KYMCO KYMCO SR25BA Manuals

Manuals and User Guides for KYMCO KYMCO SR25BA. We have 1 KYMCO KYMCO SR25BA manual available for free PDF download: Service Manual

KYMCO KYMCO SR25BA Service Manual

KYMCO KYMCO SR25BA Service Manual (197 pages)

Brand: KYMCO | Category: Scooter | Size: 30.26 MB

Table of Contents

Table of Contents
2
Location of Frame Serial Number
3
General Information
3
Location of Engine Serial Number
3
Engine/Frame Serial Number
3
Specifications
4
Service Precautions
5
Symbols
12
Torque Values
13
Standard Torque Values
13
Engine
13
Frame
14
Special Tools
14
Lubrication Points
15
Cable & Harness Routing
18
Wiring Diagram
23
Troubleshooting
24
Engine will Not Start or Is Hard to Start
24
Engine Lacks Power
25
Poor Performance at Low and Idle Speed
27
Poor Performance at High Speed
28
Poor Handling
28
Exhaust Muffler/Frame Cover
29
Service Information
29
Noisy Exhaust Muffler
29
Lack of Power
29
Frame Cover
30
Right/Left Side Skirt Removal
30
Rear Career Removal
30
Luggage Box Removal
30
Front Cover Removal
31
Front Bottom Cover Removal
31
Front Center Cover Remoavl
31
Rear Fender & Taillight Len Removal
31
Rear Handlebar Cover Removal
32
Front Handlebar Cover Removal
32
Floorboard Removal
32
Inner Leg Shield Removal
33
Under Cover Removal
33
Exhaust Muffler
33
Front Fender
33
Inspection/Adjustment
34
Engine Oil Capacity
34
Gear Oil Capacity
34
Special Tool
35
Tire Size
35
Tire Pressure
35
Maintenance Schedule
36
Throttle Operation
37
Air Cleaner
38
Air Filter Replacement
38
Maintain Interval
38
Spark Plug
38
Valve Clearance
39
Cylinder Compression
39
Final Reduction Gear Oil
40
Gear Oil Change
40
Drive Belt
40
Brake Fluid
41
Brake Disk/Brake Pad
41
Brake Lever
41
Brake System
41
Headlight Aim
42
Clutch Shoe Wear
42
Suspension
42
Front
42
Nuts/Bolts/Fasteners
43
Wheels/Tires
43
Steering Handlebar
43
Lubrication System
44
Oil Level too Low
45
Poor Lubrication Pressure
45
Oil Change
46
Oil Capacity
46
Oil Level
46
Engine Oil/Oil Filter
46
Oil Pump
47
Table of Contents
52
Injection System
52
System Diagram
53
Fi INJECTION SYSTEM
53
Parts Drawing
54
General Instructions
55
Service Information
55
Troubleshooting
56
Check Engine Lamp (Celp)
57
How to Show the Failure Code
58
- DTC Code List
  59
- Function and Structure
  63
- Disassembly of ECU Module
  63
Synerject M3A Ecu Module
63
- ECU Module Replacement
  64
- Ecu Moudle
  65
- Ecu Module Coupler
  66
To Initial Tps and Abv
67
- Ecu Adapt the New Thottle Position Voltage
  68
- Inspection or Re-Adjustment of the Output Voltage of Throttle
  68
- Fuel Pump
  69
- T-MAP Sensor
  69
- TPS (Throttle Position Sensor)
  70
- Engine Temperature Sensor
  70
- Inspection
  70
- Injector
  71
- FI Fuel Injector Cleaning Method
  72
O2 Sensor
73
Roll Sensor
74
The Ignition Switch Is Turned on
75
TPI and ABV Initialization
75
- Fi Diagnostic Tool Operation Instructions
  77
- Dtc Inspection Procedure
  78
- Dtc Clear Procedure
  81
- Data Analysis
  82
- Engine Removal/Installation
  86
- Engine Hanger Bracket Installation
  89
- Engine Installation
  89
- Cylinder Head/Valves
  90
- Abnormal Noise
  92
- Compression too High
  92
- Compression too Low
  92
- Poor Performance at Idle Speed
  92
- Camshaft Removal
  93
- Camshaft Holder Disassembly
  95
- Camshaft Inspection
  95
- Cylinder Head Removal
  96
- Cylinder Head Disassembly
  97
- Cylinder Head Inspection
  98
- Valve Spring
  98
- Valve/Valve Guide
  98
- Cylinder Head Assembly
  99
- Cylinder Head Installation
  99
- Camshaft Holder
  100
- Camshaft Installation
  100
- Cylinder/Piston
  101
- Abnormal Noisy Piston
  102
- Compression too Low or Uneven Compression
  102
- Cylinder Removal
  103
- Piston Removal
  103
- Cylinder Inspection
  105
- Piston Ring Installation
  106
- Cylinder Installation
  107
- Piston Installation
  107
- Final Reduction
  109
- Engine Starts but Motorcycle Won't Move
  110
- Final Reduction Disassembly
  111
- Final Reduction Inspection
  111
- Bearing Replacement
  112
- Transmission Case Cover
  112
- Final Reduction Assembly
  113
- Left Crankcase
  113
- Crnakcase/Crankshaft
  116
- Excessive Engine Noise
  117
- Crankcase Separation
  118
- Crankshaft Inspection
  119
- Crankcase Assembly
  120
- Front Wheel/Brake/Suspension
  122
- Front Wheel/Brake/Suspension
  124
- Service Information
  124
  - Front Wheel Wobbling
    125
  - Hard Steering (Heavy)
    125
  - Poor Brake Performance
    125
  - Steers to One Side or Does Not Track Straight
    125
- Troubleshooting
  125
- Front Wheel
  126
- Bearing Inspection
  127
- Bearing Replacement
  127
  - Brake Fluid Bleeding
    130
  - Brake Fluid Refilling
    130
  - Brake Pad/Disk Replacement
    130
- Hydraulic Brake
  130
- Brake Disk
  131
- Front Suspension
  132
- Steering Handlebar
  135
  - Ball Race Replacement
    136
  - Bottom Cone Race Replacement
    136
- Steering Stem
  136
  - Bottom Cone Race Installation
    137
  - Handlebar Installation
    138
  - Rear Wheel/Rear Brake/Rear Suspension
    139
  - Rear Wheel Wobbling
    140
  - Soft Rear Shock Absorber
    140
  - Rear Brkae
    141
  - Rear Wheel
    141
  - Brake Lining Inspection
    142
  - Rear Brake Assembly
    142
  - Rear Brake Disassembly
    142
  - Rear Shock Absorber Removal
    143
  - Battery
    145
  - Charging System Diagram
    145
  - Charging System Failure
    147
  - Intermittent Power
    147
  - Low Power
    147
  - No Power
    147
  - Battery Charging
    148
  - Battery Removal
    148
  - Battery Voltage Inspection
    148
  - Charging Performance
    149
  - Charging System
    149
  - Resistance
    149
  - Performance Test
    150
  - Regulator/Rectifier
    150
  - A.C. Generator
    151
  - Ignition System
    155
- Ignition System Layout
  156
- Ignition Circuit
  157
  - Low Peak Voltage
    158
  - No Peak Voltage
    158
  - Peak Voltage Is Normal, but no Spark Jumps at the Plug
    158
- Service Information
  158
- Troubleshooting
  158
- Ac Generator
  159
- Ignition Coil
  159
  - Modes of Trouble
    160
  - Tilt Switch
    160
  - Tilt Switch Removal
    161
  - Voltage Measure
    161
  - Starting System
    162
  - Starter Motor Won't Turn
    163
  - Performance Inspection
    164
  - Starter Motor Removal
    164
  - Starter Relay
    164
  - Volt Inspection
    164
  - Starter Clutch Removal
    165
  - Starter Relay Ground Circuit Inspection
    165
  - Clutch Body Disassembly
    166
  - Starter Clutch Disassembly
    166
  - Light/Instrument/Switch
    169
  - Fuel Gauge Pointer Does Not Register Correctly
    170
  - Fuel Gauge Pointer Fluctuates or Swing
    170
  - Light Dims
    170
  - Bulb Replacement
    171
  - Headlamp
    171
  - Taillamp/Brake Lamp/Rear Winker Lamp
    171
  - Engine Stop Switch
    172
  - Headlight Switch
    172
  - Ignition Switch
    172
  - Dimmer/Passing Switch
    173
  - Horn Switch
    173
  - Starter Switch
    173
  - Turn Signal Switch
    173
  - Fuel Gauge
    174
  - Fuel Unit
    174
  - Horn
    174
  - Stop Switch
    174
  - Speedometer
    175
  - Speedometer Replacement
    175
  - Evaporative / Emission Control System
    178
- Schematic Drawing
  178
- Evaporative Control System
  180
- Service Information
  180
  - Purge Control Valve
    181
  - P.C.V. (Crankcase Blow By)
    182
  - Purge Control Valve Flow Inspection
    182
- Charcoal Canister
  183
- Emission Control System
  184
  - Backfiring at Sudden Deceleration
    185
  - Exhaust Muffler Noise
    185
  - High CO at Idle Speed
    185
- Troubleshooting
  185
- Secondary Air Cleaner / A.I.C.V
  186
- Reed Valve
  187
- Fi Diagnostic Tool
  188
- DTC Inspection
  190
- DTC Clear
  193

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