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

2. INSPECTION/ADJUSTMENT



Cracks Damage

VALVE CLEARANCE

Inspect and adjust valve clearance while the engine is cold (below 35).

Remove four bolt. Remove the cylinder head cover protector.. Remove the cylinder head cover.

Rotate the generator flywheel to locate the camshaft on the top dead center (TDC) and align the “T” mark on the flywheel with the mark on the left crankcase cover.

After adjustment, rotate the crankshaft several turns to make sure that the valve clearance is correct.

Inspect and adjust the valve clearance. Valve Clearance: IN : 0.06mm

EX: 0.06mm Cold Engine: IN: 0.05mm

EX: 0.05mm Loosen the lock nut and adjust by turning the

adjusting bolt.

Special

Tappet Adjust E012

Check the valve clearance again after the lock nut is tightened.

CARBURETOR IDLE SPEED

The engine must be warm for accurate idle speed inspection and adjustment.

Turn the throttle stop screw to obtain the specified idle speed.

Idle Speed: 1600±100rpm When the engine misses or run erratic, adjust

Washer Deformation

the pilot screw.

“T” Mark

Feeler Gauge

HIPSTER125/150

Bolts

2-5

When adjusting the carburetor, make sure to use a E/M tester.

2. INSPECTION/ADJUSTMENT



t

Throttle Stop Screw

IGNITION TIMING

• The CDI unit is not adjustable.

• If the ignition timing is incorrect,

check the ignition system.

Remove the ignition timing eye hole cap on the left crankcase cover.

Check the ignition timing with a timing light. When the engine is running at idle speed, the ignition timing is correct if the index mark on the left crankcase cover aligns with the “F” mark on the flywheel.

CYLINDER COMPRESSION

Warm up the engine before compression test. Stop the engine, then remove the spark plug and insert a compression gauge. Open the throttle valve fully and crank the engine with the starter motor or kick lever. Measure the compression.

Compression: 13kg/cm²

If the compression is low, check for the following:

Leaky valves Valve clearance too small Leaking cylinder head gasket Worn piston rings Worn piston/cylinder

If the compression is high, it indicates that

Pilot Screw

HIPSTER125/150

carbon deposits have accumulated on the combustion chamber and the piston head.

Eye Hole

Timing Ligh

“F” Mark

Compression Gauge

2-6

2. INSPECTION/ADJUSTMENT

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ENGINE OIL

When checking the oil level, place the motorcycle on its main stand on level ground for oil level check.

After the engine is stopped for 10 minutes, check if the oil level is between the upper and lower limits through the wash window. If the oil level is low, add the recommended oil to the proper level.

Recommended Oil: SAE30W#

After oil change, be sure to tighten the drain bolt securely. Check the drain bolt washer for damage.

Oil Capacity: At disassembly : 1.0 liter At change : 0.9 liter

HIPSTER125/150

Watch Window Oil Filter Screen Cap

Engine Oil Filter Screen Cleaning Remove the oil filter screen cap.

Remove the oil filter screen and spring and then clean with compressed air.

Be careful not to install the oil filter screen in the reverse direction to avoid engine damage.

DRIVE CHAIN

Check the drive chain slack. Specified Slack: 12cm Drive Chain Adjustment:

1. Loosen the rear axle nut.

2. Adjust the right and left adjusting nuts to

align the right punch mark with the left punch mark.

3. Turn the rear wheel to see if the drive

chain slack is within the specified range.

4. Tighten the rear axle nut.

After drive chain adjustment, check the rear brake pedal free play and adjust if necessary.

Sprin

Spring

Oil Filter Screen

Rear Axle Nu

Oil Filter Screen

Punch Mark

Adjusting Nu

2-7

2. INSPECTION/ADJUSTMENT

t

BRAKE SHOE

Inspect the front brake linings for wear.

BRAKE LEVER/PEDAL

Measure the rear brake pedal free play.

Free Play: 2030mm

CLUTCH

Measure the clutch lever free play. Free Play: 1020mm When minor adjustment is required, adjust

by turning the adjusting nut on the clutch lever side. When major adjustment is required, adjust by turning the adjusting nut on the clutch cable from the right crankcase cover. Adjust by loosening the lock nut and turning the adjusting nut. After adjustment, tighten the lock nut.

BRAKE FLUID Turn the steering handlebar upright and

check if the brake fluid level is between the upper and lower limits.

Specified Brake Fluid: DOT-3

Lower Limi

Lock Nu

HIPSTER125/150

Adjusting Nu

Lock Nu

2-8

2. INSPECTION/ADJUSTMENT



SUSPENSION

FRONT

Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times. Check the entire shock absorber assembly for oil leaks, looseness or damage.

REAR Check the action of the rear shock absorber

by compressing it several times. Check the entire shock absorber assembly for oil leaks, looseness or damage. Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn.

NUTS/BOLTS/FASTENERS

Check all important chassis nuts and bolts for looseness. Tighten them to their specified torque values if any looseness is found.

WHEELS/TIRES

Check the tires for cuts, imbedded objects or other damages. Check the tire pressure.

Tire pressure should be checked when tires are cold.

TIRE PRESSURE 1 Rider 2 Riders

Front 1.75kg/cm² 1.75kg/cm² Rear 2.00kg/cm² 2.25kg/cm²

TIRE SIZE

Front 3.00-18-4PR Rear 130/90-15-4PR

Tire Pressure Gauge

HIPSTER125/150

2-9

2. INSPECTION/ADJUSTMENT

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Check the front and rear axle nuts for looseness. If the axle nuts are loose, tighten them to the specified torques.

Torques: Front : 5.57.0kg-m Rear : 6.08.0kg-m

STEERING HANDLEBAR

Check that the control cables do not interfere with handlebar rotation. Raise the front wheel off the ground and check that the steering handlebar rotates freely. If the handlebar moves unevenly, binds, or has vertical movement, adjust the steering head bearing.

HIPSTER125/150

Front Axle Nu

2-10

3. LUBRICATION SYSTEM

HIPSTER125/150

3

__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 3- 2 TROUBLESHOOTING----------------------------------------------------- 3- 2 ENGINE OIL/OIL FILTER SCREEN ------------------------------------ 3- 3 OIL PUMP/OIL FILTER ROTOR ---------------------------------------- 3- 4

3

3-0

3. LUBRICATION SYSTEM

LUBRICATION SYSTEM

HIPSTER125/150

3-1

3. LUBRICATION SYSTEM

HIPSTER125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The service and maintenance of this section can be performed with the engine installed in the frame.

• Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line.

• The oil pump must be replaced as a set when it reaches its service life.

• After the oil pump is installed, check each part for oil leaks and improper lubrication.

• When removing and installing the oil cooler, be careful not to bend or deform the oil pipe.

SPECIFICATIONS

Inner rotor-to-outer rotor clearance ⎯ 0.20

Oil pump Outer rotor-to-pump body clearance ⎯ 0.20

Rotor end-to-pump body clearance 0.0150.10 0.15

Item Standard (mm) Service Limit (mm)

TROUBLESHOOTING

Oil level too low Engine burns

• Natural oil consumption • Low or no lubrication pressure

• Oil leaks • Clogged oil passages

• Worn or poorly installed piston rings • Not use the specified oil

• Worn valve guide or seal

• Clogged or leaky oil pipe

3-2

3. LUBRICATION SYSTEM

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ENGINE OIL/OIL FILTER

OIL LEVEL

• Place the motorcycle upright on level ground for engine oil level check.

• Run the engine for 23 minutes and check the oil level after the engine is stopped for 23 minutes.

Check the oil level through the watch window. If the level is near the lower limit, fill to the upper limit with the specified engine oil.

OIL CHANGE

The engine oil will drain more easily while the engine is warm.

Remove the drain bolt to drain the engine oil thoroughly. Check the drain bolt washer for damage or deformation and replace with a new one if necessary.

Remove the oil filter screen cap and then remove the oil filter screen and spring. Clean the oil filter screen with compressed air. Check the filter screen cap O-ring for damage or deformation and replace if necessary. Install the oil filter screen, spring and filter screen cap. Torque: 1.5kg-m

Do not install the oil filter screen upside down.

Oil Capacity: At disassembly : 1.1 liter At change : 1.0 liter

Check for oil leaks and then start the engine and let it idle for few minutes. Stop the engine and recheck the oil level.

HIPSTER125/150

Lower Limi

Drain Bol

Oil Filter Screen Ca

Upper Limi

3-3

3. LUBRICATION SYSTEM

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OIL PUMP/OIL FILTER ROTOR

REMOVAL

1. Remove the kick lever.

2. Disconnect the clutch cable.

3. Remove the right crankcase cover bolts

and right crankcase cover.

4. Check the cover gasket, oil seal and O-ring

for oil leaks or damage. Replace with new ones if necessary.

When installing, make sure to use a new right crankcase cover gasket.

Remove the three screws attaching the oil filter rotor cover to remove the cover. Remove the oil filter rotor lock nut with a square socket and then remove the washer and oil filter rotor.

Remove the oil pump cap two bolts.

During installation, install the washer with the mark “OUTSIDE” facing up.

Remove the 6mm nut on top of the oil pump driven gear.

Remove the oil pump driven gear and chain. Remove the two oil pump mounting bolts. Remove the oil pump body.

Right Crankcase Cove

Oil Pum

Oil Pump Body

HIPSTER125/150

Screws

Oil Filter Roto

Oil Pump Driven Gea

Drive Gea

3-4

3. LUBRICATION SYSTEM

r

DISASSEMBLY

Remove the pump cover attaching screw.

INSPECTION

Measure the pump body-to-outer rotor clearance.

Service Limit: 0.20mm

Measure the inner rotor-to-outer rotor clearance.

Service Limit: 0.20mm

Measure the rotor end-to-pump body clearance.

Service Limit: 0.15mm

Bolts

Outer Roto

Screw

Feeler Gauge

Outer Rotor

Oil Pump Body

Feeler Gauge

HIPSTER125/150

Inner Roto

3-5

3. LUBRICATION SYSTEM

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ASSEMBLY

Install the outer rotor and inner rotor into the pump body. Insert the pump shaft.

Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor.

Install the gasket and pump cover. Tighten the screw. After installation, make sure that the pump shaft rotates freely.

INSTALLATION

Install the pump body and tighten the two mounting bolts. Install the oil pump driven gear and chain.

Tighten the 6mm nut on top of the oil pump driven gear.

Install the oil pump gear cover and tighten the two bolts. Install the oil filter rotor lock nut.

Torque: 4.05.0kg-m

During installation, install the washer with the mark “OUTSIDE” facing up.

Feeler Gauge

Pump Cove

Driven Gea

Inner Roto

Bolts

HIPSTER125/150

Outer Rotor

Gaske

Pump Shaf

nu

Pump Gear Cover

3-6

4. FUEL SYSTEM

HIPSTER125/150

4

__________________________________________________________________________________

4

FUEL SYSTEM

__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 4- 2 TROUBLESHOOTING----------------------------------------------------- 4- 3 THROTTLE VALVE DISASSEMBLY---------------------------------- 4- 4 CARBURETOR REMOVAL ---------------------------------------------- 4- 4 FLOAT/FLOAT VALVE/JETS/ACCELERATING PUMP----------- 4- 5 FLOAT LEVEL INSPECTION-------------------------------------------- 4- 8 CARBURETOR INSTALLATION --------------------------------------- 4- 9 THROTTLE VALVE ASSEMELY--------------------------------------- 4- 9 AIR CUT-OFF VALVE----------------------------------------------------- 4-10 FUEL TANK ----------------------------------------------------------------- 4-11 AIR CLEANER REMOVAL----------------------------------------------- 4-12

4-0

4. FUEL SYSTEM

HIPSTER125/150

4-1

4. FUEL SYSTEM

HIPSTER125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

Ga

soline is very dangerous. When working with gasoline, keep sparks and flames away

fro

m the working area. Gasoline is extremely flammable and is explosive under certain conditions. Be sure to work in a well-ventilated area.

• Do not bend or twist control cables. Damaged control cables will not operate smoothly.

• When disassembling fuel system parts, note the locations of O-rings. Replace them with new

ones during reassembly.

• Before float chamber disassembly, loosen the drain screw to drain the residual gasoline into a clean container.

• After the carburetor is removed, plug the intake manifold side with a clean shop towel to prevent foreign matters from entering.

• The carburetor air jets and fuel jets must be cleaned with compressed air.

• When the motorcycle is not used for over one month, drain the residual gasoline from the float

chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel.

SPECIFICATIONS

SPECIAL TOOL

Float level gauge

Item Standard Venturi dia. φ25 Identification number CVK003 Float level 17 mm Main jet 110# Slow jet 35# Idle speed 1600±100rpm Throttle grip free play 26mm Pilot screw opening 2±½

C

4-2

4. FUEL SYSTEM

TROUBLESHOOTING

Engine cranks but won’t start Engine lacks power

• No fuel in tank • Clogged air cleaner

• No fuel to carburetor • Faulty carburetor

• Cylinder flooded with fuel • Faulty ignition system

• No spark at plug

• Clogged air cleaner Lean mixture

• Intake air leak • Clogged carburetor fuel jets

• Improper throttle operation • Float level too low

• Intake air leak Engine idles roughly, stalls or runs poorly • Faulty charcoal canister

• Excessively used choke • Restricted fuel line

• Ignition malfunction

• Faulty carburetor Rich mixture

• Poor quality fuel • Float level too low

• Lean or rich mixture • Clogged air jets

• Clogged air cleaner • Clogged air cleaner

• Incorrect idle speed • Restricted A.C.V. tube

• Faulty charcoal canister • Worn throttle needle

Misfiring during acceleration

• Faulty ignition system

• Faulty carburetor

• Faulty accelerating pump

• Faulty charcoal canister

Backfiring at deceleration

• Float level too low

• Incorrectly adjusted carburetor

• Faulty A.C.V.

• Faulty exhaust muffler

• Faulty A.I.C.V.

HIPSTER125/150

4-3

4. FUEL SYSTEM

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THROTTLE VALVE DISASSEMBLY

Remove the right side cover. Remove the carburetor cap. Pull out the throttle valve.

Disconnect the throttle valve and remove the spring from the carburetor cap.

Pry off the needle retainer and remove the jet needle. Check the throttle valve and jet needle for wear or damage.

CARBURETOR REMOVAL

Loosen the drain screw to drain the gasoline from the float chamber.

• Keep sparks and flames away from the work area.

• Drain gasoline into a clean container.

Disconnect the fuel inlet tube and air cut-off valve (A.C.V.) tubes.

HIPSTER125/150

Carburetor Cap Throttle Cable

eedle Retaine

Throttle Cable

Jet Needle Throttle Valve

Right side cover

Drain Screw

4-4

4. FUEL SYSTEM

t

Loosen the air cleaner connector band screw. Remove the two carburetor lock nuts. Remove the carburetor

CARBURETOR DISASSEMBLY

FLOAT/FLOAT VALVE/JETS/ ACCELERATING PUMP

Float/Float Valve Disassembly

Remove the three float chamber attaching screws and remove the float chamber.

Remove the float pin, float and float valve.

Float/Float Valve Inspection Inspect the float valve seat for wear or

damage. Inspect the float for damage or fuel level inside the float chamber.

HIPSTER125/150

Screws

Lock Nu

Float Pin

Screw

Float Valve Sea

Floa

4-5

4. FUEL SYSTEM

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Main Jet/Jets/Pilot Screw/Throttle Stop Screw Removal

Remove the main jet, needle jet holder, and needle jet. Remove the slow jet. Remove the pilot screw and throttle stop screw.

CAUTIONS !

• Be careful not to damage the jets and jet holder when removing them.

• Before removing, turn the throttle stop screw and pilot screw in and carefully count the number of turns until they seat lightly and then make a note of this.

• Do not force the screw against its seat to avoid seat damage.

• Be sure to install the O-ring in the reverse order of removal.

Accelerating Pump Removal

Remove the two accelerating pump cover screws and accelerating pump cover. Remove the spring and accelerating pump diaphragm.

Inspection Inspect the accelerating pump diaphragm for

cracks, damage or deterioration. Replace with a new one if necessary.

Pilot Screw

Diaphrag

HIPSTER125/150

Main Je

Sprin

Accelerating Pump Cove

Slow Je

Screws

4-6

4. FUEL SYSTEM

t

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Carburetor Cleaning

Blow compressed air through all passages of the carburetor body.

Slow Jet/Main Jet Installation

Install the slow jet. Install the needle jet, needle jet holder and main jet. Install the throttle stop screw and pilot screw.

• When installing the pilot screw, return it to the original position as noted during removal

• After the carburetor is installed, be sure to perform the Exhaust Emission

Install the float valve, float and float pin.

FLOAT LEVEL INSPECTION

Turn the carburetor upside down so that the float will go down to make the float valve contact the float valve seat. Then slowly tilt the carburetor and measure the float level with the float level gauge while the float pin just contacts with float valve.

Float Level: 17mm

When adjusting, carefully bend the float pin. Check the float for proper operation and then install the float chamber.

Pilot Screw

Floa

HIPSTER125/150

Main Je

Float Pin

Float Level Gauge

Slow Je

4-7

4. FUEL SYSTEM

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Accelerating Pump Installation First install the accelerating pump

diaphragm. Install the spring. Install the accelerating pump cover and tighten the three screws.

When installing the diaphragm, be sure to position it correctly.

CARBURETOR INSTALLATION

Install the carburetor onto the intake manifold and tighten the two lock nuts.

Torque: 0.81.2kg-m Install the air cleaner connector and tighten

the band screw.

THROTTLE VALVE ASSEMBLY

Install the jet needle into the throttle valve and secure with the needle retainer.

Assemble the rubber cover, carburetor cap and throttle valve spring. Connect the throttle cable to the throttle valve.

Accelerating Pump Cove

Band Screw

eedle Retaine

Jet Needle

HIPSTER125/150

Lock Nu

Throttle Valve

Carburetor Cap

4-8

4. FUEL SYSTEM

m

AIR CUT-OFF VALVE (A.C.V.)

REMOVAL

Disconnect the tubes that go to the air cut-off valve. Remove the two attaching screws. Remove the air cut-off valve.

DISASSEMBLY Remove the two attaching screws to remove

the air cut-off valve cover. Remove the spring and diaphragm.

INSPECTION Inspect the check valve for proper operation.

Inspect the air cut-off valve diaphragm and O-ring for deterioration or damage. Replace with new ones if necessary. Clean each air passage with compressed air.

Screws Screws

Diaphrag

HIPSTER125/150

A.C.V.

Spring

4-9

4. FUEL SYSTEM

FUEL TANK

FUEL TANK REMOVAL

• Keep sparks and flames away from the work area.

• Wipe off any spilled gasoline.

Remove the right and left side covers and the right and left decorative covers under the fuel tank. Remove the three bolts attaching the rear carrier. Remove the two seat lock bolts.

Remove the auto fuel valve. Disconnect the fuel tube and remove the bolt on the end of the fuel tank. Disconnect the fuel unit wire connector and fuel gauge wire. Remove the fuel tank.

FUEL TANK INSTALLATION Install the fuel tank in the reverse order of

removal. Check that there is no fuel leakage. Check the wire connectors for proper connection.

AIR CLEANER REMOVAL

Remove the right side cover. Remove the two bolts attaching the emission control system. Remove the rear carrier. (Refer to 4-10.) Remove the seat. (Refer to 4-10.) Remove the two air cleaner case attaching bolts. Remove the air cleaner and carburetor connecting tube band.

Remove the air cleaner from the right side.

HIPSTER125/150

Bolts

4-10

5. ENGINE REMOVAL/INSTALLATION

HIPSTER125/150

5.

__________________________________________________________________________________

5

ENGINE REMOVAL/INSTALLATION

__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 5- 1 ENGINE REMOVAL ------------------------------------------------------- 5- 2 ENGINE INSTALLATION ------------------------------------------------ 5- 3

5-0

5. ENGINE REMOVAL/INSTALLATION

HIPSTER125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• A engine stand or floor jack is required to support and maneuver the engine.

• The following parts can be serviced with the engine installed in the frame:

⎯ Cylinder head/valves (Section 6) ⎯ Cylinder/piston (Section 7) ⎯ Starter motor/generator/left crankcase cover/starter clutch/camshaft (Section 8) ⎯ Clutch/gear shift mechanism (Section 9)

• When removing and installing the engine, do not use a hammer or screw driver to strike or pry the engine.

• Do not damage the crankcase mating surfaces and clean off all gasket materials from the mating surfaces.

• After crankcase assembly, check that the transmission system operates smoothly.

• After engine installation, start the engine and check that the lubrication system is normal.

Engine oil capacity: At disassembly : 1.0 liter At change : 0.9 liter

TORQUE VALUES

Engine bracket bolt 2.02.5kg-m Drive gear lock bolt 0.81.2kg-m Exhaust muffler hanger lock bolt 2.43.0kg-m Rear fork pivot nut 5.56.5kg-m Exhaust muffler joint lock nut 0.81.2kg-m

5-1

5. ENGINE REMOVAL/INSTALLATION

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ENGINE REMOVAL

Remove the carburetor. (Refer to 4-3.) Disconnect the clutch cable. Remove the crankcase breather. Remove the two exhaust muffler joint lock nuts. Remove the exhaust muffler hanger lock bolt and exhaust muffler.

• Drain the engine oil before engine removal.

• The exhaust muffler temperature is extremely high. Remove it when the engine is cold.

Remove the spark plug cap.

Disconnect the A.C. generator wire connector. Remove the starter motor wire. Remove the two bolts attaching the left rear crankcase cover and remove the rear crankcase cover. Remove the two bolts attaching the drive gear set plate and the set plate. Remove the drive gear and chain. Remove the gear shift lever bolt and gear shift lever.

Remove the three bolts attaching the engine front bracket and the bracket. Remove the two engine hanger bolts and the hanger. Remove the two bolts attaching the engine rear bracket. Remove the rear fork pivot nut and then remove the rear fork pivot and rear bracket. Remove the engine from left to right.

Bol

Rear Fork Pivot Nu

Set Plate

HIPSTER125/150

Intake Manifold

Starter Motor Wire

Rear Crankcase Cove

Generator Wire Connecto

Drive Gea

Rear Bracke

Exhaust Muffler Joint

Clutch Cable

Drive Chain

Upper Hange

Front Bracke

Bolts

5-2

5. ENGINE REMOVAL/INSTALLATION



ENGINE INSTALLATION

Install the engine in the reverse order of removal. Install the engine to its original position with a jack or other adjustable support.

• When installing the engine, do not damage the bolt thread and route the wires and cables properly.

• Install the gear shift lever by align the punch mark on the lever with that on the spindle.

• Fill the crankcase to the proper level with recommended engine oil.

• After installation, perform the following inspections and adjustments:

1. Throttle operation

2. Clutch lever free play adjustment

3. Drive chain adjustment

HIPSTER125/150

5-3

6. CYLINDER HEAD/VALVES

HIPSTER125/150

6.

__________________________________________________________________________________

CYLINDER HEAD/VALVES

__________________________________________________________________________________

SCHEMATIC DRAWING ------------------------------------------------- 6- 1 SERVICE INFORMATION------------------------------------------------ 6- 2 TROUBLESHOOTING----------------------------------------------------- 6- 3 CYLINDER HEAD COVER REMOVAL ------------------------------- 6- 4 CAMSHAFT REMOVAL-------------------------------------------------- 6- 4 CAMSHAFT INSPECTION ----------------------------------------------- 6- 5 CYLINDER HEAD REMOVAL ------------------------------------------ 6- 6 CYLINDER HEAD DISASSEMBLY ------------------------------------ 6- 7 CAMSHAFT INSTALLATION------------------------------------------- 6-10 CYLINDER HEAD COVER INSTALLATION ------------------------ 6-11

6

6-0

6. CYLINDER HEAD/VALVES

SCHEMATIC DRAWING

HIPSTER125/150

6-1

6. CYLINDER HEAD/VALVES

⎯ ⎯

m

²

m

²

⎯

HIPSTER125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The cylinder head can be serviced with the engine installed in the frame. Coolant in the radiator and water jacket must be drained first.

• When assembling, apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication.

• The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages. Clean and unclog the oil passages before assembling the cylinder head.

• After disassembly, clean the removed parts and dry them with compressed air before inspection.

• After removal, mark and arrange the removed parts in order. When assembling, install them in

the reverse order of removal.

SPECIFICATIONS

Item RH30AA RJ25AB RH30AA RJ25AB

IN 0.06 0.06

Valve clearance (cold)

EX 0.06 0.06 Cylinder head compression pressure 13kg/c Cylinder head warpage IN 30.80030.920 30.80030.920 30.75 30.75

Camshaft cam height

EX 30.41130.531 30.41130.531 30.26 30.26 IN 12.0012.015 12.0012.015 12.10 12.10

Valve rocker arm I.D.

EX 12.0012.015 12.0012.015 12.10 12.10

Valve rocker arm shaft IN 12.0011.980 12.0011.980 12.10 12.10 O.D. EX 12.0011.980 12.0011.980 12.10 12.10

IN 1.0 1.0 1.8 1.8

Valve seat width

EX 1.0 1.0 1.8 1.8 IN 5.005.012 5.005.012 4.925 4.925

Valve stem O.D.

EX 5.00 5.00 4.925 4.925 IN 5.005.012 5.005.012 5.03 5.03

Valve guide I.D.

EX 5.005.012 5.005.012 5.03 5.03

Valve stem-to-guide IN 0.0100.037 0.0100.037 0.08 0.08 Clearance EX 0.0300.057 0.0300.057 0.10 0.10

Standard (mm) Service Limit (mm)

– 13kg/c

–

0.05 0.05

6-2

6. CYLINDER HEAD/VALVES

TORQUE VALUES

Cylinder head cap nut 2.0kg-m Apply engine oil to threads Valve clearance adjusting nut 0.9kg-m Apply engine oil to threads Cylinder head cover bolt 0.81.2kg-m

SPECIAL TOOLS

Valve spring compressor

HIPSTER125/150

TROUBLESHOOTING

• The poor cylinder head operation can be diagnosed by a compression test or by tracing engine top-end noises.

Poor performance at idle speed White smoke from exhaust muffler

• Compression too low • Worn valve stem or valve guide

• Damaged valve stem oil seal

Compression too low

• Incorrect valve clearance adjustment Abnormal noise

• Burned or bend valves • Incorrect valve clearance adjustment

• Incorrect valve timing • Sticking valve or broken valve spring

• Broken valve spring • Damaged or worn camshaft

• Poor valve and seat contact • Worn cam chain tensioner

• Leaking cylinder head gasket • Worn camshaft and rocker arm

• Warped or cracked cylinder head

• Poorly installed spark plug

Compression too high

• Excessive carbon build-up in combustion

chamber

6-3

6. CYLINDER HEAD/VALVES

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CYLINDER HEAD COVER REMOVAL

Remove the cylinder head cover bolts and then remove the cylinder head cover.

CAMSHAFT REMOVAL

Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke. Remove the two bolts attaching cam chain tensioner and the tensioner.

Then, remove the four cylinder head nuts and washers.

• Diagonally loosen the cylinder head cap nuts in 2 or 3 times.

Remove the camshaft holder and dowel pins.

Cam Chain

HIPSTER125/150

Cylinder Head Cove

uts

Camshaft Gea

Bol

Cam Chain Tensione

Camshaft Holde

6-4

6. CYLINDER HEAD/VALVES

t

Remove the camshaft gear from the cam chain to remove the camshaft.

CAMSHAFT INSPECTION Check each cam lobe for wear or damage.

Measure the cam lobe height. Service Limits:

RH30AA IN: 30.75mm replace if below RJ25AB EX:30.26mm replace if below

Check each camshaft bearing for play or damage. Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play.

CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a

6mm bolt. Remove the valve rocker arms.

Cam Chain

HIPSTER125/150

Rocker Arm Shafts

CAMSHAFT HOLDER INSPECTION

Camshaft

Camshaft Bearings

Valve Rocker Arms

6mm Bol

6-5

6. CYLINDER HEAD/VALVES

r



Inspect the camshaft holder, valve rocker arms and rocker arm shafts for wear or damage.

If the valve rocker arm contact surface is worn, check each cam lobe for wear or damage.

Measure the I.D. of each valve rocker arm. Service Limits: IN: 12.10mm replace if over EX: 12.10mm replace if

over Measure each rocker arm shaft O.D. Service Limits: IN: Check replace if below EX: Check replace if below

CYLINDER HEAD REMOVAL

Remove the camshaft. (Ö6-4) Remove the carburetor and intake manifold. Remove the cylinder head.

Remove the dowel pins and cylinder head gasket. Remove the cam chain guide. Remove all gasket material from the cylinder head mating surface.

Be careful not to drop any gasket material into the engine.

Cam Chain Cam Chain

Cylinder Head Gasket

Cylinder

HIPSTER125/150

Rocker Arm Shafts

Cam Chain Tensioner Slipper

Cam Chain Tensioner Slippe

Cam Chain Guide

6-6

6. CYLINDER HEAD/VALVES



r

t

r

CYLINDER HEAD DISASSEMBLY

Remove the valve spring cotters, retainers, springs, spring seats and valve stem seals using a valve spring compressor.

• Be sure to compress the valve springs with a valve spring compressor.

• Mark all disassembled parts to ensure correct reassembly.

Remove carbon deposits from the exhaust port and combustion chamber.

Be careful not to damage the cylinder head mating surface.

Cylinder Head

Valve Spring Compressor

HIPSTER125/150

Combustion Chambe

Exhaust Po

6-7

6. CYLINDER HEAD/VALVES



INSPECTION CYLINDER HEAD Check the spark plug hole and valve areas for

cracks. Check the cylinder head for warpage with a straight edge and feeler gauge.

Service Limit: 0.05mm repair or replace if

over

VALVE SPRING FREE LENGTH Measure the free length of the inner and outer

valve springs. Service Limits:

(IN, EX) : 29.1mm replace if below

VALVE /VALVE GUIDE Inspect each valve for bending, burning,

scratches or abnormal stem wear. Check valve movement in the guide.

Measure each valve stem O.D. Service Limits: IN: 4.925mm replace if

below

EX:4.925mm replace if

below

Measure each valve guide I.D. Service Limits: IN: 5.03mm replace if over

EX: 5.03mm replace if over Subtract each valve stem O.D. from the

corresponding guide I.D. to obtain the stem-to-guide clearance. Service Limits: IN: 0.08mm replace if over EX: 0.10mm replace if over

If the stem-to-guide clearance exceeds the service limits, replace the guides as necessary. Reface the valve seats whenever the valve guides are replaced.

HIPSTER125/150

Feeler Gauge

Straight Edge

6-8

6. CYLINDER HEAD/VALVES



r

t



CYLINDER HEAD ASSEMBLY

Install the valve spring seats and valve stem seals.

Be sure to install new valve stem seals.

Apply engine oil to the inside of the valve stem seals and insert the valves into the valve guides.

Install the valve springs and retainers. Compress the valve springs using the valve spring compressor, then install the valve cotters.

• When assembling, a valve spring compressor must be used.

• Install the cotters with the pointed ends facing down from the upper side of the cylinder head.

Special Tool Valve Spring Compressor

Tap the valve stems gently with a plastic hammer to firmly seat the cotters.

Be careful not to damage the valves.

CYLINDER HEAD INSTALLATION

Install the cam chain guide. Install the dowel pins and a new cylinder head gasket.

Cylinder Head

Dowel Pins

Cam Chain Guide

I

HIPSTER125/150

Valve Spring Compresso

Plastic Hamme

Gaske

6-9

6. CYLINDER HEAD/VALVES

r



nstall the cylinder head and take out the cam chain

Assemble the camshaft holder. First install the intake and exhaust valve rocker arms; then install the rocker arm shafts.

• Install the exhaust valve rocker arm shaft on the “EX” side of the camshaft holder and the exhaust rocker arm shaft is shorter.

• Clean the intake valve rocker arm shaft off any grease before installation.

• Align the cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder.

CAMSHAFT INSTALLATION

Turn the A.C. generator flywheel so that the “T” mark on the flywheel aligns with the index mark on the crankcase. Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface (Position the intake and exhaust cam lobes down.) and install the cam chain over the camshaft gear. Install the dowel pins.

HIPSTER125/150

Cam Chain

Install the camshaft holder, washers and nuts on the cylinder head.

Valve Rocker Arms

Camshaft Holde

Punch Marks

Dowel Pins

Round Hole

6-10

6. CYLINDER HEAD/VALVES



r

N

r

t

r

t

r



Tighten the four cylinder head nuts and the two bolts between the cylinder head and cylinder.

Torque: Cylinder head cap nut: 2.0kg-m

• Apply engine oil to the threads of the cylinder head cap nuts.

• Diagonally tighten the cylinder head cap nuts in 23 times.

• First tighten the cylinder head cap nuts and then tighten the bolts between the cylinder and cylinder head to avoid cracks.

Install a new cam chain tensioner gasket. Tighten the cam chain tensioner screw.

Install the cam chain tensioner and tighten the two bolts. Install the tensioner spring and tighten the sealing bolt.

Torque: 0.30.59kg-m

CYLINDER HEAD COVER INSTALLATION

Adjust the valve clearance. (Ö3-6) Install a new cylinder head cover O-ring and install the cylinder head cover.

Be sure to install the O-ring into the groove properly.

Install and tighten the cylinder head cover bolts.

Torque: 0.81.2kg-m

Washer

Washe

Nut

u

Cam Chain Tensione

Cylinder Head Cove

HIPSTER125/150

Sealing Bol

Bol

6-11

7. CYLINDER/PISTON

HIPSTER125/150

7

__________________________________________________________________________________

CYLINDER/PISTON

__________________________________________________________________________________

SCHEMATIC DRAWING ------------------------------------------------- 7- 1 SERVICE INFORMATION------------------------------------------------ 7- 2 TROUBLESHOOTING----------------------------------------------------- 7- 2 CYLINDER REMOVAL --------------------------------------------------- 7- 3 PISTON REMOVAL-------------------------------------------------------- 7- 3 PISTON INSTALLATION------------------------------------------------- 7- 7 CYLINDER INSTALLATION -------------------------------------------- 7- 7

7

7-0

7. CYLINDER/PISTON

SCHEMATIC DRAWING

HIPSTER125/150

7-1

7. CYLINDER/PISTON

bottom of s

t

bottom of s

t

bottom of ski

bottom of s

t

HIPSTER125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The cylinder and piston can be serviced with the engine installed in the frame.

• When installing the cylinder, use a new cylinder gasket and make sure that the dowel pins are

correctly installed.

• After disassembly, clean the removed parts and dry them with compressed air before inspection. SPECIFICATIONS

Cylinder

Ring-to-groove top

top Piston, Ring end gap Second piston ring Oil side rail Piston O.D. Piston O.D. measuring position . Piston-to-cylinder clearance Piston pin hole I.D. Piston pin O.D Piston-to-piston pin clearance Connecting rod small end I.D. bore

Item

I.D. 58.00058.010 52.40052.410 58.10 52.50 Warpage Cylindricity True roundness

clearance

Second

57.97557.995 52.37052.390 57.90 52.30

15.00015.008 15.00015.008 15.06 15.06

14.99415.000 14.99415.000 14.96 14.96

15.01615.034 15.01615.034 15.06 15.06

Standard (mm) Service Limit (mm)

RH30AA

⎯ ⎯ ⎯ ⎯ ⎯ ⎯

0.0150.050 0.0150.050 0.09 0.09

0.150.30 0.150.30 0.50 0.50

0.20.9 0.20.9

9mm from

0.0100.040 0.0100.040 0.01 0.01

0.0020.014 0.0020.014 0.02 0.02

RJ25AA,RJ25AB

9mm from

kir

RH30AA

0.05 0.05

RJ25AA,RJ25AB

⎯ ⎯

9mm from

rt

TROUBLESHOOTING

kir

• When hard starting or poor performance at low speed occurs, check the crankcase breather for white smoke. If white smoke is found, it means that the piston rings are worn, stuck or broken.

Compression too low or uneven compression Excessive smoke from exhaust muffler

• Worn or damaged cylinder and piston rings • Worn or damaged piston rings

• Worn, stuck or broken piston rings • Worn or damaged cylinder and piston

Compression too high Abnormal noisy piston

• Excessive carbon build-up in combustion • Worn cylinder, piston and piston rings

chamber or on piston head • Worn piston pin hole and piston pin

• Incorrectly installed piston

7-2

7. CYLINDER/PISTON

r

t



CYLINDER REMOVAL

Remove the cylinder head. (Ö6-7)

Remove the cam chain guide. Remove the cylinder.

Remove the cylinder gasket and dowel pins. Clean any gasket material from the cylinder surface.

PISTON REMOVAL

Remove the piston pin clip. Press the piston pin out of the piston.

Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase.

Dowel Pins

Shop Towel

Gaske

Piston Pin Piston

Cam Chain

HIPSTER125/150

Cylinde

Piston Rings

7-3

7. CYLINDER/PISTON



Inspect the piston, piston pin and piston rings. Remove the piston rings.

• Take care not to damage or break the piston rings during removal.

Clean carbon deposits from the piston ring grooves.

Install the piston rings onto the piston and measure the piston ring-to-groove clearance.

Service Limits:

Top: 0.09mm replace if over 2nd: 0.09mm replace if over

Remove the piston rings and insert each piston ring into the cylinder bottom.

• Use the piston head to push each piston ring into the cylinder.

Measure the piston ring end gap. Service Limit: 0.5mm replace if over

Measure the piston pin hole I.D.

Service Limit: 15.06mm replace if below

HIPSTER125/150

7-4

7. CYLINDER/PISTON



m

Measure the piston pin O.D. Service Limit: 14.96mm replace if below

Measure the piston O.D.

• Take measurement at 9mm from the bottom and 90° to the piston pin hole.

Service Limit: 57.90mm replace if below

RH30AA 57.90mm replace if below

RJ25AB 52.3mm replace if below

Measure the piston-to-piston pin clearance.

Service Limit: 0.02mm replace if over

CYLINDER INSPECTION

Inspect the cylinder bore for wear or damage. Measure the cylinder I.D. at three levels of top, middle and bottom at 90° to the piston pin (in both X and Y directions).

Service Limit: 58.10mm repair or replace if below

RH30AA

RJ25AA

RJ25AB

Measure the cylinder-to-piston clearance. Service Limit: 0.1mm repair or replace if

over The true roundness is the difference between

the values measured in X and Y directions. The cylindricity (difference between the values measured at the three levels) is subject to the maximum value calculated.

Service Limits: True Roundness: 0.05mm repair or replace

if over Cylindricity: 0.05mm repair or replace if over

58.10mm repair or replace if over

52.50mm repair or replace if over

HIPSTER125/150

IN

Top

Middle

Botto

EX

7-5

7. CYLINDER/PISTON



Inspect the top of the cylinder for warpage. Service Limit: 0.05mm repair or replace if over

Measure the connecting rod small end I.D.

Service Limit: 15.06mm replace if below

PISTON RING INSTALLATION

Install the piston rings onto the piston. Apply engine oil to each piston ring.

• Be careful not to damage the piston and piston rings during assembly.

• All rings should be installed with the markings facing up.

• After installing the rings, they should rotate freely without sticking.

• Stagger the ring end gaps as the figure shown.

HIPSTER125/150

Top

Second

Side Rail Oil Ring Side Rail

7-6

7. CYLINDER/PISTON



t

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

PISTON INSTALLATION

Remove any gasket material from the crankcase surface.

• Be careful not to drop foreign matters into the crankcase.

Install the piston, piston pin and a new piston pin clip.

• Position the piston “IN” mark on the intake valve side.

• Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase.

CYLINDER INSTALLATION

Install the dowel pins and a new cylinder gasket on the crankcase.

Coat the cylinder bore, piston and piston rings with clean engine oil. Carefully lower the cylinder over the piston by compressing the piston rings.

• Be careful not to damage or break the piston rings.

• The piston ring end gaps should not be parallel with or at 90° to the piston pin.

Dowel Pin

HIPSTER125/150

Piston

Piston Pin Clip

Gaske

Piston Pin

Cylinde

7-7

7. CYLINDER/PISTON



Loosely install the cylinder base bolt.

Install the cam chain guide.

• Insert the tab on the cam chain guide

into the cylinder groove.

Install the cylinder head. (Ö6-13) Tighten the cylinder base bolt.

HIPSTER125/150

Cam Chain Guide

7-8

8. STARTER MOTOR/GENERATOR/LEFT CRANK CASE COVER/STARTER CLUTCH/CAMSHAFT

HIPSTER125/150

8

__________________________________________________________________________________

STARTER MOTOR/GENERATOR/LEFT CRANKCASE

COVER/STARTER CLUTCH/CAMSHAFT

__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 8-2 TROUBLESHOOTING----------------------------------------------------- 8-2 STARTER MOTOR REMOVAL ----------------------------------------- 8-3 LEFT CRANKCASE COVER/GENRATOR REMOVAL ------------ 8-3 STARTER CLUTCH REMOVAL ---------------------------------------- 8-4 CAMSHAFT REMOVAL-------------------------------------------------- 8-5 STARTER GEAR INSTALLATION ------------------------------------- 8-5 GENERATOR INSTALLATION ----------------------------------------- 8-5 LEFT CRANKCASE COVER INSTALLATION ---------------------- 8-6 STARTER MOTOR INSTALLATION ---------------------------------- 8-6

8

8-0

8. STARTER MOTOR/GENERATOR/LEFT CRANK-

CASE COVER/STARTER CLUTCH/CAMSHAFT

HIPSTER125/150

8-1

8. STARTER MOTOR/GENERATOR/LEFT CRANK CASE COVER/STARTER CLUTCH/CAMSHAFT

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The starter motor, generator, left crankcase and starter clutch can be serviced in the frame.

• Do not install the starter clutch forcedly.

• Install the generator by aligning the groove in the flywheel with the key on the crankshaft.

• Install the starter motor reduction gear shaft by aligning the shaft pin with the shaft seat groove.

SPECIFICATIONS

Item Standard (mm) Service Limit (mm) Reduction gear shaft O.D. 9.9729.987 9.932 Reduction gear shaft hole I.D. 10.03110.056 10.096 Camshaft O.D. 13.96613.984 13.926 Cam gear shaft hole I.D. 14.0614.078 14.118 Roller O.D. 9.9910.005 9.95 Starter gear shaft I.D. 22.0122.022 22.062 Starter gear shaft O.D. 42.57442.6 42.534

TORQUE VALUES

HIPSTER125/150

Flywheel lock bolt 0.81.2kg-m

SPECIAL TOOLS Flywheel holder

Flywheel puller

TROUBLESHOOTING

Hard starting and poor performance at high speed Starting noise

• Improperly tightened flywheel lock bolt • Worn reduction gear

• Worn starter gear

Starter clutch slips • Worn starter clutch roller

• Worn starter clutch roller • Faulty reduction gear shaft bearing

• Faulty starter clutch roller or spring

• Worn starter gear shaft O.D.

8-2

8. STARTER MOTOR/GENERATOR/LEFT CRANK-

r

t

N

t

r

CASE COVER/STARTER CLUTCH/CAMSHAFT

STARTER MOTOR REMOVAL

Remove the two starter motor mounting bolts and the motor. Inspect the starter motor O-ring for damage or deterioration. Inspect the starter motor pinion for wear or damage.

Remove the three bolts attaching the starter motor reduction gear cover. Remove the reduction gear cover. Remove the reduction gear, shaft and washers. Inspect the reduction gear for wear or damage. Inspect the reduction gear cover O-ring for damage or deterioration.

LEFT CRANKCASE COVER/ GENERATOR REMOVAL

Disconnect the neutral light switch wire. Remove the eight left crankcase cover bolts. Remove the left crankcase cover and two dowel pins. Clean off all gasket material from the left crankcase cover. Remove the reduction pinion.

Hold the flywheel with a flywheel holder. Remove the flywheel lock bolt. Remove the flywheel using a flywheel puller.

Bolts

eutral Light Wire

Flywheel Lock Bol

Flywheel Holde

Mounting Bolts

Cove

HIPSTER125/150

O-ring

Washers Shaf

Flywheel

Reduction Gea

Reduction Pinion

Washers

Flywheel Pulle

Flywheel Holde

8-3

8. STARTER MOTOR/GENERATOR/LEFT CRANK-

r

CASE COVER/STARTER CLUTCH/CAMSHAFT

HIPSTER125/150

STARTER CLUTCH REMOVAL

Remove the reduction pinion. Remove the starter gear.

INSPECTION Measure the starter gear shaft I.D. Service Limit: 22.062mm replace if over

Measure the starter gear shaft O.D. Service Limit: 42.534mm replace if below

Measure the starter clutch roller O.D. Service Limit: 9.95mm

Rolle

Starter Gea

Micrometer Calipers

8-4

8. STARTER MOTOR/GENERATOR/LEFT CRANK-

r

t



r

CASE COVER/STARTER CLUTCH/CAMSHAFT

HIPSTER125/150

CAMSHAFT REMOVAL

Remove the cam chain set piece. Remove the cam chain.

Remove the cam chain guide bolt.

STARTER GEAR INSTALLATION

Install the starter gear.

Torque: 0.81.2kg-m

GENERATOR INSTALLATION

Install the generator flywheel. Hold the flywheel with a flywheel holder and tighten the flywheel lock bolt.

• Install the flywheel by aligning the

groove in the flywheel with the key on the crankshaft.

• When installing, be careful not to

damage the starter clutch rollers.

Torque: 4.05.2kg-m

Lock Bol

Starter Gea

Flywheel Holde

8-5

8. STARTER MOTOR/GENERATOR/LEFT CRANK-



CASE COVER/STARTER CLUTCH/CAMSHAFT

LEFT CRANKCASE COVER INSTALLATION

Install the left crankcase cover and tighten the eight bolts. (Refer to 8-2.)

Torque: 0.81.2kg-m

Install the reduction gear, shaft and washers. Then install the reduction gear cover and tighten the three bolts.

Torque: 0.81.2kg-m

• Install the reduction gear shaft by

aligning the shaft pin with the shaft seat groove.

• Apply engine oil to the reduction gear

cover O-ring before installation.

STARTER MOTOR INSTALLATION

Apply engine oil to the starter motor O-ring and then install it. Install the starter motor. Tighten the two mounting bolts.

Torque: 0.81.2kg-m

Mounting Bolts

HIPSTER125/150

Groove

Bolts

8-6

9. CLUTCH/GEAR SHIFT MECHANISM

HIPSTER125/150

9

__________________________________________________________________________________

CLUTCH/GEAR SHIFT MECHANISM

__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 9-2 TROUBLESHOOTING----------------------------------------------------- 9-2 RIGHT CRANKCASE COVER REMOVAL --------------------------- 9-3 CLUTCH REMOVAL ------------------------------------------------------ 9-3 RIGHT CRANKCASE COVER INSTALLATION -------------------- 9-9

9

9-0

9. CLUTCH/GEAR SHIFT MECHANISM

HIPSTER125/150

9-1

9. CLUTCH/GEAR SHIFT MECHANISM

HIPSTER125/150

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• The clutch and gear shift mechanism can be serviced in the frame.

• Install the clutch plates in the same chamfer direction.

• Install the thrust washer with the chamfer facing up and the flat facing down.

SPECIFICATIONS

Item Standard (mm) Service Limit (mm) Clutch spring free length 35.5 34.2 Clutch friction disk thickness 2.82.9 2.5 Clutch plate bending 00.1 0.2 Clutch outer I.D. 111111.5 112.5

Clutch outer guide

TORQUE VALUES

I.D. 30.030.021 30.40

Clutch center lock bolt 0.81.2kg-m

SPECIAL TOOLS

Universal holder Pliers (open)

TROUBLESHOOTING

Clutch slips during acceleration Clutch won’t operate; motorcycle moves

• No free play

• Worn friction disk • Excessive free play

• Weak spring • Bent clutch plate

Clutch won’t operate Too much pressure on clutch lever

• Excessive free play • Kinked, twisted or damaged clutch cable

• Bent clutch plate • Damaged clutch lifter

Improper shifting Clutch does not operate smoothly

• Excessive clutch lever free play • Improper clutch outer groove machining

• Bent gear shift spindle

• Worn or deformed gear shift plate Gear tripping

• Damaged transmission drum grooves • Faulty gear shift cam stopper

• Faulty gear shift cam stopper • Bent gear shift spindle

• Worn gear teeth

moves slowly

9-2

9. CLUTCH/GEAR SHIFT MECHANISM

N

r

Nut

r

HIPSTER125/150

RIGHT CRANKCASE COVER REMOVAL

Drain the engine oil. Remove the kick lever. Disconnect the clutch cable. Remove the right crankcase cover attaching bolts and right crankcase cover. Remove the clutch lever and bearing.

Remove the oil filter rotor cover. (Refer to 3-3.) Remove the square nut. Remove the square nut(left hand threads) on the balance shaft driven gear. Remove the oil filter rotor.

Remove the oil pump gear cover. Remove the 6mm nut on top of the oil pump driven gear. Remove the oil pump driven gear and chain. Remove the oil pump drive gear and clutch outer drive gear from the crankshaft.

CLUTCH REMOVAL

Remove the four clutch lifter bolts. Remove the clutch lifter and four tension springs.

Kick Leve

Clutch Oute

Clutch Cable

Screws

Clutch

Tension Springs

ut

Guide Pin

Driven Gea

Clutch Lifte

9-3

9. CLUTCH/GEAR SHIFT MECHANISM

r

p

r



y

t



r

Remove the 20mm circlip using a pair of pliers and then remove the clutch center, clutch friction disks and plates.

• When rem oving the circlip, do not expand it excessively to avoid deformation.

• Install the circlip with the chamfered

Remove the balance shaft drive gear and woodruff key from the crankshaft. Remove the special flange gasket on the balance shaft driven gear, driven gear and woodruff key from the balance shaft. Remove the oil pump shaft.

Be careful not to drop or lose the woodruff keys.

Remove the thrust washer, clutch outer and outer guide.

INSPECTION CLUTCH TENSION SPRING Measure each clutch tension spring free

length. Service Limit: 34.20mm Replace the spring with a new one if it is

shorter than the service limit.

Clutch Cente

Woodruff Ke

20mm Circli

Clutch Oute

HIPSTER125/150

Square Nu

Gea

Drive Gea

Thrust Washe

9-4

9. CLUTCH/GEAR SHIFT MECHANISM

r

CLUTCH FRICTION DISK Measure each clutch friction disk thickness. Service Limit: 2.5mm

CLUTCH PLATE Measure each clutch plate bending using a

feeler gauge. Service Limit: 0.20mm

CLUTCH OUTER/OUTER GUIDE Inspect the clutch outer groove for scratches

caused by the friction disks. Measure the clutch outer I.D.

Service Limit: 112.5mm Measure the clutch outer guide I.D.

Service Limits: I.D. : 30.40mm

GEAR SHIFT MECHANISM

Remove the gear shift pedal. Remove the gear shift spindle and washer.

Clutch Friction Disk

Feeler Gauge Clutch Plate

Gear Shift Spindle

HIPSTER125/150

Vernier Calipe

Stoppe

9-5

9. CLUTCH/GEAR SHIFT MECHANISM

r

m

r

m

Remove the stopper and spring. Remove the gear shift cam bolt. Remove the gear shift cam and set pin.

Inspection Inspect the gear shift cam stopper for wear or

looseness and replace if necessary.

Check the gear shift plate for wear or deformation and replace if necessary.

Inspect the corners of the gear shift cam for wear or damage. Replace the cam if the corners are rounded.

Gear Shift Ca

Stoppe

HIPSTER125/150

Stoppe

Gear Shift Plate

Wea

Wear/Deformation

Spring

Looseness

Wea

9-6

9. CLUTCH/GEAR SHIFT MECHANISM

r

g



r



t

Installation Install the gear shift cam stopper and spring.

Tighten the 6mm lock bolt. Torque: 0.81.2kg-m

Install the set pin into the transmission drum hole.

Install the gear shift cam, aligning the pin hole in the gear shift cam with the set pin. Then, tighten the bolt. Torque: 0.81.2kg-m

• After the gear shift cam is installed, put the stopper in the gear shift cam groove and tighten the stopper bolt.

• Rotate the transmission drum to make sure that the stopper operates properly.

Install the gear shift spindle and washer. During installation, make sure that the return spring aligns with the crankcase tab.

Install the oil pump body and insert the pump shaft. Install the balance shaft drive gear and woodruff key onto the crankshaft. Install the balance shaft driven gear and woodruff key onto the balance shaft.

Be sure to align the punch marks on the drive and driven gears before installing the woodruff key onto the balance shaft.

Set pin

Gear Shift Spindle

Pump Shaf

HIPSTER125/150

Gear Shift Cam Stoppe

Sprin

Return Sprin

Drive Gea

9-7

9. CLUTCH/GEAR SHIFT MECHANISM

r



Install the clutch outer drive gear onto the crankshaft. Install the oil pump drive gear onto the crankshaft. Install oil pump driven gear and chain.

Install the clutch outer and thrust washer.

Install the thrust washer with the chamfered side facing up.

Install the oil pump chain and driven gear and secure it with the 6mm nut. Install the clutch assembly. Stagger the clutch friction disks and clutch plates and then put them on the clutch center. Then install the clutch center together with the well-arranged friction disks and plates into the clutch outer.

Install the circlip.

Install the circlip with the chamfered side facing down.

Install the tension springs and clutch lifter. Install the washers to the bolts and tighten the four bolts.

Torque: 0.81.2kg-m Install the clutch lifter guide pin.

Clutch Oute

Drive Gea

Thrust Washe

20mm Circlip

Guide Pin

Bolts

HIPSTER125/150

Chain

Driven Gea

9-8

9. CLUTCH/GEAR SHIFT MECHANISM

t

r



Install the oil filter rotor. Install the washer and tighten the square nut. Torque: 4.05.0kg-m

Install the washer with the mark “OUTSIDE” facing up.

Install the special flange gasket onto the balance shaft driven gear with the flange facing down and then loosely install the square nut (left hand threads). Tighten the square nut using the square socket.

Install the oil filter rotor cover. Check the gasket for wear or damage and replace if necessary. Install and tighten the three oil filter rotor cover screws.

Torque: 0.30.4kg-m Install the oil pump gear cover and tighten

the two bolts.

RIGHT CRANKCASE COVER INSTALLATION

First install the dowel pins and then install the gasket. Install the right crankcase cover and tighten the cover bolts.

Torque: 0.81.2kg-m

Tighten the right crankcase cover bolts diagonally.

Oil Filter Rotor Cove

Right Crankcase Cove

HIPSTER125/150

Oil Filter Roto

Square Nu

Screws

Bolts

9-9

10. CRANKCASE/CRANKSHAFT/TRANSMISSION SYSTEM/STARTER SPINDLE

HIPSTER125/150

10

__________________________________________________________________________________

CRANKCASE/GRANKSHAFT/TRANS-MI

SSION SYSTEM/STARTER SPINDLE

__________________________________________________________________________________

SERVICE INFORMATION------------------------------------------------ 10- 2 TROUBLESHOOTING----------------------------------------------------- 10- 3 CRANKCASE REMOVAL ------------------------------------------------ 10- 4 TRANSMISSION SYSTEM REMOVAL-------------------------------- 10- 4 STARTER SPINDLE ------------------------------------------------------- 10- 8 CRANKSHAFT-------------------------------------------------------------- 10-10 CRANKCASE INSTALLATION ----------------------------------------- 10-12

10

10-0

10. CRANKCASE/CRANKSHAFT/TRANSMISSION SYSTEM/STARTER SPINDLE

HIPSTER125/150

10-1

10. CRANKCASE/CRANKSHAFT/TRANS-

r

MISSION SYSTEM/STARTER SPINDLE

SERVICE INFORMATION

GENERAL INSTRUCTIONS

• During crankcase separation, do not separate the crankcase halves with an iron hammer to avoid crankcase deformation or damage.

• After separation, be careful not to damage the right and left crankcase mating surfaces to avoid oil leakage.

• Replace the gasket with a new one during reassembly of the crankcase halves.

• After transmission system disassembly, make sure that the gear shifting operation is normal

before reassembly of the remaining parts.

• Apply engine oil to the transmission system and crankshaft before reassembly.

SPECIFICATIONS

Item Standard (mm) Service Limit (mm)

Balance shaft Transmission

fork Transmission fork shaft O.D. 11.97611.994 11.936

Transmission drum O.D.

Main shaft starter gea Main shaft 4th gea Main shaft 5th gea Countershaft starter idle 19.5219.541 19.581 Countershaft 1st gea Countershaft 2nd gea

Transmission

Left crankcase side 14.97814.989 14.938

gear

Starter gea

Right crankcase 14.96614.984 14.926 Left crankcase 21.95921.98 21.919 1st gea 2nd gear 21.95921.98 21.919

Connecting rod big end side clearance 0.050.3 0.8

Crankshaft

Connecting rod big end radial clearance 00.08 0.05

Left 16.96416.984 16.924 Right 16.96416.984 16.924 Claw thickness 4.935.0 4.43 Shaft hole I.D. 1212.018 12.058

Left 12.96612.984 12.926 Right 20.95920.98 20.919

20.05520.095 20.135 2020.021 20.061

20.0220.041 20.061

Gear I.D.

20.0220.041 20.081

22.02022.041 22.081

Countershaft 3rd gea

Main Shaft O.D.

4th/5th gea

Countershaft O.D.

3rd gea

Runout 0.03 0.1

2020.021 20.061

19.95919.98 19.919

16.46616.484 16.426

19.95919.98 19.919

HIPSTER125/150

SPECIAL TOOLS

10-2

10. CRANKCASE/CRANKSHAFT/TRANSMISSION SYSTEM/STARTER SPINDLE

Bearing remover Bearing remover block Universal bearing puller Bearing outer driver, 32x35mm Bearing outer driver, 37x40mm Bearing outer driver, 42x47mm Bearing outer driver, 52x55mm Pilot, 15mm Pilot, 17mm Pilot, 20mm Pilot, 22mm Inner bearing driver handle Bearing outer driver, I.D. 30mm

TROUBLESHOOTING

HIPSTER125/150

Excessive engine noise

• Worn main shaft journal bearing

• Worn crankshaft pin bearing

• Worn transmission bearings

Transmission gear tripping

• Worn gear teeth

• Bent transmission fork

• Bent transmission fork shaft

• Damaged gear shift cam stopper

Hard shifting

• Improperly adjusted clutch

• Bent or damaged transmission fork

• Bent transmission fork shaft

• Bent gear shift spindle

• Damaged transmission drum grooves

CRANKCASE REMOVAL

The following parts must be removed before removing the crankcase:

•Cylinder head (Refer to Section 6.)

•Cylinder/piston (Refer to Section 7.)

10-3

KYMCO Hipster User Manual [fr]

Specifications and Main Features

Frequently Asked Questions

User Manual