KYMCO Movie S 125i Service Manual
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KYMCO Movie S 125i Service Manual

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Movie S 125i
By KWANG YANG Motor Co., Ltd.
1st Edition, Nov 2008
All rights reserved. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T100-SR25BA-A1

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Summary of Contents for KYMCO KYMCO Movie S 125i

  • Page 1 Movie S 125i By KWANG YANG Motor Co., Ltd. 1st Edition, Nov 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T100-SR25BA-A1...
  • Page 2 Movie S 125i PREFACE This Service Manual describes technical features servicing procedures for the Movie S 125i. TABLE OF CONTENTS Section 1 contains the precautions for all GENERAL INFORMATION operations stated in this manual. Read EXHAUST MUFFLER/FRAME COVERS them carefully before any operation is INSPECTION/ADJUSTMENT started.
  • Page 3 . GENERAL INFORMATION Movie S 125i ENGINE SERIAL NUMBER----- 1 - 0 TOOLS------------------------------- 1-11 SPECIFICATION ------------------ 1 - 1 LUBRICATION POINTS --------- 1-12 SERVICE PRECAUTIONS------- 1 - 2 CABLE & HARNESS ROUTING - 1-14 TORQUE VALUES ---------------- 1-10 WIRE DIAGRAM ---------------------1-19 TROUBLESHOOTING ----------- 1-20 ENGINE/FRAME SERIAL NUMBER Location of Frame Serial Number...
  • Page 4 . GENERAL INFORMATION Movie S 125i SPECIFICATIONS Name Movie S 125i Air cleaner type & No Paper element, wet Model No. SR25BA Fuel capacity 7.3 liters Overall length 1920 mm Overall width 700 mm Overall height 1135 mm Throttle type Butterfly type Wheel base 1284 mm...
  • Page 5 . GENERAL INFORMATION Movie S 125i SERVICE PRECAUTIONS Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
  • Page 6 . GENERAL INFORMATION Movie S 125i Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation.
  • Page 7 . GENERAL INFORMATION Movie S 125i If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity. Confirm Capacity After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation.
  • Page 8 . GENERAL INFORMATION Movie S 125i connector shall inserted completely. Snapping! If the double connector has a lock, lock it at the correct position. Check if there is any loose wire. Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
  • Page 9 . GENERAL INFORMATION Movie S 125i After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
  • Page 10 . GENERAL INFORMATION Movie S 125i Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
  • Page 11 . GENERAL INFORMATION Movie S 125i After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
  • Page 12 . GENERAL INFORMATION Movie S 125i Symbols: The following symbols represent the 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. Grease : Transmission Gear Oil (90#) Gear Oil...
  • Page 13 . GENERAL INFORMATION Movie S 125i TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 0.45～0.6　　　 5mm screw 0.35～0.5 6mm bolt, nut 6mm screw, SH bolt 0.7～1.1 8mm bolt, nut 0.8～1.2 6mm flange bolt, nut 1.0～1.4 10mm bolt, nut 1.8～2.5...
  • Page 14 . GENERAL INFORMATION Movie S 125i FRAME Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks Steering stem lock nut U-nut Front axle nut U-nut Rear axle nut 11.0 U-nut Rear shock absorber upper mount bolt Rear shock absorber lower mount bolt Speedometer cable set screw 0.45 Front shock absorber tube bolt...
  • Page 15 . GENERAL INFORMATION Movie S 125i LUBRICATION POINTS ENGINE Lubrication Points Lubricant •Genuine KYMCO Engine Oil (SAE15W-40) Valve guide/valve stem movable part •API SE, SF or SG Egnine Oil Camshaft protruding surface Valve rocker arm friction surface Camshaft drive chain...
  • Page 16 . GENERAL INFORMATION Movie S 125i FRAME The following is the lubrication points for the frame. Use grease for parts not listed. Apply clean engine oil or grease to cables and movable parts not specified. This will avoid abnormal noise and rise the durability of the scooter. Grease Front Brake Lever Pivot...
  • Page 17 . GENERAL INFORMATION Movie S 125i 1-14...
  • Page 18 . GENERAL INFORMATION Movie S 125i CABLE & HARNESS ROUTING Brake Fluid Reservoir Rear Brake Cable Front Brake Hose Seat Lock Cable Ignition Switch Separator Breather Hose Fuel Filler Cap Lock Cable Horn Regulator/Rectifier Wink Relay Tilt Switch 1-15...
  • Page 19 . GENERAL INFORMATION Movie S 125i Ignition Switch Fuel Filler Cap Wire Harness Fuel Tank Fuel Pump Seat Lock Cable Fuel Filler Cap Lock Cable Separator Breather Hose Front Brake Hose Fuel Overflow Hose 1-16...
  • Page 20 . GENERAL INFORMATION Movie S 125i Fuel Injector Spark Plug Cap Fuel Tube Vacuum Tube Temperature- Engine Temperature Manifold Absolute Sensor Pressure Sensor Air Bypass Valve Throttle Cable Throttle Body & TPS Starter Motor Secondary Air Cleaner 1-17...
  • Page 21 . GENERAL INFORMATION Movie S 125i Battery Diagnostic connector Throttle Body & TPS Fuel Injector Fuel Pump Secondary Air Cleaner Fuse set Fuel Tank Exhaust Pipe O2 sensor Ignition Coil Fuel Unit connector 1-18...
  • Page 22 . GENERAL INFORMATION Movie S 125i Starter Relay Battery Fuel Tube Fuel Injector Fuel Unit Fuel Tank Fuel Pump Fuel Tube Secondary Air Cleaner T-MAP sensor 1-19...
  • Page 23 . GENERAL INFORMATION Movie S 125i WIRING DIAGRAM 1-20...
  • Page 24 . GENERAL INFORMATION Movie S 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 25 . GENERAL INFORMATION Movie S 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 Faulty tire valve Punctured tire...
  • Page 26 . GENERAL INFORMATION Movie S 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 Clogged oil control orifice Valve train lubricated properly 11.
  • Page 27 . GENERAL INFORMATION Movie S 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 Faulty injector Normal 4.
  • Page 28 . GENERAL INFORMATION Movie S 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 40 Service Limit: 19mm...
  • Page 52 5. Fi INJECTION SYSTEM MOVIE S 125i Fi INJECTION SYSTEM SYSTEM DIAGRAM ................5-1 FI PARTS DRAWING................5-2 SERVICE INFORMATION ..............5-3 TROUBLESHOOTING................. 5-4 CHECK ENGINE LAMP (CELP) ............5-5 HOW TO SHOW THE FAILURE CODE .......... 5-6 DTC CODES LIST................. 5-7 SYNERJECT M3A ECU MODULE ..........
  • Page 53 5. Fi INJECTION SYSTEM MOVIE S 125i 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...
  • Page 54 5. Fi INJECTION SYSTEM MOVIE S 125i Fi PARTS DRAWING...
  • Page 55 5. Fi INJECTION SYSTEM MOVIE S 125i 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 56 5. Fi INJECTION SYSTEM MOVIE S 125i 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 57 5. Fi INJECTION SYSTEM MOVIE S 125i CHECK ENGINE LAMP (CELP) CELP (Check Engine Lamp) When turning on the switch, the lamp will be lighted for two seconds then off. DTC (Defect Trouble Code) Let user to know the lamp is available and connect to ECU.
  • Page 58 5. Fi INJECTION SYSTEM MOVIE S 125i 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 (The number of blinks from 1 to 25).
  • Page 59 5. Fi INJECTION SYSTEM MOVIE S 125i DTC Code List 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 60 5. Fi INJECTION SYSTEM MOVIE S 125i DTC Code List 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. problem 1.
  • Page 61 5. Fi INJECTION SYSTEM MOVIE S 125i DTC Code List 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 62 5. Fi INJECTION SYSTEM MOVIE S 125i DTC Code List 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 63 ECU (ECU MODULE) 2.Disassembly of ECU module： （Except technician who has been qualified by KYMCO, disassembling this module will be forbidden） 1. Do not remove the ECU module before ECU module coupler switching off.
  • Page 64 5. Fi INJECTION SYSTEM MOVIE S 125i 3. ECU Module Replacement When switch is on and battery is connected, don’t remove module, connect additional wire or cut any wire. 1.Make sure to replace the ECU module after the ignition switch is turned off. 2.To identify if new ECU with certain version, check with sticker on ECU or with diagnostic tool.
  • Page 65 5. Fi INJECTION SYSTEM MOVIE S 125i ECU MOUDLE ECU MODULE Removal To dismantle the throttle cable To disconnect the coupler from ECU module To release the bolts of clamp of intake manifold To remove the vacuum pipe To remove the ECU module First, push the stopper of coupler to Clamp of manifold Throttle cable Stopper release the rod, then pull back the rod to a...
  • Page 66 5. Fi INJECTION SYSTEM MOVIE S 125i Step 1 ECU MODULE COUPLER Installation 1.To confirm if the pulling rod of coupler is in a lower fixed position before installation or would fail to install the ECU module. 2.To install the coupler to ECU module (notice its direction).
  • Page 67 5. Fi INJECTION SYSTEM MOVIE S 125i Removal To push the stopper and release the pulling rod. To ensure the rod back to the lowest fixed Pulling rod position, while you hearing a click, you have succeeded in removing the ECU module ECU module and coupler are extremely Stopper expensive components just like which used...
  • Page 68 5. Fi INJECTION SYSTEM MOVIE S 125i ECU ADAPT THE NEW THOTTLE POSITION VOLTAGE Switch on and off at least three times, then ECU will adapt the new throttle position setting, each action should be stayed for more than four seconds or ECU could fail to record the new position. INSPECTION OR RE-ADJUSTMENT OF THE OUTPUT VOLTAGE OF THROTTLE 1.
  • Page 69 Connector T-MAP (Manifold Air Temperature Pressure) Sensor LGH6 To connect the PDA or KYMCO Fi diagnostic tool. Enter the Data Analyze item to check if the manifold pressure data is malfunction. (Turn on the ignition switch but engine is not...
  • Page 70 5. Fi INJECTION SYSTEM MOVIE S 125i TPS (Throttle Position Sensor) Connect the PDA or KYMCO Fi diagnostic tool. LGH6 Choose the Data Analyze Check if the TPS position data is malfunction. (Key switch ON but engine is not started) If data was incorrect when the idle and throttle fully opened, TPS is possible to be problem.
  • Page 71 5. Fi INJECTION SYSTEM MOVIE S 125i Measure resistance engine temperature sensor’s wires Standard: 8.24~14.4KΩ Torque: 60~90 kg-cm Injector INJECTOR Inspection Measure the resistance of the Injector Standard (20°C/68°F ): 10.6~15.9Ω Bolt Replace a new O-ring and lubricate with engine oil before installation. The cleaner must be used for fuel injector special only.
  • Page 72 5. Fi INJECTION SYSTEM MOVIE S 125i FI Fuel Injector Cleaning Method 1. Condition: Fuel Injector can’t spray fuel or spray with limited quantity 2. Cause: Fuel Injector blocked by carbon deposit 3. Method 1) Clean Fuel Injector with Ultrasound Cleaner with House Made Device 2) The level of detergent solution in the ultrasound tank shall not exceed the height of wiring receptacle of fuel injector 3) Inject detergent at the inlet port of fuel injector and clean for 30 minutes, t hen it can be...
  • Page 73 Measure the resistance of the O2 sensor heater. (two white wire pins) Standard (20°C/68°F ): 6.7 ~9.5Ω O2 sensor Connect the PDA or KYMCO Fi diagnostic tool. Choose the Data Analyze Check Page 05 (Key switch ON, then start engine till O2 heater activation is ON) If the figure is wrong, the O2 sensor maybe a problem.
  • Page 74 5. Fi INJECTION SYSTEM MOVIE S 125i ROLL SENSOR The engine should be stopped running when the vehicle inclines over 65° for safety. When you place the vehicle back to normal situation, you have to key-off and key-on the switch, then it can be restarted.
  • Page 75 Adjust TP screw should not be allowed. The best engine working condition had already been adjusted by KYMCO, if any change, maybe cause to engine problem. Connect the PDA or KYMCO Fi diagnostic tool. TP screw Choose the Data Analyze The ignition switch is turned on Starting engine till working temperature 80°C...
  • Page 76 5. Fi INJECTION SYSTEM MOVIE S 125i Movie S 125 Fi ： Customer： Eng.Num： Workshop Date of Date of Mileage： production repair： Reason of repair: □ maintenance □ breakdown Item Memo Date Reference ECU No Hardware Ver Software Ver Calibration Ver Air Temp.
  • Page 77 Fi INJECTION SYSTEM MOVIE S 125i Fi Diagnostic Tool Operation Instructions Part No. 3620A-LEB2-E00 LGH6 KEY FUNCTION 1 Model No. 8 D ATA Analyze 2 Down Button DTC Inspect 3 DTC indicator(Failure codes) ECU Version 4 Enter or Exit 5 Power indicator 6 UP Button Adjust (TPI and ABV reset function) 5-25...
  • Page 78 Fi INJECTION SYSTEM MOVIE S 125i DTC INSPECTION PROCEDURE Diagnostic Tool Connector Connect Fi diagnostic tool with the connector of harness wire located beside the Battery. LGH6 Press the " Enter " button Check the software version LGH6 Press the " Enter " button and then turn to the first page.
  • Page 79 Fi INJECTION SYSTEM MOVIE S 125i Press the " Enter " button to check the DTC number LGH6 Press the " Enter " button Press the " Enter " button Display what's DTC number on this DTC-List. Refer to DTC summary list. Press the "...
  • Page 80 Fi INJECTION SYSTEM MOVIE S 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 LGH6 page.
  • Page 81 Fi INJECTION SYSTEM MOVIE S 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 82 Fi INJECTION SYSTEM MOVIE S 125i DATA ANALYSIS LGH6 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 . Press the "...
  • Page 83 Fi INJECTION SYSTEM MOVIE S 125i The figure includes fuel injector interval, ignition advance angle and ABV 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 84 Fi INJECTION SYSTEM MOVIE S 125i ADJUST Need to make TPI/ABV reset after changing LGH6 new ECU and clean THROTTLE BODY and changing the engine department product, let ECU set up and set up initially Choose " Adjust " Press the " Enter " button to TPI/ABV Reset Press the "...
  • Page 122 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FRONT WHEEL/BRAKE/SUSPENSION SERVICE INFORMATION ---------------------------------------------- 12-1 TROUBLESHOOTING --------------------------------------------------- 12-2 FRONT WHEEL ------------------------------------------------------------- 12-3 BEARING REPLACEMENT ---------------------------------------------- 12-5 HYDRAULIC BRAKE ---------------------------------------------------- 12-8 FRONT SUSPENSION ---------------------------------------------------- 12-10 STEERING HANDLEBAR ----------------------------------------------- 12-13 STEERING STEM ----------------------------------------------------------- 12-14 12-0...
  • Page 123 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i 12-1...
  • Page 124 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i SERVICE INFORMATION GENERAL INSTRUCTIONS ● Remove the motorcycle frame covers before removing the front wheel. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down. ● During servicing, keep oil or grease off the brake drum and brake linings. ●...
  • Page 125 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i TROUBLESHOOTING Hard steering (heavy) ● Excessively tightened steering stem top cone race ● Broken steering balls ● Insufficient tire pressure Steers to one side or does not track straight ● Uneven front shock absorbers ●...
  • Page 126 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i FRONT WHEEL REMOVAL Jack the motorcycle front wheel off the ground. Remove bolt disconnect speedometer cable. Speedometer Cable Remove the front axle nut and pull out the axle. Remove the front wheel. Remove the front brake disk. Caliper Bolts Brake Disk...
  • Page 127 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i BEARING INSPECTION Remove the side collar and dust seal. Dust Seal Side Collar Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly. Replace the new bearings if not turning smoothly, quietly or loose.
  • Page 128 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i Apply grease to a new dust seal lip and install the dust seal. Install the side collar. Dust Seal Side Collar Pawls INSTALLATION Apply grease to the speedometer gear. Install the brake panel by aligning the speedometer retaining pawls with the hub cutouts.
  • Page 129 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i 12-7...
  • Page 130 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i Brake fluid reservoir HYDRAULIC BRAKE (FRONT BRAKE) Check the brake fluid level on level ground. When operating the brake lever, the brake reservoir cap must be tightened securely to avoid splash of brake fluid. When servicing the brake system, use shop towels to cover plastic parts and coated surfaces to avoid damage caused...
  • Page 131 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i Install the brake pads in the reverse order of removal. Keep grease or oil off the brake pads to avoid brake failure. Brake Pads Comp BRAKE DISK Measure the brake disk thickness. Service Limit: 3.0 mm Measure the brake disk runout.
  • Page 132 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i Bolts FRONT SUSPENSION REMOVAL Remove the front cover. Remove the front wheel. Remove the front shock absorber upper mount bolts. Loosen the lower mount bolts to remove the front shock absorbers. Shock Absorber DISASSEMBLY Remove the dust boot Remove the circlip Six angle bolt...
  • Page 133 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i DISASSEMBLY Shock Absorber Case Damper Take out the front shock absorber spring, damper and damper spring. INSPECTION Shock Absorber Tube Shock Absorber Spring Inspect the following items and replace if necessary. Front shock absorber tube bending or damage ...
  • Page 134 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i Absorber Set the front shock absorber in a vise. Insert the shock absorber tube into the shock absorber and tighten the hex bolt. Apply locking agent to the washer and install it together with the hex bolt.
  • Page 135 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i Bolts STEERING HANDLEBAR REMOVAL Remove the handlebar covers. Remove the rear brake lever holder bolt to remove the holder. Remove the front brake master cylinder holder bolts to remove the brake master cylinder. Rear Brake Lever Front Brake Lever Bolts Remove the throttle seat screw and throttle grip.
  • Page 136 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i Long Socket Wrench STEERING STEM REMOVAL Remove the steering stem lock nut Long Socket wrench F002 Top Cone Race Remove the top cone race Be careful not to lose the steel balls (26 on top race and 19 on bottom race).
  • Page 137 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i BOTTOM CONE RACE INSTALLATION Drive new top and bottom ball races into the steering head using the outer driver. Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race.
  • Page 138 . FRONT WHEEL/BRAKE/SUSPENSION Movie S 125i HANDLEBAR INSTALLATION Install the handlebar onto the steering stem tube and then install and tighten the bolt. Torque: 4.0 ~ 5.0 kg-m Install the front wheel. Install the brake levers. Install the handlebar covers. Collar Bolt 12-16...
  • Page 155 . IGNITION SYSTEM Movie S 125i __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT ------------------------------------------ 15-1 IGNITION CIRCUIT ------------------------------------------------------- 15-2 SERVICE INFORMATION------------------------------------------------ 15-3 TROUBLESHOOTING----------------------------------------------------- 15-3 IGNITION COIL ------------------------------------------------------------ 15-4 AC GENERATOR ---------------------------------------------------------- 15-4 TILT SWITCH --------------------------------------------------------------- 15-5 15-0...
  • Page 156 . IGNITION SYSTEM DINK 200i/125 IGNITION SYSTEM LAYOUT ABV/T-MAP/TPS/ECU Ignition switch Spark plug AC Generator 15-1...
  • Page 157 . IGNITION SYSTEM Movie S 125i IGNITION CIRCUIT 15-2...
  • Page 158 . IGNITION SYSTEM DINK 200i/125 SERVICE INFORMATION GENERAL INSTRUCTIONS Some electrical components may be damaged if terminals or connectors are disconnected while the ignition switch is “ON”. ● When servicing the ignition system, always follow the steps in the troubleshooting. ●...
  • Page 159 . IGNITION SYSTEM Movie S 125i IGNITION COIL Ignition Coil REMOVAL Remove the body covers. Disconnect the spark plug cap from the spark plug. Disconnect ignition coil primary connector. Remove the bolt and the ignition coil. Ignition Primary Coil INSPECTION Measure the resistance of ignition primary coil.
  • Page 177 EVAPORATIVE / EMISSION CONTROL SYSTEM Movie S 125i EVAPORATIVE - EMISSION CONTROL SYSTEM SCHEMATIC DRAWING ...............18- 1 EVAPORATIVE CONTROL SYSTEM ..........18- 2 TROUBLESHOOTING................18- 2 SERVICE INFORMATION..............18- 3 PERGE CONTROL VALVE ..............18- 4 P.C.V. (BLOW BY)..................18- 5 CHARCOAL CANISTER ...............18- 6 EMISSION CONTROL SYSTEM ............18- 7 TROUBLESHOOTING................18- 8 SECONDARY AIR CLEANER / A.I.C.V..........18- 9...
  • Page 178 EVAPORATIVE / EMISSION CONTROL SYSTEM Movie S 125i SCHEMATIC DRAWING Air Cleaner Charcoal Canister Throttle Body Fuel Injector Fuel Tank Catalytic converter 18-1...
  • Page 179 EVAPORATIVE / EMISSION CONTROL SYSTEM Movie S 125i EVAPORATIVE EMISSION CONTROL SYSTEM FUNCTION FOREWORD: The Evaporative Emission Control System is abbreviated to E.E.C. System. This device collects the fuel vapor from the fuel tank and then the fuel vapor is drawn into the engine for re-burning to avoid air pollution caused by the fuel vapor diffused into the air.
  • Page 180 EVAPORATIVE / EMISSION CONTROL SYSTEM Movie S 125i SERVICE INFORMATION GENERAL INSTRUCTIONS • Do not smoke or allow flames or sparks near the working area. • Note the locations of tubes for proper installation. • Replace any damaged tube with a new one. •...
  • Page 181 EVAPORATIVE / EMISSION CONTROL SYSTEM Movie S 125i PURGE CONTROL VALVE REMOVAL 1. Remove the body cover. 2. Disconnect the purge control valve vacuum tube that goes to the throttle body and the tubes that go to the air cleaner and charcoal canister.
  • Page 182 EVAPORATIVE / EMISSION CONTROL SYSTEM Movie S 125i PURGE CONTROL VALVE FLOW INSPECTION 1. Connect a vacuum pump to the purge control valve vacuum tube and apply vacuum pressure of 45mm/Hg. 2. Connect a pressure pump to the tube that goes to the charcoal canister and apply pressure.
  • Page 183 EVAPORATIVE / EMISSION CONTROL SYSTEM Movie S 125i CHARCOAL CANISTER REMOVAL 1. Remove the frame right side cover. 2. Disconnect the charcoal canister tubes that go to the fuel tank and purge control valve. 3. Remove the charcoal canister. Charcoal Canister/ Purge Control Valve INSPECTION 1.
  • Page 184 EVAPORATIVE / EMISSION CONTROL SYSTEM Movie S 125i EMISSION CONTROL SYSTEM The exhaust emission control system adopted in this model utilizes the reed valve to draw secondary air into the exhaust system for re-combustion by means of exhaust pulsation so as to minimize the exhaust emission.
  • Page 185 EVAPORATIVE / EMISSION CONTROL SYSTEM Movie S 125i TROUBLESHOOTING High CO at idle speed 1. Damaged or clogged reed valve 2. Damaged or clogged air injection cut-off valve 3. Clogged air cleaner Backfiring at sudden deceleration 1. Damaged reed valve (malfunction) 2.
  • Page 186 EVAPORATIVE / EMISSION CONTROL SYSTEM Movie S 125i Bolts SECONDARY AIR CLEANER / AIR INJECTION CUT-OFF VALVE (A.I.C.V.) REMOVAL Remove the body cover. Remove the side skirt. Remove four bolts attaching to the floorboard. Vacuum tube Disconnect the secondary air cleaner/(A.I.C.V) connecting tube.
  • Page 187 EVAPORATIVE / EMISSION CONTROL SYSTEM Movie S 125i Secondary air inlet tube REED VALVE REMOVAL Remove the frame center cover. Disconnect secondary inlet tube connector. Remove the reed valve cover and two secondary air outlet tube nuts. Bolts 　　　　　Bolt INSPECTION Check the reed valve for cracks, damage, big clearance or weak reeds.
  • Page 196 GP 125 FI SF： Customer： Eng.Num： Date of Date of Mileage： production repair： Reason of repair: □ maintenance □ breakdown Item Memo Date Reference ECU No Hardware Ver Software Ver Calibration Ver Model Name Active Occurred History Air Temp.(°C) environ.temp ± 2 °C Engine Temp.(Coiling) environ.temp ±...

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