KYMCO Hipster User Manual

Q

PREFACE

This Service Manual describes the technical features and servicing procedures for the KYMCOHipster125.

Section 1 contains the precautions for all operations stated in this manual. Read them carefully before starting any operation.

Section 2 is the inspection/ adjustment procedures, safety rules and service information for each part, starting from periodic maintenance.

Sections 3 and 4 state the servicing procedures and cautions for the removal and installation of lubrication and fuel systems.

Sections 5 through 18 give instructions for disassembly, assembly and inspection of engine, chassis frame and electrical equipment.

Most sections start with an assembly or system illustration and troubleshooting for the section. The subsequent pages give detailed procedures for the section.

The information and contents included in this manual may be different from the motorcycle in case specifications are changed.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT

OVERSEAS SERVICE SECTION

HIPSTER125/150

TABLE OF CONTENTS

GENERAL INFORMATION 1 INSPECTION/ADJUSTMENT 2 LUBRICATION SYSTEM 3 FUEL SYSTEM 4

ENGINE

ENGINE REMOVAL/INSTALLATION 5 CYLINDER HEAD/VALVES 6 CYLINDER/PISTON 7 STARTER MOTOR/GENERATOR/

LEFT CRANKCASE COVER/STARTER CLUTCH/CAMSHAFT

CLUTCH/GEAR SHIFT MECHANISM 9 CRANKCASE/CRANKSHAFT/TRANS-

MISSION SYSTEM/STARTER SPINDLE FRONT WHEEL/SUSPENSION/

STEERING

CHASSIS

REAR WHEEL/BRAKE/SUSPENSION 12 HYDRAULIC BRAKE 13 REAR CARRIER/REAR FENDER/

EXHAUST MUFFLER

ELECTRICAL

E

IGNITION SYSTEM 15

UIPMENT

CHARGING SYSTEM 16 STARTING SYSTEM 17 LIGHTS/INSTRUMENTS/SWITCHES/

HORN

8

10

11

14

18

1. GENERAL INFORMATION

HIPSTER 125/150

1

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1

GENERAL INFORMATION

__________________________________________________________________________________

ENGINE SERIAL NUMBER---------------------------------------------- 1- 1 SPECIFICATIONS---------------------------------------------------------- 1- 2 SERVICE PRECAUTIONS------------------------------------------------ 1- 4 TORQUE VALUES --------------------------------------------------------- 1-12 SPECIAL TOOLS ----------------------------------------------------------- 1-13 LUBRICATION POINTS -------------------------------------------------- 1-14 CABLE & HARNESS ROUTING ---------------------------------------- 1-15 WIRING DIAGRAM-------------------------------------------------------- 1-17 TROUBLESHOOTING----------------------------------------------------- 1-18

1-0

1. GENERAL INFORMATION

r

ENGINE SERIAL NUMBER

Location of Engine Serial Numbe

HIPSTER 125/150

1-1

1. GENERAL INFORMATION

SPECIFICATIONS

Motorcycle name & Model No. RJ25AA Motorcycle name HIPSTER125 Overall length (mm) 2250 Overall width (mm) 900 Overall height (mm) 1180 Wheel base (mm) 1475 Engine type 4 ∞ Displacement (cc) 124.1 Fuel type 92# nonleaded gasoline

Front wheel 59

Dry weight (kg)

Gross weight(kg)

Tires

Ground clearance (mm) 150

Starting system Type OHC

Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve train OHC-2V Bore x stroke (mm) 56.5 x 49.5 Compression ratio 9.4

Compression pressure (kg/cm²)

Max. output (ps/rpm) 11.5/9000

Engine

Max. torque (Kg.m/rpm) 1.0/6000

Port timing

Valve clearance (cold)

Idle speed (rpm) 1600rpm

Lubrication

System

Oil filter type Wire gauze filter

Cooling Type Air cooling

Rear wheel 80

Total 139 Front wheel 67.5 Rear wheel 91

Total 158.5 Front wheel 3.00-18-4PR Rear wheel 130/90-15-4PR

Starting motor &

kick starter

13

Intake (mm)

Exhaust (mm)

Lubrication type Oil pump type Inner/outer rotor

Oil capacity 1.0L SAE#30

Open 5.5 Close 27.5 Open 4

Close 36 Intake 0.06mm Exhaust 0.06mm

Forced pressure &

wet sump

Fuel System

Electrical

Equipment

Power Drive

System

Moving

Device

Damping

Device

Frame type Double cradle

SPECIFICATIONS

HIPSTER 125/150

Air cleaner type Paper element type Fuel capacity 12.0 liter

Carburetor

Type CVK Piston dia. (mm) φ26.5 Venturi dia.(mm) φ26 Throttle type Piston type

Ignition

System

Type CDI Ignition timing 34.5° ±2/4000rpm Spark plug NGK-DR8EA Spark plug gap 0.60.7mm

Battery Capacity 12V6AH Clutch Type Wet multi-disc clutch

Type Permanent gear meshing

Transmission Gear

Operating method Foot operated Type International type

1st gear 2.846

Reduction ratio

Tire pressure

(kg/cm²)(2 riders)

Turning angle

Brake system type

Shock absorber type

2nd gear 2.063 3rd gear 1.4 4th gear 1.130 5th gear 0.923

Front 1.75 Rear 2.25 Left 43° Right 43° Front Disk brake Rear Drum brake

Front Telescope Rear Double swing

1-2

1. GENERAL INFORMATION

y

HIPSTER 125/150

Motorcycle name & Model No. RH30AA Motorcycle name HIPSTER150 Overall length (mm) 2275 Overall width (mm) 830 Overall height (mm) 1135 Wheel base (mm) 1475 Engine type 4 ∞ Displacement (cc) 149.4 Fuel type 92# nonleaded gasoline

Front wheel 59

Dry weight (kg)

Gross weight(kg)

Tires

Ground clearance (mm) 140

Starting system Type OHC

Cylinder arrangement Single cylinder Combustion chamber type Dome head Valve train SOHC-4V Bore x stroke (mm) 62 x 49.5 Compression ratio 10

Compression pressure (kg/cm²)

Max. output (Ps/rpm) 14/9000

Engine

Max. torque (Kg.m/rpm) 1.1/7500

Port timing

Valve clearance (cold)

Idle speed (rpm) 1600rpm

Lubrication

System

Oil filter type Wire gauze filter

Cooling Type Air cooling

Rear wheel 80

Total 139 Front wheel 67.5 Rear wheel 91

Total 158.5 Front wheel 3.0-18-4PR Rear wheel 130/90-15-4PR

Starting motor &

kick starter

13

Intake (1mm)

Exhaust (1mm)

Lubrication type Oil pump type Inner/outer rotor

Oil capacity 1.0L SAE#30

Open 0 Close 30 Open 0

Close 30 Intake 0.06mm Exhaust 0.06mm

Forced pressure &

wet sump

Air cleaner type Paper element type

Fuel System

Fuel capacity 12.0L

Type CVK

Carburetor

Piston dia. (mm) φ26.5 Venturi dia.(mm) Throttle type Piston type

Ignition

System

Electrical

Equipment

Battery Capacity 12V6AH

Moving

Clutch Type Wet multi-disc clutch

Tire pressure

(kg/cm²)(2 riders)

Turning angle Brake system

type

Damping

Device

Shock absorber type

Frame type Double cradle

Type CDI Ignition timing 34.5° ±2/4000rpm Spark plug NGK-CR8EH9 Spark plug gap 0.60.7mm

Type Permanent gear meshing

Transmission Gear

Operating

ethod m

Type International type

1st gear 2.846

Reductio n

ratio

2nd gear 2.063 3rd gear 1.4 4th gear 1.130 5th gear 0.923

Front 1.75 Rear 2.25 Left 45° Right 45° Front Disk brake Rear Drum brake

Front Telescope Rear Double swing

φ26

Foot operated

1-3

1. GENERAL INFORMATION

SERVICE PRECAUTIONS

 Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when reassembling.

 When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.

 Use genuine parts and lubricants.

 When servicing the motorcycle, be sure

to use special tools for removal and installation.

 After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil before reassembly.

HIPSTER 125/150

 Apply or add designated greases and

1-4

1. GENERAL INFORMATION

lubricants to the specified lubrication points.

 After reassembly, check all parts for

proper tightening and operation.

 When two persons work together, pay

attention to the mutual working safety.

 Disconnect the battery negative (-)

terminal before operation.

 When using a spanner or other tools,

make sure not to damage the motorcycle surface.

 After operation, check all connecting

points, fasteners, and lines for proper connection and installation.

 When connecting the battery, the positive

(+) terminal must be connected first.

 After connection, apply grease to the

battery terminals.

 Terminal caps shall be installed securely.

HIPSTER 125/150

 If the fuse is burned out, find the cause

1-5

1. GENERAL INFORMATION

and repair it. Replace it with a new one according to the specified capacity.

 After operation, terminal caps shall be

installed securely.

 When taking out the connector, the lock

on the connector shall be released before operation.

 Hold the connector body when

connecting or disconnecting it.

 Do not pull the connector wire.

 Check if any connector terminal is

bending, protruding or loose.

HIPSTER 125/150

Confirm Capacity

1-6

1. GENERAL INFORMATION

 The connector shall be inserted

completely.

 If the double connector has a lock,

lock it at the correct position.

 Check if there is any loose wire.

 Check the double connector cover for

proper coverage and installation.

 Before connecting a terminal, check for

damaged terminal cover or loose negative terminal.

 Insert the terminal completely.  Check the terminal cover for proper

coverage.

 Do not make the terminal cover opening

face up.

 Secure wire harnesses to the frame with

their respective wire bands at the designated locations.

Tighten the bands so that only the

insulated surfaces contact the wire harnesses.

HIPSTER 125/150

Snapping!

1-7

1. GENERAL INFORMATION

N

 After clamping, check each wire to make

sure it is secure.

 Do not squeeze wires against the weld or

its clamp.

 After clamping, check each harness to

make sure that it is not interfering with any moving or sliding parts.

 When fixing the wire harnesses, do not

make it contact the parts which will generate high heat.

 Route wire harnesses to avoid sharp

edges or corners. Avoid the projected ends of bolts and screws.

 Route wire harnesses passing through the

side of bolts and screws. Avoid the projected ends of bolts and screws.

HIPSTER 125/150

o Contact !

1-8

1. GENERAL INFORMATION

 Route harnesses so they are neither

pulled tight nor have excessive slack.

 Protect wires and harnesses with

electrical tape or tube if they contact a sharp edge or corner.

 When rubber protecting cover is used to

protect the wire harnesses, it shall be installed securely.

 Do not break the sheath of wire.  If a wire or harness is with a broken

sheath, repair by wrapping it with protective tape or replace it.

 When installing other parts, do not press

or squeeze the wires.

HIPSTER 125/150

Do not press or squeeze the wire.

Do not pull too tight!

1-9

1. GENERAL INFORMATION

 After routing, check that the wire

harnesses are not twisted or kinked.

 Wire harnesses routed along with

handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.

 When a testing device is used, make sure

to understand the operating methods thoroughly and operate according to the operating instructions.

 Be careful not to drop any parts.

 When rust is found on a terminal, remove

the rust with sand paper or equivalent before connecting.

 Do not bend or twist control cables.

Damaged control cables will not operate smoothly and may stick or bind.

Do you understand the instrument? Is the instrument set correctly?

HIPSTER 125/150

Remove Rust !

1-10

1. GENERAL INFORMATION



 Symbols: The following symbols represent the

servicing methods and cautions included in this service manual.

: Apply engine oil to the

specified points. (Use designated engine oil for

Engine Oil

Grease

Special

lubrication.)

: Apply grease for

lubrication.

: Use special tool.

: Caution

: Warning

HIPSTER 125/150

1-11

1. GENERAL INFORMATION

m

HIPSTER 125/150

TORQUE VALUES

STANDARD TORQUE VALUES

5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut

Torque specifications listed below are for important fasteners.

ENGINE

Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Exhaust muffler joint lock nut Valve adjusting lock nut Oil bolt Cylinder bolt A.C. generator bolt Cylinder head cover bolt Oil pump bolt Oil filter lock nut Rocker arm lock bolt Cylinder head lock bolt Cylinder bolt Crankcase assembly bolt Crankshaft damper bolt Right crankcase cover bolt Left crankcase cover bolt A.C. generator coil lock bolt Starter gear set plate bolt Carburetor lock bolt

Item Torque (kg-m) Ite

0.450.6

0.81.2

1.82.0

3.04.0

5.06.0

Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks

2 2 1 2 2 1 2 1 4 2 1 3 1 2

10

1 8 4 4 1 2

5mm screw 6mm nut, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut

8 8

30

6 5

12

6

14

6 6

16

8 8x79 6x22

6 6x25

6

5

6

2.83.2

1.53.0

0.81.2

1.41.8

2.03.0

0.81.2

4.05.2

0.81.2

0.71.1

1.53.0

1.52.0

0.81.2

0.81.5

0.81.2

0.41.7

1.01.6

0.81.2

Torque (kg-m)

0.350.5

0.71.1

1.01.4

2.03.0

3.54.5

Double end bolt Double end bolt

Double end bolt

FRAME

Steering stem lock nut Front axle nut Rear axle nut

Rear shock absorber upper mount bolt Rear shock absorber lower mount bolt

Rear fork pivot nut Handlebar lock bolt Rear driven gear bolt Rear brake panel bolt

Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks

1 1 1 2 2 1 4 4 1

22 14 16 10 10 12

6

8

6.09.0

5.57.0

6.08.0

3.04.0

5.57.0

6.09.0

1.82.0

1.82.5

1-12

1. GENERAL INFORMATION

SPECIAL TOOLS

HIPSTER 125/150

Flywheel puller E005 Bearing puller 18mm E008 Lock nut socket wrench E010

Tappet adjuster E012 Oil seat & bearing install E014 Bearing puller 15mm E018 Bearing puller 12mm E020 Flywheel holder E021

Crankshaf bearing puller E030 Bearing puller 10mm E031 Race cone install F005

Tool Name Tool No. Remarks Ref. Page

1-13

1. GENERAL INFORMATION

LUBRICATION POINTS

Front Brake Fluid Tube

Grease

Throttle Cable

HIPSTER 125/150

Engine Oil

Clutch Cable

Grease

Speedometer Cable

1-14

1. GENERAL INFORMATION

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CABLE & HARNESS ROUTING

Handlebar Switch Connectors

Ignition Coil

Fuel Tube

Ignition Switch

CDI Uni

Wire Harness

HIPSTER 125/150

A.C. Generator Wire Connector

Fuel Filte

Taillight Wire Connector

1-15

1. GENERAL INFORMATION

N

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A.C.V. Vacuum Tube

A.C.V.

Accelerating Pump Cable

Purge Control Valve

Air Cleane

Vacuum Tube

Starter Relay

Starter Motor Wire

Throttle Cable

egative Cable

Clutch Cable

HIPSTER 125/150

Battery Positive Cable

Fuse Box

Winke

CDI Uni

A.I.C.V.

Ignition Coil Wire

1-16

1. GENERAL INFORMATION

WIRING DIAGRAM

HIPSTER 125/150

1-17

1. GENERAL INFORMATION

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

Inspection/Adjustment

Check if fuel reaches

carburetor by loosening

drain screw

Remove spark plug and

install it into spark plug

cap to test spark by

connecting it to engine

ground

Test cylinder compression

Start engine by follow-ing normal starting procedure

Remove spark plug and

inspect again

Fuel reaches

carburetor

Spark jumps

Normal

compression

Engine does not

fire

Dry spark plug

Symptom

Fuel does not

reach carburetor

Weak or no spark

Low or no compression

Engine fires but

does not start

Wet spark plug

HIPSTER 125/150

Probable Cause

Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage Clogged fuel filter Clogged charcoal canister Clogged auto fuel valve strainer Faulty auto fuel valve passage Clogged carburetor air balance tube

Faulty spark plug Fouled spark plug Faulty CDI unit Faulty pulser coil Faulty exciter coil Faulty ignition switch Broken or shorted ignition coil wire

Faulty or slipping clutch Valve clearance too small Valve stuck open Worn cylinder and piston rings Leaking cylinder head gasket

Faulty choke control system Leaking intake manifold Incorrect ignition timing Incorrectly adjusted pilot screw

Flooded carburetor Throttle valve excessively open Clogged air cleaner

1-18

1. GENERAL INFORMATION

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Inspection/Adjustment Symptom

Check ignition timing

Faulty CDI unit Faulty pulser coil

Mixture too lean (turn screw in) Mixture too rich (turn screw out)

Faulty intake manifold gasket Carburetor not securely tightened Damaged insulator rubber Broken vacuum tube

Faulty or fouled spark plug Faulty CDI unit Faulty A.C. generator Faulty ignition coil Faulty ignition switch

Faulty A.C. generator Damaged vacuum tube Clogged air vent hole

Check carburetor pilot

screw adjustment

Check carburetor gasket

for air leaks

Remove spark plug and install it into spark plug

cap to test spark by

connecting it to engine

ground

Check A.C. generator

Correct

Correctly adjusted

No air leak

Good spark

Good

Incorrect

Incorrectly adjusted

Air leaks

Weak or inter-

mittent spark

Faulty

HIPSTER 125/150

Probable Cause

1-19

1. GENERAL INFORMATION

N

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POOR PERFORMANCE (ENGINE LACKS POWER)

Inspection/Adjustment

Start engine and accelerate lightly for observation

Check ignition timing using a timing light

Check valve clearance

Test cylinder compression

Check carburetor for clogging

Remove spark plug and inspect

Check crankcase for oil level and condition

Remove cylinder head oil pipe bolt and inspect

Check for engine overheating

Rapidly accelerate or run at high speed

Engine speed

increases

Correct

ormal

compression

Not clogged

Plug not fouled o

discolored

Correct and no

contaminated

Valve train lubricated properly

Engine does no

overheats

Engine does not knock

Symptom

Engine speed does not increase sufficiently

Incorrect

Abnormal

compression

Clogged

Plug fouled or

discolored

Incorrect o

contaminated

Valve train not lubricated properly

Engine overheats

Engine knocks

HIPSTER 125/150

Probable Cause

Clogged air cleaner Poor fuel flow (Restricted) Clogged fuel tank cap breather hole Clogged exhaust muffler Carburetor fuel level too low Clogged carburetor high speed fuel passage

Faulty CDI unit Faulty pulser coil

Improper valve clearance adjustment Excessively worn valve seat (protruded valve stem)

Improper valve and seat contact Worn cylinder and piston rings Leaking cylinder head gasket Improper valve timing

Clean and unclog

Fouled spark plug Incorrect heat range plug

Oil level too high Oil level too low Oil not changed

Clogged oil cooler Clogged oil line Faulty oil pump

Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber Ignition timing too advanced

Excessive carbon build-up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Ignition timing too advanced

1-20

1. GENERAL INFORMATION

POOR PERFORMANCE (AT HIGH SPEED)

Inspection/Adjustment Symptom

Check ignition timing

Correct

Check valve clearance

Correct

Check fuel filter for

fuel supply

Fuel flows freely

Check carburetor for

clogged jets

Not clogged

Check valve timing

Correct

Check valve spring

tension

Not weakened

Fuel f l ow restricted

Incorrect

Clogged

Incorrect

Weak spring

HIPSTER 125/150

Probable Cause

Faulty CDI unit Faulty pulser coil

Improperly adjusted valve clearance Worn valve seat

Empty fuel tank Clogged fuel filter Clogged fuel tank cap breather hole

Clean and unclog

Cam timing gear aligning marks not aligned

Faulty spring

1-21

1. GENERAL INFORMATION

B

t

B

HIPSTER 125/150

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging

Inspection/Adjustment Symptom

Probable Cause

Start engine and test limit voltage between battery terminals

Measure resistance between AC generator coil terminals

Connect battery (+) wire to regulator/rectifier coupler red wire and battery (-) wire to engine ground and test voltage

Check regulator/rectifier coupler for loose connection

Normal voltage

Normal

Normal voltage

Voltage does no increase

Resistance too high

No voltage

Dead battery Faulty battery

Faulty coil Broken pink and yellow wires Shorted pink and yellow wires

Broken red wire

Normal

Abnormal

Faulty regulator/rectifier Poorly connected coupler

Faulty A.C. generator

Overcharging

Inspection/Adjustment Symptom

Probable Cause

Connect battery (+) wire to regulator/rectifier coupler black wire and battery (-) wire to engine ground and test voltage

Check regulator/rectifier coupler for loose connection

attery has voltage

with ignition switch “ON”

Normal

attery has no

voltage with ignition switch “ON”

Abnormal

Broken black wire

Poorly connected coupler

Faulty regulator/rectifier

1-22

1. GENERAL INFORMATION

p

NO SPARK AT SPARK PLUG

Inspection/Adjustment Symptom

Replace with a new spark

lug and inspect again

Weak or no spark

Check spark plug cap and ignition coil wire for looseness

Not loose

Check CDI unit coupler for looseness

Normal

Measure resistance between CDI unit coupler wire terminals

Normal

Check related parts

Normal

Check CDI unit with a CDI unit tester

Normal

Check ignition coil with a CDI unit tester

Abnormal

Good spark

Loose

Abnormal

HIPSTER 125/150

Probable Cause

Faulty old spark plug

Loose spark plug cap

Poorly connected coupler

Faulty ignition switch Faulty exciter coil Faulty pulser coil Faulty ignition coil

Broken wire harness Poorly connected coupler

Faulty CDI unit

Faulty ignition coil

1-23

2. INSPECTION/ADJUSTMENT

2

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HIPSTER125/150

__________________________________________________________________________________

INSPECTION/ADJUSTMENT

__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 2- 1 MAINTENANCE SCHEDULE-------------------------------------------- 2- 2 FUEL LINE/FILTER-------------------------------------------------------- 2- 3 THROTTLE OPERATION------------------------------------------------- 2- 3 AIR CLEANER -------------------------------------------------------------- 2- 4 SPARK PLUG---------------------------------------------------------------- 2- 4 VALVE CLEARANCE----------------------------------------------------- 2- 5 CARBURETOR IDLE SPEED -------------------------------------------- 2- 5 IGNITION TIMING--------------------------------------------------------- 2- 6 CYLINDER COMPRESSION--------------------------------------------- 2- 6 ENGINE OIL----------------------------------------------------------------- 2- 7 DRIVE CHAIN -------------------------------------------------------------- 2- 7 BRAKE SHOE/BRAKE PEADAL---------------------------------------- 2- 8 CLUTCH---------------------------------------------------------------------- 2- 8 BRAKE FLUID -------------------------------------------------------------- 2- 8 SUSPENSION---------------------------------------------------------------- 2- 9 NUTS/BOLTS/FASTENERS ---------------------------------------------- 2- 9 WHEELS/TIRES ------------------------------------------------------------ 2- 9 STEERING HANDLEBAR ------------------------------------------------ 2-10

2

2-0

2. INSPECTION/ADJUSTMENT

HIPSTER125/150

SERVICE INFORMATION

GENERAL

 WARNING

•Before running the engine, make sure that the working area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas which may cause death to people.

•Gasoline is extremely flammable and is explosive under some conditions. The working area must be well-ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area.

SPECIFICATIONS ENGINE CHASSIS

Throttle grip free play : 26mm Rear brake free play : 1020mm Spark plug gap : 0.60.7mm Brake fluid : DOT-3 Spark plug specification : DR8EA Valve clearance : IN: 0.06mm Cold Engine: IN: 0.05mm EX: 0.06mm EX: 0.05mm

Cylinder compression : 150cc: 13kg/cm² 125cc: 13kg/cm²

Ignition timing : 34.5±2°/4000rpm Idle speed : 1600±100rpm Engine oil capacity: At disassembly : 1.0 liter At change : 0.9 liter

TIRE PRESSURE

TIRE SIZE: Front : 3.00–18 Rear : 130/90–15

TORQUE VALUES Front axle nut 5.57.0kg-m Rear axle nut 6.08.0kg-m

Front 1.75kg/cm² 1.75kg/cm²

Rear 2.0kg/cm² 2.25kg/cm²

–4PR

1 Rider 2 Riders

2-1

2. INSPECTION/ADJUSTMENT

r

MAINTENANCE SCHEDULE

Perform the periodic maintenance at each scheduled maintenance period. I: Inspect, and Clean, Adjust, Lubricate, Refill, Repair or Replace if necessary. A: Adjust C: Clean R: Replace T : Tighten

HIPSTER125/150

Frequency

Item

Engine oil

Whicheve

comes first Ö

Ø

1000

New

R

motorcycle

300km

200 0

Regular Service Mileage (km)

300

400

500

600

700

0

R

800 0

900

1000

1100

1200

0

R

Engine oil filter

C C C

screen Fuel filter screen R Valve clearance

New

A

motorcycle

300km

A

Carburetor I I I Air Cleaner Note 2,3 I R I R I R Spark plug Clean at every 3000km and replace if necessary Brake system I I I I I I Drive chain A A A A A A Suspension I I Nuts, bolts, fasteners I T I T Tire I I I Steering head bearing I I

• In the interest of safety, we recommend these items should be serviced only by an authorized KYMCO motorcycle dealer.

Note: 1. For higher odometer readings, repeat at the frequency interval established here.

2. Service more frequently when riding in dusty or rainy areas.

3. Service more frequently when riding for long distance, in rain or at full throttle.

2-2

2. INSPECTION/ADJUSTMENT



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FUEL LINE/FILTER

Check the fuel lines and replace any parts which show signs of deterioration, damage or leakage.

Do not smoke or allow flames or sparks in your working area.

THROTTLE OPERATION

Check for smooth throttle grip movement in all steering positions. Measure the throttle grip free play.

Free Play: 26mm

Adjust the throttle grip free play by turning the adjusting nut on the throttle cable. Slide the dust boot out and adjust by loosening the lock nut and turning the adjusting nut.

Check if the punch mark on the carburetor accelerating pump is aligned. Align the punch mark by turning the adjusting nut at the accelerating pump cable.

Fuel Filte

HIPSTER125/150

Fuel Line

Dust Boo

Adjusting Nu

Lock Nu

2-3

2. INSPECTION/ADJUSTMENT

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

AIR CLEANER

AIR CLEANER REPLACEMENT

Remove the right side cover. Remove the two screws attaching the emission control system. Remove the air cleaner case cover screws and the cover. Remove the air cleaner screen and element. Check the element and replace it with a new one if it is excessively dirty or damaged.

CHANGE INTERVAL More frequent replacement is required when

riding in unusually dusty or rainy areas.

• If the air cleaner is installed improperly, dust may be sucked into the cylinder directly to reduce the engine horse-power and affect engine service life.

• Do not wash the element in any solvent

SPARK PLUG

Remove the spark plug. Check the spark plug for wear, damage and fouling deposits. Clean any fouling deposits with a spark plug cleaner or a wire brush.

Specified Spark Plug: DR8EA

Measure the spark plug gap. Spark Plug Gap: 0.60.7mm

When installing, first screw in the spark plug by hand and then tighten it with a spark plug wrench.

HIPSTER125/150

Elemen

Wash

Screw

Squeeze out and dr

Spark Plug

Screen

Engine oil

Gap, Wear, and Fouling Deposits

Squeeze out and dr

2-4

KYMCO Hipster User Manual [fr]