Kymco Dink 125 User Manual

DINK 125

OWNER'S MANUAL

KWANG YANG MOTOR CO.,LTD.

Issued: JUN.30.2006

FOREWORD

Thank you for purchasing this KYMCO scooter and welcome to the family of KYMCO
scooter riders.

Please read this owner's manual carefully before riding so that you will be thoroughly
familiar with the proper operation of your scooter controls, its features, capabilities, and
limitations.

To ensure a long, trouble-free life for your scooter, give it the proper care and
maintenance described in this manual.

For replacement parts and accessories, we recommend genuine KYMCO products.
They've been specially designed for your vehicle and manufactured to meet KYMCO's
demanding standards.

Keep this owner's manual aboard your scooter at all time so that you can refer to it
whenever you need information. This manual should be considered a permanent part of
the scooter and should remain with the scooter when it is sold.

All information, illustrations, photographs and specifications contained in this manual
are based on the latest product information available at the time of publication. Due to
improvements or other changes, there may be some discrepancies in this manual.
KYMCO reserves the right to make changes at any time without notice and without
incurring any obligation.

A

READ THIS MANUAL CAREFULLY

Your Owner's Manual contains important information on safety, operation, and
maintenance. Any one who operates this scooter should carefully read and understand
the contents of this manual before riding the scooter.

SPECIAL MESSAGES

Please read this manual and follow its instructions carefully. To emphasize special
information the words , and carry special meanings and should
be carefully reviewed.

WARNING CAUTION Note

WARNING

CAUTION

NOTE:

The Owner's Manual should be considered a permanent part of your scooter. It should
remain with the vehicle at all times and stay with the scooter if it is sold.

Indicates a strong possibility that serious injury or death may

result if instructions are not followed.

Indicates a possibility that equipment or property damage

could result if instructions are not followed.

Gives helpful information

ON-ROAD USE

This scooter is designed to be used only on the road.

B

CONTENTS

Page Page

SCOOTER SAFETY........................1

IMPORTANT SAFETY

INFORMATION................................1

PROTECTIVE APPAREL...................3

LOAD LIMITS AND GUIDELINES.......5

PARTS LOCATION..........................8

FRAME NUMBER............................12

ENGINE NUMBER...........................13

KEY NUMBER.................................14

CONTROLS..................................15

KEYS.............................................15

IGNITION SWITCH..........................15

INSTRUMENT AND INDICATORS....16

RIGHT HANDLEBAR SWITCH..........24

LEFT HANDLEBAR SWITCH............27

BRAKES.........................................29

FUEL FILL CAP................................30

SEAT..............................................32

CENTER COMPARTMENT/CENTER

COMPARTMENT LIGHT...................33

HELMET HOLDERS.........................34

CENTER HOOK ...............................35

PASSENGER FOOTPEG ..................36

STAND...........................................37

SUSPENSION.................................39

PRE-RIDE INSPECTION...............40

OPERATION.................................41

STARTING THE ENGINE.................41

RIDING...........................................45

(Cont'd)

C

Page Page

PARKING........................................49

BREAK-IN (RUNNING IN)................51

INSPECTION AND

MAINTENANCE............................53

THE IMPORTANCE OF

MAINTENANCE..............................53

MAINTENANCE SCHEDULE............54

TOOL KIT........................................57

CRANKCASE BREATHER...............57

ENGINE OIL...................................58

TRANSMISSION OIL.......................66

AIR CLEANER................................67

THROTTLE OPERATION.................68

IDLE SPEED...................................69

SPARK PLUG..................................70

COOLANT.......................................71

FRONT AND REAR SUSPENSION

INSPECTION..................................73

SIDE STAND...................................74

BRAKE FLUID................................75

BRAKE PAD WEAR........................76

BATTERY........................................77

FUSE REPLACEMENT....................80

TIRES............................................82

CLEANING...................................86

STORAGE GUIDE.........................91

SPECIFICATIONS.........................94

D

SCOOTER SAFETY

IMPORTANT SAFETY INFORMATION

Your scooter can provide many years of service and pleasure, if you take responsibility for
your own safety and understand the challenges that you can meet on the road. There is
much that you can do to protect yourself when you ride. You will find many helpful
recommendations throughout this manual. Following are a few that we consider most
important.

Wear a helmet

Scooter safety equipment starts with a quality helmet. One of the most serious injuries that
can happen is a head injury. Always wear a properly approved helmet. You should also
wear suitable eye protection.

Make yourself easy to see

To make yourself more visible, wear bright reflective clothing, position yourself so other
drivers can see you, signal before turning or changing lanes, and use your horn when it will
help others notice you.

Know your limits

Ride within the boundaries of your own skill at all times. Knowing these limits and staying
within them will help you to avoid accidents.

1

Keep your scooter in safe condition

For safe riding, it's important to inspect your scooter before every ride and perform all
recommended maintenance. Never exceed load limits, and only use accessories that have
been approved by KYMCO for this scooter.

Inspection before riding

Do not forget to perform an entire safety inspection to ensure the safety of the rider.

Be extra safety conscious on bad weather days

Riding on bad weather days, especially wet ones, requires extra caution. Braking distance
double on a rainy day. Stay off of the painted surface marks, manhole covers and greasy
appearing areas as they can be especially slippery. Use extreme caution at railway
crossings and on metal gratings and bridges. Whenever in doubt about road conditions,
slow down.

Modification

Modification of the scooter, or removal of original equipment may render the vehicle unsafe
or illegal. Obey all applicable equipment regulations in your area.

2

PROTECTIVE APPAREL

For your safety, we strongly recommend that you always wear an approved scooter helmet,
eye protection, boots, gloves, long pants, and a long-sleeved shirt or jacket whenever you
ride.

Helmets and protection

Your helmet is your most important piece of riding gear because it offers the best protection
against head injuries. A helmet should fit your head comfortably and securely. Always wear
a face shield or goggles to protect your eyes and help your vision.

Additional riding gear

In addition to a helmet and eye protection, we also recommend:

Sturdy boots with non-slip soles to help protect your feet and ankles.

Leather gloves to keep your hands warm and help prevent blisters, cuts, burns and

bruises.
A scooter riding suit or jacket for comfort as well as protection. Bright-colored and
reflective clothing can help make you more noticeable in traffic. Be sure to avoid loose
clothes that could get caught on any part of your scooter.

3

(1) (2)

(5)

(3)

(4)

(1)Wear gloves.
(2)Clothes should be close-fitting.
(3)Always wear an helmet. You

should also wear a face shield
or goggles.

(4)Wear bright or reflective

clothing.

(5)Shoes should be close-fitting,

have low heels and offer ankle
protection.

WARNING

Not wearing a helmet
increases the chance of
serious injury or death in a
crash.

Be sure you and your
passenger always wear an
approved motorcycle helmet
that fits properly. You should
also wear eye protection and
other protective apparel when
you ride.

4

LOAD LIMITS AND GUIDELINES

These general guidelines may help you
decide whether or how to equip your
scooter and how to load it safely.

Center compartment
weight limit:10 kg (22 lbs)

Load limits

Following are the load limits for your scooter:

Maximum weight capacity (Includes the
weight of the rider, passenger, all cargo and
All accessories.): 163 kg (358 lbs)

Maximum cargo weight: 18 kg (40 lbs)

Overloading the individual storage
compartments can also affect stability and
handling. So be sure to stay within the limits
given below:

Maximum weight:
In center compartment 10 kg (22 lbs)
On rear carrier 5 kg (11 lbs)
On helmet hook 3 kg (6 lbs)

5

Rear carrier weight
limit:5 kg (11 lbs)

Helmet hook weight
limit:3 kg (6 lbs)

Loading guidelines

Improperly loading your scooter can affect its stability and handling. You should ride at
reduced speeds whenever carrying cargo. Follow these guidelines whenever you carry a
passenger or cargo:

Check that both tires are properly inflated.



To prevent loose items from creating a hazard, make sure that all cargo is securely tied
down before you ride away
Place cargo weight as close to the center of the scooter as possible.



Balance cargo weight evenly on both sides.



WARNING

Overloading or improper loading can cause
changes in vehicle handling, stability and
braking which could lead to an accident.

Never exceed the stated load capacity for
this scooter.

Cargo should be properly distributed and
securely attached.

Reduce speed when carrying cargo. Allow
greater distance for braking.

6

Accessories and Modification

There are great variety of accessories available to KYMCO owners. KYMCO cannot have
direct control over the quality or suitability of accessories you may wish to purchase. The
addition of unsuitable accessories can lead to unsafe operating conditions. It is not
possible for KYMCO to test each accessory on the market or combinations of all the
available accessories; however, your dealer can assist you in selecting quality accessories
and installing them correctly.
Use extreme caution when selecting and installing the accessories for your scooter.

WARNING

Improper accessories or modifications can make your scooter unsafe and can lead
to an accident.

Never modify this scooter through improper installation or use of accessories. All
parts and accessories added to this vehicle should be genuine KYMCO or
equivalent components designed for use on this scooter and should be installed
and used according to instruction. If you have question, consult an authorized
KYMCO dealer.

No modifications

We strongly advise you not to remove any original equipment or modify your scooter in any
way that would change its design or operation.

7

PARTS LOCATION

(02)

(03)

(04)

(01)

(07)

(01) Right rearview mirror
(02) Instruments/Indicators

Left rearview mirror

(03)

Passing light control switch/

(04)

Headlight dimmer switch/
Turn signal switch/
Horn button
Left rear suspension spring

(05)

preload adjuster
Right rear suspension spring

(06)

preload adjuster
Engine stop switch/Headlight

(07)

switch/Start button

(05)

(06)

8

(14)

(08)

(08)

Front brake lever

(09)

Throttle grip

(10)

Front brake fluid reservoir

(11)

Ignition switch
(12) Fuel fill cap
(13)

Rear brake fluid reservoir

(14)

Rear brake lever

(13)

(12)

(11)

(10)

(09)

9

(18)

(17)

(15)(16)

(15) Battery/Fuse box/

Spare fuse

(16)

Center compartment

(17)

Helmet holder

(18)

Coolant fill cap

(19) Coolant level
(20) Side stand
(21) Center stand
(22) Left passenger footpeg
(23) Air cleaner

(19)

(20)

(21)

(22)

(23)

10

(25)

(24)

(26) (27)

(24) Helmet hook
(25) Seat
(26) Right passenger footpeg
(27) Oil filler cap/Dipstick

11

FRAME NUMBER

The read frame number (1), please remove the cover on
inner cover with a flat head screwdriver.
Always check that the frame number stamped on
your scooter is the same written in document and
warranty scooter is the same written in document
and warranty card.
Please write down your frame number in place below.

FRAME NUMBER:

12

(1)

ENGINE NUMBER

The engine number is stamped on left engine case.
Please write down your engine number in place
below.

ENGINE NUMBER:

13

KEY NUMBER

The key number (1) will be needed when you order
replacement part. Record the number for your reference.

IGNITION KEY NUMBER:

(1)

14

CONTROLS

KEYS

This scooter has two ignition switch keys and shutter keys.

IGNITION SWITCH

Function

“ ” Position:
All electrical circuits are cut off. The engine will not start.

" ” Position:
The ignition circuit is completed and engine can now be started. The key cannot be removed from
the ignition switch.

“ ” Position: To lock the steering, turn the handlebar all the way to the left. Push down and turn the
key to the " ” position and remove the key. All electrical circuits are cut off.

“ ” Position:
To open the fuel fill cap, turn the key to the " ” position. Make sure that the key is at the " ”
position when starting the engine.

.

15

INSTRUMENT AND INDICATORS

(1)

(2) (3) (4)

(5)

5

(10)

(9)

TRIP
ODO

mph

Km/h

4

3

2

1

0

6

7

8

9

10

(6)

(7)

(8)

(1) Multi-function display (2) Tachometer (3) Left turn signal indicator
(4) Right turn signal indicator (5) High beam indicator (6) Oil service indicator
(7) Met-in indicator (8) Overheating indicator (9) Adjust button
(10) Mode button

16

(1) Multi-fuction display

The display includes the following functions:

(1)

Initial display

When the ignition switch is turned ON, the
multi-function display will temporarily show all
the modes so that you can make sure the liquid
crystal display functioning properly.

(4)

mph

Km/h

TRIP
ODO

(2)

(1) Speedometer
(2)

Odometer/Trip meter/Oil service meter
Fuel gauge

(3)
(4) Digital clock

(3)

Speedometer

Shows riding speed.

Press and hold the Mode button for more than
2 seconds to select mph or Km/h.

mph

Km/h

17

Odometer/Tripmeter/Oil service meter

Press and hold the Mode button for more than
2 seconds to

select mph or Km/h for
speedometer and mile or km for
odometer/tripmeter/oil service meter.

mph

To select Odometer/Tripmeter/Oil service
meter:
Press and hold Adjust button for more than 2
seconds to select Odometer/Tripmeter/Oil
service meter.

Km/h

Odometer
Shows accumulated mileage.

Tripmeter
Shows mileage per trip.

Oil service meter
Shows mileage for oil service frequency.

18

Odometer

ODO

Tripmeter

TRIP

Oil service meter

To reset the tripmeter:

1. Press and hold Adjust button for more than 2

seconds to select TRIP.

TRIP

2. Press and hold both the Mode button and

Adjust button in the same time until the
tripmeter is reset.

TRIP

To reset the oil service meter:

1. Press and hold Adjust button for more than 2
seconds to select oil service meter.

2. Press and hold both the Mode button and
Adjust button in the same time until the oil
service meter is reset.

19

Fuel gauge

Digital clock

The fuel gauge shows the approximate fuel
supply available in a graduated display. The
normal operating fuel range is with the section
between the segment F and segment E. When
the segment E or the fuel indicator flashes, fuel
will be low and you should refill the tank as
soon as possible.

(3)

(1)

(2)

(1) Segment E (2) Segment F
(3) Fuel indicator

Show the time (hours and minutes) while the
ignition is ON.
To adjust the time manually, proceed as
follows:

1. Turn the ignition switch ON.

2. Press and hold Adjust button for more than 2

seconds to select ODO mode.

Note:

Digital clock can be adjust in ODO mode only,
never select tripmeter or oil service meter
mode when you want to adjust your digital
clock.

3. Press and hold both the Mode button and

Adjust button in the same time for more than
2 seconds. The clock will be set in the adjust
mode with the hour display flashing.

20

4. To set the hour, press the Adjust button until
the desired hour.

6. To set the minute, press the Adjust button
until the desired minute.

5. Press the Mode button. The minute display
will start flashing.

7. To end the adjustment, press both the Mode
and Adjust buttons in the same time. The
display will stop flashing automatically and
the adjustment will be cancelled if the button
is not pressed for about 10 seconds.

21

(2) Tachometer

(5) High beam indicator “ ”

Shows engine revolutions per minute (rpm).

Initial display

When the ignition switch is turned ON, the
indicator of tachometer will run from zero to
maxi limit then zero

so that you can make sure

the tachometer properly.

(3) Left turn signal indicator “ “

Flashes when the left turn signal operates.

(4) Right turn signal indicator “ “

Flashes when the right turn signal operates.

Lights when the headlight high beam is turned
on.

(6) Oil service indicator “ ”

If the oil service indicator comes on while
driving, this indicates that the engine oil should
be changed at each maintenance interval.

NOTE:

The oil service indicator comes on when the
vehicle's ignition is turned on and must come
off when the engine is running.

To reset oil service indicator:
Refer to the

page 19

(7) Seat unlock indicator "MET-IN"

Lights when the seat is not locked fully.

22

(8) Overheating indicator “ ”

When the coolant is over specified
temperature, the overheating indicator comes
on.
If this occurs, stop the engine and check the
reserve tank coolant level. Read and
to not ride the vehicle until the problem has
been corrected.

NOTE:

1. The overheating indicator comes on when
the vehicle's ignition is turned on and must
come off when the engine is running.

2. Restart after making sure that the indicator is
out. Continuous use while the indicator is
lighting may cause damage to the engine.

page 71

23

RIGHT HANDLEBAR SWITCH

Headlight switch (1)

“”

position

The headlight and taillight turn on.

position

"”
The position light and taillight turn on.

position

""

The headlight, position and taillight turn off.

24

ENGINE

STOP

(1)

Electric starter button " ” (2)

Push in the electric starter button to rotate the starter
motor.

NOTE:

!

If the brake lever is not squeezed, the starter motor will
not rotate.

!

This scooter is equipped with interlock switches for the
ignition circuit and the starter circuit. The engine can
only be started if the side stand is fully up.

CAUTION

To prevent electrical system damage, do not
operate the starter motor more than five
seconds at a time and make sure the engine
stop switch is run and side stand is fully up.

ENGINE

ENGINE

STOP

STOP

(2)

25

Engine stop switch (3)

“ ” position

The ignition circuit is off. The engine cannot start or run.

" ” position

The ignition circuit is on and the engine can run.

26

ENGINE

ENGINE

STOP

STOP

(3)

LEFT HANDLEBAR SWITCH

Turn signal switch (1)

Use the turn signal switch while turning to another
direction or shifting to another lane. The turn signal light
will wink when the switch is operated,
" ” For turning to the "left".
" ”For turning to the "right".
The instrument turn signal indicator light will also wink
when the switch is operated.
Push the switch and it will release.

(1)

Horn button " ” (2)

Press the button to sound the horn.

(2)

27

Dimmer switch (3)

LIGHTS

" ” position

The headlight low beam and taillight turn on.

" " position

The headlight high beam and taillight turn on. The high
beam indicator light also turns on.

(3)

Passing light control switch (4)

When this switch is pressed, the headlight flashes on to
signal approaching cars or when passing.

28

(4)

PASSING

LIGHTS

BRAKES

Rear brake lever (Left handlebar)

The rear brake are applied by squeezing the rear brake
lever gently towards the grip. The brake light will be lit
when the lever is squeezed inward.

Front brake lever (Right handlebar)

The brake is applied by squeezing the front brake lever
gently towards the grip. The brake light will be lit when
the lever is squeezed inward.

29

FUEL FILL CAP

To open the fuel fill cap:

Insert the ignition key in the ignition switch and turn
it to the “ ” position (the key can not remove).
Rotate the key clockwise to the “ ” position and
open the fuel fill cap (1).

Do not overfill the tank. There should be no fuel in
the filler neck (2).
After refueling, be sure to lock the fuel fill cap firmly.

(2)

(1)

30

To lock the fuel fill cap:

Push fuel fill cap down into place.

WARNING

Petrol is highly flammable and explosive. You
can be burned or seriously injured when
handling fuel.

!

Stop the engine and keep heat, sparks, and
flame away.

!

Refuel only out doors.

!

Wipe up spills immediately.

Fuel recommendation

Use unleaded petrol with a research octane number
of 91 or higher. Unleaded gasoline can extend spark
plug life and exhaust components life.

Turn the ignition key from “ ” to " ” position to
restarting.

31

SEAT

(1)

To unlock the seat “SEAT OPEN”

(1) Ignition key at the " ” position (The engine is

running.):
Push the key and turn it counterclockwise from
" ” to "SEAT OPEN" position.

(2) Ignition key at the " “ position (The engine is

stopped.):
Turn it counterclockwise from " " to "SEAT
OPEN” position.

Pull the seat up to lift the seat.

To lock seat:

Lower and push down on the reverse side of the
hooks of the seat until it locks. Make sure the seat is
secure before riding.

NOTE:

The lamplight and "MET-IN" indicator light will come
on while the seat is unlock, make sure the seat is
locked.

32

(2)

CENTER COMPARTMENT/CENTER COMPARTMENT LIGHT

The center compartment (1) is below the seat.
Opening and closing:See "SEAT" .

MAXIMUM WEIGHT LIMIT: 10kg (22 lbs)

The center compartment light (2) will be turned ON automatically when the seat is opened.
Kept ON as long as the seat is opened regardless of the position of the ignitino switch.

(page 32)

CAUTION

Never exceed the maximum weight limit;
handling and stability may be severely affected.

The center compartment may become heated by
the engine. Do not store food and other articles
which are flammable or susceptible to heat
damage in this compartment.

Do not direct water under pressure against the
center compartment as water will be forced into
the compartment.

(1)

(2)

33

HELMET HOLDERS

To use the helmet holders, unlock the seat

32)

, hook your helmet fastener ring to the holder and

lock the seat securely.

(see page

WARNING

Riding with a helmet attached to the holder can
interfere with the rear wheel or suspension and
could cause a crash in which you can be
seriously hurt or killed.

Use the helmet holder only while parked. Do not
ride with a helmet secured by the holder.

34

CENTER HOOK

1. When using it, pull out the hook (1) from the inside.

2. Pushing the lock lever (2) left to unlock and hang your
bag on the hook on the footboard.

3. To remove a bag unlock the lock lever. Lift the bag off
the hook.

4. When not using it, push the hook back into its original
position to avoid hooking tour clothes during riding.

(1)

35

PASSENGER FOOTPEG

1. When using it, kick the button (1).

2. When not using it, push the passenger footpeg into its
original position.

(1)

36

STAND

This scooter is equipped with a center stand and side
stand.

Center stand (1)

To place the scooter on the center stand, place your foot
on the stand extension and then rock the scooter to the
rear and upward with the passenger hand rail with your
right hand, while steadying the handlebars with your left
hand.

Side stand (2)

An interlock switch is provided to cut off the ignition circuit
when the side stand is down.
The side stand down indicator will light when the side
stand left down and ignition switch is ON.
The side stand/ignition interlock switch works as follows:

!

If the side stand is down, the engine can not be started.

!

If the engine is running and the side stand is put down,
the engine will stop running.

(1)

(2)

37

WARNING

Riding with the side stand incompletely
retracted can result in an accident when you
turn left.

!

Check operation of the side stand/ignition

interlock system before riding.

!

Always retract the side stand completely
before starting off.

CAUTION

Park the scooter on firm, level ground to help
prevent it from falling over.

If you must park on an incline, aim the front of
the scooter uphill and place the scooter on the
center stand, or the scooter on the side stand
may roll off.

38

SUSPENSION

Each shock absorber (1) has adjustment positions for
different load or riding conditions.
Use a pin spanner (2) to adjust the rear shocks.
Be certain to adjust both shock absorbers to the same
position.

(2)

(1)

39

PRE-RIDE INSPECTION

For your safety, it is very important to take a few
moments before each ride to walk around your
scooter and check its condition. If you detect
any problem, be sure you take care of it, or
have it corrected by your KYMCO dealer.

3. Coolant level: add coolant if required. Check
for leaks .

4. Front and rear brakes: check operation;

make sure there is no brake fluid leakage

(page 75)

(page 71)

.

WARNING

Improperly maintaining this scooter or
failing to correct a problem before
riding can cause a crash in which you
can be seriously hurt or killed.

Always perform a pre-ride inspection
before every ride and correct any
problems.

1. Engine oil level: add engine oil if required

(page 59)

2. Fuel level: fill fuel tank when necessary

(page 30)

. Check for leaks.

. Check for leaks.

5. Tires: check condition and pressure

.

82)

6. Throttle: check for smooth opening and full

closing in all steering positions.

7. Lights and horn: check that headlight,

tail/brake light, turn signals, indicators and
horn function properly.

8. Engine stop switch: check for proper function

(page 26).

9. Side stand ignition cut-off system: check for

proper function .

10. Steering: check for condition and

smoothness.

40

(page 74)

(page

OPERATION

STARTING THE ENGINE

Always follow the proper starting procedure described below.
This scooter is equipped with a side stand ignition cut-off system. The engine cannot be started if
the side stand is down. A running engine will shut off if the side stand is lowered.
To protect the catalytic converter in your scooter's exhaust system, avoid extending idling and the
use of leaded petrol.
Your scooter's exhaust contains poisonous carbon monoxide gas. High levels of carbon monoxide
can collect rapidly in enclosed areas such as a garage. Do not run the engine with the garage door
closed. Even with the door open, run the engine only long enough to move your scooter out of the
garage.
Do not use the electric starter for more than 5 seconds at a time. Release the starter button for
approximately 10 seconds before pressing it again.

41

1. Place the scooter on its center stand and make sure to
put the side stand up.

2. Make sure the engine stop switch is at " ” (RUN).

3. Turn the ignition switch to " “ (ON)

4. Squeeze the rear brake lever.

The electric starter will only work when the rear brake
lever is squeezed and the side stand is up.

42

5. With the throttle closed, push the starter button.
Release the starter button as soon as the engine
starts.

6. Be sure to keep the throttle closed and the while
warming up the engine.

7. Allow the engine to warm up before riding.

Do not "BLIP" the throttle (open and close rapidly) as the
scooter will move forward suddenly.
Do not leave the scooter unattended while the engine is
warming up.

ENGINE

ENGINE

STOP

STOP

Close

43

If you cannot restart a warm engine:

1. Place the scooter on its center stand and squeeze the
rear brake lever.

2. Open the throttle 1/8 - 1/4 turn while starting the
engine.

44

RIDING

Allow the engine oil to circulate before riding

Allow sufficient idling time after warm or cold engine start
up before applying load or revving the engine. This allows
time for the lubricating oil to reach all critical engine
components.

Review scooter safety before you ride.

Make sure flammable materials such as dry grass or
leaves do not come in contact with the exhaust system
when riding, idling, or parking your scooter.

1. Make sure the throttle is closed before moving the

scooter off the center stand.

2. Stand on the left side of the scooter and push it

forward and off the center stand.

(page1-7)

45

3. Mount the scooter from the left side keeping at least
one foot on the ground to steady the scooter.

4. Before starting off, indicate your direction with the turn

signals, and check for safe traffic conditions. Grasp the
handlebars firmly with both hands. Never attempt one­handed operation; loss of vehicle control could result.

5. To accelerate, open the throttle gradually; the scooter

will move forward.
Do not "BLIP" the throttle (open and close rapidly) as
the scooter will move forward suddenly, causing
possible loss of control.

Close

6. To decelerate, close throttle.

Open

46

7. When slowing down the scooter, coordination of the
throttle and front and rear brakes is most important.
Both front and rear brakes should be applied together.
Independent use of only the front or rear brake reduces
stopping performance.
Excessive brake application may cause either wheel to
lock, reducing control of the scooter.

8. When approaching a corner or turn, close the throttle

fully and slow the scooter down by applying both front
and rear brakes at the same time.

9. After completing the turn, open the throttle gradually to

accelerate the scooter.

47

10. When descending a steep grade, close the throttle
fully and apply both brakes to slow the scooter.

Avoid continuous use of the brakes, which may result
in overheating and reduction of braking efficiency.

11. When riding on wet or loose surfaces, be especially

cautious.
When riding in wet or rainy conditions or on loose
surfaces, the ability to maneuver and stop will be
reduced. For your safety:

!

Exercise extreme caution when braking, accelerating

or turning.

!

Ride at slower speeds and allow for extra stopping

distance.

!

Keep the scooter as upright as possible.

!

Use extreme caution when riding over slippery
surfaces such as railroad tracks, iron plates, manhole
covers, painted lines, etc.

48

PARKING

1. After stopping the scooter turn the ignition switch counterclockwise to the " ” (OFF) position and
remove the key.

2. Use the center stand to support the scooter while parked.

Park the scooter on firm, level ground to prevent it from falling over.
If you must park on a slight incline, aim the front of the scooter uphill to reduce the possibility of
rolling off the center stand or overturning.

49

3. Lock the steering to help prevent theft.

The exhaust pipe and muffler become very hot during
operation and remain sufficiently hot to inflict burns if
touched even after shutting off the engine.

( see page 15)

Make sure flammable materials such as dry grass or
leaves do not come in contact with the exhaust system
when parking your scooter.

WARNING

A hot muffler can burn you.
The muffler will be hot
enough to burn you for some
time after stopping the
engine.

Park the scooter where
pedestrians or children are
not likely to touch the muffler.

50

To unlock

To lock

BREAK-IN (RUNNING-IN)

The first 1600 km (1000 miles) are the most
important in the life of your scooter. Proper
break-in operation during this time will help
ensure maximum life and performance from
your new scooter. Proper break-in operation
allows the machined surfaces to polish each
other and mate smoothly.
Scooter reliability and performance depend on
special care and restraint exercised during the
break-in period. It is especially important that
you avoid operating the engine in a manner
which could expose the engine parts to
excessive heat.
The following guidelines explain proper break-in
procedures.

Maximum throttle operation
recommendation

The maximum recommended throttle operation
during the break-in period:

Initial 800 km (500 miles):

less than 1/2 throttle

Up to 1600 km (1000 miles):

less than 3/4 throttle

Vary the engine speed

The engine speed should be varied and not
held at a constant speed. This allows the parts
to be "loaded" with pressure, and then
unloaded, allowing the parts to cool. This aids
the mating process of the parts. It is essential
that some stress be placed on the engine
components during break-in to ensure this
mating process. Do not, though, apply
excessive load on the engine.

Avoid constant low speed

Operating the engine at constant low speed
(light load) can cause parts to glaze and not
seat in. Allow the engine to accelerate freely
through the gears, without exceeding the
recommended maximum limits. Do not,
however, use full throttle for the first 1600 km
(1000 miles).

51

Breaking in the new tires

New tires need proper break-in to assure
maximum performance, just as the engine
does. Wear in the tread surface by gradually
increasing your cornering lean angles over the
first 160 km (100 miles) before attempting
maximum performance. Avoid hard
acceleration, hard cornering, and hard braking
for the first 160 km (100 miles).

WARNING

Failure to perform break-in of the tires
could cause tire slip and loss of
control.

Use extra care when riding on new tires.
Perform proper break-in of the tires as
described in this section and avoid
hard acceleration, hard cornering, and
hard braking for the first 160 km (100
miles).

Observe your first and most critical service

The 1000 km (600 miles) service is the most
important service your scooter will receive.
During break-in all of the engine components
will have worn in and all of the other parts will
have seated in. All adjustments will be restored,
all fasteners will be tightened, and the dirty oil
will be replaced.
Timely performance of the 1000 km (600 miles)
service will ensure optimum service life and
performance from the engine.

NOTE:

The 1000 km (600 miles) service should be
performed as outlined in the maintenance
schedule section of this owner's manual. Pay
particular attention to the caution and warning
in maintenance schedule section.

52

INSPECTION AND MAINTENANCE

WARNING

THE IMPORTANCE OF MAINTENANCE

A well-maintained scooter is essential for safe,
economical and trouble-free riding. It will also
help reduce air pollution.

To help you properly care for your scooter, the
following pages include a maintenance
schedule for regularly scheduled maintenance.

These instructions are based on the
assumption that the scooter will be used
exclusively for its designed purpose. Sustained
high speed operation or operation in unusually
wet or dusty conditions will require more
frequent service than specified in the
maintenance schedule. Consult your KYMCO
dealer for recommendations applicable to your
individual needs and use.
If your overturns or becomes involved in a
crash, be sure your KYMCO dealer inspects all
major parts, even if you are able to make some
repairs.

Improperly maintaining this scooter or
failing to correct a problem before you
ride can cause a crash in which you can
be seriously hurt or killed.

Always follow the inspection and
maintenance recommendations and
schedules in this owner's manual.

WARNING

Running the engine indoors or in a
garage can be hazardous. Exhaust gas
contains carbon monoxide, a gas that is
colorless and odorless and can cause
death or severe injury.

Only run the engine outdoors where
there is fresh air.

53

MAINTENANCE SCHEDULE

Perform the pre-ride inspection at each scheduled maintenance period.

(see page 40)

This interval should be judged by odometer reading or months, whichever comes first.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE
The following maintenance schedule specifies all maintenance required to keep your scooter in
peak operating condition. Maintenance work should be performed in accordance with standards
and specifications of KYMCO by properly trained and equipped technicians. Your KYMCO dealer
meets all of these requirements.

＊

Should be serviced by your KYMCO dealer, unless the owner has the proper tools and service
data and is mechanically qualified.

＊＊

In the interest of safety, we recommend these items be serviced only by your KYMCO dealer.
KYMCO recommends that your KYMCO dealer should road test your scooter after each periodic
maintenance is carried out.

NOTE:

1 At higher odometer readings, repeat at the frequency interval established here.
2 Service more frequently if the scooter is ridden in unusually wet or dusty areas.
3 Service more frequently when riding in rain or at full throttle.
4 Clean every 2000 km (1200 mi) after replacement and replace every 5000 km (3000 mi).
5 Replace every 1 year, or every 4000km (2400mi), whichever comes first. Replacement requires

mechanical skill.

6 Replace every 10000 km (6000 mi), or once a year it at every 5000 km (3000 mi). Replacement

requires mechanical skill.
7 Replace every 2 years. Replacement requires mechanical skill.
8 Replace every 6000 km (3700 mi). Replacement requires mechanical skill.

54

FREQUENCY

ITEM

＊

AIR CLEANER

＊

THROTTLE OPERATION

＊

VALVE CLEARANCE

＊

FUEL LINE
CRANKCASE BREATHER
ENGINE OIL

＊

ENGINE OIL FILTER
ENGINE OIL STRAINER

＊

SCREEN

＊

ENGINE IDLE SPEED
RADIATOR COOLANT

＊

COOLING SYSTEM
SECONDARY AIR

＊

SUPPLY SYSTEM

WHICHEVER
COMES
FIRST

X 1000 km

X 1000 mi
NOTE
NOTE 2
NOTE 4

NOTE 3

NOTE 8

NOTE 6

MONTH

ODOMETER READING [NOTE (1)]

9

7

5

3

1

0.3

4.2

3

1.8

0.6

0.2
18

12

6

3

III

A

C

AAA

RRR

CCC

III

R

R

II

II

CCCCCC

R

II

II

11

REFER

6.6

5.4
30

24

RR67
RRRSPARK PLUGS

RRRR 64~65
RR

62~63

71~73

TO

PAGE

-

68

-

--

57

-

69

-

-

55

ITEM

＊

＊

＊＊

＊

＊
＊

＊

＊＊

＊＊

FREQUENCY

TRANSMISSION OIL
DRIVE BELT
CLUTCH SHOE WEAR
BRAKE FLUID
BRAKE PAD WEAR
BRAKE SYSTEM
BRAKE LIGHT SWITCH
SIDE STAND
SUSPENSION
HEADLIGHT AIM
NUTS, BOLTS, FASTENERS
WHEELS/TIRES
STEERING BEARINGS

WHICHEVER
COMES
FIRST

X 1000 km
X 1000 mi

NOTE MONTH
NOTE 5

NOTE 7

ODOMETER READING [NOTE (1)]

11

9

7

5

3

1

0.3

0.2

R

I

I

5.4

4.2

3

1.8

0.6
24

18

12

6

3

RRR

I-

I
IRII
IIII

I

II

I

I75
I
II
II

II
II
II
II
II
II

6.6
30

I
I
I

IIII

REFER

75~76

TO

PAGE

66

-

76

-

74
73

-

-

-

-

56

TOOL KIT

To assist you in the performance of periodic
maintenance, a tool kit (1) is supplied and in the center
compartment .

CRANKCASE BREATHER

1. Remove the crankcase breather tube plug (1) from the
tube and drain deposits into a suitable container.

2. Reinstall the crankcase breather tube plug.

Service more frequently when riding in rain, at full throttle,
or after the scooter is washed or overturned. Service if
the deposit level can be seen in the transparent section
of the drain tube.

(see page 32)

(1)

(1)

57

ENGINE OIL

Engine oil recommendation

Use a premium quality 4-stroke motor oil to
ensure longer service life of your scooter.
Use only oils which are rated, under the

SG

API service classification. The recommended
viscosity is . If a SAE 10W-30

SAE 10W-30

motor oil is not available, select an alternative
according to the right chart.

Oil capacity: see page 94

Single
Garde

Multi
Garde

OIL VISCOSITIES

10W

10W

20W

20W

20

20

30

30

20W-40 , 20W-50

20W-40, 20W-50

15W-40 , 15W-50

15W-40, 15W-50

10W-40

10W-40

10W-30

10W-30

40

40

58

20W-40 , 20W-50

-10 0 1020 3040C

020406080100F

5W-50

0

0

Engine oil level check

(1)

(2)

Check the engine oil level each day before riding the scooter.
The level must be maintained between the upper (1) and lower level (2) marks on the oil filler
cap/dipstick.

1. Start the engine and let it idle for a few minutes.

2. Stop the engine and put the scooter on its center stand on level ground.

3. After a few minutes, remove the oil filler cap/dipstick, wipe it clean, and reinsert the oil filler

cap/dipstick without screwing it in. Remove the oil filler cap/dipstick. The oil level should be
between the upper and lower marks on the oil filler cap/dipstick.

4. If required, add the specified oil up to the

upper level mark. Do not overfill.

5. Reinstall the oil filler cap/dipstick. Check for oil leaks.

NOTE:

!

Let the engine and exhaust system cool before working

in those areas.

(see page 58)

59

Engine oil replacement

Engine oil quality is the chief factor affecting engine service life. Change the engine oil as specified
in the maintenance schedule .
When running in very dusty conditions, oil changes should be performed more frequently than
specified in the maintenance schedule.

Please dispose of used engine oil in a manner that is compatible with the environment. We suggest
you take it in a sealed container to your local recycling center or service station for reclamation. Do
not throw it in the trash or pour it on the ground or down a drain.

Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged
periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to
thoroughly wash your hands with soap and water as soon as possible after handling used oil.

(see page 55)

Change the engine oil with the engine at normal
operating temperature and the scooter on its center stand
to assure complete and rapid draining.

1. Remove the oil filler cap/dipstick (1) from the right
crankcase cover.

2. Place a container under the left crankcase.

60

(1)

3. Remove the oil drain plug (2) to drain the oil.

4. Reinstall the drain plug and tighten the drain plug to
specification.

Oil drain plug torque: 25 N-m (2.5 kgf-m, 18lbf-ft)

5. Fill the crankcase with the recommended grade oil

(see page 58)

Oil capacity (after draining):

and install the oil fill cap.

0.9 liter (0.95 US qt, 0.8 lmp qt)

6. Start the engine and let it idle for 2 3 minutes.

7. Stop the engine and check that the oil level is at the

upper level mark on the oil filler cap/dipstick with the
scooter upright on firm, level ground. Make sure there
are no oil leaks.

NOTE:

Let the engine and exhaust system cool before working
in those areas.

－

61

(2)

Oil strainer screen clean

Change the engine oil with the engine at normal
operating temperature and the scooter on its center stand
to assure complete and rapid draining.

NOTE:

Let the engine and exhaust system cool before working
in those areas.

1. Remove the oil filler cap/dipstick (1) from the right

crankcase cover.

(1)

62

2. Place a drain pan under the crankcase and remove

the oil strainer screen cap (2).
The spring (3) and oil strainer screen (4) will come out
when the drain plug is removed.
Let the engine oil drain out.

3. Clean the oil strainer screen.

4. Check that the oil strainer screen, sealing rubber and

drain plug O-ring are in good condition.

5. Install the oil strainer screen, spring and oil strainer

screen cap.

Oil strainer screen cap torque:

15N-m (1.5 kgf-m, 11lbf-ft)

5. Fill the crankcase with the recommended grade oil

(see page 58)

and install the oil filler cap.

Oil capacity (after draining):

0.9 liter (0.95 US qt, 0.8 lmp qt)

(2)

6. Start the engine and let it idle for 2 3 minutes.

－

7. Stop the engine and check that the oil level is at the

upper level mark on the oil filler cap/dipstick with the
scooter upright on firm, level ground. Make sure there
are no oil leaks.

63

(4)

(3)

(2)

Oil filter replacement

Change the engine oil with the engine at normal
operating temperature and the scooter on its center
stand to assure complete and rapid draining.

NOTE:

Let the engine and exhaust system cool before working
in those areas.

1. Remove the oil filler cap/dipstick (1) from the right

crankcase cover.

(1)

64

2. Place a drain pan under the crankcase.

Remove three bolt and then remove the oil filter cap
(2) and O-ring (3).
The spring (4) will come out when the filter cap is
removed.
Let the engine oil drain out.

3. Remove and discard the oil filter (5).

4. Check that the O-ring are in good condition.

5. Install the new oil filter, spring, O-ring and cap.

Cap bolt torque: 12 N-m (1.2 kgf-m, 8.6 lbf-ft)

6. Fill the crankcase with the recommended grade oil

(see page 58)

Oil capacity (after draining):

and install the oil filler cap.

0.9 liter (0.95 US qt, 0.8 lmp qt)

(2)

(3)

7. Start the engine and let it idle for 2 3 minutes.

8. Stop the engine and check that the oil level is at the
upper level mark on the oil filler cap/dipstick with the
scooter upright on firm, level ground. Make sure there
are no oil leaks.

－

65

(5)

(4)

TRANSMISSION OIL
Oil change

1. Place the scooter in its center stand.

2. Place a drain pan under the drain bolt (1).

3. Remove the transmission oil drain bolt.

4. Remove the transmission oil filler bolt (2), slowly turn the rear wheel and drain the oil.

After draining the oil completely, install the oil drain bolt with a new sealing washer and tighten it.

Torque: 13 N-m (1.3 kgf-m, 9.5 lbf-ft)

5. Fill the transmission case with recommended oil.

Recommended transmission oil: SAE 90
Oil capacity (at draining):

0.18 liter (0.2 US qt, 0.16 lmp qt)

6. Install the transmission oil filler bolt with a new sealing

washer and tighten it.

Torque: 13 N-m (1.3 kgf-m, 9.5 lbf-ft)

66

(2)

(1)

AIR CLEANER

The air cleaner should be serviced at regular intervals.
Service more frequently when riding in unusually wet or
dusty areas.

Air cleaner element replacement

1. Remove the band (1).

2. Remove a bolt from the crankcase and six screws from

the air cleaner cover (2), then remove air cleaner
cover.

3. Remove six screws from the air cleaner element (3),

then remove and discard this air cleaner element.

4. The new air cleaner element installation is in the

reverse order of removal.

Use the KYMCO genuine air cleaner element or an
equivalent air cleaner element specified for your model.
Using the wrong KYMCO air cleaner element or a non­KYMCO air cleaner element which is not of equivalent
quality may cause premature engine wear or
performance problems.

(1)

(2)

(3)

67

THROTTLE OPERATION

1. Check for smooth rotation of the throttle grip from the

fully open to the fully closed position at both full
steering positions.

2. Measure the throttle grip free play at the throttle grip

flange.
The standard free play should approximately:

2~6mm(0.08 ~ 0.24 in)

To adjust the free play:

1. Slide the rubber sleeve (1) back to expose the throttle

cable adjuster (2).

2. Loosen the lock nut (3), then turn the adjuster to obtain

the correct free play.

2~6mm
(0.08 ~ 0.24 in)

3. Tighten the lock nut and reinstall the sleeve.

68

(3)

(2)

(1)

IDLE SPEED

The engine must be at normal operating temperature for
accurate idle speed adjustment. Ten minutes of stop-and­go riding is sufficient.

1. Warm up the engine place the scooter on its center

stand.

(1)

2. Open the seat .

3. Open the carburetor cover (1).

4. Adjust idle speed with the throttle stop screw (2).

Idle speed: 1700 150 rpm

(see page 32)

69

Push

(2)

SPARK PLUG

Remove the carbon deposits from the spark plug with a small wire
brush or a spark plug cleaning machine. Readjust the spark plug gap
to specified limit by using a spark plug gap thickness gauge. The
spark plug should be replaced periodically. Whenever removing the
carbon deposits, be sure to observe the operational color of the
spark plug's porcelain tip. This color tells you whether or not the
standard spark plug is suitable for your type of usage. A normal
operating spark plug should be light brown or tan color. If the spark
plug is very white or glazed appearing, then it has been operating
much too hot. This spark plug should be replaced with the colder
plug.

CAUTION

An improper spark plug may have an incorrect fit or heat
range for your engine. This may cause severe engine
damage which will not be covered under warranty.

Never use a spark plug with an improper heat range.
Severe engine damage could result.

Recommended plug: DPR7EA-9

70

0.8 - 0.9 mm
(0.032 - 0.036 in)

COOLANT
Inspection

The reserve tank is under footboard left. Check the
coolant level through the inspection window (1) at the
front fender while the engine is at the normal operating
temperature with the scooter in an upright position. If the
coolant level is below the LOWER level mark (3), remove
screw (4) and reserve tank lid (5) and reserve tank cap
(6) and add coolant mixture until it reaches the upper
level mark (2).
Always add coolant to the reserve tank. Do not attempt to
add coolant by removing the radiator cap.
If the reserve tank is empty, or if coolant loss is
excessive, check for leaks and see your KYMCO dealer
for repair.

(2)

(3)

F
L

(1)

(4)

(5)

(6)

71

Coolant replacement

Coolant recommendation

Coolant should be replaced by a KYMCO
dealer, unless the owner has proper tools and
service data and is mechanically qualified.

Always add coolant to the reserve tank. Do not
attempt to add coolant by removing the radiator
cap.

WARNING

Removing the radiator cap while the
engine is hot can cause the coolant to
spray out, seriously scalding you.

Always let the engine and radiator cool
down before removing the radiator cap.

The owner must properly maintain the coolant
to prevent freezing, overheating, and corrosion,
use only high quality ethylene glycol antifreeze
containing corrosion protection inhibitors
specifically recommended for use in aluminum
engines.(See antifreeze container label.)
Use only low-mineral drinking water or distilled
water as a part of the antifreeze solution. Water
that is high in mineral content or salt may be
harmful to the aluminum engine.
Using coolant with silicate inhibitors may cause
premature wear of water pump seals or
blockage of radiator passages.
Using tap water may cause engine damage.
The factory provides a 50:50 solution of
antifreeze and distilled water in this scooter.
This coolant solution is recommended for most
operating temperatures and provides good
corrosion protection.

72

A higher concentration of antifreeze decreases
the cooling system performance and is
recommended only when additional protection
against freezing is needed. A concentration of
less than 40:60 (40% antifreeze) will not
provide proper corrosion protection. During
freezing temperatures, check the cooling
system frequently and add higher
concentrations of antifreeze (up to a maximum
of 60% antifreeze) if required.

FRONT AND REAR SUSPENSION
INSPECTION

1. Check the fork assembly by locking the front
brake and pumping the fork up and down
vigorously. Suspension action should be
smooth and there must be no oil leakage.

2. Swing arm bearings should be checked by
pushing hard against the side of the rear
wheel while the scooter is on the center
stand. Free play indicates worn bearings.

3. Carefully inspect all front and rear
suspension fasteners for tightness.

73

SIDE STAND

Perform the following maintenance in accordance with
the maintenance schedule.

Functional check:

!

Check the spring for damage or loss of tension and the
side stand assembly for freedom of movement.

!

Check the side stand ignition cut-off system:

1. Place the scooter on its center stand.

2. Put the side stand up and start the engine.

3. Lower the side stand. The engine should stop as you
put the side stand down.

If the side stand system does not operate as described,
see your KYMCO dealer for service.

Side stand up

Side stand down

74

BRAKE FLUID

Brake fluid level:

With the scooter in an upright position, check the front
and rear fluid level. It should be above the lower level
mark. If the level is at or below the lower level mark " ",
check the brake pads for wear .
Worn pads should be replaced. If the pads are not worn,
have your brake system inspected for leaks.

(see page 76)

L

L

The recommended brake fluid is brake fluid from a
sealed container, or an equivalent.

Other checks:

Make sure there are no fluid leaks. Check for
deterioration or cracks in the hoses and fittings.

DOT 4

75

BRAKE PAD WEAR

Brake pad wear depends upon the severity of usage, the
type of riding, and road conditions. (Generally, the pads
will wear faster on wet and dirty roads.) Inspect the pads
at each regular maintenance interval.

Front brake

Check the cutout in each pad.
If either pad is worn to the cutout, replace both pads as a
set. See your KYMCO dealer for this service.

Rear brake

Check the cutout in each pad.
If either pad is worn to the cutout, replace both pads as a
set. See your KYMCO dealer for this service.

76

BATTERY

It is not necessary to check the battery
electrolyte level or add distilled water as the
battery is a maintenance-free (sealed) type. If
your battery seems weak and/or is leaking
electrolyte (causing hard starting or other
electrical troubles), contact your KYMCO
dealer.

NOTE:

Your battery is a maintenance-free type and
can be permanently damaged if the cap strip is
removed.

WARNING

The battery gives off explosive
hydrogen gas during normal operation.

A spark or flame can cause the battery
to explode with enough force to kill or
seriously hurt you.

Wear protective clothing and a face
shield, or have a skilled mechanic do
the battery maintenance.

77

Battery removal

(Always keep ignition switch is OFF)

The battery is in the battery box below seat.

1. Open the seat

(see page 32).

2. Remove the two screws and battery cover (1).

3. Remove the screws and then remove the battery

four

retainer (2).

78

(1)

(2)

4. Pull battery out to expose the terminal leads

5. Disconnect the negative (-) terminal lead (3) from the
battery first, then disconnect the positive (+) terminal
lead (4).

6. Remove the battery from the battery box.

Battery installation:

Install in the reverse order of the removal.

NOTE:

When install the battery, first connect the positive (+)
cable and then negative (-) cable to avoid short circuit.

79

(4)

(3)

FUSE REPLACEMENT

When frequent fuse failure occurs, it usually indicates a
short circuit or an overload in the electrical system. See
your KYMCO dealer for repair.

NOTE:

Never use a fuse with a different rating from that
specified. Serious damage to the electrical system or a
fire may result, causing a dangerous loss of lights or
engine power.

Fuse list

!

20A (Yellow) CHARGE fuse protects battery charging
system.

!

15A (Blue) MAIN fuse protects all electrical circuits.

!

15A (Blue) RELAY fuse protects the starter motor relay.

!

10A (Red) FAN fuse protects the cooling fan motor.

Blown fuse

80

Fuse box :

The fuse box is located under the battery in the battery
box .
The specified fuses (2) are:

(yellow)

1. Open the seat .

(see page 32)

10A (red), 15A (blue), 20A

(3)

(1)

2. Open the battery cover. .

3. Open the fuse box cover (1).

4. Pull out the old fuse and install a new fuse. The spare

fuse (3) are located in the battery retainer.

5. Close the fuse box covers and seat.

(see page 78)

81

(2)

TIRES

WARNING WARNING

Failure to follow these warnings may
result in an accident due to tire failure.
The tires on your scooter form the
crucial link between your scooter and
the road.

Follow these instructions:

!

Check tire condition and pressure,
and adjust pressure before each ride.

!

Avoid overloading your scooter.

!

Replace a tire when worn to the
specified limit, or if you find damage
such as cuts or cracks.

!

Always use the size and type of tires
specified in this owner's manual.

!

Balance the wheel after tire
installation.

!

Read this section of owner's manual
carefully.

Failure to perform break-in of the tires
could cause tire slip and loss of
control.

Use extra care when riding on new
tires. Perform proper break-in of the
tires referring to the break-in section
and avoid hard acceleration, hard
cornering, and hard braking for the first

Check the tire inflation pressure and tire tread
condition at the periodic inspection. For
maximum safety and good tire life, the tire
pressures should be inspected more often.

82

Tire pressure

Insufficient air pressure in the tires not only
hastens tire wear but also seriously affects the
stability of the scooter. Under inflated tires
make smooth cornering difficult and
overinflated tires decrease the amount of tire in
contact with the ground which can lead to skids
and loss of control. Be sure that the tire
pressure is within the specified limits at all
times. Tire pressure should only be adjusted
when the tires are cold.

Tire tread condition

Proper tire condition and proper tire type affect
vehicle performance. Cuts or cracks in the tires
can lead to tire failure and loss of vehicle
control. Worn tires are susceptible to puncture
failures and subsequent loss of vehicle control.
Tire wear also affects the tire profile, changing
vehicle handling characteristics.

Cold inflation tire pressure

Solo riding

Front

Rear

175 kpa

(1.75 kgf/cm ,

25 psi)

200 kpa

(2 kgf/cm ,

28 psi)

2

2

Two-up riding

175 kpa

(1.75 kgf/cm ,

25 psi)

225 kpa

(2.25 kgf/cm ,

32 psi)

Check tire conditions each day before you ride.
Replace tires if tires show visual evidence of
damage, such as cracks or cuts, or if tread
depth is less than

mm (0.08 in) rear

2

1.6 mm (0.06 in) front, 2

.

NOTE:

2

These wear limits will be reached before the
wear bars molded into the tire make contact
with the road.

83

When you replace a tire, be sure to replace it
with a tire of the size listed below. If you use a
different size of tire, scooter handling may be
adversely affected, possibly resulting loss of
scooter control.

Rear

Size

Type

Front

120/70-13 140/70-12

TUBELESS TUBELESS

Be sure to balance the wheel after repairing a
puncture or replacing the tire. Proper wheel
balance is important to avoid variable wheel-to­road contact, and to avoid uneven tire wear.

WARNING

An improperly repaired, installed, or
balanced tire can cause loss of control
or shorten tire life.

!

Ask your KYMCO dealer or qualified
mechanic to perform tire repair,
replacement, and balancing because
proper tools and experience are
required.

!

Install tires according to the rotation
direction shown by arrows on the
sidewall of each tire.

84

WARNING

Failure to follow these instructions about tubeless tires may result in an accident
due to tire failure. Tubeless tires require different service procedures than tube
tires.

!

Tubeless tires require an air-tight seal between the tire bead and wheel rim.
Special tire irons and rim protectors or a specialized tire mounting machine must
be used for removing and installing tires to prevent tire or rim damage which could
result in an air leak.

!

Repair puncture in tubeless tires by removing the tire and applying an internal
patch.

!

Do not use an external repair plug to repair a puncture since the plug may work
loose as a result of the cornering forces experienced in a scooter tire.

!

After repairing a tire, do not exceed 80 km/h (50 mph) for the first 24 hours, 130
km/h (80 mph) thereafter. This is to avoid excessive heat build-up which could
result in a tire repair failure and tire deflation.

!

Replace the tire if it is punctured in the sidewall area, or if a puncture in the tread
area is larger than 6 mm (3/16 in). These punctures cannot be repaired adequately.

85

CLEANING

Clean your scooter regularly to protect the surface finishes and inspect for damage, wear, and oil,
coolant or brake fluid leakage.

Avoid cleaning products that are not specifically designed for scooter or automobile surfaces. They
may contain harsh detergents or chemical solvents that could damage the metal, paint, and plastic
on your scooter.

If your scooter is still warm form recent operation, give the engine and exhaust system time to cool
off.

We recommend avoiding the use of high pressure water spray (typical in coin-operated car
washes).

NOTE:

High pressure water (or air) can damage certain parts of the scooter.

Washing the scooter

1. Rinse the scooter thoroughly with cool water to remove loose dirt.

2. Clean the scooter with a sponge or soft cloth using cool water. Avoid directing water to muffler

outlets and electrical parts.

86

3. Clean the plastic parts using a cloth or sponge

dampened with a solution of mild detergent and water.
Rub the soiled area gently rinsing it frequently with
fresh water. Take care to keep brake fluid or chemical
solvents off the scooter. They will damage the plastic
and painted surfaces.

The inside of the headlight lens may be clouded
immediately after washing the scooter. Moisture
condensation inside the headlight lens will disappear
gradually by lighting the headlight in high beam. Run the
engine while keeping the headlight on.

4. After cleaning, rinse the scooter thoroughly with plenty

of clean water. Strong detergent residue can corrode
alloy parts.

5. Dry the scooter start the engine, and let it run for

several minutes.

87

6. Test the brakes before riding the scooter. Several

applications may be necessary to restore normal
braking performance.

Braking efficiency may be temporarily impaired
immediately after washing the scooter. Anticipate longer
stopping distance to avoid a possible accident.

Finishing touches

After washing your scooter, consider using a commercially-available spray cleaner/polish or quality
liquid or paste wax to finish the job. Use only a non-abrasive polish or wax made specifically for
scooter or automobiles. Apply the polish or wax according to the instructions on the container.

88

Removing road salt

The salt contained in the road surface freezing prevention medicine which a road was sprayed with
in winter, and the seawater becomes the cause which rust occurs in. Wash your scooter by the
following point after it runs through such a place.

1. Clean the scooter using cool water .

Do not use warm water. This worsens the effect of the salt.

2. Dry the scooter and the surface of the metal is protected with the wax.

Painted aluminum wheel maintenance

Aluminum may corrode from contact with dirt, mud, or road salt. Clean the wheels after riding
through any of these substances, use a wet sponge and mild detergent. Avoid stiff brushes, steel
wool, or cleaners containing abrasives or chemical compounds.

After washing, rinse with plenty of water and dry with a clean cloth .

Apply touch-up paint to the wheels where damage has resulted.

Exhaust pipe maintenance

The exhaust pipe is stainless steel but may become stained by oil or mud. If necessary, remove
heat stains with a liquid kitchen abrasive.

(see page 86)

89

Clean the windshield

Using plenty of water, clean the windshield with a soft cloth or sponge. (Avoid using detergents or
any kind of chemical cleaner on the windshield.) Dry with a soft, clean cloth.

To avoid possible scratching or other damage, use only water and a soft cloth or sponge to clean
the windshield.

For a dirtier windshield, use a diluted neutral detergent with a sponge and plenty of water. Make
sure to wash off all the detergent. (Detergent residue may cause windshield cracks.)

Replace the windshield if scratches cannot be removed and they obstruct clear vision.

Do not let battery electrolyte, brake fluid or other acid chemicals get on the windshield and screen
garnish. They will damage the plastic.

90

STORAGE GUIDE

Extended storage, such as for winter, requires that you take certain steps to reduce the effects of
deterioration from non-use of the scooter. In addition, necessary repairs should be made before
storing the scooter; otherwise, these repairs may be forgotten by the time the scooter is removed
from storage.

Storage

1. Change the engine oil and filter.

2. Make sure the cooling system is filled with a 50/50% antifreeze solution.

3. Drain the carburetor and empty the fuel tank into an approved petrol container using a

commercially available hand siphon or an equivalent method. Spray the inside of the tank with
an aerosol rust-inhibiting oil. Reinstall the fuel fill cap on the tank.

WARNING

Petrol is highly flammable and explosive. You can be burned or seriously injured
when handling fuel.

!

Stop the engine and keep heat, sparks, and flame away.

!

Refuel only outdoors

!

Wipe up spills immediately.

91

4. To prevent rusting in the cylinders, perform the following:

Remove the spark plug caps from the spark plugs, using tape or string, secure the caps to

．

any convenient plastic body part so that they are positioned away from the spark plugs.

Remove the spark plugs from the engine and store them in a safe place. Do not connect the

．

spark plugs to the spark plug caps.

Pour a tablespoon (15 20 cc) of clean engine oil into each cylinder and cover the spark plug

．－

holes with a piece of cloth.

Crank the engine several times to distribute the oil.

．

Reinstall the spark plugs and spark plug caps.

．

5. Remove the battery. Store in an area protected from freezing temperatures and direct sunlight.

Slow charge the battery once a month.

6. Wash and dry the scooter. Wax all painted surfaces. Coat chrome with rustinhibiting oil.

7. Inflate the tires to their recommended pressures. Place the scooter on blocks to raise both tires

off the ground.

8. Cover the scooter (don't use plastic or other coated materials)and store in an unheated area,

free of dampness with a minimum of daily temperature variation. Do not store the scooter in
direct sunlight.

92

Removal from storage

1. Uncover and clean the scooter.

2. Change the engine oil if more than 1 months have passed since the start of storage.

3. Charge the battery as required. Install the battery.

4. Drain any excess aerosol rust-inhibiting oil from the fuel tank. Fill the fuel tank with fresh petrol.

5. Perform all Pre-ride inspection checks . Test ride the scooter at low speeds in a

safe riding area away from traffic.

(see page 40)

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SPECIFICATIONS

DIMENSIONS

Overall length 2030 mm (81.2 in)
Overall width 760 mm (30.4 in)
Overall height 1255 mm (50.2 in)
Wheel base 1390 mm (55.6 in)

WEIGHT

Dry weight 138 kg (303.6 lbs)

CAPACITIES

Engine oil After draining 0.9 L (0.95 US qt, 0.8 lmp qt)

After disassembly 1.1 L (1.2 US qt, 1 lmp qt)

Transmission oil

After draining 0.18 L (0.2 US qt, 0.16 lmp qt)

After disassembly 0.2 L (0.21 US qt, 0.18 lmp qt)
Fuel tank 11 L (2.86 US gal, 2.31 lmp gal)
Maximum weight capacity 163 kg (358 lbs)

94