Page 1: Table Of Contents
PREFACE TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION technical features and servicing FRAME COVERS/EXHAUST MUFFLER procedures for the KYMCO MOVIE 125. INSPECTION/ADJUSTMENT LUBRICATION SYSTEM Section 1 contains the precautions for FUEL SYSTEM all operations stated in this manual.
Page 2: Engine Serial Number
. GENERAL INFORMATION ENGINE SERIAL NUMBER ....1- 1 LUBRICATION POINTS......1-13 SPECIFICATIONS .........1- 2 CABLE & HARNESS ROUTING..1-15 SERVICE PRECAUTIONS.....1- 3 WIRING DIAGRAM.......1-20 TORQUE VALUES........1-11 TROUBLESHOOTING......1-21 TOOLS.............1-12 ENGINE SERIAL NUMBER Location of Engine Serial Number...
Page 3: Specifications
. GENERAL INFORMATION SPECIFICATIONS Cooling Type Forced air cooling Name & Model No. SD25AA Motorcycle Name & Type Overall length (mm) 1820 Overall width (mm) Air cleaner type & No Paper element, wet Overall height (mm) 1095 Fuel capacity 7.8 liters Wheel base (mm) 1215 Type...
Page 4: Service Precautions
. GENERAL INFORMATION SERVICE PRECAUTIONS n Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. n When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
Page 5 . GENERAL INFORMATION n Apply or add designated greases and lubricants to the specified lubrication points. n After reassembly, check all parts for proper tightening and operation. n When two persons work together, pay attention to the mutual working safety. n Disconnect the battery negative (-) terminal before operation.
Page 6 . GENERAL INFORMATION n If the fuse is burned out, find the cause and Confirm repair it. Replace it with a new one Capacity according to the specified capacity. n After operation, terminal caps shall be installed securely. n When taking out the connector, the lock on the connector shall be released before operation.
Page 7 . GENERAL INFORMATION n The connector shall be inserted completely. n If the double connector has a lock, lock it at the correct position. Snapping! n Check if there is any loose wire. n Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
Page 8 . GENERAL INFORMATION n After clamping, check each wire to make sure it is secure. n Do not squeeze wires against the weld or its clamp. n After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
Page 9 . GENERAL INFORMATION n Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! n Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. n When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
Page 10 . GENERAL INFORMATION n After routing, check that the wire harnesses are not twisted or kinked. n 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. Do you understand the instrument? Is the instrument set...
Page 11 . GENERAL INFORMATION n 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 12: Torque Values
. GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 5mm screw 6mm bolt, nut 6mm screw, SH bolt 8mm bolt, nut 6mm flange bolt, nut 10mm bolt, nut 8mm flange bolt, nut 12mm bolt, nut 10mm flange bolt, nut Torque specifications listed below are for important fasteners.
Page 13: Tools
. GENERAL INFORMATION SPECIAL TOOLS Tool Name Tool No. Remarks Ref. Page Valve adjuster Valve guide driver Valve guide reamer Valve spring compressor Lock nut wrench, 39mm Bearing driver Bearing driver Bearing remover, 12mm Remover set, 12mm Remover head, 12mm Remover shaft Remover weight Bearing remover set, 15mm...
Page 14: Lubrication Points
. GENERAL INFORMATION LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part •Genuine KYM CO Engine Oil (SAE10W-30) Cam lobes •API SE, SF or SG Engine Oil Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall...
Page 15 . GENERAL INFORMATION FRAME The following is the lubrication points for the frame. Use general purpose 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 motorcycle. Grease Front Brake Lever Pivot...
Page 16: Cable & Harness Routing
. GENERAL INFORMATION CABLE & HARNESS ROUTING Front Stop Switch Wire Front Brake Reservoir Rear Stop Switch Wire Front Brake Fluid Tube Throttle Cable Rear Brake Cable Ignition Switch Speedometer Cable Instrument Cable Charging Indicator Buzzer Secondary Air Cleaner Resistor Regulator/Rectifier Horn Front Brake Fluid...
Page 17: General Information
. GENERAL INFORMATION Regulator/Rectifier Charging Indicator Secondary Air Inlet Tube Wire Harness Speedometer Cable Throttle Cable Resistor Front Brake Fluid Tube Rear Brake Cable Secondary Air Inlet Tube 1-16...
Page 18 . GENERAL INFORMATION Battery (+) Cable CDI Unit Battery (-) Cable Wire Harness Ground Fuse Battery (-) Cable CDI Unit Reserve Fuse Battery (+) Cable 1-17...
Page 19 . GENERAL INFORMATION Crankcase Breather Tube Vacuum Tee Ignition Coil Throttle Cable Fuel Valve Vacuum Tube Auto Bystarter Wire Fuel Tube A.C. Generator Wire Fuel Vapor Recovery Tube Ground 1-18...
Page 20 . GENERAL INFORMATION Fuel Vapor Tube Fuel Unit Fuel Tube Carburetor Vacuum Tube Charcoal Canister/ Purge Control Valve Auto Bystarter Wire Starter Relay Throttle Cable Starter Relay Starter Motor Wire Wire Harness Crankcase Breather Fuel Unit Tube Reed Valve Vacuum Tee Auto Bystarter 1-19...
Page 21: Wiring Diagram
. GENERAL INFORMATION WIRING DIAGRAM Orange Black Pink White Brown Green LG Light green Violet Light blue Blue Gray Yellow 1-20...
Page 22: Troubleshooting
. GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Fuel does not Fuel reaches Clogged fuel tank cap breather...
Page 23 . GENERAL INFORMATION ENGINE LACKS POWER Inspection/Adjustment Symptom Probable Cause Start engine and accelerate Clogged air cleaner lightly for observation Restricted fuel flow Clogged fuel tank cap breather hole Clogged exhaust muffler Engine speed Engine speed does not Faulty auto bystarter increases increase sufficiently Split carburetor vacuum piston...
Page 24 . GENERAL INFORMATION POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil Check carburetor pilot screw adjustment Mixture too rich (turn screw Correctly adjusted Incorrectly out) Mixture too lean (turn screw...
Page 25 . GENERAL INFORMATION POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil Check valve clearance Improperly adjusted valve Correctly adjusted Incorrectly adjusted clearance Worn valve seat Check fuel pump for fuel supply Empty fuel tank Clogged fuel tube or filter...
Page 26 . GENERAL INFORMATION POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage of battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator coil terminals Faulty A.C.
Page 27 . GENERAL INFORMATION NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Good spark Weak or no spark Faulty spark plug Check spark plug cap and high-tension wire for looseness Not loose Loose Loose spark plug cap Check CDI unit...
Page 28: Frame Covers/Exhaust Muffler
. FRAME COVERS/EXHAUST MUFFLER FRAME COVERS LAYOUT...
Page 29 . FRAME COVERS/EXHAUST MUFFLER SERVICE INFORMATION...... 2-1 FRAME COVERS........2-2 TROUBLESHOOTING ......2-1 EXHAUST MUFFLER REMOVAL ..2-6 SERVICE INFORMATION GENERAL INSTRUCTIONS • When removing frame covers, use special care not to pull them by force because the cover joint claws may be damaged. •...
Page 30 . FRAME COVERS/EXHAUST MUFFLER Bolts FRAME COVERS REAR HAND GRIP REMOVAL Remove the six bolts attaching the rear hand grip. Remove the rear hand grip. The installation sequence is the reverse of removal. Rear Hand Grip Screws FRAME REAR COVER REMOVAL Disconnect the third stoplight wire connector.
Page 31 . FRAME COVERS/EXHAUST MUFFLER Seat Nuts Met-in Box Remove the fuel tank cap. Remove the two seat attaching bolts and the seat. Remove the two bolts and two nuts attaching the met-in box. Remove the met-in box. The installation sequence is the reverse of removal.
Page 32 . FRAME COVERS/EXHAUST MUFFLER Front Cover Screws FRONT COVER REMOVAL Remove the bolt on the front of the front cover. Remove the twelve screws that combine the front cover with the front tool box. Remove the front cover and disconnect the headlight wire connector.
Page 33 . FRAME COVERS/EXHAUST MUFFLER CDI Unit FLOOR BOARD REMOVAL Remove the battery cover. Remove the battery cables. Remove the battery. Remove the CDI unit. ＊ When removing, first disconnect • the battery negative (-) cable and then the positive (+) cable. When installing, first connect the •...
Page 34 . FRAME COVERS/EXHAUST MUFFLER EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts. Remove the two exhaust muffler lock bolts to remove the exhaust muffler. Remove the exhaust muffler joint packing collar. When installing, first install the exhaust muffler packing collar onto the engine and then install the exhaust muffler.
Page 35: Inspection/Adjustment
. INSPECTION/ADJUSTMENT SERVICE INFORMATION..... 3-0 FINAL REDUCTION GEAR OIL..3- 7 MAINTENANCE SCHEDULE....3-2 DRIVE BELT .......... 3- 7 FUEL LINE ..........3-3 BRAKE SHOE........3- 8 THROTTLE OPERATION...... 3-3 BRAKE ADJUSTING NUT....3- 8 AIR CLEANER.......... 3-4 HEADLIGHT AIM ......... 3- 9 SPARK PLUG ...........
Page 36 . INSPECTION/ADJUSTMENT Cylinder compression : 12.8kg/cm -570rpm Ignition timing : BTDC 13±3°/1700±100rpm CHASSIS Front brake free play: 10_ 20mm Rear brake free play: 10_ 20mm TIRE PRESSURE 1 Rider 2 Riders Front 1.75kg/cm 1.75kg/cm Rear 2.00kg/cm 2.25kg/cm TIRE SIZE: Front : 100 - 90 - 10 : 100 - 90 - 10 Rear TORQUE VALUES...
Page 37: Maintenance Schedule
In the interest of safety, we recommend these items should be serviced only by an • authorized KYMCO motorcycle dealer. Note: 1. For higher odometer readings, repeat at the frequency interval established here. 2. Service more frequently when riding in dusty or rainy areas.
Page 38: Fuel Line
. INSPECTION/ADJUSTMENT Fuel Filter FUEL LINE Remove the met-in box. ( 2-3) Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. ＊ Do not smoke or allow flames or sparks in your working area. Fuel Line 2-6mm THROTTLE OPERATION...
Page 39: Air Cleaner
. INSPECTION/ADJUSTMENT Screws AIR CLEANER AIR CLEANER REPLACEMENT Remove the rear side covers. ( 2-2) Remove the five air cleaner case cover screws and the cover. Remove the air cleaner element by removing the two screws. Check the element and replace it if it is excessively dirty or damaged.
Page 40: Valve Clearance
. INSPECTION/ADJUSTMENT Cylinder Head Cover VALVE CLEARANCE ＊ Inspect and adjust valve clearance while the engine is cold (below 35℃ ). Remove the center cover. ( 2-4) Remove the cylinder head cover. ( 7-3) Bolts Turn the flywheel counterclockwise so that the “T”...
Page 41: Ignition Timing
. INSPECTION/ADJUSTMENT Timing Hole Cap IGNITION TIMING ＊ The CDI unit is not adjustable. If the ignition timing is incorrect, check the ignition system. ( 15-6) Remove the rear right side cover. ( 2-2) Remove the timing hole cap. Timing Light Check the ignition timing with a timing light.
Page 42: Final Reduction Gear Oil
. INSPECTION/ADJUSTMENT Oil Check Bolt/Sealing Washer FINAL REDUCTION GEAR OIL OIL LEVEL CHECK ＊ Place the motorcycle on its main stand on level ground for oil level check. Stop the engine and remove the oil check bolt. The oil level shall be at the oil check bolt hole. If the oil level is low, add the recommended oil to the proper level.
Page 43: Brake Shoe
. INSPECTION/ADJUSTMENT Arrows BRAKE SHOE Replace the brake shoes if the arrow on the wear indicator plate aligns with the punch mark on the brake panel when the brake is fully applied. Refer to page 13-3 for brake shoe replacement. Punch Mark BRAKE SYSTEM FRONT BRAKE...
Page 44: Headlight Aim
. INSPECTION/ADJUSTMENT Adjusting Nut If the free play do not fall within the limit, adjust by turning the adjusting nut. HEADLIGHT AIM Turn the ignition switch ON and start the engine. Turn on the headlight switch. Adjust the headlight aim by turning the headlight aim adjusting screw.
Page 45: Nuts/Bolts/Fasteners
. INSPECTION/ADJUSTMENT REAR Check the action of the rear shock absorber by compressing it 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 46: Steering Handlebar
. INSPECTION/ADJUSTMENT STEERING HANDLEBAR Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing. ( 12-20) 3-11...
Page 47: Lubrication System
. LUBRICATION SYSTEM LUBRICATION SYSTEM Rocker Arm Shaft Crankshaft Oil Filter Screen Oil Pump...
Page 48 . LUBRICATION SYSTEM SERVICE INFORMATION...... 4-1 ENGINE OIL/OIL FILTER .......4-2 TROUBLESHOOTING ......4-1 OIL PUMP..........4-3 SERVICE INFORMATION GENERAL INSTRUCTIONS • The maintenance of lubrication system can be performed with the engine installed in the frame. • Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.
Page 49 . LUBRICATION SYSTEM ENGINE OIL/OIL FILTER OIL LEVEL Upper Level ＊ Place the motorcycle upright on • Lower level ground for engine oil level check. Level Run the engine for 2_ • minutes and check the oil level after the engine is stopped for 2_ 3 minutes.
Page 50 . LUBRICATION SYSTEM Bolts Pulser Coil OIL PUMP REMOVAL Remove the A.C. generator flywheel. ( 14-6) Remove the nine right crankcase cover bolts and the right crankcase cover. Stator Right Crankcase Cover Remove the gasket and dowel pins. Remove the starter idle gear and starter clutch.
Page 51 . LUBRICATION SYSTEM Bolts Remove the two oil pump mounting bolts and the oil pump. Oil Pump Screw DISASSEMBLY Remove the screw and disassemble the oil pump. Pump Body Outer Rotor INSPECTION Measure the pump body-to-outer rotor clearance. Service Limit: 0.12mm Pump Body Outer Rotor Measure the inner rotor-to-outer rotor...
Page 52 . LUBRICATION SYSTEM Measure the rotor end-to-pump body clearance. Service Limit: 0.2mm Outer Rotor Inner Rotor ASSEMBLY Install the outer rotor, inner rotor and pump shaft into the pump body. ＊ Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.
Page 53 . LUBRICATION SYSTEM Bolts After the oil pump is installed, tighten the two mounting bolts. Install the pump driven gear and drive chain by aligning the pump driven gear with the cutout in the pump shaft. Install and tighten the pump driven gear nut. Torque: 1.0kg-m Pump Driven Gear Bolts...
Page 54 . LUBRICATION SYSTEM Right Crankcase Install the right crankcase cover and tighten Cover the nine bolts. Torque: 0.9kg-m ＊ Diagonally tighten the bolts in 2_ times. Bolts Pulser Coil Stator...
Page 55: Fuel System
. FUEL SYSTEM FUEL SYSTEM...
Page 56 . FUEL SYSTEM SERVICE INFORMATION......5-1 CARBURETOR INSTALLATION..5- 9 TROUBLESHOOTING......5-1 PILOT SCREW ADJUSTMENT ...5-10 CARBURETOR REMOVAL....5-2 FUEL TANK...........5-10 AUTO BYSTARTER ........5-3 AUTO FUEL VALVE......5-11 AIR CUT-OFF VALVE......5-5 FUEL UNIT..........5-12 VACUUM CHAMBER......5-5 AIR CLEANER ........5-12 FLOAT CHAMBER........5-6 SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ Gasoline is very dangerous.
Page 57 . FUEL SYSTEM TROUBLESHOOTING Engine is hard to start Misfiring during acceleration • No spark at plug • Faulty ignition system • Compression too low • Lean mixture • No fuel to carburetor -Clogged fuel filter Engine idles roughly, stalls or runs poorly -Restricted fuel line •...
Page 58: Carburetor Removal
. FUEL SYSTEM CARBURETOR REMOVAL Remove the frame body cover. ( 2-3) Disconnect the auto bystarter wire connector. Auto Bystarter Wire Fuel Tube Loosen the drain screw and drain the fuel from the float chamber. Disconnect the fuel tube and vacuum tube at the carburetor.
Page 59 . FUEL SYSTEM Connect a hose to the fuel enriching circuit of Vacuum Pump the carburetor. Connect the auto bystarter yellow wire to the positive (+) terminal of a battery and green wire to the negative (-) terminal. Wait 5 minutes and blow the hose with mouth or vacuum pump.
Page 60 . FUEL SYSTEM Spring AIR CUT-OFF VALVE DISASSEMBLY Disconnect the vacuum tube from the air cut- off valve. Remove the two screws to remove the air cut- off valve cover, spring and vacuum diaphragm. Vacuum Diaphragm Air Cut-off valve Cover Screws ASSEMBLY Install the vacuum diaphragm onto the...
Page 61 . FUEL SYSTEM Push the needle holder in and turn it left to remove the needle holder. Remove the spring and jet needle from the piston. ＊ Be careful not to damage the vacuum diaphragm. Jet Needle INSPECTION Inspect the needle for stepped wear. Inspect the vacuum piston for wear or damage.
Page 62 . FUEL SYSTEM Float Float Valve Remove the float pin, float and float valve. Float Pin Valve Seat INSPECTION Inspect the float valve and valve seat for damage or clogging. Inspect the float valve and valve seat contact area for stepped wear or contamination. ＊...
Page 63 . FUEL SYSTEM Needle Jet Needle Jet Holder ASSEMBLY Install the slow jet, needle jet, needle jet holder, main jet and pilot screw. ＊ Return the pilot screw to the original position as noted during removal. Standard Opening: 3± turns Pilot Screw Slow Jet Main Jet...
Page 64: Carburetor Installation
. FUEL SYSTEM Float Level Gauge FLOAT LEVEL INSPECTION ＊ • Check the operation of the float valve and float before float level inspection. • Measure the float level by placing the float level gauge on the float chamber face parallel with the main jet. Measure the float level.
Page 65: Pilot Screw Adjustment
. FUEL SYSTEM PILOT SCREW ADJUSTMENT * ADJUSTMENT ＊ • The pilot screw is factory pre-set and no adjustment is necessary. During carburetor disassembly, note the number of turns of the pilot screw and use as a reference when reinstalling it. •...
Page 66: Fuel Tank
. FUEL SYSTEM FUEL TANK REMOVAL Remove the frame body cover. ( 2-2, 2-3) Disconnect the fuel unit wire connector. Fuel Unit Wire Connector Auto Fuel Valve Disconnect the fuel tube and vacuum tube at the auto fuel valve. Vacuum Tube Remove the four fuel tank mounting bolts and fuel tank.
Page 67 . FUEL SYSTEM AUTO FUEL VALVE ＊ No Smoking! ＊ First clean the fuel tube. Disconnect the fuel tube and vacuum tube from the carburetor. Connect a vacuum pump to the vacuum tube and apply vacuum. Check if fuel flows out. •...
Page 68 . FUEL SYSTEM Arrow Install the fuel unit retainer and turn the retainer clockwise to secure it. ＊ Make sure that the arrow on the retainer is aligned with the arrow on the fuel tank. Connect the fuel unit wire connector. Retainer AIR CLEANER Loosen the air cleaner connecting tube band...
Page 69: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION 4.0kg-m 7.0kg-m...
Page 70 6. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION......6-1 ENGINE INSTALLATION...... 6-4 ENGINE REMOVAL ........6-2 SERVICE INFORMATION GENERAL INSTRUCTIONS • A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the motorcycle body, cables and wires during engine removal. •...
Page 71: Engine Removal
. ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Disconnect the battery negative cable. Remove the frame body cover. ( 2-2) Disconnect the engine negative cable. Disconnect the spark plug high tension wire. Disconnect the auto bystarter wire connector. Auto Bystarter Wire Connector Ignition Coil Wire Starter Relay Disconnect the starter motor cable from the starter relay.
Page 72 6. ENGINE REMOVAL/INSTALLATION Remove the air cleaner bolts. Remove the rear brake adjusting nut, connecting pin and rear brake cable. Rear Shock Absorber Upper Mount Bolt Remove the rear shock absorber upper mount bolt. Engine Mounting Bolt Remove the four A.C. generator cooling fan cover bolts and cooling fan cover.
Page 73: Engine Installation
. ENGINE REMOVAL/INSTALLATION Stopper Rubbers Inspect the engine hanger bushings and stopper rubbers for wear or damage. Bushings Bolt Engine Hanger Bracket ENGINE HANGER BRACKET INSTALLATION Install the engine hanger bracket to the engine. Install the engine hanger bracket bolt and tighten the nut.
Page 74: Cylinder Head/Valves
. CYLINDER HEAD/VALVES 0.8kg-m 2.0kg-m 1.2kg-m...
Page 75 7. CYLINDER HEAD/VALVES SERVICE INFORMATION.....7-1 VALVE GUIDE REPLACEMENT...7- 9 TROUBLESHOOTING......7-2 VALVE SEAT INSPECTION & REFACING..7-10 CAMSHAFT REMOVAL......7-3 CYLINDER HEAD ASSEMBLY....7-12 CYLINDER HEAD REMOVAL....7-6 CYLINDER HEAD INSTALLATION..7-13 CYLINDER HEAD DISASSEMBLY..7-7 CAMSHAFT INSTALLATION....7-14 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder head can be serviced with the engine installed in the frame. •...
Page 76: Troubleshooting
. CYLINDER HEAD/VALVES TORQUE VALUES Cylinder head nut 2.0kg-m Apply engine oil to threads Valve clearance adjusting nut 0.9kg-m Apply engine oil to threads SPECIAL TOOLS Valve spring compressor Valve seat cutter, 24.5mm 45° IN/EX Valve seat cutter, 25mm Plane cutter 32° IN Valve seat cutter, 22mm Plane cutter 32°...
Page 77: Camshaft Removal
7. CYLINDER HEAD/VALVES Cylinder Head Cover CAMSHAFT REMOVAL Remove the center cover. ( 2-3) Remove the four cylinder head cover bolts to remove the cylinder head cover. Remove the two nuts attaching the secondary air inlet tube. O-ring Remove the cam chain tensioner cap screw and the O-ring.
Page 78 . CYLINDER HEAD/VALVES Bolt Remove the two cylinder head bolts. Remove the four cylinder head nuts and washers. ＊ Diagonally loosen the cylinder head nuts in 2 or 3 times. Washer Camshaft Holder Remove the camshaft holder and dowel pins. Camshaft Dowel Pins Remove the camshaft gear from the cam chain...
Page 79 7. CYLINDER HEAD/VALVES Camshaft Bearings 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. CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 5mm bolt.
Page 80: Cylinder Head Removal
. CYLINDER HEAD/VALVES Intake Manifold CYLINDER HEAD REMOVAL Remove the camshaft. ( 7-3) Remove the carburetor. ( 5-3) Remove the exhaust muffler. ( 2-6) Remove the carburetor intake manifold. Remove the cooling fan cover. ( 14-6) Remove the engine cover bolts and screws. Separate the engine cover joint claws.
Page 81: Cylinder Head Disassembly
7. CYLINDER HEAD/VALVES Cylinder Head Remove the cylinder head. Bolts Dowel Pins Cylinder Head Gasket Remove the dowel pins and cylinder head gasket. Remove the cam chain guide. Cam Chain Guide Remove all gasket material from the cylinder mating surface. ＊...
Page 82 . CYLINDER HEAD/VALVES Remove carbon deposits from the combustion chamber. Clean off any gasket material from the cylinder head mating surface. ＊ Be careful not to damage the cylinder head mating surface. INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for cracks.
Page 83: Valve Guide Replacement
7. CYLINDER HEAD/VALVES Valve Guide Reamer Ream the guides to remove any carbon build- up using a valve guide reamer. Special Valve Guide Reamer ＊ During this operation, rotate the reamer clockwise and do not insert or remove it straight when it is stopped. Measure each valve guide I.D.
Page 84: Valve Seat Inspection & Refacing
. CYLINDER HEAD/VALVES Valve Guide Reamer Ream the new valve guides with a valve guide reamer. ＊ Use cutting oil on the reamer • during this operation. Rotate the reamer clockwise and • do not insert or remove it straight when it is stopped.
Page 85 7. CYLINDER HEAD/VALVES VALVE SEAT GRINDING Roughness Remove any roughness or irregularities from the seat using a 45° cutter. ＊ Be careful not to grind too much. Use a 32° cutter to remove the upper existing valve seat material. Old Seat Width Use a 60°...
Page 86: Cylinder Head Assembly
. CYLINDER HEAD/VALVES Inspect the valve seat contact area. Contact too High If the contact area is too high on the valve, the seat must be lowered using a 32° cutter. If the contact area is too low on the valve, the seat must be raised using a 60°...
Page 87: Cylinder Head Installation
7. CYLINDER HEAD/VALVES Tap the valve stems gently with a plastic hammer for 2_ 3 times to firmly seat the cotters. ＊ Be careful not to damage the valves. Dowel Pins Gasket CYLINDER HEAD INSTALLATION Install the dowel pins and a new cylinder head gasket.
Page 88: Camshaft Installation
. CYLINDER HEAD/VALVES Cam Chain Camshaft Gear CAMSHAFT INSTALLATION Turn the 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 camshaft gear with the cylinder head surface (Position the intake and exhaust cam lobes down.) and install the camshaft onto the...
Page 89 7. CYLINDER HEAD/VALVES Apply engine oil to a new O-ring and install Tighten the cam chain tensioner cap screw. ＊ Be sure to install the O-ring into the groove properly. O-ring Install a new cylinder head cover O-ring and install the cylinder head cover. Install and tighten the cylinder head cover bolts.
Page 90: Cylinder/Piston
. CYLINDER/PISTON Do not bend...
Page 91 . CYLINDER/PISTON SERVICE INFORMATION ......8-1 PISTON REMOVAL.........8-3 TROUBLESHOOTING......8-1 PISTON INSTALLATION.......8-6 CYLINDER REMOVAL......8-2 CYLINDER INSTALLATION ....8-6 SERVICE INFORMATION GENERAL INSTRUCTIONS • The cylinder and piston can be serviced with the engine installed in the frame. • After disassembly, clean the removed parts and dry them with compressed air before inspection. SPECIFICATIONS Item Standard (mm)
Page 92: Cylinder Removal
. CYLINDER/PISTON Cylinder CYLINDER REMOVAL Remove the cylinder head. ( 7-6) Remove the cam chain guide. Remove the cylinder base bolts. Remove the cylinder. Dowel Pins Remove the cylinder gasket and dowel pins. Clean any gasket material from the cylinder surface.
Page 93 . CYLINDER/PISTON Inspect the piston, piston pin and piston rings. Remove the piston rings. ＊ Take care not to damage or break the piston rings during removal. Clean carbon deposits from the piston ring grooves. Install the piston rings onto the piston and measure the piston ring-to-groove clearance.
Page 94 . CYLINDER/PISTON Measure the piston pin O.D. Service Limit: 14.96mm replace if below Measure the piston O.D. ＊ Take measurement at 9mm from the bottom and 90° to the piston pin hole. Service Limit: 52.3mm replace if below Measure the piston-to-piston pin clearance. Service Limit: 0.02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage.
Page 95 . CYLINDER/PISTON Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if below Measure the connecting rod small end I.D. Service Limit: 15.06mm replace if below PISTON RING INSTALLATION Install the piston rings onto the piston. Apply engine oil to each piston ring.
Page 96: Piston Installation
. CYLINDER/PISTON PISTON INSTALLATION Remove any gasket material from the crankcase surface. ＊ Be careful not to drop foreign matters into the crankcase. Install the piston, piston pin and a new piston pin clip. ＊ Position the piston “IN” mark •...
Page 97 . CYLINDER/PISTON Loosely install the cylinder base bolts. Cam Chain Guide Install the cam chain guide. ＊ Insert the tab on the cam chain guide into the cylinder groove. Install the cylinder head. ( 7-13) Tighten the cylinder base bolts. Cylinder Base Bolt...
Page 98: Drive And Driven Pulleys/Kick Starter
9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER 5.5kg-m 5.5kg-m 5.5kg-m...
Page 99 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER SERVICE INFORMATION ......9-1 DRIVE PULLEY........9- 3 TROUBLESHOOTING......9-1 CLUTCH/DRIVEN PULLEY....9- 8 LEFT CRANKCASE COVER ....9-2 KICK STARTER........9-14 SERVICE INFORMATION GENERAL INSTRUCTIONS • The drive pulley, clutch and driven pulley can be serviced with the engine installed. •...
Page 100: Left Crankcase Cover
9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Air Tube Band LEFT CRANKCASE COVER REMOVAL Loosen the drive belt air tube band screw. Screw Cable Clamp Left Crankcase Cover Remove the left crankcase cover bolts and left crankcase cover. Remove the seal rubber and dowel pins. Bolts Dowel Pins INSTALLATION...
Page 101 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Intake Cover Install the drive belt air tube and tighten the tube band screw. Tube Band Screw Starting Ratchet Drive Pulley Face DRIVE PULLEY REMOVAL Remove the left crankcase cover. Hold the drive pulley using an universal holder and remove the drive face nut and starting ratchet.
Page 102 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Drive Pulley Collar Remove the movable drive face assembly. Remove the drive pulley collar. Movable Drive Face Assembly Ramp Plate DISASSEMBLY Remove the ramp plate. Remove the weight rollers. Weight Roller...
Page 103 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER INSPECTION Check each weight roller for wear or damage. Measure each weight roller O.D. Service Limit: 17.4mm replace if below Measure the movable drive face bushing I.D. Service Limit: 24.06mm replace if over Check the drive pulley collar for wear or damage.
Page 104 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER ASSEMBLY Install the weight rollers into the movable drive face. Weight Roller Ramp Plate Install the ramp plate.
Page 105 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Drive Pulley Collar Insert the drive pulley collar into the movable drive face. INSTALLATION Install the movable drive face onto the crankshaft. Movable Drive Face Assembly Drive Pulley Collar Driven Pulley Lay the drive belt on the driven pulley. Set the drive belt on the drive pulley collar.
Page 106 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Drive Pulley Face Install the drive pulley face, starting ratchet and drive face nut. ＊ When installing the drive pulley • face, compress it to let the drive belt move downward to the lowest position so that the drive pulley can be tightened.
Page 107 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Check the clutch shoes for wear or damage. Measure the clutch lining thickness. Service Limit: 1.5mm replace if below Clutch/Driven Pulley CLUTCH/DRIVEN PULLEY DISASSEMBLY Clutch Spring Compressor Hold the clutch/driven pulley assembly with the clutch spring compressor.
Page 108 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Guide Roller Pin Guide Roller Pull out the guide roller pins and guide rollers. Remove the movable driven face from the driven face. Movable Driven Face O-ring Oil Seal Remove the oil seal from the movable driven face.
Page 109 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Check the movable driven face for wear or damage. Measure the movable driven face I.D. Service Limit: 34.06mm replace if over DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face.
Page 110 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Press a new needle bearing into the driven face. Special Bearing Driver Pilot, 20mm Circlip CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch. ＊ Keep grease off the clutch linings. Clutch Lining Retainer Plate 9-12...
Page 111 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER CLUTCH ASS EMBLY Circlip Clutch Weights/Shoes Springs Install the damper rubbers on the drive plate pins. Install the clutch weights/shoes and clutch springs onto the drive plate. Install the retainer plate and secure with the circlips.
Page 112 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Guide Roller Guide Roller Pin Install the movable driven face onto the driven face. Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face. Movable Driven Face Driven Face Install the seal collar.
Page 113 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Clutch Outer Install the clutch outer. Hold the clutch outer with the universal holder. Install and tighten the clutch outer nut. Torque: 5.5kg-m Special Universal Holder Install the drive belt. ( 9-7) Install the left crankcase cover. ( 9-2) Universal Holder KICK STARTER REMOVAL...
Page 114 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER Kick Starter Spindle Remove the kick starter spindle and return spring from the left crankcase cover. Remove the kick starter spindle bushing. Return Spring Spindle Return Spring INSPECTION Inspect the kick starter spindle and gear for wear or damage.
Page 115 9. DRIVE AND DRIVEN PULLEYS/ KICK STARTER INSTALLATION Install the kick starter spindle bushings and return spring onto the left crankcase cover. ＊ When installing the return spring, use a screw driver to press the inward and outward return spring hooks into their original positions respectively.
Page 116: Final Reduction
. FINAL REDUCTION 10-0...
Page 117 . FINAL REDUCTION SERVICE INFORMATION ......10-1 FINAL REDUCTION INSPECTION..10-2 TROUBLESHOOTING......10-1 BEARING REPLACEMENT ....10-3 FINAL REDUCTION DISASSEMBLY..10-2 FINAL REDUCTION ASSEMBLY ..10-4 SERVICE INFORMATION GENERAL INSTRUCTIONS • When replacing the drive shaft, use a special tool to hold the bearing inner race for this operation. SPECIFICATIONS Specified Oil: GEAR OIL SAE 90# Oil Capacity:...
Page 118 . FINAL REDUCTION FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler. Remove the rear wheel. ( 13-2) Remove the rear brake cable. ( 13-3) Remove the left crankcase cover. ( 9-2) Remove the clutch/driven pulley. ( 9-8) Drain the transmission gear oil into a clean container.
Page 119: Bearing Replacement
. FINAL REDUCTION Drive Shaft Bearing Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage. Countershaft Bearing Final Shaft Bearing Final Shaft Inspect the drive shaft and gear for wear or damage. Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage.
Page 120 . FINAL REDUCTION BEARING REPLACEMENT (LEFT CRANKCASE) Remove the drive shaft. Remove the drive shaft oil seal. Remove the left crankcase bearings using a bearing remover. Bearing Remover, 12mm Drive new bearings into the left crankcase. Install a new drive shaft oil seal. Pilot FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase.
Page 121 . FINAL REDUCTION Install the countershaft and gear into the left crankcase. Install the washer onto the countershaft. Install the dowel pins and a new gasket. Countershaft Washer Install the transmission case cover. Transmission Case Cover Install and tighten the transmission case cover bolts.
Page 122 • Place the motorcycle on its main stand on level ground. • Check the oil sealing washer for wear or damage. Specified Gear Oil: KYMCO SIGMA GEAR OIL 90# Oil Capacity: At disassembly : 0.11 liter Drain Bolt Oil Check Bolt Hole/Oil Filler At change : 0.09 liter...
Page 123: Crankcase/Crankshaft
. CRANKCASE/CRANKSHAFT 11-0...
Page 124 . CRANKCASE/CRANKSHAFT SERVICE INFORMATION ......11-1 CRANKSHAFT........11-4 TROUBLESHOOTING......11-1 CRANKCASE ASSEMBLY....11-5 CRANKCASE SEPARATION....11-2 SERVICE INFORMATION GENERAL INSTRUCTIONS • This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation. • The following parts must be removed before separating the crankcase. -Cylinder head ( Section 7) -Cylinder/piston ( Section 8) -Drive and driven pulleys ( Section 9)
Page 125: Crankcase Separation
. CRANKCASE/CRANKSHAFT CRANKCASE SEPARATION Threaded Holes Cam Chain Cover Remove the two cam chain cover bolts on the left crankcase and remove the cam chain cover. Check the oil seal and O-ring for wear or deterioration. ＊ Before removing the cam chain cover, screw two 6mm bolts into the threaded holes in the cam chain cover.
Page 126 . CRANKCASE/CRANKSHAFT Remove the crankshaft from the left crankcase. Clean off all gasket material from the crankcase mating surfaces. ＊ Avoid damaging the crankcase mating surfaces. Remove the oil seal from the right crankcase. Check the oil seal lip for wear or deterioration.
Page 127: Crankshaft Inspection
. CRANKCASE/CRANKSHAFT CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance. Service Limit: 0.55mm replace if over Connecting Rod Big End Measure the connecting rod big end radial clearance at two points at right angels to the shaft. Service Limit: 0.05mm replace if over Measuring Location Measure the crankshaft runout.
Page 128: Crankcase Assembly
. CRANKCASE/CRANKSHAFT CRANKCASE ASSEMBLY Install the crankshaft into the left crankcase. Gasket Install the dowel pins and a new gasket onto the left crankcase. ＊ Place the right crankcase over the crankshaft and onto the left crankcase. Dowel Pins Crankcase Bolts Tighten the two crankcase attaching bolts.
Page 129 . CRANKCASE/CRANKSHAFT O-rings O-ring Install the two O-rings. Install a new oil seal and O-ring onto the cam chain cover. Install the cam chain cover onto the left crankcase and tighten the two bolts. Torque: 0.9kg-m Oil Seal Bolts 11-6...
Page 130: Front Wheel/Front Brake/ Front Suspension
. FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION 4.5kg- 0.9kg-m 4.5kg-m 12-0...
Page 131 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SERVICE INFORMATION....12-1 HYDRAULIC BRAKE ......12-10 TROUBLESHOOTING ......12-2 FRONT SHOCK ABSORBER ....12-16 FRONT WHEEL........12-3 STEERING HANDLEBAR ....12-19 FRONT BRAKE........12-6 STEERING STEM ........12-20 HYDRAULIC BRAKE DRAWING..12-9 SERVICE INFORMATION GENERAL INSTRUCTIONS •...
Page 132: Troubleshooting
. FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION SPECIAL TOOLS Lock nut wrench Driver handle A Lock nut wrench Outer driver, 37x40mm Outer driver, 28x30mm Pilot, 10mm Rear shock absorber attachment Bearing remover Shock absorber compressor Bearing remover head, 10mm Ball race remover Damper compressor Pliers (close) TROUBLESHOOTING...
Page 133: Front Wheel
. FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Speedometer Cable FRONT WHEEL REMOVAL Jack the motorcycle front wheel off the ground. Remove the speedometer cable set screw and disconnect the speedometer cable. Remove the front brake cable. Screw Front Brake Cable Remove the front axle nut and pull out the axle.
Page 134 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Side Collar FRONT WHEEL BEARING Remove the side collar and dust seal. Dust Seal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly. Also check if the outer race fits tightly in the hub.
Page 135 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Side Collar Apply grease to a new dust seal lip and install the dust seal. Install the side collar. Dust Seal Pawls INSTALLATION Apply grease to the brake panel dust seal lip. Apply grease to the speedometer gear engaging and sliding parts.
Page 136: Front Brake
. FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION FRONT BRAKE Remove the front wheel. ( 12-3) Remove the front brake panel. INSPECTION Measure the brake drum I.D. Service Limit: 111mm replace if over Remove the brake shoes and springs, and replace the brake shoes. ＊...
Page 137 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Speedometer Gear Dust Seal Brake Panel Brake Shoe Return Spring Brake Cam 1.0kg-m Felt Seal Brake Arm Wear Indicator Plate Brake Cam ASSEMBLY Apply grease to the anchor pin and brake cam. Install the brake cam. Felt Seal Wear Indicator Plate Install the return spring by aligning the spring...
Page 138 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Brake Arm Install the brake arm on the brake cam by aligning the punch marks on the brake arm and brake cam. Install and tighten the brake arm bolt. Torque: 1.0kg-m Brake Cam Apply grease to the brake panel collar and Speedometer Gear install it into the brake panel.
Page 139: Hydraulic Brake Drawing
. FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION HYDRAULIC BRAKE DRAWING 12-9...
Page 140: Hydraulic Brake
. FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION HYDRAULIC BRAKE (FRONT Upper Limit BRAKE) BRAKE FLUID REPLACEMENT/AIR BLEEDING 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. •...
Page 141 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Brake Pads Install the brake pads in the reverse order of removal. Tighten the brake pad pin bolt. Torque: 1.5_ 2.0kg-m ＊ Keep grease or oil off the brake pads to avoid brake failure. BRAKE DISK Measure the brake disk thickness.
Page 142 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Spring Master Cylinder Remove the washer, main piston and spring from the brake master cylinder. Clean the inside of the master cylinder and brake reservoir with brake fluid. Main Washer Snap Ring Piston INSPECTION Measure the brake master cylinder I.D.
Page 143 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Punch Mark Fluid Tube Bolt Place the brake master cylinder on the handlebar and install the holder with the “up” mark facing up. Also align the punch mark with the holder joint seam. First tighten the upper bolt and then tighten the lower bolt.
Page 144 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Remove the pistons from the brake caliper. If necessary, use compressed air to squeeze out the pistons through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed pistons.
Page 145 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION ASSEMBLY Clean all removed parts. Apply silicon grease to the pistons and oil seals. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out. ＊...
Page 146: Front Shock Absorber
. FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Mount Bolts FRONT SHOCK ABSORBER REMOVAL Remove the front cover. ( 2-4) Remove the front inner fender. Remove the front wheel. ( 12-3) Remove the front shock absorber upper mount bolts. Loosen the lower mount bolts to remove the front shock absorbers.
Page 147 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Front Shock Absorber Damper Take out the front shock absorber spring, damper and damper spring. Shock Absorber Shock Absorber Tube Damper Spring Spring INSPECTION Inspect the following items and replace if necessary. •Front shock absorber tube bending or damage •Weak front shock absorber spring •Damper and damper rod bending...
Page 148: Steering Stem
. FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Front Shock 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.) Torque: 1.5_ 3.0kg-m Add engine oil into the front shock absorber.
Page 149 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Rear Brake Lever Brake Master Cylinder STEERING HANDLEBAR REMOVAL Remove the handlebar covers. ( 2-4) 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.
Page 150 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Steering Stem Lock Nut Wrench STEERING STEM REMOVAL Remove the steering stem lock nut. Special Steering Stem Lock Nut Wrench Lock Nut wrench 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 151 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Outer Driver, 37x40mm Drive new top and bottom ball races into the steering head using the outer driver. Special Outer Driver 37x40mm INSTALLATION 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 152 . FRONT WHEEL/FRONT BRAKE/ FRONT SUSPENSION Bolt HANDLEBAR INSTALLATION Install the handlebar onto the steering stem tube and then install and tighten the bolt. Torque: 4.5kg-m Install the front wheel. ( 12-15) Install the brake levers. ( 12-19) Install the handlebar covers. ( 2-4) Collar 12-22...
Page 153: Rear Wheel/Rear Brake/ Rear Suspension
. REAR WHEEL/REAR BRAKE/ REAR SUSPENSION 4.0kg-m 2.5kg-m 1.0kg-m 11.0kg-m 1.2kg-m 3.5kg-m 13-0...
Page 154 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION SERVICE INFORMATION ......13-1 REAR BRAKE.........13-2 TROUBLESHOOTING......13-1 REAR SHOCK ABSORBER....13-5 REAR WHEEL ...........13-2 SERVICE INFORMATION GENERAL INSTRUCTIONS • During servicing, keep oil or grease off the brake drum and brake linings. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Radial æ...
Page 155: Rear Brake
. REAR WHEEL/REAR BRAKE/ REAR SUSPENSION Rear Axle Nut REAR WHEEL REMOVAL Remove the exhaust muffler joint lock nuts and exhaust muffler lock bolts. Remove the exhaust muffler. ( 2-6) Remove the rear axle nut to remove the rear wheel. INSPECTION Measure the rear wheel rim runout.
Page 156 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION BRAKE LINING INSPECTION Measure the brake lining thickness. Service Limit: 2.0mm replace if below ＊ Keep oil or grease off the brake linings. Brake Arm Brake Shoe REAR BRAKE DISASSEMBLY Remove the rear brake adjusting nut and disconnect the rear brake cable.
Page 157 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION Punch Mark Wear Indicator Plate Apply engine oil to the felt seal and install it to the brake cam. Install the wear indicator plate and brake arm. ＊ Align the wide groove on the wear indicator plate with the wide tooth of the brake cam.
Page 158: Rear Shock Absorber
. REAR WHEEL/REAR BRAKE/ REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL Remove the frame body cover. ( 2-2) Remove the air cleaner case. ( 5-13) Bolt Remove the rear shock absorber upper and lower mount bolts. Remove the rear shock absorber. Bolt Rear Shock Absorber Compressor DISASSEMBLY...
Page 159 . REAR WHEEL/REAR BRAKE/ REAR SUSPENSION Spring INSPECTION Inspect the damper rod for bending or damage. Inspect the damper for oil leaks. Inspect the damper rubber for deterioration or damage. Damper Damper Rod Rubber Measure the front shock absorber spring free length.
Page 160: Battery/Charging System/A
. BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Resistors Regulator/Rectifier Battery Fuse Charging Indicator A.C. Generator CHARGING CIRCUIT Ignition Switch Battery 12V7AH Regulator/ Rectifier Charging Indicator Auto Charging Bystarter Indicator Light 14-0...
Page 161 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR CHARGING SYSTEM LAYOUT ...14-0 REGULATOR/RECTIFIER.....14-5 SERVICE INFORMATION.....14-1 A.C. GENERATOR CHARGING COIL...14-6 TROUBLESHOOTING......14-2 A.C. GENERATOR LIGHTING COIL..14-6 BATTERY..........14-3 RESISTOR INSPECTION......14-6 CHARGING SYSTEM......14-4 A.C. GENERATOR........14-6 SERVICE INFORMATION A.C. GENERATOR/IGNITION COIL GENERAL INSTRUCTIONS The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes.
Page 162 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR TORQUE VALUES Pulser coil bolt 0.5kg-m Coil lock bolt 0.9kg-m Flywheel nut 5.5kg-m Cooling fan bolt 0.9kg-m SPECIAL TOOLS Universal holder Flywheel puller TESTING INSTRUMENTS Kowa electric tester Sanwa electric tester TROUBLESHOOTING No power Intermittent power •...
Page 163 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Battery Cover Screw BATTERY REMOVAL Remove the battery cover screws on the floor board. Open the battery cover and remove the battery by removing the bolt and band. First disconnect the battery negative (-) cable and then the positive (+) cable.
Page 164 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Perform this test with a fully charged. battery (-) Terminal CHARGING SYSTEM SHORT CIRCUIT TEST Disconnect the ground wire from the battery and connect an ammeter across the battery negative (-) terminal and the ground wire. Turn the ignition switch OFF and check for short circuit.
Page 165 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Rgulator/Rectifier REGULATOR/RECTIFIER MAIN HARNES S CIRCUIT INS PECTION Remove the front cover. ( 2-4) Remove the regulator/rectifier 4P coupler and check for continuity between the wire harness terminals according to the following : Item (Wire Color) Judgement Between battery (red) Battery has...
Page 166 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Charging Coil Wire A.C. GENERATOR CHARGING COIL ＊ The inspection of A.C. generator charging coil can be made with the engine installed. INSPECTION Disconnect the A.C. generator 3P connector. Measure the resistance between the A.C. generator white wire and engine ground with an electric tester.
Page 167 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Charging Indicator CHARGING INDICATOR INSPECTION Remove the front cover. ( 2-4) Remove the charging indicator 6P coupler. Measure the resistance between each terminal. Use an electric tester for testing. Take readings in KW range. Unit: KW Probe(+) Red/ Brown/...
Page 168 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Remove the cooling fan by removing the four cooling fan attaching bolts. Cooling Fan Universal Holder Hold the flywheel with an universal holder. Remove the flywheel nut. Special Universal Holder Remove the A.C. generator flywheel using the flywheel puller.
Page 169 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Remove the A.C. generator wire set plate. Remove the pulser coil bolts. Remove the A.C. generator wire rubber sleeve and pulser coil from the right crankcase. Remove the two bolts and A.C. generator stator. Bolts Wire Set Plate INSTALLATION Flywheel...
Page 170 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR A.C. Generator Wire Connect the A.C. generator wire connector. Connector Woodruff Key Clean the taper hole in the flywheel off any burrs and dirt. Install the woodruff key in the crankshaft keyway. Universal Holder Install the flywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key.
Page 171 . BATTERY/CHARGING SYSTEM/ A.C. GENERATOR Install the fan cover. Install the rear right side cover. ( 2-2) Fan Cover 14-11...
Page 172: Ignition System
. IGNITION SYSTEM Ignition Switch Spark Plug CDI Unit Pulser Coil A.C. Generator IGNITION CIRCUIT Ignition Switch Y W G Spark Plug Regulator/ CDI Unit Br/L Rectifier Ignition Coil Charging Indicator Control Unit Battery Pulser Coil A.C. Generator 15-0...
Page 173 . IGNITION SYSTEM SERVICE INFORMATION...... 15-1 IGNITION COIL ........15-4 TROUBLESHOOTING ......15-2 PULSER COIL .........15-6 CDI UNIT INSPECTION ......15-3 SERVICE INFORMATION GENERAL INSTRUCTIONS • Check the ignition system according to the sequence specified in the Troubleshooting. ( 1-28) • The ignition system adopts CDI unit and the ignition timing cannot be adjusted. •...
Page 174 . IGNITION SYSTEM TROUBLESHOOTING High voltage too low No high voltage • Weak battery or low engine speed • Faulty ignition switch • Loose ignition system connection • Faulty CDI unit • Faulty CDI unit • Poorly connected or broken CDI ground wire •...
Page 175 . IGNITION SYSTEM CDI Unit CDI UNIT INSPECTION Remove the two battery cover screws. Disconnect the CDI coupler and remove the CDI unit. Measure the resistance between the terminals using the electric tester.. ＊ • Due to the semiconductor in circuit, it is necessary to use a specified tester for accurate testing.
Page 176 . IGNITION SYSTEM Ignition Coil IGNITION COIL REMOVAL Remove the frame body cover. ( 2-2) Remove the spark plug cap. Disconnect the ignition coil wires and remove the ignition coil bolt and ignition coil. INSPECTION CONTINUITY TEST ＊ This test is to inspect the continuity of ignition coil.
Page 177 . IGNITION SYSTEM PULSER COIL INSPECTION ＊ This test is performed with the stator installed in the engine. Remove the frame body cover. ( 2-2) Disconnect the A.C. generator connector. Measure the pulser coil resistance between the blue/yellow and green wire terminals. Resistance: 40_ 300W/20℃...
Page 178: Starting System
. STARTING SYSTEM Stop Switches Starter Relay Starter Button Starter Motor STARTING CIRCUIT Fuse Ignition Switch Rear Stop Switch Starter Motor Starter Button Battery Starter Relay Front Stop Switch 16-0...
Page 179 . STARTING SYSTEM SERVICE INFORMATION ......16-1 STARTER RELAY........16-4 TROUBLESHOOTING......16-1 STARTER CLUTCH.......16-6 STARTER MOTOR ........16-2 SERVICE INFORMATION GENERAL INSTRUCTIONS • The removal of starter motor can be accomplished with the engine installed. • For the starter clutch removal, refer to Section 4. SPECIFICATIONS Item Standard (mm)
Page 180 . STARTING SYSTEM Bolts STARTER MOTOR REMOVAL ＊ Before removing the starter motor, turn the ignition switch OFF and remove the battery ground. Then, turn on the ignition switch and push the starter button to see if the starter motor operates properly.
Page 181 . STARTING SYSTEM STARTER MOTOR CASE CONTINUITY CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover. Also check for the continuity between the wire terminal and each brush. Replace if necessary. Wire Terminal Measure the length of the brushes.
Page 182 . STARTING SYSTEM Front Cover Commutator ASSEMBLY Apply grease to the dust seal in the front cover. Install the brushes onto the brush holders. Apply a thin coat of grease to the two ends of the armature shaft. Insert the commutator into the front cover. ＊...
Page 183: Starter Clutch
. STARTING SYSTEM Yellow/Red Wire STARTER RELAY GROUND CIRCUIT INSPECTION Disconnect the starter relay wire connector. Check for continuity between the yellow/red wire terminal and ground. There should be continuity when the starter button is depressed. If there is no continuity, check the starter button for continuity and inspect the wire.
Page 184 . STARTING SYSTEM Shaft Starter Idle Gear Remove the starter clutch lock nut. Special Lock Nut Wrench ＊ Note that the lock nut is left threaded. Remove the starter clutch. Remove the starter idle gear and shaft. Lock Nut Lock Nut Wrench INSPECTION Inspect the operation of the starter drive gear when it is assembled on the clutch.
Page 185 . STARTING SYSTEM Measure the clutch cover O.D. Service Limit: 27.94mm replace if over Clutch Cover Starter Idle Gear Measure the starter idle gear I.D. Service Limit: 10.05mm replace if over Measure the starter idle gear shaft O.D. Service Limit: 9.94mm replace if below Idle Gear Shaft Plunger Clutch Body...
Page 186 . STARTING SYSTEM ASSEMBLY Anchor Pin Hole Clutch Cover Install the springs, plungers and rollers onto the clutch body. Install the clutch cover by aligning the clutch cover anchor pin with the hole in the clutch body. Apply locking agent to the threads of the clutch cover bolts and tighten them.
Page 187: Lights/Instruments/Switches
. LIGHTS/INSTRUMENTS/SWITCHES ELECTRICAL EQUIPMENT LAYOUT Headlight Stop Switches Dimmer Switch Turn Signal Switch Fuel Unit Horn Button Ignition Switch Auto Bystarter Auto Bystarter Resistor Headlight Switch Starter Button 17-0...
Page 188: Service Information
. LIGHTS/INSTRUMENTS/SWITCHES ELECTRICAL EQUIPM ENT LAYOUT..17-0 HANDLEBAR SWITCHES....17-3 SERVICE INFORMATION......17-1 STOP SWITCHES........17-5 TROUBLESHOOTING......17-1 HORN............17-5 HEADLIGHT..........17-2 FUEL GAUGE ........17-5 FRONT TURN SIGNAL LIGHT .....17-2 FUEL UNIT..........17-6 POSITION/REAR TURN SIGNAL LIGHT...17-2 AUTO BYSTARTER......17-6 IGNITION SWITCH .........17-3 INSTRUMENTS........17-8 SERVICE INFORMATION GENERAL INSTRUCTIONS • An electric tester is needed to measure or test the electric equipment. •...
Page 189: Headlight
. LIGHTS/INSTRUMENTS/SWITCHES HEADLIGHT BULB REPLACEMENT Remove the front cover. ( 2-4) Remove the rubber boot from the bulb socket. Remove the bulb socket by turning it counter- clockwise. Remove the bulb for replacement. Install a new bulb, aligning the groove on the bulb socket with the tab on the bulb.
Page 190: Ignition Switch
. LIGHTS/INSTRUMENTS/SWITCHES IGNITION SWITCH INSPECTION Remove the front cover. ( 2-4) Disconnect the ignition switch wire coupler. Check for continuity between the wire terminals. Color Black/ Black Green White Position LOCK ○ ○ ○ ○ Ignition Switch Coupler ○ ○ Replacement Remove the two mounting bolts to remove the ignition switch holder.
Page 191 . LIGHTS/INSTRUMENTS/SWITCHES STARTER SWITCH Headlight Switch FREE PUSH ○ ○ Color Yellow/Red Green Starter Switch HORN SWITCH BATZ FREE PUSH ○ ○ Color Light Green Black Horn Button TURN SIGNAL SWITCH ○ ○ ○ ○ Color Light Blue Orange Gray Turn Signal Switch DIMMER SWITCH Dimmer Switch...
Page 192: Stop Switches
. LIGHTS/INSTRUMENTS/SWITCHES STOP SWITCH INSPECTION Remove the handlebar front cover. ( 2-4) Disconnect the front stop switch wire coupler. Check for continuity between the wire terminals when the front brake lever is applied. The switch is normal if there is continuity.
Page 193: Auto Bystarter
. LIGHTS/INSTRUMENTS/SWITCHES INSPECTION Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions. RESISTANCES Unit: W Float Upper Lower Color 45 480_ 480_ 520 35_ Y/W_ L/W 480_ 520 480_ The installation sequence is the reverse of removal.
Page 194: Instruments
. LIGHTS/INSTRUMENTS/SWITCHES Instruments INSTRUMENTS BULB REPLACEMENT Remove the front cover. ( 2-4) Remove the bulb socket and replace the bulb. The installation sequence is the reverse of removal. Bulb Socket Switch Couplers Switch Couplers Bulb Socket INSTRUMENTS REPLACEMENT Remove the handlebar front cover. ( 2-4) Remove the handlebar rear cover.
Page 195 . LIGHTS/INSTRUMENTS/SWITCHES DISASSEMBLY Remove the screws to disassemble the instruments. Bulb Socket ASSEMBLY/INSTALLATION The assembly and installation sequence is the reverse of removal. Clamp Fuel Gauge Wires 17-8...
Page 196: Evaporative Emission Control System
. EVAPORATIVE EMISSION CONTROL SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EVAPORATIVE EMISSION CONTROL SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ............18- 1 EVAPORATIVE EMISSION CONTROL SYSTEM FUNCTION..18- 2 TROUBLESHOOTING ..............18- 2 EVAPORATIVE EMISSION CONTROL SYSTEM MAINTENANCE SCHEDULE ............. 18- 3 SERVICE INFORMATION ............
Page 197 . EVAPORATIVE EMISSION CONTROL SYSTEM SCHEMATIC DRAWING Fuel Tank Purge Control Valve Charcoal Canister S EVAPORATIVE EMISSION CONTROL SYSTEM LOCATION 18-1...
Page 198: Evaporative Emission Control System Function
. EVAPORATIVE EMISSION CONTROL SYSTEM 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 carburetor and 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 199 . EVAPORATIVE EMISSION CONTROL SYSTEM 1. EMISSION CONTROL SYSTEM MAINTENANCE SCHEDULE: Service Mileage (KM) Item Inspection 300 1000 3000 5000 7000 9000 1100 Drive belt Belt thickness ○ Drive chain Chain tension & length ○ ○ ○ ○ ○ ○ Cam chain Chain length ○...
Page 200: Service Information
. EVAPORATIVE EMISSION CONTROL SYSTEM 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 201: Motorcycle Engine Evaporative Emission
. EVAPORATIVE EMISSION CONTROL SYSTEM MOTORCYCLE ENGINE EVAPORATIVE EMISSION CONTROL SYSTEM TEST A. LEAKAGE TEST PIPING DIAGRAM (SIMPLE) Fuel Tank Fuel Vapor Carburetor Purge Control Valve Vacuum Air Cleaner Fresh Air Engine Fuel Valve Charcoal Canister Exhaust Muffler 1. Charcoal Canister Plug (Point Å) Charcoal Release Leak-...
Page 202: Purge Control Valve
. EVAPORATIVE EMISSION CONTROL SYSTEM To Air Cleaner PURGE CONTROL VALVE REMOVAL 1. Remove the frame rear cover. ( 2-2) 2. Remove the rear right side cover. ( 2- 3. Disconnect the purge control valve vacuum tube that goes to the carburetor and the tubes that go to the air cleaner.
Page 203 . EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE FLOW INSPECTION 1. Connect a vacuum pump to the vacuum tube that goes to the carburetor and apply vacuum pressure of 45mm/Hg. Pressure Pump 2. Connect a pressure pump to the tube that goes to the charcoal canister and apply pressure.
Page 204: Charcoal Canister
. EVAPORATIVE EMISSION CONTROL SYSTEM To Fuel Tank To Purge Control Valve CHARCOAL CANISTER REMOVAL Remove the charcoal canister. ( 18-6) To Air Blow-by Tube INSPECTION 1. Plug the tube that goes to the fuel tank and plug the blow-by tube. 2.
Page 205: Pcv (Positive Crankcase Ventilation) System
. EVAPORATIVE EMISSION CONTROL SYSTEM P.C.V. (POSITIVE CRANKCASE VENTILATION) SYSTEM P.C.V. REMOVAL 1. Remove the frame rear cover. ( 2-2) 2. Remove the rear left side cover. ( 2-2) 3. Remove the P.C.V., air cleaner cover screws and the air cleaner cover. 4.
Page 206: Exhaust Emission Related System Inspection
. EVAPORATIVE EMISSION CONTROL SYSTEM Emission Tester EXHAUST EMISSION RELATED SYSTEM INSPECTION Clean or replace the air cleaner. ( 3-4) Clean and adjust the carburetor. ( 5-3) Inspect the auto choke system. ( 5-4) Clean and inspect the spark plug. ( 3-4) Inspect the ignition system.
Page 207: Exhaust Emission Control System
. EXHAUST EMISSION CONTROL SYSTEM __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST EMISSION CONTROL SYSTEM __________________________________________________________________________________ SCHEMATIC DRAWING ............19-1 EXHAUST EMISSION CONTROL SYSTEM FUNCTION..... 19-2 TROUBLESHOOTING ..............19-2 SERVICE INFORMATION ............19-3 SECONDARY AIR CLEANER............. 19-4 AIR INJECTION CUT-OFF VALVE (A.I.C.V.)......19-5 REED VALVE ................
Page 208 . EXHAUST EMISSION CONTROL SYSTEM SCHEMATIC DRAWING Secondary Carburetor Air Cleaner Reed Valve Air Injection Cut-off Valve EXHAUST EMISSION CONTROL SYSTEM LOCATION Secondary Air Cleaner Reed Valve Charcoal Canister/ Purge Control Valve Air Injection Cut-off Valve 19-1...
Page 209 . EXHAUST EMISSION CONTROL SYSTEM EXHAUST 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 210 . EXHAUST EMISSION CONTROL SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS • During operation, be careful to avoid scalding caused by the exhaust muffler. • Note the locations of tubes for proper installation. • Replace any damaged tube with a new one. •...
Page 211 . EXHAUST EMISSION CONTROL SYSTEM Secondary Air Cleaner SECONDARY AIR CLEANER REMOVAL 1. Remove the front cover. ( 2-4) 2. Disconnect the secondary air cleaner connecting tube. Remove the air cleaner attaching bolts and the air cleaner. Connecting Tube Bolt Cover Screws Air Outlet Tube...
Page 212 . EXHAUST EMISSION CONTROL SYSTEM Air Injection Cut-off Valve Vacuum Tube Bolt AIR INJECTION CUT-OFF VALVE (A.I.C.V.) REMOVAL 1. Remove the front right side cover. ( 2-4) 2. Disconnect all the tubes that go to the air injection cut-off valve. 3.
Page 213: Reed Valve
. EXHAUST EMISSION CONTROL SYSTEM REED VALVE REMOVAL 1. Remove the frame center cover. 2. Remove the floor board. 3. Disconnect the secondary air inlet tube connector. 4. Remove the four cylinder head cover bolts and two secondary air outlet tube bolts.

KYMCO MOVIE 125 Manual

Preface

3. Inspection/Adjustment 3

7. Cylinder Head/Valves

12. Front Wheel/Front Brake/ Front Suspension

17. Lights/Instruments/Switches

Quick Links

TABLE OF CONTENTS

Chapters

Troubleshooting

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Summary of Contents for KYMCO MOVIE 125

Table of Contents