KYMCO Downtown 125i 2009 Manual de usuario

DOWNTOWN 125i

By KWANG YANG Motor Co., Ltd.

1st Edition, April 2009

unauthorized use without the written

permission of KWANG YANG Motor Co., Ltd.

is expressly prohibited.

T100-LFA7-A2

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DOWNTOWN 125i

PREFACE

This Service Manual describes the

technical features and servicing

procedures for the KYMCO

Downtown 125i.

Section 1 contains the precautions for

all operations stated in this manual.

Read them carefully before any

operation is started.

Section 2 is the removal/installation

procedures for the frame covers which

are subject to removal/installation

frequency during maintenance and

servicing operations.

Section 3 describes the inspection/

adjustment procedures, safety rules

and service information for each part,

starting from periodic maintenance.

Sections 5 to 11 give instructions for

disassembly, assembly and

adjustment of engine parts. Section

13-14 is the AFI system. Section 15 to

16 is the removal/ installation of

chassis. Section 17 to 20 states the

testing and measuring methods of

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.

KWANG YANG MOTOR CO., LTD.

QUALITY TECHNOLOGY DEPT.

EDUCATION SECTION

TABLE OF CONTENTS

GENERAL INFORMATION

EXHAUST MUFFLER/FRAME

COVERS

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE AND DRIVEN PULLEYS

FINAL REDUCTION

A.C. GENERATOR/STARTER

CLUTCH

CRANKCASE/CRANKSHAFT

COOLING SYSTEM

Fi DIAGNOSTIC TOOL OPERATION

FUEL INJECTION SYSTEM

HANDLEBAR/FRONT

WHEEL/FRONT BRAKE/FRONT

SHOCK ABSORBER/STEERING

STEM

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER`

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

LIGHTS/METERS/SWITCHES

The information and contents

included in this manual may be

different from the motorcycle in case

specifications are changed.

CHASSIS ELE

TRI

EQUIPMENT

ENGINE

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ENGINE SERIAL NUMBER ................... 1- 1

Location of Engine Serial Number

ENGINE SERIAL NUMBER

1-1

1. GENERAL INFORMATION

-1-

SPECIFICATIONS

SERVICE PRECAUTIONS

TORQUE VALUES

SPECIAL TOOLS....................................1-12

...................................

.....................

..................................

LUBRICATION POINTS..........................1-14

DOWNTOWN 125i

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1. GENERAL INFORMATION

SPECIFICATIONS

-2-

Name DOWNTOWN125i

Model No. SK25AA

Overall length 2200mm

Overall width 800 mm

Overall height 1410 mm

Wheel base 1542 mm

Engine type O.H.C.

Displacement 124.8cc

Fuel Used 92# nonleaded gasoline

Front wheel 68

Net weight (kg) Rear wheel 96

Total 164

Front wheel 70

Gross weight(kg) Rear wheel 104

Total 178

Front wheel 120/80-14

Rear wheel 150/70-13

RR Ground clearance 140 mm

Perform- Braking distance (m) 7.9m/30km/h

ance Min. turning radius 2600mm

Starting system Starting motor

Type liquid cooled 4 stroke

Cylinder arrangement Single cylinder

Combustion chamber type Semi-sphere

Valve arrangement O.H.C.4V

Bore x stroke (mm) 54 x 54.5

Compression ratio 11.7:1

Compression pressure

(kg/cm²)15

Max .horsepower (ps/rpm) 15/8750~9000

Max. torque (kg m/rpm) 1.17/8500~8750

Intake Open 8 °BTDC

Port (1mm) Close 31° BTDC

timing Exhaust Open 32° BTDC

(1mm) Close 6 °BTDC

Valve Intake 0.10 mm

clearance Exhaust 0.10 mm

Idle speed (rpm) 1850rpm

Lubrication type Forced pressure &

Wet sump

Oil pump type Inner/outer rotor type

Oil filter type Full-flow filtration

Oil capacity 1.2 L

Exchanging capacity 1.0 L

Cooling Type Liquid cooling

Tires

Engine

Lubrication

System

Air cleaner type & No Paper element, wet

Fuel capacity 12.5 L

Throttle type Butterfly type

Type ECU

Spark plug NGK CR7E

Sparkpluggap 0.6～0.7mm

Battery Capacity 12V10AH

Clutch Type Dry multi-disc clutch

Type Non-stage transmission

Operation Automatic centrifugal

type

Type Two-stage reduction

Reduction 1st 0.83~2.2

ratio 2nd 10.41

Front Caster angle 28°

Axle Trail length 140mm

Tire pressure Front 2.0

(kg/cm²)1

person Rear 2.25

Turning Left 40?

angle Right 40?

Brake system Front Disk brake

type Rear Disk brake

Front Telescope

Suspension

type Rear DOUBLE SWING

Frame type PIPE UNDER BONE

Reduction

Gear

Transmis-

sion Gear

Fuel System Power Drive System

Electrical Equip.

Ignition System

Moving Device Damping

Device

DOWNTOWN 125i

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1-3

SERVICE PRECAUTIONS

When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to specified torque

diagonally.

Use genuine parts and lubricants.

When servicing the motorcycle, be sure to

use special tools for removal and installation.

After diassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

Make sure to install new gasket, O-rings, circlips,

cotter pins, etc. When reassembling.

1. GENERAL INFORMATION

-3-

DOWNTOWN 125i

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1. GENERAL INFORMATION

Disconnect the battery negative (-) terminal

before operation.

-4-

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.

When using a spanner or other tools, make

sure not to damage the motorcycle surface.

After operation, check all connecting points,

fasteners, and lines for proper connection

and installation.

When connecting the battery, the positive

(+) terminal must be connected first.

After connection, apply grease to

the battery terminals.

Terminal caps shall be installed securely.

DOWNTOWN 125i

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1-5

Confirm

Capacity

If the fuse is burned out, find the cause

and repair it. Replace it with a new one

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.

Hold the connector body when connecting

or disconnecting it.

Do not pull the connector wire.

Check if any connector terminal is bending,

protruding or loose.

1. GENERAL INFORMATION

-5-

DOWNTOWN 125i

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click

If the double connector has a lock, lock it

at the correct position.

The connector shall be inserted completely.

Check if there is any loose wire.

Before connecting a terminal, check for

damaged terminal cover or loose negative

terminal.

Check the double connector cover for

proper coverage and installation.

Insert the terminal completely.

Check the terminal cover for proper coverage.

Do not make the terminal cover opening

face up.

Secure wire harnesses to the frame with

their respective wire bands at the designated

locations.

Tighten the bands so that only the insulated

surfaces contact the wire harnesses.

1. GENERAL INFORMATION

-6-

DOWNTOWN 125i

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1-7

No contact !

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.

When fixing the wire harnesses, do not make

it contact the parts which will generate high

heat.

Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of bolts

and screws.

Route wire harnesses passing through the side

of bolts and screws. Avoid the projected ends

of bolts and screws.

1. GENERAL INFORMATION

-7-

DOWNTOWN 125i

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Do not pull

too tight!

Do not press or

squeeze the wire.

Route harnesses so they are neither pulled

tight nor have excessive slack.

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.

Do not break the sheath of wire.

If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape

or replace it.

When installing other parts, do not press

or squeeze the wires.

1. GENERAL INFORMATION

-8-

DOWNTOWN 125i

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