1.093 1.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 1.100 1.098 1.095 1.092 1.089 1.086 1.083 1.080 1.077 1.074 1.071 COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS) Freezing Point Mixing Rate KYMCO SIGMA Coolant Concentrate Distilled Water -9℃ -15℃ -25℃ -37℃...

  • Page 231: Cooling System Testing

    . COOLING SYSTEM K-XCT 125i COOLING SYSTEM TESTING RADIATOR CAP INSPECTION ＊ Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap.

  • Page 232: Coolant Replacement

    . COOLING SYSTEM K-XCT 125i COOLANT REPLACEMENT PREPARATION ● The effectiveness of coolant decreases with the accumulation of rest or if there is a change in the mixing proportion during usage. Therefore, best performance change coolant regularly as specified in he maintenance schedule.
  • Page 233 . COOLING SYSTEM K-XCT 125i 12-5...
  • Page 234 . COOLING SYSTEM K-XCT 125i Fill the system with the recommended coolant through the filler opening up to the filler neck (1). Bleed air from the system as follow: 1. Start the engine and let it idle for 23 minutes.

  • Page 235: Radiator

    . COOLING SYSTEM K-XCT 125i RADIATOR REMOVAL Drain the coolant. Disconnect the siphon hose (1) and air bleed hose (2). Loosen the hose bands, then disconnect the input radiator hose and output radiator hose from the radiator. Disconnect the thermal switch connectors .
  • Page 236 . COOLING SYSTEM K-XCT 125i Remove bolts and then remove the radiator from frame. INSTALLATION Installation is in the reverse order of removal. Refill the coolant 12-8...

  • Page 237: Fan Motor

    . COOLING SYSTEM K-XCT 125i FAN MOTOR REMOVAL Remove the radiator Remove the three mounting bolts (1) and then remove the fan motor (2) INSPECTION Battery Check the fan motor to operate using an available battery. INSTALLATION Installation is in the reveres order of removal.

  • Page 238: Fan Motor Switch

    . COOLING SYSTEM K-XCT 125i FAN MOTOR SWITCH REMOVAL Disconnect the fan motor switch connectors Remove the thermostat(1). INSPECTION Place the thermal switch in the stove with water as shown and raise the water temperature gradually to check for the temperature at which the starts to operate.

  • Page 239: Water Pump

    . COOLING SYSTEM K-XCT 125i Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.
  • Page 240 . COOLING SYSTEM K-XCT 125i Bolts Water Pump Cover Remove four bolts and the water pump cover, gasket and two dowel pins. Impeller (Left Hand Threads) Remove the water pump impeller. ＊ The impeller has left hand threads. Seal Washer (Porcelain)
  • Page 241 . COOLING SYSTEM K-XCT 125i WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove five bolts attaching the water pump assembly. Remove the water pump assembly, gasket and dowel pins. Water Pump Shaft Remove the water pump shaft clip and...
  • Page 242 . COOLING SYSTEM K-XCT 125i Water Pump Assembly Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover. Tighten five bolts to secure the water pump assembly. ＊ When installing the water pump...
  • Page 243 . COOLING SYSTEM K-XCT 125i Impeller (Left Hand Threads) Install the impeller onto the water pump shaft. Torque: 1.2 kgf-m (12 N-m, 9 lbf-ft) ＊ The impeller is with left hand threads. Dowel Pins Install two dowel pins and a new gasket.

  • Page 244: Water Temperature Sensor

    . COOLING SYSTEM K-XCT 125i WATER TEMPERATURE SENSOR REMOVAL Remove the luggage box Drain the coolant Disconnect the water temperature sensor connectors (1). Remove the water temperature sensor (2) from thermostat. INSPECTION Sensor Connect the water temperature sensor to the ohmmeter and dip it in water contained in a pan which is placed on an electric heater.
  • Page 245 . COOLING SYSTEM K-XCT 125i INSTALLATION Tighten the water temperature sensor. Torque: 0.8 kgf-m (8 N-m, 5.8 lbf-ft) Connect the sensor connectors. After the water temperature sensor has been installed, fill coolant and perform air bleeding . 12-17...

  • Page 246: Thermostat

    . COOLING SYSTEM K-XCT 125i THERMOSTAT THERMOSTAT REMOVAL REMOVAL Drain the coolant Remove the luggage box Bolts Disconnect the water hose (1) from the thermostat housing. Remove the mounting bolt (2) and the thermostat housing attaching the cylinder head. INSTALLATION The installation sequence is the reverse of removal.
  • Page 247 . COOLING SYSTEM K-XCT 125i Screws DISASSEMBLY Remove two screws and separate the thermostat housing halves. Thermostat Thermostat Remove the thermostat from the thermostat housing. 12-19...
  • Page 248 . COOLING SYSTEM K-XCT 125i INSPECTION Suspend the thermostat in a pan of water over a burner and gradually raise the water Thermostat temperature to check its operation. Technical Data Thermometer 71 ± 1.5°C Begins to open Full-open 80°C 3.5 mm (0.14 in)

  • Page 249: 13. Fi Diagnostic Tool Operation

    13. Fi DIAGNOSTIC TOOL OPERATION K-XCT 125i Fi Diagnostic Tool Operation Instructions Part No. 3620A-LEB2-E00 KEY FUNCTION Model No. DATAAnalyze Down Button DTC Inspect DTC indicator(Failure codes) ECU Version Enter or Exit Power indicator UP Button Adjust(TPI andABV reset function)
  • Page 250 13. Fi DIAGNOSTIC TOOL OPERATION K-XCT 125i Fi diagnostic tool Outlook Fi diagnostic tool Outlook......13-0 Adjust............13-8 Diagnostic Standard Specifications ..13-9 DTC Inspection Precedure DTC Inspection Precedure ........13-2 Diagnostic Standard Specifications ............13-5 DTC Clear Procedure DTC Clear Procedure 13-6...
  • Page 251 13. Fi DIAGNOSTIC TOOL OPERATION K-XCT 125i DTC INSPECTION PROCEDURE Diagnostic Tool Connector Connect Fi diagnostic tool with the connector of harness wire located beside the Battery. Press the " Enter " button Check the software version Press the " Enter " button and then turn to the first page.
  • Page 252 13. Fi DIAGNOSTIC TOOL OPERATION K-XCT 125i Press the " Enter " button to check the DTC number Press the " Enter " button Press the " Enter " button Display what's DTC number on this DTC-List. Refer to DTC summary list.
  • Page 253 13. Fi DIAGNOSTIC TOOL OPERATION K-XCT 125i Press the " UP " button Press the " Enter " button and then turn to the previous page. Press the " UP " button Press the " Enter " button and then turn to the first page.
  • Page 254 13. Fi DIAGNOSTIC TOOL OPERATION K-XCT 125i DTC CLEAR PROCEDURE Choose " Load DTC " Press the " Down " button Press the " Enter " button The DTC indicator is lighting at that time. Clearing DTC completed until the DTC indicator is off.
  • Page 255 13. Fi DIAGNOSTIC TOOL OPERATION K-XCT 125i DATA ANALYSIS Choose " Data Analyze " Press the " Enter " button to enter page 01. The figure includes engine speed, idle speed setpoint and battery voltage. Refer to standard specifications .
  • Page 256 13. Fi DIAGNOSTIC TOOL OPERATION K-XCT 125i The figure includes fuel injector interval, ignition advance angle andABV angle. Refer to standard specifications . Press the " Down " button to enter page 05. The figure includes O2 sensor voltage, O2 heater working condition and O2 correction.
  • Page 257 13. Fi DIAGNOSTIC TOOL OPERATION K-XCT 125i ADJUST Need to make TPI/ABV reset to operate after changing new ECU and clean THROTTLE BODY and changing the engine department product, let ECU set up and set up initially Choose "Adjust "...
  • Page 258 13. Fi DIAGNOSTIC TOOL OPERATION K-XCT 125i 13-9...
  • Page 259 K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) FUEL SYSTEM (Auto Control Fuel Injection System) SYSTEM DIAGRAM ................14-1 SYSTEM LOCATION ................. 14-2 SERVICE INFORMATION ............... 14-3 TROUBLESHOOTING ............... 14-4 CHECK ENGINE LAMP (CELP) ............. 14-5 HOW TO SHOW THE FAILURE CODE ........14-6 CELP FAILURE CODES CHART ............

  • Page 260: System Diagram

    K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) SYSTEM DIAGRAM KEY ON FUEL PUMP ROLL T-MAP Voltage 曲軸感知器 曲軸感知器 進氣壓力及 感知器 含氧(O2) 大氣壓力感 感知器 知器 INDUCTIVE INJECTOR 進氣壓力及大氣壓力 感知器 IGNITION COIL 感知器 KEY OFF 14-1...

  • Page 261: System Location

    K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) SYSTEM LOCATION 01: Inductive ignition coil 02: Fuel pump 03: ECU 04: Fuel injector 05: WTS sensor 06: T-MAP sensor 07: ABV 08: TPS 09: Roll sensor(Angle detect sensor) 10: CPS 11: O2/O2 HT sensor 14-2...

  • Page 262: Service Information

    K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ Gasoline is very dangerous. 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 263: Troubleshooting

    K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) TROUBLESHOOTING Engine won’t start Backfiring or misfiring during acceleration  Battery voltage too low  Ignition system malfunction  Fuel level too low  Pinched or clogged fuel hose Poor performance (drive ability) and poor ...

  • Page 264: Check Engine Lamp (Celp)

    K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) CHECK ENGINE LAMP (CELP)  When turning on the switch, the lamp will be lighted for 2 seconds then off. Let user to know the lamp is available and connect to ECU.

  • Page 265: How To Show The Failure Code

    K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) How To Show Failure Code  You can read the failure code by as below :  Turn switch on. The CELP will be lighted for 2 seconds then off. The CELP start to blink to show the failure codes ...

  • Page 266: Celp Failure Codes Chart

    K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) CELP Failure Code Chart(1) Blink Failure Fault Priority Fault management Codes description P0217 Engine 1.Slow down the vehicle and go to workshop for temperature checking immediately. overheat 2.Confirm if the engine temperature sensor or electric circuit is abnormality.
  • Page 267 K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) CELP Failure Code Chart(2) Blink Failure Fault description Priority Fault management Codes 1.Make sure if the connector of Throttle position sensor is P1122 Throttle position sensor connected correctly. movement speed 2.Check if theThrottle position sensor is adjusted.
  • Page 268 K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) CELP Failure Code Chart(3) Blink Failure Fault description Priority Fault management Codes 1. Check if the connector of ignition coil is loosen. P0350 Ignition coil or electric 2. Check if the ECU send signal to Ignition coil. circuit malfunction 3.
  • Page 269 K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) CELP Failure Code Chart(4) Blink Failure Fault description Priority Fault management Codes 1. Check if the lamp of CELP is broken. P0650 CELP electric circuit 2. Check if wires of CELP is broken. malfunction 1.

  • Page 270: Maintaining By Checking Component

    K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) Maintaining By Checking Component ECU(Engine Control Unit) Outlook checking Voltage inspection Connect the meter (+) probe to the F4(R/W)wire and the meter (-) probe to the H4(G/B) wire to measure the voltage.
  • Page 271 K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) FUEL PUMP Connect the meter (+) probe to the red/black wire and the meter (-) probe to the green wire to measure the voltage from the ECU input to fuel pump unit.
  • Page 272 K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) T-MAP(Manifold Air Temperature Pressure) Sensor Connect the PDA or KYMCO Fi diagnostic tool. Into the Data Analyze item . Check if the manifold pressure data malfunction. (Key switch ON but engine is not start ) If data was incorrect.
  • Page 273 K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) WTS (Water Temperature Sensor) Connect the meter (+) probe to the V/G wire and the meter (-) probe to the G/L wire to measure the voltage Standard : 5±0.25 V Measure the resistance of the WTS Standard (20°C/68°F ): 2.075±10%kΩ...
  • Page 274 Measure the resistance of the O2 sensor heater. (2 white wire pin) Standard (20°C/68°F ): 6.7 ~9.5Ω Connect the PDA or KYMCO Fi diagnostic tool. Into the Data Analyze item . Check Page 05 (Key switch ON then start engine...

  • Page 275: Maintaining Special Notice

    Standard: Normal: 0.4~1.4V OVER 65°: 3.7~4.4 V Maintaining Special Notice Never adjust those two TP screws, those were adjusted to be the best condition by KYMCO, if change this condition it may cause instable riding. TP screws 14-16...
  • Page 276 K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) Connect the PDA or KYMCO Fi diagnostic tool. Into the Data Analyze item . Check ignition advance data malfunction. (Key switch is ON then start engine until 80 ° C) 20 °...
  • Page 277 K-XCT 125 i FUEL SYSTEM (Auto Control Fuel Injection System) 14-18...

  • Page 278: Handlebar/Front Wheel/Front Brake/Front

    15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 15- 2 TROUBLESHOOTING ----------------------------------------------------- 15- 3 Steering Stem Removal ----------------------------------------------------- 15- 4 Steering Stem Installation --------------------------------------------------- 15-11...
  • Page 279 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM SERVICE INFORMATION GENERAL INSTRUCTIONS  Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.
  • Page 280 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling  Excessively tightened steering stem top  Bent rim  Loose front axle cone race  Broken steering balls  Bent spoke plate ...
  • Page 281 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 282 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 283 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 284 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 285 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 286 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 287 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 288 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 289 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 290 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 291 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 292 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 293 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 294 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 295 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 296 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 297 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 298 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 299 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 300 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 301 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 302 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 303 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 304 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 305 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 306 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 307 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 308 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 309 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 310 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 311 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 312 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 313 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 314 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 315 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 316 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 317 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 318 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 319 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 320 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 321 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 322 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 323 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 324 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 325 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 326 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 327 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 328 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 329 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 330 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 331 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 332 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 333 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 334 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 335 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 336 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 337 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 338 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 339 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 340 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 341 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 342 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 343 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 344 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 345 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 346 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 347 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 348 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 349 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 350 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...
  • Page 351 15. HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ K-XCT 125i FRONT SHOCK ABSORBER/STEERING STEM...

  • Page 352: Rear Brake/Rear Fork/Rear Wheel/Rear Shock Absorber

    16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER _________________________________________________________________________________________ SERVICE INFORMATION -------------------------------------------------------------- 16-1 TROUBLESHOOTING ------------------------------------------------------------------- 16-1 Shock Absorbers --------------------------------------------------------------------------- 16-2 Rear Fork ------------------------------------------------------------------------------------ 16-10 Front Wheel --------------------------------------------------------------------------------- 16-15...
  • Page 353 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i SERVICE INFORMATION GENERAL INSTRUCTIONS  When performing the services stated in this section, the engine and exhaust muffler must be cold to avoid scalding.  During servicing, keep oil or grease off the brake pads and brake disk.
  • Page 354 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-2...
  • Page 355 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-3...
  • Page 356 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-4...
  • Page 357 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-5...
  • Page 358 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-6...
  • Page 359 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-7...
  • Page 360 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-8...
  • Page 361 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-9...
  • Page 362 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-10...
  • Page 363 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-11...
  • Page 364 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-12...
  • Page 365 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-13...
  • Page 366 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-14...
  • Page 367 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-15...
  • Page 368 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-16...
  • Page 369 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-17...
  • Page 370 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-18...
  • Page 371 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-19...
  • Page 372 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-20...
  • Page 373 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-21...
  • Page 374 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-22...
  • Page 375 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-23...
  • Page 376 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-24...
  • Page 377 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-25...
  • Page 378 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-26...
  • Page 379 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-27...
  • Page 380 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-28...
  • Page 381 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-29...
  • Page 382 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-30...
  • Page 383 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-31...
  • Page 384 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-32...
  • Page 385 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-33...
  • Page 386 16. REAR BRAKE/REAR FORK/REAR K-XCT 125i WHEEL/REAR SHOCK ABSORBER 16-34...
  • Page 387 16. REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER K-XCT 125i 16-35...

  • Page 388: Battery/Charging System

    . BATTERY/CHARGING SYSTEM K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT ---------------------------------------- 17-1 CHARGING CIRCUIT ----------------------------------------------------- 17-1 SERVICE INFORMATION ------------------------------------------------ 17-2 TROUBLESHOOTING ----------------------------------------------------- 17-3 BATTERY -------------------------------------------------------------------- 17-4 CHARGING VOLTAGE INSPECTION ------------------------------- 17-6 REGULATOR/RECTIFIER ---------------------------------------------- 17-7...

  • Page 389: Battery/Charging System

    . BATTERY/CHARGING SYSTEM K-XCT 125i REGULATOR/RECTIFIER CHARGING SYSTEM LAYOUT BATTERY CHARGING CIRCUIT 17-1...

  • Page 390: Service Information

    . BATTERY/CHARGING SYSTEM K-XCT 125i SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention ...

  • Page 391: Troubleshooting

    . BATTERY/CHARGING SYSTEM K-XCT 125i TROUBLESHOOTING No power Intermittent power  Dead battery  Loose battery cable connection  Disconnected battery cable  Loose charging system connection  Fuse burned out  Loose connection or short circuit in  Faulty ignition switch...

  • Page 392: Battery

    . BATTERY/CHARGING SYSTEM K-XCT 125i BATTERY REMOVAL/INSTALLATION The battery is in the battery box behind seat. Remove the seat. Remove the screw and then remove the battery cover Pull battery out to expose the terminal leads Disconnect the negative (-) terminal lead from the battery first, then disconnect the positive (+) terminal lead.
  • Page 393 . BATTERY/CHARGING SYSTEM K-XCT 125i VOLTAGE INSPECTION Remove the battery cover . Measure the battery voltage using a commercially available digital multimeter. Voltage (20ºC/68ºC): Fully charged: 13－13.2 V Insufficient charged: below 12.3 V BATTERY CHARGING Remove the battery Connect the charger positive (+) cable to the battery positive (+) terminal.

  • Page 394: Charging Voltage Inspection

    . BATTERY/CHARGING SYSTEM K-XCT 125i CHARGING VOLTAGE INSPECTION Be sure that the battery is in good condition before performing this test. ＊ Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch. Failure to follow this precaution can damage the tester or electrical components.

  • Page 395: Regulator/Rectifier

    . BATTERY/CHARGING SYSTEM K-XCT 125i REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the regulator/rectifier connectors. Check the connector for loose contacts of corroded terminals. Regulator/Rectifier Measure the voltage between the Red/White wire terminal and ground.
  • Page 396 . BATTERY/CHARGING SYSTEM K-XCT 125i Check the continuity between the Green wire terminal and ground. There should be continuity at all times. Measure the resistance between each Yellow wire terminals. Disconnect the regulator/rectifier connector. Check for continuity between each Yellow wire terminal regulator/rectifier side and ground.

  • Page 397: Ignition System

    . IGNITION SYSTEM K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT ----------------------------------------- 18-1 SERVICE INFORMATION ------------------------------------------------ 18-2 TROUBLESHOOTING ----------------------------------------------------- 18-3 IGNITION COIL INSPECTION ------------------------------------------ 18-4 18-0...

  • Page 398: Ignition System

    . IGNITION SYSTEM K-XCT 125i IGNITION SYSTEM LAYOUT Roll sensor Ignition coil 18-1...

  • Page 399: Service Information

    . IGNITION SYSTEM K-XCT 125i SERVICE INFORMATION GENERAL INSTRUCTIONS Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. ● When servicing the ignition system, always follow the steps in the troubleshooting..

  • Page 400: Troubleshooting

    . IGNITION SYSTEM K-XCT 125i TROUBLESHOOTING LOW PEAK VOLTAGE ● Cranking speed is too low (battery is undercharged). ● Poorly connected connectors or an open circuit in the ignition system. ● Faulty ignition-coil. ● Faulty ignition control module. NO PEAK VOLTAGE ●...

  • Page 401: Ignition Coil Inspection

    . IGNITION SYSTEM K-XCT 125i IGNITION COIL INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the body cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Check cylinder compression and check that the spark plug (1) is installed correctly in the cylinder.
  • Page 402 . IGNITION SYSTEM K-XCT 125i IGNITION PULSE GENERATOR INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the ignition pulse generator connector. Measure the pulse generator resistance between the Green/White wire and Blue/Yellow wire.
  • Page 403 . IGNITION SYSTEM K-XCT 125i IGNITION COIL REMOVAL/INSTALLATION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the spark plug cap attaching the spark plug (1). Disconnect the ignition coil connector. Remove two bolts attaching the ignition coil .

  • Page 404: Starting System

    . STARTING SYSTEM K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT ----------------------------------------- 19-1 SERVICE INFORMATION------------------------------------------------ 19-2 TROUBLESHOOTING----------------------------------------------------- 19-2 STARTER MOTOR --------------------------------------------------------- 19-3 STARTER RELAY INSPECTION---------------------------------------- 19-5 19-0...

  • Page 405: Starting System

    . STARTING SYSTEM K-XCT 125i STARTING SYSTEM LAYOUT Start relay Battery Start motor 19-1...

  • Page 406: Service Information

    . STARTING SYSTEM K-XCT 125i SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.

  • Page 407: Starter Motor

    . STARTING SYSTEM K-XCT 125i STARTER MOTOR INSPECTION Disconnect the starter motor cable from the start relay. Connect the start motor cable directly to the battery positive terminal. If the starter motor fail to work, the starter motor is faulty.
  • Page 408 . STARTING SYSTEM K-XCT 125i INSTALLATION Coat a new O-ring (1) with engine oil and install it into the start motor groove. Install the starter motor into the crankcase. Install the two mounting bolts and engine ground cable, then tighten the bolts securely.

  • Page 409: Starter Relay Inspection

    . STARTING SYSTEM K-XCT 125i START RELAY INSPECTION Release the rubber cap (1) and remove the nut (2), then disconnect the start motor cable. Turn the ignition switch to “ON”position. Squeeze and hold the brake lever fully then push the starter switch.

  • Page 410: 20. Lights/Meters/Switches

    20. LIGHTS/METERS/SWITCHES K-XCT 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/METERS/SWITCHES __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 20- 1 HEADLIGHT ---------------------------------------------------------------- 20- 2 AIM ---------------------------------------------------------------------------- 20- 4 FRONT TURN SIGNALS -------------------------------------------------- 20- 4 TAILLIGHTS ---------------------------------------------------------------- 20- 6 REAR TURN SIGNALS ---------------------------------------------------- 20- 7...
  • Page 411 20. LIGHTS/METERS/SWITCHES K-XCT 125i SERVICE INFORMATION GENERAL ＊ A halogen head light bulb becomes very hot while the head light is turned on, and remains for a while after it is turned off. Be sure to let it cool down before servicing.
  • Page 412 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-2...
  • Page 413 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-3...
  • Page 414 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-4...
  • Page 415 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-5...
  • Page 416 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-6...
  • Page 417 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-7...
  • Page 418 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-8...
  • Page 419 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-9...
  • Page 420 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-10...
  • Page 421 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-11...
  • Page 422 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-12...
  • Page 423 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-13...
  • Page 424 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-14...
  • Page 425 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-15...
  • Page 426 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-16...
  • Page 427 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-17...
  • Page 428 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-18...
  • Page 429 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-19...
  • Page 430 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-20...
  • Page 431 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-21...
  • Page 432 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-22...
  • Page 433 20. LIGHTS/METERS/SWITCHES K-XCT 125i 20-23...

Table of Contents