KYMCO Hipster User Manual [fr]

4.6 (30)

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/

8

 

 

LEFT CRANKCASE COVER/STARTER

 

 

CLUTCH/CAMSHAFT

 

 

 

CLUTCH/GEAR SHIFT MECHANISM

9

 

 

 

 

 

 

CRANKCASE/CRANKSHAFT/TRANS-

10

 

 

MISSION SYSTEM/STARTER SPINDLE

 

 

 

FRONT WHEEL/SUSPENSION/

11

 

 

STEERING

CHASSIS

 

 

 

REAR WHEEL/BRAKE/SUSPENSION

12

 

 

 

 

 

 

 

 

HYDRAULIC BRAKE

13

 

 

 

 

 

 

REAR CARRIER/REAR FENDER/

14

 

 

EXHAUST MUFFLER

 

 

 

ELECTRICAL

 

IGNITION SYSTEM

15

 

 

 

 

CHARGING SYSTEM

18

EQUIPMENT

 

STARTING SYSTEM

17

 

LIGHTS/INSTRUMENTS/SWITCHES/

 

 

 

HORN

 

 

 

 

 

1. GENERAL INFORMATION

HIPSTER 125/150

 

 

 

 

 

1

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

HIPSTER 125/150

ENGINE SERIAL NUMBER

Location of Engine Serial Number

1-1

1. GENERAL INFORMATION

SPECIFICATIONS

HIPSTER 125/150

Motorcycle name & Model No.

Motorcycle name

Overall length (mm)

Overall width (mm)

Overall height (mm)

Wheel base (mm)

Engine type

Displacement (cc)

Fuel type

Front wheel Dry weight (kg) Rear wheel

Total

Front wheel Gross weight(kg) Rear wheel

Total

Tires Front wheel Rear wheel

Ground clearance (mm)

 

Starting system

 

 

 

Type

 

 

 

Cylinder arrangement

 

Combustion chamber type

 

Valve train

 

 

 

Bore x stroke (mm)

 

Compression ratio

 

Compression pressure

 

(kg/cm²)

 

 

Engine

Max. output (ps/rpm)

Max. torque (Kg.m/rpm)

 

Intake

 

Open

 

 

 

 

Port

(mm)

 

Close

 

timing

Exhaust

 

Open

 

 

(mm)

 

Close

 

Valve clearance

Intake

 

(cold)

Exhaust

 

Idle speed (rpm)

 

Lubrication System

Lubrication type

 

Oil pump type

 

Oil filter type

 

Oil capacity

 

 

 

Cooling

Type

 

 

RJ25AA

HIPSTER125

2250

900

1180

1475

4

124.1

92# nonleaded gasoline

59

80

139

67.5

91

158.5

3.00-18-4PR

130/90-15-4PR

150

Starting motor & kick starter

OHC

Single cylinder

Semi-sphere

OHC-2V

56.5 x 49.5

9.4

13

11.5/9000

1.0/6000

5.5

27.5

4

36

0.06mm

0.06mm

1600rpm

Forced pressure & wet sump

Inner/outer rotor

Wire gauze filter

1.0L SAE#30

Air cooling

SystemFuel

Air cleaner type

 

Fuel capacity

 

Carburetor

Type

 

Piston dia. (mm)

 

 

 

 

 

 

Venturi dia.(mm)

 

 

 

Throttle type

Electrical Equipment

Ignition System

Type

 

Spark plug gap

 

 

 

Ignition timing

 

 

 

Spark plug

 

 

 

Battery

Capacity

 

 

 

Clutch

Type

 

 

 

GearTransmission

Type

 

System

DrivePower

Operating method

Type

 

 

 

 

 

 

 

 

 

1st gear

 

 

 

Reduction

2nd gear

 

 

 

3rd gear

 

 

 

ratio

4th gear

 

 

 

 

 

 

 

 

5th gear

 

 

Tire pressure

Front

Device

Moving

(kg/cm²)(2 riders)

Rear

 

 

Right

 

 

Turning angle

Left

 

 

Front

 

 

Brake system type

Damping Device

 

 

Rear

Shock absorber

Front

 

 

 

 

 

 

 

type

 

Rear

 

 

 

 

 

 

 

 

Frame type

 

 

Paper element type

12.0 liter

CVK

φ26.5

φ26

Piston type

CDI

34.5° ±2/4000rpm

NGK-DR8EA

0.6 0.7mm

12V6AH

Wet multi-disc clutch

Permanent gear meshing

Foot operated

International type

2.846

2.063

1.4

1.130

0.923

1.75

2.25

43°

43°

Disk brake

Drum brake

Telescope

Double swing

Double cradle

SPECIFICATIONS

1-2

1. GENERAL INFORMATION

HIPSTER 125/150

Motorcycle name & Model No.

Motorcycle name

Overall length (mm)

Overall width (mm)

Overall height (mm)

Wheel base (mm)

Engine type

Displacement (cc)

Fuel type

Front wheel Dry weight (kg) Rear wheel

Total

Front wheel Gross weight(kg) Rear wheel

Total

Tires Front wheel Rear wheel

Ground clearance (mm)

 

Starting system

 

 

 

Type

 

 

 

Cylinder arrangement

 

Combustion chamber type

 

Valve train

 

 

 

Bore x stroke (mm)

 

Compression ratio

 

Compression pressure

 

(kg/cm²)

 

 

Engine

Max. output (Ps/rpm)

Max. torque (Kg.m/rpm)

 

Intake

 

Open

 

 

 

 

Port

(1mm)

 

Close

 

timing

Exhaust

 

Open

 

 

(1mm)

 

Close

 

Valve clearance

Intake

 

(cold)

Exhaust

 

Idle speed (rpm)

 

Lubrication System

Lubrication type

 

Oil pump type

 

 

 

 

Oil filter type

 

 

Oil capacity

 

Cooling

Type

 

 

RH30AA

HIPSTER150

2275

830

1135

1475

4

149.4

92# nonleaded gasoline

59

80

139

67.5

91

158.5

3.0-18-4PR

130/90-15-4PR

140

Starting motor & kick starter

OHC

Single cylinder

Dome head

SOHC-4V

62 x 49.5

10

13

14/9000

1.1/7500

0

30

0

30

0.06mm

0.06mm

1600rpm

Forced pressure & wet sump

Inner/outer rotor

Wire gauze filter

1.0L SAE#30

Air cooling

 

Air cleaner type

 

SystemFuel

Fuel capacity

 

Carburetor

Type

 

Piston dia. (mm)

 

 

 

 

Venturi

 

 

 

dia.(mm)

 

 

 

Throttle type

Electrical Equipment

Ignition System

Type

 

Spark plug gap

 

 

Ignition timing

 

 

Spark plug

 

Battery

Capacity

 

Moving

Clutch

Type

 

Transmission

Type

 

 

 

 

 

 

Operating

 

 

 

method

 

 

 

Type

 

 

 

 

1st gear

 

Gear

Reductio

2nd gear

 

n

3rd gear

 

 

ratio

4th gear

 

 

 

5th gear

 

Tire pressure

Front

 

(kg/cm²)(2 riders)

Rear

 

Turning angle

Left

 

Right

 

 

 

 

 

 

 

Brake system

Front

Damping Device

type

 

Rear

Shock absorber

Front

 

type

 

Rear

 

 

 

 

 

 

 

Frame type

 

 

Paper element type

12.0L

CVK

φ26.5

φ26

Piston type

CDI

34.5° ±2/4000rpm

NGK-CR8EH9

0.6 0.7mm

12V6AH

Wet multi-disc clutch

Permanent gear meshing

Foot operated

International type

2.846

2.063

1.4

1.130

0.923

1.75

2.25

45°

45°

Disk brake

Drum brake

Telescope

Double swing

Double cradle

1-3

1. GENERAL INFORMATION

HIPSTER 125/150

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.

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

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

No 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 pull too tight!

Do not press or squeeze the wire.

1-9

1. GENERAL INFORMATION

HIPSTER 125/150

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?

Remove Rust !

1-10

1. GENERAL INFORMATION

HIPSTER 125/150

Symbols:

The following symbols represent the servicing methods and cautions included in this service manual.

Engine Oil

Grease

Special

:Apply engine oil to the specified points. (Use designated engine oil for lubrication.)

:Apply grease for lubrication.

:Use special tool.

:Caution

: Warning

1-11

1. GENERAL INFORMATION

HIPSTER 125/150

TORQUE VALUES

STANDARD TORQUE VALUES

Item

Torque (kg-m)

Item

Torque (kg-m)

5mm bolt, nut

0.45 0.6

5mm screw

0.35 0.5

6mm bolt, nut

0.8 1.2

6mm nut, SH bolt

0.7 1.1

8mm bolt, nut

1.8 2.0

6mm flange bolt, nut

1.0 1.4

10mm bolt, nut

3.0 4.0

8mm flange bolt, nut

2.0 3.0

12mm bolt, nut

5.0 6.0

10mm flange bolt, nut

3.5 4.5

Torque specifications listed below are for important fasteners.

ENGINE

Item

Q‘ty

Thread dia.(mm)

Torque (kg-m)

Remarks

 

 

 

 

 

Cylinder head bolt A

2

8

2.8 3.2

Double end bolt

Cylinder head bolt B

2

8

2.8 3.2

Double end bolt

Oil filter screen cap

1

30

1.5 3.0

 

Exhaust muffler joint lock nut

2

6

0.8 1.2

Double end bolt

Valve adjusting lock nut

2

5

1.4 1.8

 

Oil bolt

1

12

2.0 3.0

 

Cylinder bolt

2

6

0.8 1.2

 

A.C. generator bolt

1

14

4.0 5.2

 

Cylinder head cover bolt

4

6

0.8 1.2

 

Oil pump bolt

2

6

0.7 1.1

 

Oil filter lock nut

1

16

1.5 3.0

 

Rocker arm lock bolt

3

8

1.5 2.0

 

Cylinder head lock bolt

1

8x79

1.5 2.0

 

Cylinder bolt

2

6x22

0.8 1.2

 

Crankcase assembly bolt

10

6

0.8 1.5

 

Crankshaft damper bolt

1

6x25

0.8 1.2

 

Right crankcase cover bolt

8

6

0.8 1.2

 

Left crankcase cover bolt

4

6

0.8 1.2

 

A.C. generator coil lock bolt

4

5

0.4 1.7

 

Starter gear set plate bolt

1

6

1.0 1.6

 

Carburetor lock bolt

2

6

0.8 1.2

 

FRAME

 

 

 

 

 

 

 

 

 

Item

Q‘ty

Thread dia.(mm)

Torque (kg-m)

Remarks

 

 

 

 

 

Steering stem lock nut

1

22

6.0 9.0

 

Front axle nut

1

14

5.5 7.0

 

Rear axle nut

1

16

6.0 8.0

 

Rear shock absorber upper mount bolt

2

10

3.0 4.0

 

Rear shock absorber lower mount bolt

2

10

3.0 4.0

 

Rear fork pivot nut

1

12

5.5 7.0

 

Handlebar lock bolt

4

6

6.0 9.0

 

Rear driven gear bolt

4

8

1.8 2.0

 

Rear brake panel bolt

1

8

1.8 2.5

 

1-12

1. GENERAL INFORMATION

HIPSTER 125/150

SPECIAL TOOLS

Tool Name

Tool No.

Remarks

Ref. Page

 

 

 

 

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

 

 

 

 

 

 

1-13

1. GENERAL INFORMATION

HIPSTER 125/150

LUBRICATION POINTS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine Oil

 

Grease

 

 

 

Throttle Cable

Clutch Cable

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Grease

Speedometer Cable

Front Brake Fluid Tube

1-14

1. GENERAL INFORMATION

HIPSTER 125/150

CABLE & HARNESS ROUTING

 

Handlebar Switch

Connectors

CDI Unit

A.C. Generator

Wire Harness

Wire Connector

Fuel Filter

 

Ignition Coil

Fuel Tube

Ignition Switch

Taillight Wire

Connector

1-15

KYMCO Hipster User Manual

1. GENERAL INFORMATION

HIPSTER 125/150

Negative Cable

Battery Positive

Starter Relay

Cable

Fuse Box

 

Starter Motor Wire

Winker

 

 

Throttle Cable

 

 

Purge Control

Vacuum Tube

CDI Unit

 

Valve

 

Ignition Coil

 

 

A.I.C.V.

 

 

Wire

 

 

 

A.C.V. Vacuum

Tube

A.C.V.

Accelerating Pump

Cable

Air Cleaner

Clutch Cable

 

1-16

1. GENERAL INFORMATION

HIPSTER 125/150

WIRING DIAGRAM

1-17

1. GENERAL INFORMATION

TROUBLESHOOTING

ENGINE WILL NOT START OR IS HARD TO START

 

 

Symptom

Inspection/Adjustment

 

 

 

 

 

Check if fuel reaches carburetor by loosening drain screw

Fuel reaches

 

Fuel does not

carburetor

 

reach carburetor

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground

Spark jumps

 

Weak or no spark

 

 

 

Test cylinder compression

Normal

 

Low or no

compression

 

compression

Start engine by follow-ing normal starting procedure

 

 

Engine does not

 

Engine fires but

 

 

fire

 

does not start

 

 

 

 

Remove spark plug and

 

 

 

 

inspect again

 

 

 

 

 

 

 

 

 

 

 

Dry spark plug

 

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

HIPSTER 125/150

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Inspection/Adjustment

 

Symptom

 

 

 

Check ignition timing

Correct

 

Incorrect

 

 

 

Check carburetor pilot screw adjustment

Correctly adjusted

 

Incorrectly adjusted

 

 

 

Check carburetor gasket for air leaks

No air leak

 

Air leaks

 

 

 

Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground

Good spark

 

Weak or inter-

 

mittent spark

 

 

 

Check A.C. generator

Good

 

Faulty

 

 

 

Probable Cause

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

1-19

1. GENERAL INFORMATION

POOR PERFORMANCE (ENGINE LACKS POWER)

 

Inspection/Adjustment

 

Symptom

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Start engine and accelerate

 

 

 

 

 

 

 

 

lightly for observation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine speed

 

Engine speed does not

 

 

 

increases

 

increase sufficiently

 

 

 

 

 

 

 

 

 

 

 

Check ignition timing using

 

 

 

 

 

 

 

 

a timing light

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Correct

 

Incorrect

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Check valve clearance

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Correct

 

Incorrect

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Test cylinder compression

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Normal

 

Abnormal

 

 

compression

 

compression

 

 

 

 

 

 

 

 

 

 

Check carburetor for

 

 

 

 

 

 

 

 

clogging

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Not clogged

 

Clogged

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Remove spark plug and

 

 

 

 

 

 

 

 

inspect

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Plug not fouled or

 

Plug fouled or

 

 

discolored

 

discolored

 

 

 

 

 

 

 

 

 

 

Check crankcase for oil

 

 

 

 

 

 

 

 

level and condition

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Correct and not

 

Incorrect or

 

 

contaminated

 

contaminated

 

 

 

 

 

 

 

 

 

 

Remove cylinder head oil

 

 

 

 

 

 

 

 

pipe bolt and inspect

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Valve train lubricated

 

Valve train not

 

 

 

properly

 

lubricated properly

 

 

 

 

 

 

 

 

 

 

 

Check for engine overheating

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine does not

 

Engine overheats

 

 

overheats

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Rapidly accelerate or run at

 

 

 

 

 

 

 

 

high speed

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Engine does not knock

 

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

 

Incorrect

 

 

 

Check valve clearance

Correct

 

Incorrect

Check fuel filter for fuel supply

Fuel flows freely

 

Fuel flow restricted

 

 

 

Check carburetor for clogged jets

Not clogged

 

Clogged

 

 

 

Check valve timing

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

Correct

 

Incorrect

Cam timing gear aligning marks

 

 

 

not aligned

 

 

 

Check valve spring tension

Not weakened

 

Weak spring

Faulty spring

 

 

 

 

1-21

1. GENERAL INFORMATION

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

Normal voltage

Voltage does not increase

Normal

Resistance too high

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

Normal voltage

No voltage

Check regulator/rectifier coupler for loose connection

Normal

Abnormal

Overcharging

Inspection/Adjustment

Symptom

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

Battery has voltage with ignition switch “ON”

Battery has no voltage with ignition switch “ON”

Normal

 

Abnormal

 

 

 

Dead battery

Faulty battery

Faulty coil

Broken pink and yellow wires Shorted pink and yellow wires

Broken red wire

Faulty regulator/rectifier Poorly connected coupler

Faulty A.C. generator

Probable Cause

Broken black wire

Poorly connected coupler

Faulty regulator/rectifier

1-22

1. GENERAL INFORMATION

HIPSTER 125/150

NO SPARK AT SPARK PLUG

Inspection/Adjustment

 

Symptom

 

Probable Cause

 

 

 

 

 

Replace with a new spark plug and inspect again

Weak or no spark

 

Good spark

Faulty old spark plug

 

 

 

 

Check spark plug cap and ignition coil wire for looseness

Not loose

 

Loose

Loose spark plug cap

 

 

 

 

Check CDI unit coupler for looseness

Normal

 

Abnormal

Poorly connected coupler

 

 

 

 

Measure resistance between CDI unit coupler wire terminals

Normal Abnormal

Check related parts

Normal Abnormal

Check CDI unit with a

CDI unit tester

Normal Abnormal

Check ignition coil with a CDI unit tester

Abnormal

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 HIPSTER125/150

2

__________________________________________________________________________________

2

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

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

2-0

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

: 2 6mm

CHASSIS

 

Throttle grip free play

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

 

 

 

 

 

 

 

 

 

 

 

 

1 Rider

 

2 Riders

 

 

 

 

 

 

Front

 

 

1.75kg/cm²

 

1.75kg/cm²

 

 

 

 

 

 

Rear

 

 

2.0kg/cm²

 

2.25kg/cm²

 

 

 

 

 

 

TIRE SIZE:

 

 

 

 

 

Front : 3.00184PR

 

 

 

Rear : 130/90154PR

 

 

 

TORQUE VALUES

 

 

 

Front axle nut

5.5 7.0kg-m

 

Rear axle nut

6.0 8.0kg-m

 

2-1

2. INSPECTION/ADJUSTMENT HIPSTER125/150

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

Frequency Whichevercomes

 

 

 

Regular Service Mileage (km)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Item

first Ö

 

 

 

 

 

 

 

 

 

 

 

 

 

Ø

1000

200

300

400

500

600

700

800

900

1000 1100 1200

 

 

 

 

 

R

New

0

0

0

0

0

0

0

0

0

0

0

Engine oil

 

 

R

 

R

 

R

 

R

 

 

R

 

motorcycle

 

 

 

 

 

 

 

 

300km

 

 

 

 

 

 

 

 

 

 

 

Engine oil filter

 

 

 

 

C

 

 

 

C

 

 

 

 

C

screen

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fuel filter screen

 

 

 

 

 

 

 

 

 

 

 

R

 

 

Valve clearance

 

A

New

 

A

 

 

 

A

 

 

 

 

A

 

motorcycle

 

 

 

 

 

 

 

 

 

 

300km

 

 

 

 

 

 

 

 

 

 

 

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 HIPSTER125/150

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.

Fuel Filter

Fuel Line

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

Dust Boot Adjusting Nut

the adjusting nut on the throttle cable.

 

Slide the dust boot out and adjust by

 

loosening the lock nut and turning the

 

adjusting nut.

 

Lock 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.

2-3

2. INSPECTION/ADJUSTMENT

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 of high vaporability

HIPSTER125/150

Element Screen

Screw

 

 

 

 

 

 

 

 

Wash

Squeeze out

Engine

Squeeze out

 

oil

 

and dry

 

and dry

 

 

 

 

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

Spark Plug

Gap, Wear, and

Fouling Deposits

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.

2-4

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