Table of Contents
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PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO Zing
125/150.
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section 2 is the inspection/ adjustment
procedures, safety rules and service
information for each part, starting from
periodic maintenance.
Sections 3 and 4 state the servicing
procedures and cautions for the removal
and installation of lubrication and fuel
systems.
Sections 5 through 19 give instructions
for disassembly, assembly and inspection
of engine, chassis frame and electrical
equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages
give detailed procedures for the section.
The information and contents included
in this manual may be different from
the motorcycle in case specifications
are changed.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
CLUTCH/CAMSHAFT
CRANKCASE/CRANKSHAFT/TRANS-
MISSION SYSTEM/STARTER SPINDLE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
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Chapters
Table of Contents
Troubleshooting
Related Manuals for KYMCO RF25AA
Summarization of Contents
General Information
Specifications
Detailed technical data for all motorcycle components and systems.
Service Precautions
Essential guidelines for safe and effective motorcycle servicing.
Torque Values
Specified tightening torques for critical fasteners during assembly.
Special Tools
List of specialized tools required for specific maintenance tasks.
Lubrication Points
Diagram indicating all points requiring lubrication.
Cable & Harness Routing
Visual guide for routing wires and cables to prevent damage.
Wiring Diagram
Electrical system schematic for troubleshooting and repair.
Troubleshooting
Common issues and solutions for engine performance problems.
Inspection and Adjustment
Service Information
General information and safety warnings for inspection and adjustment procedures.
Maintenance Schedule
Periodic maintenance intervals and tasks for various motorcycle systems.
Fuel Line and Filter
Procedures for inspecting and maintaining the fuel supply system.
Throttle Operation
Steps to check and adjust throttle grip free play for smooth operation.
Air Cleaner
Instructions for air cleaner inspection, cleaning, and replacement.
Spark Plug
Guidance on spark plug inspection, cleaning, and gap measurement.
Valve Clearance
Procedure for checking and adjusting engine valve clearances.
Carburetor Idle Speed
Steps for setting and adjusting the engine's idle speed.
Ignition Timing
Method for checking and verifying the engine's ignition timing.
Cylinder Compression
Procedure for testing engine cylinder compression for health assessment.
Engine Oil
Instructions for checking engine oil level and performing oil changes.
Drive Chain
Steps for inspecting drive chain slack and performing adjustments.
Brake and Clutch Systems
Inspection and adjustment procedures for brake and clutch controls.
Suspension
Inspection procedures for front and rear suspension components.
Wheels and Tires
Checks for wheel and tire condition, including pressure.
Steering Handlebar
Inspection of handlebar operation and steering stem for smooth movement.
Lubrication System
Service Information
General instructions and safety precautions for lubrication system service.
Troubleshooting
Diagnosing and resolving common lubrication system issues.
Engine Oil and Oil Filter Screen
Procedures for checking oil level and servicing the oil filter screen.
Oil Pump and Oil Filter Rotor
Steps for removing, inspecting, and installing the oil pump and filter rotor.
Oil Cooler Removal and Installation
Instructions for removing and installing the engine oil cooler.
Fuel System
Service Information
General instructions and safety precautions for fuel system servicing.
Troubleshooting
Diagnosing and resolving common fuel system problems.
Carburetor Removal
Step-by-step guide for removing the motorcycle's carburetor.
Throttle Valve Disassembly
Procedure for disassembling the carburetor's throttle valve assembly.
Float, Float Valve, Jets, and Accelerating Pump
Details on servicing carburetor float, jets, and accelerating pump.
Float Level Inspection
Method for measuring and adjusting the carburetor float level.
Air Cleaner Removal
Instructions for removing the air cleaner assembly.
Fuel Tank
Procedures for removing and installing the motorcycle's fuel tank.
Engine Removal and Installation
Service Information
General instructions and requirements for engine removal/installation.
Torque Values
Specified torques for engine mounting bolts and related components.
Engine Removal
Detailed steps for safely removing the engine from the motorcycle frame.
Engine Installation
Comprehensive guide for reinstalling the engine into the motorcycle frame.
Cylinder Head and Valves
Service Information
General guidelines for servicing the cylinder head and valves.
Specifications
Technical data and service limits for cylinder head and valve components.
Troubleshooting
Diagnosing issues related to cylinder head and valve performance.
Cylinder Head Removal
Step-by-step instructions for removing the cylinder head assembly.
Rocker Arm Set Removal
Procedure for removing the rocker arm assembly.
Cylinder Head Disassembly
Steps for disassembling the cylinder head, including valves.
Valve Guide Replacement
Instructions for replacing worn valve guides.
Valve Seat Inspection and Refacing
Procedures for inspecting valve seats and performing refacing.
Cylinder Head Assembly
Guide for reassembling the cylinder head with valves and springs.
Cylinder Head Installation
Steps for installing the reassembled cylinder head onto the engine.
Cylinder and Piston
Service Information
General instructions for servicing cylinder and piston components.
Troubleshooting
Diagnosing common problems related to cylinder and piston.
Specifications
Technical data and service limits for cylinder, piston, and rings.
Cylinder Removal
Steps for removing the cylinder from the engine block.
Piston Removal
Procedure for removing the piston from the cylinder.
Inspection
Inspection of piston, piston pin, and piston rings for wear.
Cylinder Inspection
Measuring cylinder bore for wear, roundness, and cylindricity.
Piston Installation
Guide for installing piston rings onto the piston and into the cylinder.
Cylinder Installation
Steps for installing the cylinder over the piston and onto the crankcase.
Starter Motor, Generator, Left Crankcase Cover, Starter Clutch, and Camshaft
Service Information
General instructions for servicing starter, generator, and related parts.
Specifications
Technical data for starter motor, generator, and camshaft components.
Troubleshooting
Diagnosing problems with the starting and generating systems.
Starter Motor Removal
Steps for removing the starter motor from the engine.
Left Crankcase Cover and Generator Removal
Procedures for removing the left crankcase cover and generator.
Camshaft Removal
Steps for removing the engine camshaft.
Starter Motor Installation
Guide for installing the starter motor onto the engine.
Clutch and Gear Shift Mechanism
Service Information
General instructions for servicing the clutch and gear shift systems.
Specifications
Technical data and service limits for clutch and gear shift components.
Troubleshooting
Diagnosing issues with clutch operation and gear shifting.
Clutch Removal
Step-by-step guide for removing the clutch assembly.
Gear Shift Mechanism
Procedures for inspecting and servicing the gear shift linkage.
Clutch Friction Disk
Measuring clutch friction disk thickness for wear.
Clutch Plate
Checking clutch plate bending for warpage.
Front Wheel, Suspension, and Steering
Service Information
General instructions for front wheel, suspension, and steering service.
Specifications
Technical data for front wheel, fork, and steering components.
Troubleshooting
Diagnosing problems with steering, suspension, and wheel performance.
Handlebar Removal
Steps for removing the motorcycle handlebars.
Front Wheel Removal
Procedure for removing the front wheel assembly.
Front Fork Removal
Detailed steps for removing the front fork assembly.
Steering Stem Removal
Procedures for removing the steering stem and bearings.
Rear Wheel, Brake, and Suspension
Service Information
General instructions for rear wheel, brake, and suspension service.
Specifications
Technical data for rear wheel, brake, and suspension components.
Troubleshooting
Diagnosing issues with rear wheel, brake, and suspension.
Rear Wheel Removal
Steps for removing the rear wheel assembly.
Rear Brake Removal
Procedure for removing the rear brake panel and components.
Rear Shock Absorber Removal
Steps for removing the rear shock absorbers.
Rear Fork Removal
Procedure for removing the rear fork assembly.
Hydraulic Brake
Service Information
General instructions and safety for hydraulic brake system service.
Specifications
Technical data and limits for brake system components.
Troubleshooting
Diagnosing and resolving hydraulic brake system problems.
Brake Fluid Change and Air Bleed
Procedures for changing brake fluid and bleeding the system.
Brake Pad Replacement
Steps for replacing worn brake pads.
Brake Master Cylinder Removal
Procedure for removing the hydraulic brake master cylinder.
Brake Caliper Removal
Steps for removing the hydraulic brake caliper.
Rear Carrier, Rear Fender, and Exhaust Muffler
Service Information
General instructions for servicing rear carrier, fender, and muffler.
Torque Values
Specified torques for rear carrier and exhaust muffler mounting.
Rear Carrier Removal
Steps for removing the rear carrier.
Rear Fender Removal
Procedure for removing the rear fender.
Exhaust Muffler Removal
Steps for safely removing the exhaust muffler.
Ignition System
Service Information
General instructions for servicing the ignition system.
Specifications
Technical data for spark plug, ignition coil, and related components.
Troubleshooting
Diagnosing and resolving ignition system problems.
Ignition Coil Continuity Test
Checking ignition coil resistance for proper function.
CDI Unit Removal
Steps for removing the CDI unit.
CDI Unit Inspection
Testing the CDI unit for proper operation using resistance measurements.
Pulser Coil Inspection
Checking pulser coil resistance.
Exciter Coil Inspection
Checking exciter coil resistance.
Charging System
Service Information
General instructions for servicing the charging system.
Specifications
Technical data for battery, A.C. generator, and regulator/rectifier.
Torque Values
Specified torques for A.C. generator mounting.
Troubleshooting
Diagnosing and resolving charging system issues.
Battery Removal
Steps for safely removing the motorcycle battery.
Battery Voltage Inspection
Measuring battery open circuit voltage to assess charge state.
Performance Test
Testing the charging system's output under various conditions.
A.C. Generator Inspection
Checking A.C. generator resistance and output.
Regulator/Rectifier Removal
Procedure for removing the regulator/rectifier unit.
Starting System
Service Information
General instructions for servicing the starting system.
Specifications
Technical data for starter motor brush length.
Troubleshooting
Diagnosing and resolving problems with the starting system.
Starter Motor Removal
Steps for removing the starter motor.
Starter Motor Disassembly
Procedures for disassembling the starter motor.
Starter Motor Assembly
Guide for reassembling the starter motor components.
Starter Relay Inspection
Testing the starter relay for proper operation.
Starter Motor Installation
Steps for installing the starter motor onto the engine.
Lights, Instruments, Switches, and Horn
Service Information
General instructions for servicing electrical components.
Specifications
Bulb types and specifications for lights and indicators.
Headlight Removal
Steps for removing and installing the headlight assembly.
Instrument (Speedometer) Removal
Procedure for removing the speedometer and its components.
Ignition Switch
Inspection and testing of the main ignition switch.
Handlebar Switches
Inspection and testing of various handlebar-mounted switches.
Starter Button
Checking continuity of the starter button switch.
Horn Button
Checking continuity of the horn button switch.
Fuel Gauge
Testing the fuel gauge for proper operation.
Fuel Unit Removal
Steps for removing the fuel sender unit from the tank.
Evaporative and Exhaust Emission Control System
Schematic Drawing
Diagram illustrating the evaporative emission control system layout.
Evaporative Emission Control System Function
Explanation of how the evaporative emission system works.
Troubleshooting
Diagnosing and resolving issues with the emission control systems.
Service Information
General instructions and safety for emission system service.
Emission Control System Maintenance Schedule
Schedule for maintaining emission control system components.
Motorcycle Engine Evaporative Emission Control System Test
Procedures for testing the evaporative emission control system.
Purge Control Valve Removal
Steps for removing the purge control valve.
Charcoal Canister Inspection
Checking the charcoal canister for proper function and condition.
P.C.V. (Positive Crankcase Ventilation) System
Information on the PCV system, its removal, and inspection.
Carburetor Adjustment
Procedures for adjusting the carburetor for optimal idle and performance.
Exhaust Emission Test and Adjustment
Performing exhaust emission tests and adjustments.
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