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Summary of Contents for KYMCO Downtown 125i
- Page 1 DOWNTOWN 125i By KWANG YANG Motor Co., Ltd. 1st Edition, April 2009 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited. T100-LFA7-A2...
- Page 2 DOWNTOWN 125i PREFACE TABLE OF CONTENTS This Service Manual describes the GENERAL INFORMATION technical features servicing EXHAUST MUFFLER/FRAME procedures KYMCO Downtown 125i. COVERS INSPECTION/ADJUSTMENT Section 1 contains the precautions for all operations stated in this manual. LUBRICATION SYSTEM Read them...
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Page 3: General Information
1. GENERAL INFORMATION DOWNTOWN 125i ENGINE SERIAL NUMBER ....1- 1 LUBRICATION POINTS......1-14 SPECIFICATIONS ........SERVICE PRECAUTIONS ..... TORQUE VALUES ........SPECIAL TOOLS........1-12 ENGINE SERIAL NUMBER Location of Engine Serial Number - 1 -... - Page 4 1. GENERAL INFORMATION DOWNTOWN 125i SPECIFICATIONS Air cleaner type & No Paper element, wet Fuel capacity 12.5 L Name DOWNTOWN125i Model No. SK25AA Butterfly type Throttle type Overall length 2200mm Overall width 800 mm Overall height 1410 mm Type Wheel base...
- Page 5 1. GENERAL INFORMATION DOWNTOWN 125i SERVICE PRECAUTIONS Make sure to install new gasket, O-rings, circlips, cotter pins, etc. When reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to specified torque diagonally.
- Page 6 1. GENERAL INFORMATION DOWNTOWN 125i Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two person work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation.
- Page 7 1. GENERAL INFORMATION DOWNTOWN 125i If the fuse is burned out, find the cause Confirm and repair it. Replace it with a new one Capacity according to the specified capacity. After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation.
- Page 8 1. GENERAL INFORMATION DOWNTOWN 125i The connector shall be inserted completely. click If the double connector has a lock, lock it at the correct position. Check if there is any loose wire. Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
- Page 9 1. GENERAL INFORMATION DOWNTOWN 125i After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
- Page 10 1. GENERAL INFORMATION DOWNTOWN 125i Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner. When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
- Page 11 1. GENERAL INFORMATION DOWNTOWN 125i After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
- Page 12 1. GENERAL INFORMATION DOWNTOWN 125i Symbols : The following symbols represent the servicing methods and cautions included in this service manual. :Apply engine oil to the specified points. (Use designated engine oil for lubrication). Engine Oil :Apply grease for lubrication.
- Page 13 1. GENERAL INFORMATION DOWNTOWN 125i TORQUE VALUES STANDAR TORQUE VALUES Item Torque (kg - f m) Item (kg - f 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...
- Page 14 1. GENERAL INFORMATION DOWNTOWN 125i 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 (Refer to the “STARTER A120E00003 CLUTCH” section in the chapter 10.)
- Page 15 1. GENERAL INFORMATION DOWNTOWN 125i SPECIAL TOOLS Illustration (Note: the special tools may differ Tool Name Tool No. slightly from those shown in the figure of this manual.) Bearing puller A120E00037 Valve spring compressor (Refer to the “CYLINDER A120E00040 HEAD” section in the chapter 6.) Lock nut wrench (Refer to the “STEERING...
- Page 16 DOWNTOWN 125i LUBRICATION POINTS ENGINE Lubrication Points Lubricant Valve guide/valve stem movable part Genuine KYMCO Engine Oil (SAE15W-40) Cam lobes API , SJ Engine Oil Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves...