Page 1: Table Of Contents
X -Town 125 ABS/ CBS PREFACE TABLE OF CONTENTS This Service Manual describes the technical features servicing GENERAL INFORMATION procedures for the KYMCO X-Town 125 ABS/ CBS. EXHAUST MUFFLER/FRAME COVERS Section 1 contains the precautions for all operations stated in this manual.
Page 2: General Information
1. GENERAL INFORMATION X -Town 125 ABS/ CBS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION ________________________________________________________________________________ ENGINE SERIAL NUMBER ------------------------------------------------------------- 1-1 SPECIFICATIONS --------------------------------------------------------------------------- 1-2 SERVICE PRECAUTIONS -------------------------------------------------------------- 1-3 TORQUE VALUES --------------------------------------------------------------------------- 1-8 SPECIAL TOOLS ----------------------------------------------------------------------------- 1-9 LUBRICATION POINTS ---------------------------------------------------------------- 1-11...
Page 3: Engine Serial Number
1. GENERAL INFORMATION X -Town 125 ABS/ CBS ENGINE SERIAL NUMBER Location of Engine Serial Number...
Page 4: Specifications
1. GENERAL INFORMATION X -Town 125 ABS/ CBS SPECIFICATIONS Oil filter type Full-flow filtration Name X-Town 125 Oil capacity 1.2L Model No. KS25AD Exchanging capacity 1.0L Overall length 2250 mm Fuel system Overall width 800 mm Air cleaner type & No...
Page 5: Service Precautions
1. GENERAL INFORMATION X -Town 125 ABS/ CBS  Apply or add designated greases and lubricants to the specified lubrication SERVICE PRECAUTIONS points.  Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling.  When two persons work together, pay ...
Page 6 1. GENERAL INFORMATION X -Town 125 ABS/ CBS  Before connecting a terminal, check for  After operation, terminal caps shall be damaged terminal cover or loose negative installed securely. terminal. Confirm Capacity  When taking out the connector, the lock on ...
Page 7 1. GENERAL INFORMATION X -Town 125 ABS/ CBS  Protect wires and harnesses with electrical  Do not squeeze wires against the weld or tape or tube if they contact a sharp edge its clamp. or corner. Do not pull too tight！...
Page 8 1. GENERAL INFORMATION X -Town 125 ABS/ CBS  Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent surrounding parts steering positions.  When a testing device is used, make sure...
Page 9 1. GENERAL INFORMATION X -Town 125 ABS/ CBS Symbols:  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.
Page 10: Torque Values
1. GENERAL INFORMATION X -Town 125 ABS/ CBS TORQUE VALUES STANDAR TORQUE VALUES Item Torque (kgf-m) Item Torque (kgf-m) 5mm bolt, nut 0.45~0.6 5mm screw 0.45~0.6 6mm bolt, nut 0.8~1.2 6mm screw, SH bolt 0.7~1.1 8mm bolt, nut 1.8~2.5 6mm flange bolt, nut 1.0~1.4...
Page 11: Special Tools
1. GENERAL INFORMATION X -Town 125 ABS/ CBS SPECIAL TOOLS Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Flywheel puller A120E00003 (Refer to the “STARTER CLUTCH” section in the chapter10.)
Page 12 1. GENERAL INFORMATION X -Town 125 ABS/ CBS SPECIAL TOOLS Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) A120E00037 Bearing puller Valve spring compressor (Refer to the “CYLINDER A120E00040 HEAD”...
Page 13: Lubrication Points
1. GENERAL INFORMATION X -Town 125 ABS/ CBS LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part ·GenuineKYMCOEngineOil(SAE5W-50) Cam lobes ·API , SJ Engine Oil Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...
Page 14 1. GENERAL INFORMATION X -Town 125 ABS/ CBS CABLE & HARNESS ROUTING Headlight Relay Starter Relay Fuel Pump Relay ECU Relay Winker Relay Coolant Cap Angle Detect Sensor Wheel Speed Sensor Radiator Ignition Switch ABS ECU(X-Town 125ABS) Carbon Canister 1-12...
Page 15 1. GENERAL INFORMATION X -Town 125 ABS/ CBS Regulator Met-in Box Light Wire Throttle Body Engine Temperature Sensor Fuel Injector Fuel Pump Fuel Tank O₂ Sensor Ignition Coil CBS Pump(X-Town 125 CBS) Radiator Temperature Wheel Speed Sensor Radiator Sensor 1-13...
Page 16 1. GENERAL INFORMATION X -Town 125 ABS/ CBS Regulator/Rectifier Ignition Switch Fuel Filler Cap Oil Filter Screen Horn 1-14...
Page 17 1. GENERAL INFORMATION X -Town 125 ABS/ CBS Troubleshooting Vehicle can not be started Preliminary 6 Step Inspection 1. Is the battery fully charged (12 V or higher). See the Battery topic for more information. 2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay (It will turn off automatically in 5-10 seconds) 3.
Page 18 1. GENERAL INFORMATION X -Town 125 ABS/ CBS General 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 ...
Page 19 1. GENERAL INFORMATION X -Town 125 ABS/ CBS 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.
Page 20 1. GENERAL INFORMATION X -Town 125 ABS/ CBS 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...
Page 21 1. GENERAL INFORMATION X -Town 125 ABS/ CBS POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause 1. Check ignition timing Incorrect  Improper ignition timing Correct 2. Inspect the fuel flow Abnormal  Faulty pressure regulator Normal 3. Inspect the fuel injector Abnormal ...
Page 22 1. GENERAL INFORMATION X -Town 125 ABS/ CBS 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 ...
Page 23: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ EXHAUST MUFFLER/FRAME COVERS __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 2- 1 TROUBLESHOOTING ----------------------------------------------------- 2- 1 FASTENER REMOVAL AND REINSTALLATION ------------------ 2- 2 FRAME COVERS REMOVAL/INSTALLATION --------------------- 2- 3...
Page 24: Exhaust Muffler/Frame Covers
. EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS  When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged.  Make sure to route cables and harnesses according to the Cable & Harness Routing.
Page 25: Fastener Removal And Reinstallation
. EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS FASTENER REMOVAL AND REINSTALLATION REMOVAL Depress the head of fastener center piece . Pull out the fastener. INSTALLATION Let the center piece stick out toward the head so that the pawls  close.
Page 26: Frame Covers Removal/Installation
. EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS FRAME COVERS REMOVAL/ INSTALLATION SEAT Unlock the seat with the ignition key. Open the seat. Remove the two nuts and seat damper unit. Remove the two nuts and the seat. Installation is in the reverse order of removal.
Page 27 . EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS Center Cover Center Cover CENTER COVER Remove the luggage box. Remove the center cover. ＊ During removal, do not pull the joint claws forcedly to avoid damage. Installation is in the reverse order of removal.
Page 28 . EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS Installation is in the reverse order of removal. BODY COVER Rear Center Cover Remove the seat and luggage box(2-3) Remove the rear carrier cover(2-4). Remove the rear carrier(2-4). Remove two fasteners and then remove...
Page 29 . EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS Disconnect the taillight connector. , then remove the body cover. Installation is in the reverse order of removal. UPPER/LOWER HANDLEBAR COVER Remove the four screws and then remove upper handlebar cover.
Page 30 . EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS WINDSHIELD/WINDSHIELD GARNISH Remove five bolts and windshield garnish. screws FRONT CENTER COVER Remove the windshield Remove two screws and fastener then remove the front center cover. Remove the front cover. Installation is in the reverse order of removal...
Page 31 . EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS FRONT COVER Remove two bolts. Remove fourteen screws from the inner cover. Remove ten fastener from the cowl under. Disconnect headlight/position light connector and right/left turn signal light connectors.
Page 32 . EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS Remove the front cover Installation is in the reverse order of removal. FRONT FENDER Remove four screws attaching to the front fender. Installation is in the reverse order of removal. RIGHT/LEFT FLOORBOARD Remove the body cover（2-5）.
Page 33 . EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS INNER COVER Remove the front cover. Remove right/left floorboard. Remove one screws Remove the ignition key garnish Remove remove the handler panel. ＊ During removal, do not pull the joint claws forcedly to avoid damage.
Page 34 . EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS screw Remove six screws and two bolts bolt screw Remove one screw ,connect the left front box assy and inner cover Disconnect the DC power connectors. DC power connectors Remove the fuel tank fill cap and collection of fuel spill tank .
Page 35 . EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS speedometer wires METER PANEL Remove the front cover Remove the inner cover. Disconnect the speedometer wires Remove two bolts then remove meter panl Installation is in the reverse order of removal.
Page 36 . EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS UNDER COVER Remove four bolts Remove the under cover. bolt TIRE FENDER Remove the body cover. Remove four bolts attaching to the tire fender Installation is in the reverse order of removal.
Page 37: Exhaust Muffler
. EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS EXHAUST MUFFLER REMOVAL Disconnect the connector with O2 heater/O2 sensor. Nuts Remove the two exhaust pipe joint nuts Remove three muffler mount bolts and muffler and gasket. 2-14...
Page 38 . EXHAUST MUFFLER/FRAME COVERS X -Town 125 ABS/ CBS INSTALLATION Replace the gasket with a new one. Install the exhaust muffler and three mounting bolt. Install and tighten the two exhaust pipe joint nuts to the specified torque Torque: 20 N•m (2 kgf•m,)
Page 39: Inspection/Adjustment
3. INSPECTION/ADJUSTMENT X -Town 125 ABS/ CBS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ INSPECTION / ADJUSTMENT ________________________________________________________________________________ SERVICE INFORMATION --------------------------------------------------------------------- 3- 1 MAINTENANCE SCHEDULE------------------------------------------------------------------ 3- 2 FUEL LINE ------------------------------------------------------------------------------------------ 3- 3 THROTTLE OPERATION ---------------------------------------------------------------------- 3- 3 ENGINE OIL --------------------------------------------------------------------------------------- 3- 4 TRANSMISSION OIL ---------------------------------------------------------------------------- 3- 8...
Page 40: Inspection/Adjustment
3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS SERVICE INFORMATION GENERAL ！ WARNING  Before running the engine, make sure that the working area is well ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas, which may cause death to people.
Page 41: Maintenance Schedule
KVMCO standards and specifications by properly trained and equipped technicians. Your KYMCO dealer meets all of these requirements. * Should be serviced by your KYMCO dealer, unless you have the proper tools, service data and are technically qualified.
Page 42 3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS WHICHEVER ODOMETER READING (NOTE1) COMES FIRST FREQUENCY X 1000km 5 10 15 REFER X 1000 mi ITEM PAGE 6 12 18 MONTH CLUTCH SHOE WEAR BRAKE FLUID NOTE 6 BRAKE PAD WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH STEERING BEARINGS HEADLIGHT AIM NUTS,BOLTS,FASTENERS...
Page 43: Fuel Line
3. INSPECTION/ADJUSTMENT X -Town 125 ABS/ CBS FUEL LINE Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage. THROTTLE OPERATION Check the throttle grip for smooth movement. Measure the throttle grip free play.
Page 44: Engine Oil
3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS ENGINE OIL Engine oil recommendation Use a premium quality 4-stroke motor oil to ensure longer service life of your scooter. Use only oils which are rated, SJ under the API service classification. The recommended viscosity is SAE 5W-50. If a SAE 5W-50 motor oil is not available, select an alternative according to the chart.
Page 45 3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS 1. Remove the oil filler cap/dipstick(1) from the right crankcase cover. 2. Place a container under the left crankcase. 3. Remove the oil drain plug (2) to drain the oil. 4. Reinstall the drain plug and tighten the drain plug to specification.
Page 46 3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS Oil filter replacement Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. ＊ Let the engine and exhaust system cool before working in those areas. 1.
Page 47 3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS Oil filter replacement Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. ＊ Let the engine and exhaust system cool before working in those areas. 1.
Page 48: Transmission Oil
3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS TRANSMISSION OIL Oil change 1. Place the scooter in its center stand. 2. Place a drain pan under the drain bolt (1). 3. Remove the transmission oil drain bolt. 4. Remove the transmission oil filler bolt (2), slowly turn the rear wheel and drain the oil.
Page 49: Air Cleaner
Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model. Using the wrong KYMCO air cleaner element or a non-KYMCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems.
Page 50: Spark Plug
NGK CR7E / CPR7EA-9 Measure the spark plug gap. Spark Plug Gap: 0.8~0.9 mm ＊ When installing, first screw in the spark plug by hand and then tighten it with a spark plug wrench. X -Town 125 ABS/ CBS 3-11...
Page 51: Valve Clearance
3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS VALVE CLEARANCE Remove the four bolts , then remove cylinder head cover. Timing hole cap Remove the timing hole cap and O-ring Remove the crankshaft hole cap and O-ring . Crankshaft hole cap Turn the A.C. generator flywheel to the top dead center (TDC) on the compression stroke so that the “T”...
Page 52: Idle Speed
3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS Adjust by loosening the valve adjusting screw lock-nut and turning the adjusting screw until there is a slight drag on the thickness gauge . Valve Clearance: IN: 0.10 mm EX:0.10 mm Apply oil to the valve adjusting screw locknut threads and seating surface.
Page 53: Cylinder Compression
3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS CYLINDER COMPRESSION Warm up the engine before compression test. Remove the center cover and spark plug cap. Remove the spark plug . Insert a compression gauge. Open the throttle valve fully and push the starter button to test the compression. Compression: X-Town 125:15 kg/cm²...
Page 54: Clutch Shoe Wear
3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually. If the scooter tends to creep, or the engine stalls, check the clutch shoes for wear and replace if necessary (refer to the “DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY”...
Page 55: Coolant
②. If the reserve tank is empty, or if coolant loss is excessive, check for leaks and see your KYMCO dealer for repair. 3-16...
Page 56 3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS CBS PUMP Combination Braking System (CBS) Combination Braking System , the rider's action of depressing the rear brake lever applies both front and rear brakes, The amount of each brake applied is determined by CBS pump. Depressing the front brake lever only applies the front brake.
Page 57: Brake Fluid
Inspect the pads at each regular maintenance interval. Front brake /Rear brake Check the cutout in each pad. If either pad is worn to the cutout, replace both pads as a set. See your KYMCO dealer for this service. 3-18...
Page 58: Nuts/Bolts/Fasteners
3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS NUTS/BOLTS/FASTENERS Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found. WHEELS/TIRES Tire pressure Insufficient air pressure in the tires not only hastens tire wear but also seriously affects the stability of the scooter.
Page 59: Suspension
3. INSPECTION/ADJUSTMENT X-Town125 ABS/CBS SUSPENSION Check the action of the front/rear shock absorbers by compressing them several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn.
Page 60: Side Stand
3. Lower the side stand. The engine should stop as you put the side stand down. ＊ If the side stand system does not operate as described, see your KYMCO dealer for service. Down Engine limit lever rubber gasket Engine limit lever rubber gasket is made of...
Page 61: Lubrication System
. LUBRICATION SYSTEM X -Town 125 ABS/ CBS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM --------------------------------- 4- 1 SERVICE INFORMATION ----------------------------------------------- 4- 2 TROUBLESHOOTING ---------------------------------------------------- 4- 2 OIL PUMP ------------------------------------------------------------------- 4- 3...
Page 62: Lubrication System Diagram
. LUBRICATION SYSTEM X -Town 125 ABS/ CBS LUBRICATION SYSTEM DIAGRAM Rocker Arm Shaft Crankshaft Oil Strainer Screen Oil Pump Oil Filter Screen...
Page 63: Service Information
. LUBRICATION SYSTEM X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS  The oil pump service may be done with the engine installed in the frame.  When removing and installing the oil pump use care not to allow dust or dirt to enter the engine.
Page 64: Oil Pump
. LUBRICATION SYSTEM X -Town 125 ABS/ CBS OIL PUMP Bolts REMOVAL Remove the flywheel and driven gear (refer to the “STARTER CLUTCH” section in the chapter 10). Remove the bolt and then oil separator cover. ＊ When removing and installing the oil pump, be careful not to allow dust or dirt to enter the engine.
Page 65 . LUBRICATION SYSTEM X -Town 125 ABS/ CBS Arrow Mark INSTALLATION Install the oil pump and oil separator and tighten the two bolts. The arrow mark must be keep upward. ＊ Make sure the pump shaft rotates freely and arrow on the oil pump is upside.
Page 66 . LUBRICATION SYSTEM X -Town 125 ABS/ CBS DISASSEMBLY Remove the screw and disassemble the oil pump as shown. Pump cover Outer Rotor Inner Rotor Pump body Screw Dowel pin Pump shaft ASSEMBLY Install the outer rotor, inner rotor and pump shaft into the pump body.
Page 67: Engine Removal/Installation
. ENGINE REMOVAL/INSTALLATION X-Town 125 ABS/ CBS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL/INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION ------------------------------------------------ 5-1 ENGINE REMOVAL/INSTALLATION --------------------------------- 5-2 ENGINE HANGER --------------------------------------------------------- 5-8...
Page 68 5. ENGINE REMOVAL/INSTALLATION X-Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS  A floor jack or other adjustable support is required to support and maneuver the engine. Be careful not to damage the scooter body, cables and wires during engine removal. ...
Page 69 . ENGINE REMOVAL/INSTALLATION X-Town 125 ABS/ CBS ENGINE REMOVAL/INSTALLATION REMOVAL ＊ Remove the air cleaner Disconnect the ECU connector (A) Disconnect the O2 heater/O2 sensor connector Disconnect the throttle cable(B) ＊ Remove a bolt from fuel hose guide (C). Disconnect the fuel hose (D) from fuel injector.
Page 70 . ENGINE REMOVAL/INSTALLATION X-Town 125 ABS/ CBS Loosen the rear axle nut. Support the scooter securely on its main stand. Remove two bolts (1) attaching to rear brake hose clamps. Remove the two bolts (2), then remove the rear brake caliper. Disconnect the alternator connector (3).
Page 71 . ENGINE REMOVAL/INSTALLATION X-Town 125 ABS/ CBS Remove the bolts and engine ground cable. Remove the spark plug cap .
Page 72 . ENGINE REMOVAL/INSTALLATION X-Town 125 ABS/ CBS Disconnect the lower radiator hose from lower radiator pipe. Remove the right and left rear shock absorber lower mount bolts .
Page 73 . ENGINE REMOVAL/INSTALLATION X-Town 125 ABS/ CBS Remove the engine mount nut Pull out the engine mount bolt. Remove the engine from the frame. ＊ At removing the engine, be careful not to catch your hand or finger between the engine hanger and crankcase.
Page 74 . ENGINE REMOVAL/INSTALLATION X-Town 125 ABS/ CBS INSTALLATION Installation is in the reverse order of removal. Tighten the engine mounting bolt/nut to the specified torque. Torque: 5 kgf-m (50 N-m) Tighten the right and left rear shock absorber lower mount bolts to the specified torque. Torque: 4.0kgf-m (40N-m) Install the rear brake caliper and tighten the mount bolts to the specified torque.
Page 75 . ENGINE REMOVAL/INSTALLATION X-Town 125 ABS/ CBS ENGINE HANGER REMOVAL Remove the engine mount nut and pull it out. ＊ Be careful to put the engine down. Remove the left/right engine hanger mount bolt. Remove the engine from frame. INSTALLATION Installation is in the reverse order of removal.
Page 76: Cylinder Head/Valves
6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER HEAD/VALVES ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 6- 1 SERVICE INFORMATION --------------------------------------------------------------------- 6- 2 TROUBLESHOOTING -------------------------------------------------------------------------- 6- 3 CYLINDER HEAD COVER --------------------------------------------------------------------- 6- 4 CAMSHAFT HOLDER--------------------------------------------------------------------------- 6- 5...
Page 77: Cylinder Head/Valves
6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS SCHEMATIC DRAWING...
Page 78: Service Information
6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS  The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water hoses must be drained.  When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.
Page 79: Troubleshooting
6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS SPECIAL TOOLS Valve spring compressor A120E00040 TROUBLESHOOTING  The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises. Poor performance at idle speed White smoke from exhaust muffler ...
Page 80: Cylinder Head Cover
6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS CYLINDER HEAD COVER REMOVAL Remove four bolts then remove the cylinder head cover INSTALLATION Install a new cylinder head cover O-ring and install the cylinder head cover. ＊ Be sure to install the O-ring into the groove properly.
Page 81: Camshaft Holder
6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS CAMSHAFT HOLDER REMOVAL Turn the A.C. generator flywheel so that the T mark on the flywheel aligns with the index mark on the crankcase. Hold the round hole on the camshaft gear facing up and location is the top dead center on the compression stroke.
Page 82 6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS DISASSEMBLY Take out the valve rocker arm shafts Remove the valve rocker arms. Rocker Arm Shafts INSPECTION Camshaft Holder Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage.
Page 83: Camshaft
6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS CAMSHAFT REMOVAL Tensioner Sealing Bolt Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke.
Page 84 6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS INSPECTION Camshaft Inspect camshaft lobes for pitting/scratches/blue discoloration. Camshaft Bearings If any defects are found, replace the camshaft with a new one, then inspect lubrication system. Check each camshaft bearing for play or damage.
Page 85 6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS INSTALLATION Punch Marks Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear...
Page 86 6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS DISASSEMBLY Valve Spring Compressor Remove the valve spring cotters, retainers, springs, spring seats, oil seals and valves using a valve spring compressor. ＊ • Be sure to compress the valve springs with a valve spring compressor.
Page 87 6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS INSPECTION Combustion Chamber Remove carbon deposits from the exhaust port and combustion chamber. ＊ Be careful not to damage the cylinder head mating surface. Exhaust Port Valve /Valve guide Inspect each valve for bending, burning, scratches or abnormal stem wear.
Page 88: Cylinder Head
6. CYLINDER HEAD/VALVES X -Town 125 ABS/ CBS Cylinder head Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and feeler gauge. Valve Spring Compressor ASSEMBLY Install the valve spring seats and oil seal.
Page 89: Cylinder/Piston
7. CYLINDER/PISTON X -Town 125 ABS/ CBS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CYLINDER/PISTON ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 7-1 SERVICE INFORMATION --------------------------------------------------------------------- 7-2 TROUBLESHOOTING -------------------------------------------------------------------------- 7-2 CYLINDER AND PISTON ---------------------------------------------------------------------- 7-3...
Page 90: Cylinder/Piston
7. CYLINDER/PISTON X -Town 125 ABS/ CBS SCHEMATIC DRAWING...
Page 91: Service Information
7. CYLINDER/PISTON X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS  When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are correctly installed.  After disassembly, clean the removed parts and dry them with compressed air before inspection.
Page 92 7. CYLINDER/PISTON X -Town 125 ABS/ CBS CYLINDER AND PISTON REMOVAL Remove the cylinder head (refer to “CYLINDER HEAD” section in the chapter Remove the water hose attached the cylinder. Remove the two cylinder bolts/washers (2). Remove the cylinder Remove the cylinder gasket (4) and dowel pins (3).
Page 93 7. CYLINDER/PISTON X -Town 125 ABS/ CBS Spread each piston ring and remove it by lifting up at a point opposite the gap ＊ Do not damage the piston ring by spreading the ends too far. Clean carbon deposits from the piston ring grooves.
Page 94 7. CYLINDER/PISTON X -Town 125 ABS/ CBS Piston/Piston pin Measure the piston O.D. at the point (A) from 10 mm the bottom and 90° to the piston pin hole. Calculate the cylinder-to-piston clearance Measure the piston pin hole. Take the maximum reading to determine the I.D..
Page 95 7. CYLINDER/PISTON X -Town 125 ABS/ CBS Cylinder Check the cylinder for warpage with a straight edge and feeler gauge in the directions shown. Check the cylinder wall for wear or damage. Measure and record the cylinder I.D. at three levels in an X and Y axis.
Page 96 7. CYLINDER/PISTON X -Town 125 ABS/ CBS Inspect the exhaust side and intake side chain guides. Wear/Damage → Replace. INSTALLATION Piston ring Carefully install the piston rings into the piston ring grooves with the markings facing ＊ Be careful not to damage the piston and rings.
Page 97 7. CYLINDER/PISTON X -Town 125 ABS/ CBS CYLINDER/PISTON Clean any gasket material attached the cylinder mating surfaces of the crankcase and oil passage. Apply engine oil to the piston pin. Apply engine oil to the connecting rod small end and piston pin hole.
Page 98 7. CYLINDER/PISTON X -Town 125 ABS/ CBS Apply engine oil to the cylinder wall, piston and piston ring outer surfaces. Pass the cam chain through the cylinder and install the cylinder over the piston. ＊ Be careful not to damage the piston rings and cylinder walls.
Page 99: Drive And Driven Pulleys
8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 8- 1 SERVICE INFORMATION --------------------------------------------------------------------- 8- 2 TROUBLESHOOTING -------------------------------------------------------------------------- 8- 2 LEFT CRANKCASE COVER ------------------------------------------------------------------ 8- 3 DRIVE PULLEY,DRIVE BELT AND DRIVEN PULLEY --------------------------------- 8- 4...
Page 100: Drive And Driven Pulleys
8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS SCHEMATIC DRAWING...
Page 101: Service Information
8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS  The drive pulley, clutch and driven pulley can be serviced with the engine installed.  Avoid getting grease and oil on the drive belt and pulley faces. Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley.
Page 102: Left Crankcase Cover
8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS LEFT CRANKCASE COVER REMOVAL Remove the bolts attaching to the left crankcase cover. Remove the gasket and dowel pins. Dowel Pins INSTALLATION Install the dowel pins and gasket. Install the left crankcase cover. Install and tighten ten bolts diagonally to specified torque.
Page 103: Drive Pulley,Drive Belt And Driven Pulley
8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS DRIVE PULLEY, DRIVE BELT Nut/Ratchet AND DRIVEN PULLEY REMOVAL Remove the left crankcase cover Use the special tool to hold the drive pulley, then remove the nut and ratchet. Special tool: Drive Pulley Face Universal Holder Universal holder...
Page 104 8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS Remove the movable drive face assembly. Movable Drive Face Assembly Drive belt inspection Check the drive belt for cracks, separation or abnormal or excessive wear. Replace a new belt at every 15000KM ＊...
Page 105 8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS Boss INSTALLATION Apply lubricant to the drive face boss inner surface, then install the movable drive face assembly. Movable Drive Face Assembly Install the clutch outer onto the driven pulley assembly. Compress the driven pulley assembly by hand, then install the drive belt into the driven Clutch Outer/Driven Pulley Assembly...
Page 106 8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS Nut/Ratchet Install the drive pulley face and ratchet. Use the special tool to hold drive pulley face, then tighten the nut to the specified torque. Torque: DINK 200i: 5.8 5.5~6.5 kgf-m (55~65 N-m) Special tool: Universal holder A120E00017 Noted:...
Page 107 8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS DRIVE PULLEY DISASSEMBLY Remove the drive face boss. Boss Ramp Plate Remove the ramp plate Take out six weight rollers. Weight Roller...
Page 108 8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS DRIVE PULLEY INSPECTION Weight rollers Check each roller for wear or damage. Measure outside diameter. Service limit: 19.8 mm (0.792 Ramp plate Movable drive face/Slide pieces/Drive pulley face Check the movable drive face splines for wear, cracks or damage.
Page 109 8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS DRIVE PULLEY ASSEMBLY Clean the movable drive face, drive pulley face, weight rollers, slide pieces, ramp plate and drive face boss. ＊ Remove any excess grease. Install the weight rollers. ＊ The direction of all weight rollers is the same.
Page 110 8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS Lock Nut Wrench DRIVEN PULLEY DISASSEMBLY Hold the clutch/driven pulley assembly with the clutch spring compressor. ＊ Be sure to use a clutch spring compressor to avoid spring damage. Special tool: Clutch Spring Compressor A120E00034 Set the tool in a vise and remove the clutch...
Page 111 8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS Remove the spring. Remove the spring collar on the movable driven face. Remove the three guide pins/rollers, then remove the movable driven face. Remove the needle bearing from driven face. Remove the snap ring, then remove the bearing from driven face.
Page 112 8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS DRIVEN PULLEY INSPECTION Grooves Check the driven pulley for smooth operation. If any scratches or damage is found then replace as a set. Check guide pins and rollers for wear or damage.
Page 113 8. DRIVE AND DRIVEN PULLEYS X-Town 125 ABS/ CBS Apply Grease DRIVEN PULLEY ASSEMBLY Clean any oil from the drive belt sliding surfaces on the driven face. Filling 12 g of grease to driven face inner side. Apply grease to lips of the new dust seals and install into the movable driven face.
Page 114 9.FINAL REDUCTION X -Town 125 ABS/ CBS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ FINAL REDUCTION ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 9-1 SERVICE INFORMATION --------------------------------------------------------------------- 9-2 TROUBLESHOOTING -------------------------------------------------------------------------- 9-2 FINAL REDUCTION ----------------------------------------------------------------------------- 9-3 BEARING REPLACEMENT ------------------------------------------------------------------- 9-7...
Page 115: Schematic Drawing
9.FINAL REDUCTION X -Town 125 ABS/ CBS SCHEMATIC DRAWING...
Page 116: Service Information
9.FINAL REDUCTION X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS The servicing operations of this section can be made with the engine  installed. When replacing the drive shaft, use a special tool to hold the bearing inner ...
Page 117: Final Reduction
9.FINAL REDUCTION X -Town 125 ABS/ CBS Final Reduction Removal Drain the transmission gear oil into a clean container Remove the driven pulley Remove the nine bolts from the transmission case cover, and then remove the transmission case cover. Remove the dowel pins and gasket.
Page 118 9.FINAL REDUCTION X -Town 125 ABS/ CBS Inspection Inspect the countershaft and gear for wear or damage. Inspect the final gear and final gear shaft for wear, damage or seizure. Check the driveshaft for wear or damage. Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage.
Page 119 9.FINAL REDUCTION X -Town 125 ABS/ CBS Drive Shaft Bearing Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage. Drive Shaft Bearing Final Shaft Bearing Final Gear Shaft Bearing...
Page 120 9.FINAL REDUCTION X -Town 125 ABS/ CBS Installation Final Gear Shaft/ Final Gear Install the final gear and final gear shaft. Install the Countershaft Install the driveshaft. Counter Shaft Drive Shaft Dowel pins Install new gasket. Install the two dowel pins.
Page 121: Bearing Replacement
9.FINAL REDUCTION X -Town 125 ABS/ CBS Bearing Replacement Transmission Case Cover Remove the transmission case cover Remove the transmission case cover bearings by using the special tool. Special tool: Bearing puller A120E00037 Install the new bearings or new oil seal into the transmission case cover by using the special tool.
Page 122 9.FINAL REDUCTION X -Town 125 ABS/ CBS After installation, fill the transmission case with the specified oil. Specified gear oil: SAE90# Oil capacity : At disassembly: 0.13 liter At change : 0.12 liter Drain Bolt Install and tighten the oil check bolt.
Page 123: Generator/Starter Clutch
10. A.C. GENERATOR/STARTER CLUTCH X -Town 125 ABS/ CBS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ A.C. GENERATOR/STARTER CLUTCH ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 10-1 SERVICE INFORMATION --------------------------------------------------------------------- 10-2 TROUBLESHOOTING -------------------------------------------------------------------------- 10-2 ALTERNATOR STATOR ----------------------------------------------------------------------- 10-3 STARTER CLUTCH ----------------------------------------------------------------------------- 10-6 10-0...
Page 124 10. A.C. GENERATOR/STARTER CLUTCH X -Town 125 ABS/ CBS SCHEMATIC DRAWING 10-1...
Page 125 10. A.C. GENERATOR/STARTER CLUTCH X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS  All operations and inspections in this section can be made with the engine installed.  Should drain the coolant before removing the right crankcase cover.  Be careful not to drain the coolant when the engine temperature is high. (Perform this operation when the engine is cold.)
Page 126 10. A.C. GENERATOR/STARTER CLUTCH X -Town 125 ABS/ CBS A.C.GENERATOR Removal Drain the engine oil. Disconnect the alternator stator connectors. Remove the 10 bolts from the right crankcase cover and then remove the cover. Remove the two dowel pins and gasket.
Page 127 10. A.C. GENERATOR/STARTER CLUTCH X -Town 125 ABS/ CBS INSPECTION Check the stator and pulse coil for damage. INSTALLATION Stator Install the stator and tighten the stator mount bolts to the specified torque. Torque: 1 kgf-m Apply sealant to the grommet seating surface and install it to the cover groove properly.
Page 128 10. A.C. GENERATOR/STARTER CLUTCH X -Town 125 ABS/ CBS STARTER CLUTCH REMVOAL Remove the right crankcase cover Hold the flywheel with a special tool and remove the flywheel nut. Special tool: Flywheel holder A120E00021 Flywheel Holder Flywheel Flywheel Puller Remove the flywheel by using the special tool.
Page 129 10. A.C. GENERATOR/STARTER CLUTCH X -Town 125 ABS/ CBS Starter Driven Gear Remove the starter driven gear. INSPECTION Install the driven gear into the flywheel. Check the operation of the sprag clutch by turning the driven gear. You should be able to turn the driven gear clockwise smoothly, but the gear should not turn counterclockwise.
Page 130 10. A.C. GENERATOR/STARTER CLUTCH X -Town 125 ABS/ CBS Starter Driven Gear INSTALLATION Install the starter driven gear onto the crankshaft. Shaft Reduction Gear Apply oil to the starter reduction gear shaft. Install the starter reduction gear and shaft to the right crankcase.
Page 131 10. A.C. GENERATOR/STARTER CLUTCH X -Town 125 ABS/ CBS Hold the flywheel with the special tool and tighten the flywheel nut. Torque: 5.0~6.0 kgf-m Special tool: Flywheel holder A120E00021 Flywheel Holder Flywheel Install the dowel pins and gasket. Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 or 3steps.
Page 132: Crankcase/Crankshaft
11. CRANKCASE/CRANKSHAFT X -Town 125 ABS/ CBS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ CRANKCASE/CRANKSHAFT ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 11-1 SERVICE INFORMATION --------------------------------------------------------------------- 11-2 TROUBLESHOOTING -------------------------------------------------------------------------- 11-2 CRANKCASE SEPARATION ------------------------------------------------------------------ 11-3 CRANKCASE ASSEMBLY --------------------------------------------------------------------- 11-4 11-0...
Page 133 11. CRANKCASE/CRANKSHAFT X -Town 125 ABS/ CBS SCHEMATIC DRAWING 11-1...
Page 134 11. CRANKCASE/CRANKSHAFT X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS  This section covers crankcase separation to service the crankshaft. The engine must be removed for this operation.  When separating the crankcase, never use a driver to knock the crankcase forcedly to prevent damaging the mating surfaces.
Page 135 11. CRANKCASE/CRANKSHAFT X -Town 125 ABS/ CBS CRANKCASE SEPARATION Remove the two right crankcase attaching bolts. Bolts Remove the left crankcase bolts. Right Crankcase Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase.
Page 136 11. CRANKCASE/CRANKSHAFT X -Town 125 ABS/ CBS Oil Seal Remove the oil seal from the left crankcase. Left Crankcase CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces. ＊ Avoid damaging the crankcase mating surfaces. Oil Seal Install a new oil seal into the left crankcase.
Page 137 11. CRANKCASE/CRANKSHAFT X -Town 125 ABS/ CBS Place the left crankcase down and install the Crankshaft into the left crankcase. ＊ • Avoid damaging the oil seal. • Apply grease to the lip of the oil seal. Change a new gasket.
Page 138 11. CRANKCASE/CRANKSHAFT X -Town 125 ABS/ CBS Cam Chain Tensioner Slipper Install the cam chain. Install the cam chain tensioner slipper. Install and tighten the cam chain tensioner slipper bolt. Torque: 1.0kgf-m Bolt 11-6...
Page 139: Cooling System
12. COOLING SYSTEM X -Town 125 ABS/ CBS ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ COOLING SYSTEM ________________________________________________________________________________ SCHEMATIC DRAWING ----------------------------------------------------------------------- 12--1 SERVICE INFORMATION --------------------------------------------------------------------- 12--2 TROUBLESHOOTING -------------------------------------------------------------------------- 12--2 COOLING SYSTEM TESTING --------------------------------------------------------------- 12--4 RADIATOR ----------------------------------------------------------------------------------------- 12--8 FAN MOTOR -------------------------------------------------------------------------------------- 12--10 FAN MOTOR SWITCH ------------------------------------------------------------------------- 12--11...
Page 140: Schematic Drawing
12. COOLING SYSTEM X -Town 125 ABS/ CBS SCHEMATIC DRAWING 12-1...
Page 141: Service Information
12. COOLING SYSTEM X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS  The water pump must be serviced after removing the engine. Other cooling system service can be done with the engine installed in the frame.  The engine must be cool before servicing the cooling system.
Page 142 -44.5℃ 55 % ＊  Use coolant of specified mixing rate. (The mixing rate of 860cc KYMCO SIGMA coolant concentrate + 859cc distilled water is 50%.)  Do not mix coolant concentrate of different brands.  Do not drink the coolant, which is poisonous.
Page 143: Cooling System Testing
12. COOLING SYSTEM X -Town 125 ABS/ CBS COOLING SYSTEM TESTING RADIATOR CAP INSPECTION ＊ Removing the radiator cap while the engine is hot can cause the coolant to spray out, seriously scalding you. Always let the engine and radiator cool down before removing the radiator cap.
Page 144 12. COOLING SYSTEM X -Town 125 ABS/ CBS COOLANT REPLACEMENT PREPARATION ● The effectiveness of coolant decreases with the accumulation of rest or if there is a change in the mixing proportion during usage. Therefore, for best performance change the coolant regularly as specified in he maintenance schedule.
Page 145 12. COOLING SYSTEM X -Town 125 ABS/ CBS Remove the screw (3) and reserve tank lid (4). Remove the reserve tank cap and drain the coolant from the reserve tank. Reinstall and tighten the drain bolt securely. Fill the reserve tank to the upper level line.
Page 146 12. COOLING SYSTEM X -Town 125 ABS/ CBS Fill the system with the recommended coolant through the filler opening up to the filler neck (1). Bleed air from the system as follow: 1. Start the engine and let it idle for 2− 3 minutes.
Page 147: Radiator
12. COOLING SYSTEM X -Town 125 ABS/ CBS Radiator Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects are clogging the radiator, wash them off. Carefully straighten any bent fins.
Page 148 12. COOLING SYSTEM X -Town 125 ABS/ CBS Remove three nuts (10) and then remove the radiator from frame. INSTALLATION Installation is in the reverse order of removal. Refill the coolant 12-9...
Page 149: Fan Motor
12. COOLING SYSTEM X -Town 125 ABS/ CBS FAN MOTOR REMOVAL Remove the radiator Remove the three mounting bolts (1) and then remove the fan motor (2) INSPECTION Battery Check the fan motor to operate using an available battery. INSTALLATION Installation is in the reveres order of removal.
Page 150: Fan Motor Switch
12. COOLING SYSTEM X -Town 125 ABS/ CBS FAN MOTOR SWITCH REMOVAL Disconnect the fan motor switch connectors Remove the thermostat(1). INSPECTION Place the thermal switch in the stove with water as shown and raise the water temperature gradually to check for the temperature at which the starts to operate.
Page 151: Water Pump
12. COOLING SYSTEM X -Town 125 ABS/ CBS Right Crankcase Cover WATER PUMP MECHANICAL SEAL (WATER SEAL) INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage. If the mechanical seal is leaking, remove the right crankcase cover and replace the mechanical seal.
Page 152 12. COOLING SYSTEM X -Town 125 ABS/ CBS Bolts Water Pump Cover Remove five bolts and the water pump cover, gasket and two dowel pins. Impeller (Left Hand Threads) Remove the water pump impeller. ＊ The impeller has left hand threads.
Page 153 12. COOLING SYSTEM X -Town 125 ABS/ CBS WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover. Remove five bolts attaching the water pump assembly. Remove the water pump assembly, gasket and dowel pins. Remove the water pump shaft clip and...
Page 154 12. COOLING SYSTEM X -Town 125 ABS/ CBS Water Pump Assembly Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover. Tighten five bolts to secure the water pump assembly.
Page 155 12. COOLING SYSTEM X -Town 125 ABS/ CBS Impeller (Left Hand Threads) Install the impeller onto the water pump shaft. 1.2 kgf-m (12 N-m, 9 lbf-ft) Torque: ＊ The impeller has left hand threads. Dowel Pins Install two dowel pins and a new gasket.
Page 156: Thermosensor
12. COOLING SYSTEM X -Town 125 ABS/ CBS WATER TEMPERATURE SENSOR REMOVAL Remove the luggage box Drain the coolant Disconnect the water temperature sensor connectors (1). Remove the water temperature sensor (2) from thermostat. Thermosensor INSPECTION Connect the water temperature sensor to the ohmmeter and dip it in water contained in a pan which is placed on an electric heater.
Page 157: Thermostat
12. COOLING SYSTEM X -Town 125 ABS/ CBS THERMOSTAT THERMOSTAT REMOVAL REMOVAL Drain the coolant Remove the luggage box Disconnect the water hose (1) from the thermostat housing. Remove the mounting bolt (2) and the thermostat housing attaching the cylinder head.
Page 158 12. COOLING SYSTEM X -Town 125 ABS/ CBS DISASSEMBLY Remove two screws and separate the thermostat housing halves. Screws Thermosta Thermosta Remove the thermostat from the thermostat housing. 12-19...
Page 159 12. COOLING SYSTEM X -Town 125 ABS/ CBS INSPECTION Suspend the thermostat in a pan of water Thermostat over a burner and gradually raise the water temperature to check its operation. Thermometer Technical Data 71 ± 1.5°C Begins to open Full-open 80℃...
Page 160: Fi Diagnostic Tool Operation
13. Fi DIAGNOSTIC TOOL OPERATION X -Town 125 ABS/ CBS Fi Diagnostic Tool Operation Instructions Part No. 3620A-LEB2-E00 ① ② ⑤ ④ ③ KEY FUNCTION ① Model No. ⑥ UP Button ② Down Button ⑦ Adjust (TPI and ABV reset function) ③...
Page 161 13. Fi DIAGNOSTIC TOOL OPERATION X -Town 125 ABS/ CBS Fi diagnostic tool outlook ....................... 13-0 DTC Inspection Procedure ...................... 13-2 DTC Clear Procedure ....................... 13-5 Data Analysis ........................... 13-6 Adjust ............................13-8 Diagnostic Standard Specifications ..................13-9 13-1...
Page 162: Dtc Inspection Procedure
13. Fi DIAGNOSTIC TOOL OPERATION X -Town 125 ABS/ CBS DTC INSPECTION PROCEDURE Connect Fi diagnostic tool with the connector of harness wire located beside the Battery. Diagnostic Tool Connector Press the " Enter " button Check the software version Press the "...
Page 163 13. Fi DIAGNOSTIC TOOL OPERATION X -Town 125 ABS/ CBS Press the " Enter " button to check theDTCnumber Press the " Enter " button Press the " Enter " button Display what'sDTCnumber on this DTC-List. Refer toDTCsummary list. Press the " Enter " button and then turn to the...
Page 164 13. Fi DIAGNOSTIC TOOL OPERATION X -Town 125 ABS/ CBS Press the "UP" button Press the " Enter " button and then turn to the previous page. Press the "UP" button Press the " Enter " button and then turn to the first page.
Page 165: Dtc Clear Procedure
13. Fi DIAGNOSTIC TOOL OPERATION X -Town 125 ABS/ CBS DTC CLEAR PROCEDURE Choose " Load DTC" Press the "Down" button Press the " Enter " button TheDTCindicator is lighting at that time. ClearingDTCcompleted until theDTC indicator is off. 13-5...
Page 166: Data Analysis
13. Fi DIAGNOSTIC TOOL OPERATION X -Town 125 ABS/ CBS DATA ANALYSIS Choose " Data Analyze " Press the " Enter " button to enter page 01. The figure includes engine speed, idle speed setpoint and battery voltage. Refer to standard specifications .
Page 167 13. Fi DIAGNOSTIC TOOL OPERATION X -Town 125 ABS/ CBS The figure includes fuel injector interval, ignition advance angle andABVangle. Refer to standard specifications . Press the "Down" button to enter page 05. The figure includes O2sensor voltage,O2 heater working condition and O2 correction.
Page 168: Adjust
13. Fi DIAGNOSTIC TOOL OPERATION X -Town 125 ABS/ CBS ADJUST Need to make TPI/ABV reset to operate after changing new ECU and clean THROTTLE BODY and changing the engine department product, let ECU set up and set up initially Choose "Adjust "...
Page 169: Diagnostic Standard Specifications
13. Fi DIAGNOSTIC TOOL OPERATION X -Town 125 ABS/ CBS Diagnostic Standard Specifications Reason of repair: □Maintenance □Breakdown Item Data Reference Memo ECU No ACJ1 Hardware Ver Software Ver Calibration Ver Model Name Active Occurred History Air Temp.(°C) environ.temp ± 2 °C Engine Temp.(Cooling)
Page 170 13. Fi DIAGNOSTIC TOOL OPERATION X -Town 125 ABS/ CBS 13-10...
Page 171 FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS FUEL SYSTEM (Auto Control Fuel Injection System) SYSTEM DIAGRAM ................14-1 SYSTEM LOCATION................. 14-2 SERVICE INFORMATION ..............14-3 TROUBLESHOOTING............... 14-4 CHECK ENGINE LAMP (CELP) ............14-5 HOW TO SHOW THE FAILURE CODE ........... 14-6 CELP FAILURE CODES CHART............
Page 172: System Diagram
X -Town 125 ABS/ CBS FUEL SYSTEM (Auto Control Fuel Injection System) SYSTEM DIAGRAM KEY ON FUEL PUMP 感知器 ROLL Voltage 進氣壓力及 T-MAP INDUCTIVE INJECTOR IGNITION COIL KEY OFF 14-1...
Page 173: System Location
FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS SYSTEM LOCATION 01: Inductive ignition coil 02: Fuel pump 03: ECU 04: Fuel injector 05: WTS sensor 06: T-MAP sensor 07: ABV 08: TPS 09: Roll sensor(Angle detect sensor)
Page 174: Service Information
FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS 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 175 FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS TROUBLESHOOTING Engine won’t start Backfiring or misfiring during acceleration Battery voltage too Ignition system malfunction lowFuel level too low Pinched or clogged fuel hose Poor performance (drive ability) and poor...
Page 176: Check Engine Lamp (Celp)
FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS CHECK ENGINE LAMP (CELP) *When turning on the switch, the lamp will be lighted for 2 seconds then off. Let user to know the lamp is available and connect to ECU.
Page 177 FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS 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 178 FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS CELP Failure Code Chart(1) Blink Failure Fault Priority Fault management Codes description P0217 Engine 1.Slow down the vehicle and go to workshop for temperature checking immediately. overheat 2.Confirm if the engine temperature sensor or electriccircuit is abnormality.
Page 179 FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS CELP Failure Code Chart(2) Blink Failure Fault description Priority Fault management Codes P1122 Throttle position sensor Make sure if the connector of Throttle position sensor is connected correctly.
Page 180 FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS CELP Failure Code Chart(3) Blink Failure Fault description Priority Fault management Codes Ignition coil or electric 1. Check if the connector of ignition coil is loosen. 2. Check if the ECU send signal to Ignition coil.
Page 181 FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS CELP Failure Code Chart(4) Blink Failure Fault description Priority Fault management Codes CELP electric circuit 1. Check if the lamp of CELP is broken. 2. Check if wires of CELP is broken.
Page 182: Maintaining By Checking Component
FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS Maintaining By Checking Component ECU(Engine Control Unit) Outlook checking Voltage inspection Connect the meter (+) probe to the F4(R/W)wire and the meter (-) probe to the H4(G/B) wire to measure the voltage.
Page 183 X -Town 125 ABS/ CBS FUEL SYSTEM (Auto Control Fuel Injection System) FUEL PUMP Connect the meter (+) probe to the red/black wire and the meter (-) probe to the green wire to measure the voltage from the ECU input to fuel pump unit.
Page 184 FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS T-MAP(Manifold Air Temperature Pressure) Sensor Connect the PDA or KYMCO Fi diagnostic tool. Into the Data Analyze item . Check if the manifold pressure data malfunction. (Key switch ON but engine is not start ) If data was incorrect.
Page 185 FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS WTS (Water Temperature Sensor) Connect the meter (+) probe to the V/G wire and the meter (-) probe to the G/L wire to measure the voltage Standard : 5±0.25 V Measure the resistance of the WTS Standard (20°C/68°F ): 2.075±10%kΩ...
Page 186 O2 SENSOR Measure the resistance of the O2 sensor heater. (2 white wire pin) Standard (20°C/68°F ): 6.7 ~9.5Ω Connect the PDA or KYMCO Fi diagnostic tool. Into the Data Analyze item . Check Page 05 (Key switch ON then start engine...
Page 187: Maintaining Special Notice
Standard: Normal: 0.4~1.4V OVER 65°: 3.7~4.4 V Maintaining Special Notice Never adjust those two TP screws, those were adjusted to be the best condition by KYMCO, if change this condition it may cause instable riding. TP screws 14-16...
Page 188 FUEL SYSTEM (Auto Control Fuel Injection System) X -Town 125 ABS/ CBS Connect the PDA or KYMCO Fi diagnostic tool. Into the Data Analyze item . Check ignition advance data malfunction. (Key switch is ON then start engine until 80 ° C) 20 °...
Page 189: Handlebar/Frontwheel/ Front Brake/Front Shock Absorber/ Steering Stem
15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 15- 1 TROUBLESHOOTING----------------------------------------------------- 15- 2 HANDLEBAR --------------------------------------------------------------- 15- 3 FRONT WHEEL------------------------------------------------------------- 15- 7...
Page 190 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS  Remove the motorcycle frame covers before removing the front wheel, steering handlebar, front shock absorber and front fork. Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down.
Page 191 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS TROUBLESHOOTING Hard steering (heavy) Front wheel wobbling Excessively tightened steering stem top Bent rim cone race Loose front axle Broken steering balls Bent spoke plate Insufficient tire pressure...
Page 192 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS HANDLEBAR REMOVAL Remove the lower handlebar cover and front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Remove the two bolts (1) and disconnect the brake light switch wire (2), then remove the rear brake master cylinder.
Page 193 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS INSTALLATION Install the handlebar onto the steering stem and install the handlebar collar, lock nut and bolt. Tighten the bolt to the specified torque. Torque: 4.5 kgf-m (45 N-m, 32 lbf-ft)
Page 194 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS DISASSEMBLY Remove two screws (1) attaching right handlebar switch. Disconnect the throttle cable (2) attaching the throttle grip. Remove the right headlight switch. Remove two screws (3) and then remove the turn light switch.
Page 195 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS ASSEMBLY Install the turn light switch. ＊ Align the pin on the turn light switch with the hole on the handlebar. Install the headlight switch. ＊ Align the pin on the headlight switch with the hole on the handlebar.
Page 196: Front Wheel
15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS FRONT WHEEL REMOVAL Jack the scooter front wheel off the ground. Remove the bolt , then pull out the axle . Remove the front wheel and collar. 15-7...
Page 197 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS INSTALLATION Apply grease to the collar (1), then install the collar onto the wheel. Install the speedometer speed wheel sensor(2) 15-8...
Page 198 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS DISASSEMBLY Remove the side collar (1) and dust seal (2). Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly.
Page 199 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS Remove the front wheel bearing (5) by using the special tool. Special tool: Bearing puller A120E00037 ASSEMBLY Install the front wheel bearing (5) by using the special tool.
Page 200: Front Brake Fluid
15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS FRONT BRAKE FLUID FLUID REPLACEMENT/AIR BLEEDING ＊ ● A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent.
Page 201 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS Brake fluid draining Make sure that the master cylinder parallel to the ground, before removing the reservoir cover. Remove the two screws (1). Remove the reservoir cover , diaphragm plate and diaphragm .
Page 202 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS Loosen the bleed valve and pump the brake lever. Stop operating the brake when no more fluid flows out of the bleed valve. Brake fluid filling/Air bleeding ＊...
Page 203 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS If the brake bleeder is not available, perform the following procedure. Pump up the system pressure with the brake lever until these are not air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt.
Page 204: Front Brake Pad
15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS FRONT BRAKE PAD BRAKE PAD REPLACEMENT Remove two caliper mounting bolts (1), then remove the caliper. Remove the brake pads(2). ＊ Always replace the brake pads in pairs to ensure even disc pressure.
Page 205 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS Install new pads so that their ends rest on the pad retainer on the brake properly. Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper.
Page 206: Brake Disc Inspection
15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks. Measure the brake disc thickness. Service limits: 3 mm (0.12 in) 15-17...
Page 207: Front Shock Absorber
15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS FRONT SHOCK ABSORBER REMOVAL Remove the front cover and front fender. (refer “FRAME CVOERS REMOVAL/INSTALLATION” section in the chapter 2). Remove the front brake caliper Remove the front wheel...
Page 208 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS REMOVAL Remove the steering handlebar Remove the front shock absorber Remove the front brake hose and speed wheel Sensor connector Hold the steering stem top cone race and remove the steering stem lock nut by using the special tool.
Page 209 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS Ball Inspect the ball races, cone races and steel balls for wear or damage. Replace if necessary. Remove the top balls. Remove the upper ball race by using a chisel if necessary.
Page 210: Steering Stem
15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS INSTALLATION Install the new bottom cone race onto the steering stem. Install the new upper and bottom ball races into the frame. Apply grease to the top and bottom ball races and install new steel balls on the top ball race and new steel balls on the bottom ball race.
Page 211 15.HANDLEBAR/FRONT WHEEL/FRONT BRAKE/ FRONT SHOCK ABSORBER/STEERING STEM X -Town 125 ABS/ CBS Top Ball Cone Race special tool Remove Bottom Ball Race special tool Remove Bottom Ball Race Top Ball Cone Race special tool Install special tool Install 15-22...
Page 212 16. REAR ASSEMBLY X-town 125 ABS/CBS Rear Assembly REAR BRAKE/REAR FORK/REAR WHEEL/ REAR SHOCK ABSORBER SCHEMATIC DRAWING --------------------------------------------------------------- 16-1 SERVICE INFORMATION-------------------------------------------------------------- 16-2 TROUBLESHOOTING------------------------------------------------------------------- 16-2 REAR BRAKE----------------------------------------------------------------------------- 16-3 REAR FORK ------------------------------------------------------------------------------- 16-6 REAR WHEEL----------------------------------------------------------------------------- 16-7 REAR SHOCK ABSORBER ------------------------------------------------------------ 16-7 16-1...
Page 213: Schematic Drawing
16. REAR ASSEMBLY X-town 125 ABS/CBS SCHEMATIC DRAWING SERVICE INFORMATION GENERAL INSTRUCTIONS When performing the services stated in this section, the engine and exhaust  muffler must be cold to avoid scalding.  During servicing, keep oil or grease off the brake pads and brake disk. 16-2...
Page 214: Troubleshooting
16. REAR ASSEMBLY X-town 125 ABS/CBS SPECIFICATIONS Item Standard (mm) Rear wheel rim runout Rear brake disk thickness Rear brake disk runout Rear brake master cylinder I.D. 27.00 Rear brake master cylinder piston O.D. 26.95 TORQUE VALUES Exhaust Muffler Lock Bolt 35 N-m /4 kgf•m Exhaust Muffler Pipe Nut 20 N-m/2 kgf•m...
Page 215: Rear Brake/Rear Fork/Rear
16. REAR ASSEMBLY X-town 125 ABS/CBS 1. Rear Brake 1.1. Rear Brake Caliper Removal First remove the exhaust muffler. Remove the rear brake fluid tube bolt and disconnect the brake fluid tube. Remove two bolts attaching the rear brake caliper. Remove the rear brake caliper.
Page 216 16. REAR ASSEMBLY X-town 125 ABS/CBS 1.3. Disassembly Remove two brake pads dowel pins and three bolts from the brake caliper. Remove the brake pads. Remove the piston from the brake caliper. If necessary, use compressed air to squeeze out the piston through the brake fluid inlet opening and place a towel under the caliper to avoid contamination caused by the removed...
Page 217 16. REAR ASSEMBLY X-town 125 ABS/CBS 1.4. Assembly Clean all removed parts. Apply silicon grease to the piston and oil seal. Lubricate the brake caliper cylinder inside wall with brake fluid. Install the brake caliper piston with grooved side facing out. ✻...
Page 218 16. REAR ASSEMBLY X-town 125 ABS/CBS 1.5. Installation Install the brake caliper to the rear fork and tighten the two bolts. Torque: 27 N-m Connect the brake fluid tube to the brake caliper and install fluid tube bolt, copper washers and tighten the fluid tube bolt.
Page 219: Rear Fork
16. REAR ASSEMBLY X-town 125 ABS/CBS 2. Rear Fork 2.1. Removal Remove the exhaust muffler. Remove the rear brake cal7iper. Remove the right rear shock absorber lower mount bolt. Remove the rear axle nut and remove the collar. Remove the rear fork. 2.2.
Page 220: Rear Wheel
16. REAR ASSEMBLY X-town 125 ABS/CBS 3. Rear Wheel 3.1. Removal Remove the exhaust muffler. Remove the rear brake caliper. Remove the rear fork. Remove the rear axle collar. Remove the rear wheel. 3.2. Inspection Measure the rear wheel rim runout. 3.3.
Page 221: Rear Shock Absorber
16. REAR ASSEMBLY X-town 125 ABS/CBS 4. Rear Shock Absorber 4.1. Removal Remove the met-in box and carrier. Remove the body cover, center cover and rear fender A together. Remove the right/left rear shock absorber upper and lower mount bolts. Remove the right and left rear shock absorbers.
Page 222: Battery/Charging System
. BATTERY/CHARGING SYSTEM X-Town 125 ABS/ CBS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY/CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT ---------------------------------------- 17-1 CHARGING CIRCUIT ----------------------------------------------------- 17-1 SERVICE INFORMATION------------------------------------------------ 17-2 TROUBLESHOOTING----------------------------------------------------- 17-3 BATTERY -------------------------------------------------------------------- 17-4 CHARGING VOLTAGE INSPECTION -------------------------------- 17-6 REGULATOR/RECTIFIER ----------------------------------------------- 17-7 17-0...
Page 223: Battery/Charging System
. BATTERY/CHARGING SYSTEM X-Town 125 ABS/ CBS CHARGING SYSTEM LAYOUT REGULATOR/RECTIFIER BATTERY 17-1...
Page 224: Service Information
. BATTERY/CHARGING SYSTEM X-Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS ＊ The battery electrolyte (sulfuric acid) is poisonous and may seriously damage the skin and eyes. Avoid contact with skin, eyes, or clothing. In case of contact, flush with water and get prompt medical attention The battery can be charged and discharged repeatedly.
Page 225: Troubleshooting
. BATTERY/CHARGING SYSTEM X -Town 125 ABS/ CBS TROUBLESHOOTING No power Intermittent power ● Dead battery ● Loose battery cable connection ● Disconnected battery cable ●Loose charging system connection ● Fuse burned out ●Loose connection or short circuit in ignition system ●...
Page 226: Battery
. BATTERY/CHARGING SYSTEM X -Town 125 ABS/ CBS BATTERY REMOVAL/INSTALLATION The battery is in the battery box behind seat. 1. Remove the seat. 2. Remove 2 screws and then remove the battery retainer 4. Pull battery out to expose the terminal leads 5.
Page 227 . BATTERY/CHARGING SYSTEM X -Town 125 ABS/ CBS VOLTAGE INSPECTION Remove the battery cover . Measure the battery voltage using a commercially available digital multimeter. Voltage (20ºC/68ºC): Fully charged: 13－13.2 V Insufficient charged: below 12.3 V BATTERY CHARGING Remove the battery Connect the charger positive (+) cable to the battery positive (+) terminal.
Page 228: Charging Voltage Inspection
. BATTERY/CHARGING SYSTEM X -Town 125 ABS/ CBS CHARGING VOLTAGE INSPECTION Be sure that the battery is in good condition before performing this test. ＊ Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch. Failure to follow this precaution can damage the tester or electrical components.
Page 229: Regulator/Rectifier
. BATTERY/CHARGING SYSTEM X -Town 125 ABS/ CBS REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the regulator/rectifier connectors (1). Check the connector for loose contacts of （1）...
Page 230 . BATTERY/CHARGING SYSTEM X -Town 125 ABS/ CBS Check the continuity between the Green wire terminal and ground. There should be continuity at all times. Measure the resistance between each Yellow wire terminals. Standard: 0.4－0.6  (20ºC/68ºF) Disconnect the regulator/rectifier connector.
Page 231 . BATTERY/CHARGING SYSTEM X -Town 125 ABS/ CBS REMOVAL/INSTALLATION Remove the body cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the regulator/rectifier connectors (1). Remove the two bolts (2), attaching regulator/rectifier (3). Installation is in the reverse order of removal.
Page 232: Ignition System
. IGNITION SYSTEM X -Town 125 ABS/ CBS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT ------------------------------------------ 18-1 SERVICE INFORMATION------------------------------------------------ 18-2 TROUBLESHOOTING----------------------------------------------------- 18-3 IGNITION COIL INSPECTION ------------------------------------------ 18-4 18-0...
Page 233: Ignition System
. IGNITION SYSTEM X -Town 125 ABS/ CBS IGNITION SYSTEM LAYOUT Roll sensor Ignition coil 18-1...
Page 234: Service Information
. IGNITION SYSTEM X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is “ON” and current is present. ● When servicing the ignition system, always follow the steps in the troubleshooting..
Page 235: Troubleshooting
. IGNITION SYSTEM X -Town 125 ABS/ CBS TROUBLESHOOTING LOW PEAK VOLTAGE ● Cranking speed is too low (battery is undercharged). ● Poorly connected connectors or an open circuit in the ignition system. ● Faulty ignition-coil. ● Faulty ignition control module.
Page 236: Ignition Coil Inspection
. IGNITION SYSTEM X -Town 125 ABS/ CBS IGNITION COIL INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the body cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Check cylinder compression and check that the spark plug (1) is installed correctly in the cylinder.
Page 237 . IGNITION SYSTEM X -Town 125 ABS/ CBS IGNITION PULSE GENERATOR INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the ignition pulse generator connector (1). Measure the pulse generator resistance between the Green/White wire and Blue/Yellow wire.
Page 238 . IGNITION SYSTEM X -Town 125 ABS/ CBS IGNITION COIL REMOVAL/INSTALLATION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the spark plug cap attaching the spark plug (1). Disconnect the ignition coil connector (2).
Page 239: Starting System
. STARTING SYSTEM X -Town 125 ABS/ CBS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT ----------------------------------------- 19-1 STARTING CIRCUIT ------------------------------------------------------ 19-1 SERVICE INFORMATION------------------------------------------------ 19-2 TROUBLESHOOTING----------------------------------------------------- 19-2 STARTER MOTOR --------------------------------------------------------- 19-3 STARTER RELAY INSPECTION---------------------------------------- 19-5 19-0...
Page 240: Starting System
. STARTING SYSTEM X -Town 125 ABS/ CBS STARTING SYSTEM LAYOUT Battery Start relay Start motor 19-1...
Page 241: Service Information
. STARTING SYSTEM X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL INSTRUCTIONS ●The removal of starter motor can be accomplished with the engine installed. ● After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air from the cooling system.
Page 242: Starter Motor
. STARTING SYSTEM X -Town 125 ABS/ CBS STARTER MOTOR INSPECTION Disconnect the starter motor cable ( 2) from the start relay(1). Connect the start motor cable directly to the battery positive terminal (3). If the starter motor fail to work, the starter motor is faulty.
Page 243 . STARTING SYSTEM X -Town 125 ABS/ CBS INSTALLATION Coat a new O-ring (1) with engine oil and install it into the start motor groove. Install the starter motor into the crankcase. Install the two mounting bolts and engine ground cable, then tighten the bolts securely.
Page 244: Starter Relay Inspection
. STARTING SYSTEM X -Town 125 ABS/ CBS START RELAY INSPECTION Release the rubber cap (1) and remove the nut (2), then disconnect the start motor cable. Turn the ignition switch to “ON”position. Squeeze and hold the brake lever fully then push the starter switch.
Page 245: Lights/Meters/Switches
20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LIGHTS/METERS/SWITCHES __________________________________________________________________________________ SERVICE INFORMATION------------------------------------------------ 20- 1 BULB REPLACEMENT --------------------------------------------------- 20- 2 BRAKE LIGHT SWITCH-------------------------------------------------- 20- 6 IGNITION SWITCH -------------------------------------------------------- 20- 6 HANDLEBAR SWITCH --------------------------------------------------- 20- 7 LUGGAGE BOX LIGHT SWITCH -------------------------------------- 20- 9...
Page 246: Service Information
20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS SERVICE INFORMATION GENERAL ＊ A halogen head light bulb becomes very hot while the head light is turned on, and remains for a while after it is turned off. Be sure to let it cool down before servicing.
Page 247: Bulb Replacement
20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS BULB REPLACEMENT POSITION LIGHT Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Remove the bulb socket (1). Remove the bulb (2) and replace with a new one.
Page 248 20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS HEADLIGHT ＊ A halogen headlight bulb becomes very hot while the headlight is ON, and remain for a while after it is turned OFF. Be sure to let it cool down before servicing.
Page 249 20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS FRONT TURN SIGNAL LIGHT Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Turn the bulb socket (1), then remove the front turn signal light . Push and turn the bulb counterclockwise to remove it, then replace with a new one..
Page 250 20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS Rear turn signal light Push and turn the bulb counterclockwise to remove it, then replace with a new one. Installation is in the reverse order of removal. Rear Turn Signal Light 20-5...
Page 251: Brake Light Switch
20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS BRAKE LIGHT SWITCH Remove the upper handlebar cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect front or rear light switch connectors and check for continuity between the switch terminals (1).
Page 252: Handlebar Switch
20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS HANDLEBAR SWITCH INSPECTION Hazard Light Engine Stop Switch Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Right handlebar switch Disconnect the right handlebar switch connector and check for continuity for switch side connector terminals.
Page 253 20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS Left handlebar switch Disconnect the left handlebar switch Dimmer Switch connector and check for continuity for switch side connector terminals. Continuity should exist between the color code wires as follows: Turn Signal light Switc...
Page 254: Luggage Box Light Switch
20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS LUGGAGE BOX LIGHT SWITCH INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Disconnect the luggage box light switch connector (2) and check the luggage box light switch (1) for continuity between the switch terminals.
Page 255: Fuel Pump
20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS FUEL PUMP REMOVAL Remove the seat and luggage box Remove the center cover Remove the fuel pump connector Be sure to relieve the fuel pressure before removing fuel pump or fuel hose. Remove the six nuts (1) and fuel unit connector(2) then remove the fuel hose.(3)
Page 256 20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS INSPECTION Connect the fuel unit wire connectors and turn the ignition switch “ON”. ＊ Before performing the following test, operate the turn signals to determine that the battery circuit is normal. Measure the resistance between the Yellow/White and Blue/White terminals of the fuel unit connector.
Page 257: Side Stand Switch
20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS SIDE STAND SWITCH INSPECTION Remove the luggage box (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2). Side stand switch is located on side stand Disconnect the side stand switch connector (1).
Page 258: Horn
20. LIGHTS/METERS/SWITCHES X -Town 125 ABS/ CBS HORN INSPECTION Remove the front cover (refer to the “FRAME COVERS REMOVAL/INSTALLATION” section in the chapter 2) Disconnect the horn connectors (1) from the horn. Connect a 12 V battery to the horn terminals.
Page 259 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS ANTI-LOCK BRAKE SYSTEM (ABS) ABS Indicator Light ---------------------------------------- --------- 21－01 ABS Introduction -------------------------------------------- --------- 21－02 ABS Parts Location ----------------------------------------- --------- 21－03 Wheel Speed ------------------------------------------------- --------- 21－04 ABS ECU & ABS Hydraulic Unit ------------------------ --------- 21－06 ABS ECU GUARANTEE---------------------------------- --------- 21－07...
Page 260 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS ABS Indicator Light The ABS indicator light in the meter position. This light will comes on when the ignition switch is turned on and goes off shortly after the vehicle starts moving at speed 6km/hr min. It stays off.
Page 261 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS ABS Introduction ABS is designed to help prevent the wheels from locking up when the brakes are applied hard while running straight. The ABS automatically regulates brake force. Intermittently gaining gripping force and braking force helps prevent wheel lock-up and allows stable steering control while stopping.
Page 262 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS Parts Location Front Wheel speed Sensor Front Wheel speed Sensor Rotor Front Wheel speed Sensor’s connector Rear Wheel speed Sensor Rotor Rear Wheel speed Sensor Rear Wheel speed Sensor’s connector ABS ECU & ABS Hydraulic Unit...
Page 263 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS WHEEL SENSOR REMOVAL & INSPECTION Front Wheel Speed Sensor Remove the front wheel speed sensor. Install the front wheel speed sensor. Front Wheel Speed Sensor Rotor Remove a bolt attaching to the front wheel speed sensor Front Wheel speed Sensor’s connector...
Page 264 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS Remove the rear wheel speed sensor. Rear Wheel Speed Sensor Rotor Rear Wheel Speed Sensor Remove the connector of rear wheel speed sensor Rear Wheel speed Sensor’s connector <Rear Wheel Speed Sensor>...
Page 265 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS ABS ECU & ABS Hydraulic Unit Disconnect the ECU connector,and remove the holder screw ECU Connector ECU Holder Screw ECU Holder Bolt Oil Tube Bolts Remove the screws attaching to the Hydraulic Unit.
Page 266 DIAGNOSTIC TOOL OPERATION 1. Connect the KYMCO Fi Diagnostic tool 2. Put the side stand upward and ENG. stop switch is at “RUN” position. 3. Connect the diagnostic tool connector. (KYMCO Fi Diagnostic tool Power comes from vehicle’s Battery) Self-Diagnostic Tool Connector...
Page 267: Abs System
ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS 4. Choose Fi ECU Version and then push down button for three times. ACJ1 5. Choose No.2 ABS SYS ECU and then push up button to previous. 6. Confirming ECU Version and then enter ABS system.
Page 268 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS 7. Choose ECU Version and then push “Enter” button. 8. Confirm ABS ECU Version if is LEA7-E00 1.1.1 A7-E00 9. Choose DTC Inspect 21-9...
Page 269 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS 10. Load DTC (Active 、Occurred、History) DTC DISPLAYED 1. Rear wheel speed sensor disconnect 2. Front wheel speed sensor disconnect 21-10...
Page 270 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS DTC CLEARED 1. Choose “Clear DTC” and then push “Enter” button. 2. Clearing DTC completed until the DTC red lamp is off. DATA ANALYZE 1. Choose “DATA Analyze” and then push “Enter” button...
Page 271 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS 2. Front wheel speed & Rear wheel speed & Battery volt Battery volt: Standard 9.6~16.7V KYMCO Diagnosis 01 Fr Speed 5 km/hr Re Speed 5 km/hr Battery Volt 12.6V ＊ You can turn the front or rear wheel to check if the wheel speed is figured.
Page 272 ANTI-LOCK BRAKE SYSTEM (ABS) X -Town 125 ABS/ CBS Bosch ABS8m DTC List Bosch ABS8m DTC LIST Code NO (Diagnostic Tool ) Description (PDA) 3620A-LEB2- 5013 Rear Inlet Valve malfunction(EV) 5014 Rear Outlet Valve malfunction (AV) 5017 Front Inlet Valve malfunction (EV)

This manual is also suitable for:

X -town 125 cbs

KYMCO X -Town 125 ABS Service Manual

Preface

Exhaust Muffler/Frame Covers

Inspection/Adjustment

Lubrication System

Cylinder Head/Valves

Cylinder/Piston

Drive and Driven Pulleys

Final Reduction

Cooling System

Fi Diagnostic Tool Operation

Fuel System (Auto Control Fuel Injection System) 14

Handlebar/Front Wheel/Front Brake/ Front Shock Absorber/Steering Stem

Rear Assembly

Battery/Charging System

Ignition System

Starting System

Quick Links

TABLE OF CONTENTS

Chapters

Troubleshooting

Related Manuals for KYMCO X -Town 125 ABS

Summary of Contents for KYMCO X -Town 125 ABS

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Table of Contents