Dear KYMCO Motorcycle Users:
Thank you for purchasing this KYMCO Motorcycle and welcome to the family of KYMCO Motorcycle riders.To enj oy safer and
more pleasant riding,become throughly familiar with this owner manual before you ride the Motorcycle.
You safety depends not only on your own alertness and familiarity with the Motorcycle but also the Motorcycle mechanical
condition.
A pre-ride inspection before every outing and regular maintenance are essential.The quality of each KYMCO motorcycle is
guaranteed.
Note:1.The infomation and specifications stated in this manual are for reference
only and subject to change without notice.
2.When starting the engine,the battery must be installed to facilitate
starting and increase the engine performance.
3.Our company reserves to design the alteration's rights.If the product is not
the same as the Manual.please according to the actual product.we will not
notice you again.
TABLE OF CONTENTS
1.PRECAUTIONS FOR A SAFE RIDING……………………………………………………………………………………1
2.ASSEMBLY PARTS…………………………………………………………………………………..…………..……….3
3.OPERATION INSTRUCTIONS…………………………………………………………………..……………..……….5
IGNITION SWITCH/STEERING&HANDLEBAR LOCK……………………………....………………………………..5
ELECTRIC STARTER BUTTON.HEADLIGHT SWITCH………………………………….………………..………….6
HEADLIGHT DIMMER SWITCH…………………………………………………………………………..……………. 7
HORN BUTTON/TURN SIGNAL SWITCH……..………………………………………………………..……………….7
SEAT LOCK/MET-IN BOX.HELMET BUCKLE…………………………………..……………………..……………….8
INSTRUMENTS …………..………………………………………………………………………………..……………….9
4.PRE-RIDEINSPECTION…………………………………………………………………………………………….…….10
ADVANCE INSPECTION.ENGINE OIL LEVEL INSPECTION/REFILLING………………………..…………………10
BRAKE INSPECTION.TIRE INSPECTION……………………………………………………………..…………………11
FUEL LEVEL INSPECTION/REFILLING………………………….……………………………………..……………….13
STEERING HANDLEBAR.INSTRUMENT LIGHTS INSPECTION……………………………………..……………….14
BRAKE LEVER FREE PLAY INSPECTION&ADJUSTMENT……………………………………………..…………….15
CLUTCH PANEL INSPECTION&ADJUSTMENT………….…………………………………………..…………………15
CHOKEKNOB…………………………………………………………………………………………………………….…17
TABLE OF CONTENTS
5.ENGINE STARTING METHODS…………………………………………………………………………………….…….19
USE THE ELECTRIC STARTER BUTTON……………………………………………………………………………….. 20
START WITH THE KICK LEVER…………………………………………………………………………………………...21
6.NORMAL RIDING METHOD…………..…………………………………………………………………………………..22
7.PRECAUTIONS FOR RIDING……………….………………………………………………………………………….….24
8.ACCELE ROGRAPH LOCK………………………………………………………………………………………………...27
9.HOW TO STOP RIDING……………………………………………………………………………………………………..28
10.EASY MAINTENANCE……………………………………………………………………………………………………...30
AIR CLEANER INSPECTION AND AIR CLEANER CLEANING&REPLACEMENT……………………..……………...30
BATTERY….………………………………………………………………………………………………………………….. 32
FUSE CHANGE………………………………………………………………………………………………………………...33
ENGINE OIL CHANGE……………………..………………………………………………………………………………...34
SPARK PLUG INSPECTION………..…………………………………………………………………………………….…..35
11.IMPORTANT NOTICES……………………………………………………………………………………………………...37
POLLUTION-FREE PERIODIC MAINTENANCE SCHEDULE………………………..……………………………….….38
SPECIFICATIONS……………………………………………………………………………………………………………..39
12.EXEXHAUST EMISSION CONTROL SYSTEM…………..………………………………………………………40
1.PRECAUTIONS FOR A SAFE RIDING
(1)CLOTHES
· To relax and wear comfortable clothes are the
main points for a safe riding.
· To observe traffic laws,keep a cool mind,relax
and be careful will provide you a safe riding.
①Wear helmet and fasten it tightly.
②Have the clothes well arranged.Fasten shirt cuffs
and keep them from hooking the brake lever.
③Wear low-heeled shoes for a safe riding.
④When riding,use both hands to grasp the
handlebar.It is very dangerous to hold the
handlebar with one hand.
! CAUTION:
·
A motorcycle rider should not wear loose or too
long clothes to avoid danger.
·During riding or 10 minutes after the motorcycle
is stopped,do not touch the exhaust muffler to
avoid scalding.
·When parking the motorcycle,keep it away from
dry lawn or inflammables to avoid danger.
1
(2)RIDING METHOD
·The safety of two wheel vehicles is influenced by
sitting position.The rider should sit on the central
part of the seat cushion.If the rider sits on the rear
part of the seat,the load of front wheel will
decrease.As a result,the handlebar will swing and
cause danger to the rider.
·When making a turn,it will be easier for the rider
to steer the motorcycle by leaning the body inward
slightly.The motorcycle will lose its balance if the
rider fails to keep his body leaning inward.
·When riding on a damaged or macadam road.Slow down
the speed and hold the handlebar tightly.
2
2.ASSEMBLY PARTS
①Tool Box
②Fuel Tank Cap
③Taillight/Stoplight
④L.Rear Turn Signal Light
⑤Main Stand
⑥Side Stand
⑦Engine Serial Number
⑧Change Gear Shift Pedall
⑨L.Front Turn Signal Light
⑩Turn Signal Switch
Headlight Dimmer
Switch
Passing Signal Switch
Horn Button
3
①Instruments
②Headlight
③R.Front Turn
Signal Light
④Rear Brake Lever
⑤Kick Lever
⑥Frame Serial Number
⑦Exhaust Muffler
⑧R.Rear Turn
Signal Light
⑨Ignition Switch
⑩Headlight Switch
Electric Starter Button
11
Escutcheon plate
4
3.OPERATION INSTRUCTIONS
(1) IGNITION SWITCH/STEERING&HANDLEBAR LOCK
① ON :At this position,power is connected to
start the engine.The key cannot be taken out.
② OFF :At this position,power is cut off and the
engine stops.The key can be taken out.
③ LOCK:At this position,the steering handlebar is
locked.The key can be taken out.
《Locking Method》
Turn the steering handlebar left to the full and
then push and turn the ignition switch key left
to the “ LOCK ” position,the handlebar can be
locked.
《Unlocking Method》
Turn the ignition switch key right to the “OFF”
and the“LOCK” is released automatically.
CAUTION:
·
After locking,turn the handlebar gently to make
sure that it is locked.
·Do not trun the ignition switch to the “LOCK”
Position during riding,otherwise the handlebar
will be out of control and cause accidents.
·Don`t park your motorcycle at a place to hinder the
traffic.
5
(2)ELECTRIC STARTER BUTTON
·To start the engine,first turn on the ignition
switch and then push the electric starter button.At
this time,be sure to fully apply the front or rear
brake lever (pedal) in order to connect the power.
CAUTION:
·
During engine running,do not push the electric
starter button to avoid engine demage.
·Turn the headlight switch off and turn signal
switch off before using the electric starter button.
·Release the electric starter button immediately
after the engine is started.
(3)HEADLIGHT SWITCH
At this position,the position light,headlight,instru ment
●
lights and taillight turn off together.
At this position,the position light,instrument lights and
taillight light turn on .
¤ At this position,the position light,headlight,instrument
lights and taillight light all turn on.
6
(4)HEADLIGHT DIMMER SWITCH
① Switch to this position for using high beam.
② Wh e n r id in g i n do wn t ow n a r ea or there is a car coming
from the opposite direction,use low beam to avoid
affecting the visibility of coming cars.
③PASSING When passing,if there are cars coming from the
opposite direction,press and release the
PASSING switch and the headlight will wink to
warn the coming cars.
CAUTION:
This indicator comes on when the long distance light is
turned on.
(5)HORN BUTTON/TURN SIGNAL SWITCH
·When the ignition switch key is turned the“ON”position,
push the horn button and it will sound.
to the right.
②←For turning to the left.③Push the
turn signal switch button to release it.
·The horn and turn signal switch do not work when the
①→For turning
④Horn button.
ignition switch is the“OFF”.
CAUTION:
·
The turn signal light will not release automatically. Be
sure to reset it after use;otherwise it may affect the
traffic safety.
7
(6)SEAT LOCK
·Unlock the seat and put the helmet in the MET-IN box.
《Un l oc k i n g Method》
Stop the engin and turn the ignition switch to the “OFF”
position.Insert the ignition switch key into the seat lock
and turn it right.
·To lock the seat,push on it until it lock automatically.
Make sure the seat is secure before riding.
CAUTION:
Never put the key inside the seat cushion to lock the seat.
(7)HELMET BUCKLE
1.Open the seat with the ignition switch key and lift up the
seat.
2.Put the helmet retaining ring into the helmet buckle.
3.Put down the seat and it will lock automatically.
·Take out the helmet in the reserve order of the above steps.
CAUTION:
·
When riding,wear the helmet and do not retain it on the
motorcycle to avoid damage of coated parts.
8
(8)INSTRUMENTS
① MILEAGE COUNTER:The total riding mileage is
indicated by kilometer.The figure in black and
white is an unit of 100m.
②TURN SIGNAL INDICATOR:When the turn signal switch
is operated,this indicator will wink.
③HIGH BEAM INDICATOR:This indicator comes on when
the long distance light is turned on.
④FUEL GAUGE:The fuel gauge is to show the volume
of gasoline in the fuel tank.If the fuel gauge
pointer is at the red arer,the fuel is
insufficient.Refill nonleaded gasoline as soon
as possible.
⑤ SPEEDOMETER:The riding speed is indicated by
km/hour or mph.
⑥SPEED POSITION INDICATOR:When the engine is at
the neutral or the others speed position,this
indicator will come on
when the ignition switch is on.
①②②③
⑥⑤ ④
9
4.PRE-RIDE INSPECTION
(1)ADVANCE INSPECTION
· Get into a good habit of inspection before
riding.For the sake of safety and to prevent
vehicle damage and traffic accidents,the
pre-ride inspection is absolutely required.
CAUTION:
·
Be sure to perform inspection and maintenance for
your new motorcycle after it is ridden for 300km.
(2)ENGINE OIL LEVEL INSPECTION/REFILLING
·Place the motorcycle on its main stand.Take out
the oil dipstick and wipe it clean.
·Directly insert the oil dipstick into the engine
oil. (Don`t screw it in.)
· Take out the oil dipstick and check the oil
level.If it is close to the lower limit,add
engine oil to the upper limit.
CAUTION:
·The temperature of engine and exhaust muffler is
very high. When checking the oil level,be careful
to avoid scalding.
· Riding with insufficient engin oil will cause
breakdown easily.
10
(3)BRAKE INSPECTION
·
·The brake lever should have proper free play.
· “ Free play ” means the distance from the
·Measure the free play at the brake lever pedal
Ride the motorcycle at low speed on a dry road
and respectively apply the front brake lever
and rear brake pedal to check the brake
performance.
position of loose brake to the position of fully
applied brake.
end and check if it is within the specified
value of (2～3cm rear brake).
(4)TIRE INSPECTION
1.TIRE TRESSURE CHECK
·Check if the tire pressure is normal when the tire
is in contact with level ground.
·If there is any abnormal condition,check the tire
pressure with a tire pressure gauge.
·Measure the tire pressure under room temperature.
·The tire pressure must not overpass 2.50kg/cm
11
2.CRACKS & DAMAGE
· Check the tire-contact area for crack or damage.
3.ABNORMAL WEAR
·Check the tire-contact area for abnormal wear.
4.FOREIGN OBJECTS OF METAL PLECE & GRAVEL
·Check the tires and tire-contact area for
imbedded objects of metal plece and gravel.
5.DEPTH OF TIRE GROOVE
·If the tire is worn to the wear limit indication
mark,replace it with a new one.
NORMAL PRESSURE(1 Rider/2 Riders)
Front Wheel 1.75/2.0kg/cm
Rear Wheel 1.75/2.25kg/cm
CAUTION:
·
Abnormal tire pressure,crack,damage and abnormal
wear will cause unsteady handlebar and result in
tire break.
·If the tire has cracks or is worn to the wear limit
indication mark,replace it with a new one.
12
(5)FUEL LEVEL INSPECTION/REFILLING
Check if the fuel is sufficient.
·
·If the fuel gauge pointer is at red grid,refill
#92 or#95 nonleaded gasoline as soon as
possible.
《Refilling Method》
1.Stop the engin and turn the ignition switch to the
“OFF” position.
2.Insert the ignition switch key into the seat lock
(Refer to P8) and turn it right to unlock the seat.
3.Open the seat.
4.Turn the fuel tank cap counterclockwise with hand
to open the cap.
5.Turn the fuel tank cap clockwise to tighten it.
6.Close the fuel tank cap in the reverse order of
opening.
CAUTION:
·
Be sure to stop the engine before refilling.
·The gasoline level shall not exceed the reference
plate;otherwise the fuel will penetrate out.
·When refilling,do not add other additives to
avoid engine breakdown.
①Unlock ②Lock
13
(6)STEERING HANDLEBAR
Visually inspect the steering handlebar for
·
damage.
·Apply the front brake and move the handlebar
upward and downward to check for abnormal noise.
·Move the steering handlebar
upward,downward,rightward and leftward to check
for any loose parts.
·Check if the handlebar rotates freely.
·If any abnormal condition is found,go to your
motorcycle dealer or for inspection.
(7)INSTRUMENT LIGHTS INSPECTION
Check the speedometer pointer for proper
·
operation.
·Check the fuel gauge pointer for proper
operation.
·Check the turn signal indicator and high beam
indicator for proper operation.
14
(8)BRAKE LEVER FREE PLAY INSPECTION & ADJUSTMENT
·Adjust the rear brake pedal free play with the
brake adjusting nuts.
·After adjustment,fully apply the rear brake pedal
and check if the free play is within the specitied
value(2～3cm).
①Increase play ②Decrease play
CAUTION:
·
After the brake is adjusted,align the groove of
adjusting nut with the pin in order to avoid
accident and danger during riding.
(9)CLUTCH PANEL INSPECTION & ADJUSTMENT
·Check the clutch panel for proper operation.
·If adjustment is necessary,turn the adjusting
bolt by loosing the lock nut.
①Lock Nut ②Adjusting Bolt
CAUTION:
·
If it is hard to adjust for you ,go to a KYMCO
distributor or service station for inspection.
15
(10)HORN/LIGHTS INSPECTION
·
Turn the ignition switch to the “ON” position
and push the horn button to check if it sounds.
·Headlight/Tailight Inspection:
Start the engine and turn on the headlight switch
to check if the headlight and taillight are good
and check the light shells for dirt and damage.
·Stoplight Inspection:
Apply the front and rear brake levers
respectively to check if the stoplight is
good.And also check the stoplight shell for dirt
and damage.
·Turn Signal Light Inspection:
Operate the turn signal switch to make sure
whether the right/left front and rear turn signal
lights can wink and buzz.Also check the light
shells for dirt and damage.
① Headlight ②Taillight/Stoplight
③ Turn signal light ④ Horn button
CAUTION:
·Replace any dirty or damaged lights with new ones
to avoid danger during riding.
④
16
(11)CHOKE KNOB
·For cold starting,pull down the choke
knob.After the engine warms up,restore the
choke knob to its original position.
CAUTION:
·Do not use the choke knob for a long
time;otherwise the mixture will become too
rich and cause engine stop.
(12)DRIVE CHAIN INSPECTION/ADJUSTMENT
·The chain should have a slack of 1～2cm in its
center between the two sprockets.
·Adjustment:Loosen the rear axle nut and turn the
adjusting nut until the index mark is aligned
with the punch mark on the adjuster.Then
tighten the rear axle nut.
① Rear Axle Nut ② Adjusting Nut
·The rear wheel will move backward during
adjustment,so the rear brake free play shall
also be adjusted.
17
(13)FRONT/REAR SHOCK ABSORBER INSPECTION
·Check the condition of the front/rear shock
absorbers by pressing down on the handlebar and
seat several times.
(14)BRAKE PERFORMANCE INSPECTION
·Fully apply the front and rear brake lever pedal
and move the motorcycle forward to see if the
braking effect is good.
(15)REAR MIRROR ANGLE CHECK
·Sit on the motorcycle uprightly and make a viewing
test bof the rear mirror angle.
(16)LICENSE PLATE CHECK
·Check the license plate for dirt and damage,then
tighten it.
(17)REFLECTOR CHECK
·Check the reflector for dirt and damage.
(18)PREVIOUS ABNORMAL PARTS INSPECTION
·Make sure that the previous abnormal parts are
repaired.
(19)LUBRICATION POINT CHECK
·Visually check if all motorcycle lubrication
points are lubriated properly.
18
5.ENGINE STARTING METHODS
(1)TURN THE IGNITION SWITCH“ON”
·Unlock the steering handlebar.
·Turn the ignition switch“ON”position.
CAUTION:
·Check the gasoline volume and engine oil level
before starting the engine.
(2)USE NEUTRAL POSITION
·The engine must be started in the neutral
position.When the ignition switch is ON,the neutral
position indicator comes on.
19
(3)USE THE ELECTRIC STARTER BUTTON
·Push the electric starter button without rotating
the throttle grip.
·If the engine fails to start after the electric
starter button is pressed for 3～4 seconds,rotate
the throttle grip for 1/8～1/4 turn to facilitate
starting.
·When the motorcycle is not used for a long time or
the fuel tank is empty,if the engine is still hard
to start after the fuel tank is refilled with
gasoline,pull up the choke knob,slightly turn the
throttle grip and push the electric starter button
for several times to start the engine.
·In order to avoid battery overcharge,do not press
the starter button more than 5 seconds.
·If the engine does not start after the electric
starter button is pushed for 5 seconds,wait for more
than 5 seconds and then push the button again or
start the engine by the kick lever.
CAUTION:
·Don`t push the electric starter button while the
engine is running;otherwise the engine will be
damaged.
·After the engine warms up,restore the choke knob to
its original position.
①
N
②
③
④
20
(4)START WITH THE KICK LEVER
1.Place the motorcycle on its main stand on
levelground.
2.Depress the kick lever with force.
·When the engine is cold and does not start after
the kick lever is depressed for 3～4
times,rotate the throttle grip for 1/8～1/4
turn to facilitate starting.
·Warm up the engine for a little while (about
2～3 minutes)after cold start.
·After the engine is started,do not accelerate
suddenly and keep riding at low speed to prolong
the engine service life.
CAUTION:
·After the engine is started,the kick lever must
be returned to its original position.
·The exhaust contains poisonous carbon monoxide
which is harmful to human body.Never run the
engine in a closed area.
·Turn off all light switches before starting the
motorcycle.
21
6.NORMAL RIDING METHOD
(1)STARTING THE ENGINE
·Start the engine by referring to the starting
methods specified in Section 5.
CAUTION:
·Keep your finger away from the button
immediately after the engine is started to
avoid engine damage.
·The rear brake pedal should be kept at the
braking position before riding.
(2)REBOUND THE MAIN STAND
·Keep the rear brake pedal at braking position
and push the motorcycle forward,then the main
stand will rebound automatically.
CAUTION:
·After starting the engine and before moving,do
not turn the throttle grip to increase the
engine rpm.
22
(3)CORRECT SITTING POSITION
·Ride astride on the motorcycle from the left
side and sit upright.Touch the ground with
left foot to avoid slipping.
CAUTION:
·The rider must wear helmet,gloves and goggles.
·Do not wear any clothes which will affect
riding safety.
(4)SHIFTING
·Depress the change gear shift pedal into the
1st speed.Slowly rotate the throttle grip at
the same time.Then the motorcycle will move
smoothly.
CAUTION:
·When changing speed,the throttle grip must be
turned to the closed
position.Otherwise,damage to the engine and
drive chain can result.
23
7.PRECAUTIONS FOR RIDING
(1)CORRECT RIDING
·Before moving,turn on the turn signal light and
make sure whether the rear side is safe.
·Do not rush into the car lanes and always keep
the motorcycle to the right side to avoid
danger.
CAUTION:
·Moderate riding will prolong the engine
service life.The clutch linings are worn more
quickly when often ridden at low speed.
(2)SPEED CONTROL
·The speed is controlled by the throttle grip.
① RO TATE The speed will become faster.Don`t be hasty
to accelerate.
When riding on an ascending
road,rotate the throttle grip gradually
to increase the horse power.
② RESTORE The speed will become slower.
Restore the throttle grip quickly.
CAUTION:
·Apply the brake level while restoring the throttle
grip. This will shorten the brake time required to
slow down.
24
(3)PROPER RIDING WILL PROLONG THE ENGINE LIFE
·For a new motorcycle,keep the speed below 60km
perhour within the first 1000km of riding.
·Avoid sudden acceleration and long-time riding
at high speed.
·In hot weather,the engine overheats easily at
long-time idling.Stop the engine in this case.
CAUTION:
·Moderate riding will prolong the engine life.
(4)APPLY BOTH FRONT LEVER AND REAR BRAKES
PEDALWHEN BRAKING
·First restore the throttle grip to the closed
position and then pull the brake lever and
depress the brake padel tight
·The best way to brake the motorcycle is to pull
the brake lever and depress the brake padel“slowly”
at the very
beginning,then pull them tight.
CAUTION:
·Apply single brake lever will cause the motorcycle to
slip.
·During riding,never brake the motorcycle
suddenly, otherwise it may cause the motorcycle
to slip and could be very dangerous.
60km
25
(5)DO NOT MAKE SUDDEN STOP OR SHARP TURN
·Sudden stop and sharp turn are the main causes
for slipping and could be very dangerous.
·In rainy days the road is slippery.Sudden stop
will cause the motorcycle to slip.Be careful to
avoid danger.
(6)BE MORE CAREFUL WHILE RIDING IN RAINY DAYS
A longer braking distance is required in rainy
·
days than in sunny days.Be sure to slow down and
brake the motorcycle slowly as soon as possible.
·When riding on a descending road,restore the
throttle grip to closed position and slow down by
making intermittent braking.
CAUTION:
A longer braking distance is required in rainy
·
days.Be sure to slow down and brake the
motorcycle slowly as soon as possible.
26
Accele rograph lock
·Lock the method
The insert switch key
·Unlocking method
Insert the key to lock the hole
Hazard Switch
Press this switch,four turn toface the
light the to is bright at the some time.
27
9.HOW TO STOP RIDING
(1)WHILE GO NEAR THE PARKING PLACE
·
Turn on the turn signal light in advance.Watch
out vehicles coming behind or adide and stop the
motorcycle to the right side slowly.
·Restore the throttle grip to closed position and
apply the front and rear brakes as soon as
possible.
·At this moment,the stoplight will come on to warm
the vehicles coming behind.
(2)WHILE THE MOTORCYCLE IS COMPLETELY STOPPED
·
Return the turn signal switch to its original
position.
·Turn the ignition switch key to the“OFF”
position to stop the engine.
CAUTION:
·
During riding,never operate the ignition switch
key.
·When the ignition switch key is turned to the
“OFF”position,the electric system does not
work.Turn off the ignition switch key after the
motorcycle is fully stopped.
28
(3)PARKING
Place the motorcycle on its main stand on level
·
ground and do not hinder the traffic.
·Stand on the left side and grip the handlebar
straight with left hand and the side rod or rear
carrier with right hand.Then,step down the main
stand evenly with right foot and pull the
motorcycle backward by force with right hand.
CAUTION:
·
The motorcycle may easily fall down if it is
parked on an uneven ground.
(4)HANDLEBAR
After parking,be sure to lock the steering
·
handlebar and take out the key to prevent
pilferage.(Refer to P5.)
CAUTION:
·
Don`t park your motorcycle at a place to hinder
the traffic. Park the motorcycle at a safe
place and be sure to take out the key to prevent
pilferage.
29
10.EASY MAINTENANCE
(1)AIR CLEANER INSPECTION AND AIR CLEANER
CLEANING & REPLACEMENT
· Take out the air cleaner and visually check if
it is dirty or clogged.
1.Remove the screws attaching the air cleaner
cover and remove the air cleaner cover.
2.Remove the air cleaner element.
3.The installation sequence is the reverse of
removal.
· Soak the element in clean engine oil and squeeze
out the excess oil and then install the element
and air cleaner.
·Replace the air cleaner element at very 2000km.
·The air cleaner requires more frequent cleaning
or replacing when ridden in unusually dusty
areas.When replacing,refer to P39 Periodic
Inspection & Maintenance Schedule.
CAUTION:
·
Be careful not to allow water to enter the air
cleaner; otherwise it may result in hard
starting.
·If the air cleaner is not installed properly,dust
may be sucked into the cylinder directly to
reduce engine horsepower and affect the service
life of engine.
30
(2)FUEL SYSTEM
·Fuel Leakage Inspection
Check the fuel line between the fuel tank
andcarburetor for fuel leakage.
①Fuel tank ②Fuel tube connector ③Carburetor
CAUTION:
·
Check and replce any broken or damaged tube
connector to avoid breakdown due to running out
of gasoline.
(3)APPEARANCE CLEANING
·
Often wipe clean the motorcycle appearance to
prevent accumulated dust affecting the function
of components.
CAUTION:
·
If a motorcycle is not used for a long time,check
the operation of each part and replace
lubricants before riding.Ride the motorcycle
only after its performance is confirmed.
· When waxing the motorcycle,make sure that the
ingredients of the wax will not damage the paint
of the motorcycle.
31
(4)BATTERY
·The battery fluid level should be kept
within the upper and lower level lines.When
the fluid level nears the lower level
line,refill with distilled water to the
upper level line.
·When cleaning the terminal terminals,remove
the screws attaching the battery cover on
the seat and then open the battery cover.
·When battery terminals are corroded,take
out the battery for cleaning. After
cleaning,apply a thin coat of grease or
Vaseline to battery terminals and then
install the battery.
CAUTION:
If the motorcycle will not be used for a long
·
time,the battery will discharge electricity by
itself. Remove the battery and put it in a cool
place after it is fully charged to prevent
electricity leakage.
·A clogged or kinked breather tube will increase
the battery inside pressure and result in cracks.
·The battery fluid will overflow to corrode the
motorcycle if too much distilled water is filled.
·Turn off the ignition switch before removal or
installation.The negative(-)terminal shall be
removed first and thepositive(+)terminal shall
be installed first.
·Tighten the loose terminal nuts securely.
32
(5)FUSE CHANGE
Turn off the main switch and check if the fuse
·
is burnedout.
· When the fuse is burned out,replace with a
specified fuse.
·Check for the cause of breakdown before
replacing.
Ignition Switch Fuse Specification:10A
CAUTION:
·Be careful not to excessively expand the fuse clip
duringremoval.
·After a new fuse is installed, check the fuse clip
for looseness which is the main cause of trouble.
·Never use fuse of unspecified capacity,it may
cause wire overheating and burning out.
·When replacing electric appliances
(lights,instruments),be sure to use the
recommended genuine parts.
·When washing the motorcycle,avoid flushing it.
·If the cause can not be found,contact our
distributor or service station for inspection
33
. (6)ENGINE OIL CHANGE
1. Place the motorcycle on its main stand on level
ground.
2.Remove the oil dipstick.
3.Remove the drain bolt to drain the oil.
4.Refill fresh engine oil for 0.9 liter.Firmly
tighten the oil dipstick.
5.Warm up the engine and check the oil level again
after the engine is stopped for 20～30 seconds.
·Specified Oil:SAE20W50
·API service classification:SF
·Capacity/Exchanging Capacity:1.0L/0.9L
CAUTION:
·
When changing the engine oil,also clean the oil
strainer and reinstall it.
·Use the specified engine oil.
·Change engine oil at first 300km and then change
it at every 1000km.
·Engine oil will deteriorate easily and require
more frequent change if the motorcycle is often
ridden in dusty and cold areas or ridden for short
distance.
·Do not mix engine oil of different classes or
viscosities.It may cause damage for engine.
34
(7)SPARK PLUG INSPECTION
· Check the spark plug side electrodes for wear.
· Fouling deposits on spark plug electrodes and
big gap may result in weak spark.
· Spark Plug Removal:
1.Remove the spark plug with a spark plug remover.
2.The installation sequence is the reverse of
removal.
· Spark Plug Cleaning:
1.Itis better to remove spark plug deposits with a
spark plug cleaner.
2.If a spark plug cleaner is not available,clean
with a wire brush.
· The side electrode gap is 0.6～0.7mm.
· Specified Spark Plug: CHAMPION-P-PZ9HC
① Decarbonizing ② Cracks,Damage
③ Gap,Wear,Fouling Deposits
CAUTION:
· Clean the spark plug at every 2000km and replace
it with a new one at every 5000km or when the
center electrode is burned out.
· First screw in the spark plug with fingers and
then tighten with a spark plug wrench.
· Use unspecified spark plug may damage the
engine.
35
(8)BRAKE FLUID LEVEL INSPECTION/REFILLING
· Remove the two screws from the brake fluid tank
and take off the cover.
· Add recommended brake fluid DOT-4 into the tank
until the fluid level reaches the upper limit
and then put on the cover and tighten the
screws.
· Recommended Brake Fluid:DOT-4
CAUTION:
· Do not mix brake fluid of different brands.It may
cause brake failure and is very dangerous.When
refilling brake fluid, use towels to cover and
protect the painted and coated
surfaces.(Replace at 10000km or every year.)
(9)RUBBER COVER INSPECTION FOR WIRE AND CABLE
· The cable cores are protected by the rubber
cover outside the connector.Check the rubber
cover frequently for proper installation.
· When washing the motorcycle,do not flush the
rubber cover directly or brush it.Use a wet rag
to wipe off dirt and dust.
① Rubber Cover ② Check Points
36
11.IMPORTANT NOTICES
(1)WHEN THE ENGINE FAILS TO START OR STOPS DURING
RIDING
·
Is the gasoline enough?
·If the fuel gauge pointer is at the red
line,refill #92 or #95 nonleaded gasoline.
·Is the way to start the engine correct?
·Is there any other faulty parts?
(2)IN CASE OF BREAKDOWN
·For any trouble occurred during riding,go to a
KYMCO distributor or service station for
inspection.
CAUTION:
·For the sake of safety and to prevent vehicle
damage and save your precious time,the pre-ride
inspection is absolutely required. Please read
this User`s Manual carefully and get into a good
habit of inspection before riding.
37
(3)POLLUTION-FREE PERIODIC MAINTENANCE SCHEDULE
In order to have a safe riding,maintain good performance,prelong the motor c ycle service
life and reduce pollution,make sure to perform the periodic inspection and maintenance.
I:Inspect and clean,Lubricate,refill,repair or replace if necessary.
A:Adjust C:Clean R:Replace T:Tighten
Ttem
√
√ Engine oilstrainer
√ Gear oil
√ Spark plug
√ Valve clearance
√ Carburetor
√ Drive belt
√ Drive chain ○○ AAAAA A A
√ Air cleaner ○○ IRIRI R I
√ Battery Electrolyte ○○ IIIII I I I
√ Fuel Filter Screen ○○ R
√ Brake System ○○ IIIII I I I
√ Clutch Lever Free Play ○○AAAAAAA
√ Bolts & Nuts ○○TTT
√ Tire Pressure ○○ IIIII I I I
Engine oil
Cooling water
Motor oil Strainer ○×
Engine oil Pump ○×IIII
2stroke 2stroke 300 1000 3000 5000 7000 9000 11000 13000
√ Regular Service Mileage (KM)
×
×
○
○
○
○
○
○
○ Replace at every 1000km. I
○ C C Clean at every 5000km
○ RRRR
○ I
○ Clean(C)at every 2000km and replace(R)at every 5000km
○ AAAA
○ II I
○ II
Daily Preride
Inspection
The above items are applicable to different models.Perform suitable items for each model.
When exceeding the listed mileages,perform maintenance according to the listed intervals.
The air cleaner requires more frequent cleaning or replacing when ridden in unusually dusty areas.
38
(4)SPECIFICATIONS
ACTIVE 110
Engine Type OHC air cooled 4-cycle Overall Length 1995mm
Displacement 107 cc Overall Width 790mm
Bore×Stroke φ52.4×49.5 mm
Compression Ratio 9.27 Dry Weight 100kg
Max.Output 5.00/7000 kw/(r/min) Wheel Base 1265mm
Max.Torque
Tire Size FR:2.5-17 RR:2.75-17 Fuel Type Nonleaded gasoline 90#
Transmission Type Left Foot Operated Gear Shift Pedal Engine Oil Capacity 1.0 liter
Clutch Wet Multi-Disc Clutch Fuel Tank Capacity 3.5 liter
Ignition C.D.I Engine Oil Type SAE15W/40
Starting System Starting Motor And Kic Starter Fuse 10A
Idle Speed 1600rpm Battery 12V5AH
The economic oil comsumption 2.1L/100km
7.55/4500 N·m/rpm /min
Overall Height 1180mm
Spark Plug CHAMPION-P-PZ9HC
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