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
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GENERAL INFORMATION |
1 |
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INSPECTION/ADJUSTMENT |
2 |
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LUBRICATION SYSTEM |
3 |
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FUEL SYSTEM |
4 |
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ENGINE |
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ENGINE REMOVAL/INSTALLATION |
5 |
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CYLINDER HEAD/VALVES |
6 |
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CYLINDER/PISTON |
7 |
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STARTER MOTOR/GENERATOR/ |
8 |
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LEFT CRANKCASE COVER/STARTER |
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CLUTCH/CAMSHAFT |
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CLUTCH/GEAR SHIFT MECHANISM |
9 |
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CRANKCASE/CRANKSHAFT/TRANS- |
10 |
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MISSION SYSTEM/STARTER SPINDLE |
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FRONT WHEEL/SUSPENSION/ |
11 |
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STEERING |
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CHASSIS |
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REAR WHEEL/BRAKE/SUSPENSION |
12 |
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HYDRAULIC BRAKE |
13 |
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REAR CARRIER/REAR FENDER/ |
14 |
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EXHAUST MUFFLER |
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ELECTRICAL |
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IGNITION SYSTEM |
15 |
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CHARGING SYSTEM |
18 |
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EQUIPMENT |
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STARTING SYSTEM |
17 |
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LIGHTS/INSTRUMENTS/SWITCHES/ |
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HORN |
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1. GENERAL INFORMATION
HIPSTER 125/150
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1 |
1 |
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__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
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)
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Starting system |
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Type |
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Cylinder arrangement |
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Combustion chamber type |
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Valve train |
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Bore x stroke (mm) |
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Compression ratio |
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Compression pressure |
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(kg/cm²) |
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Engine |
Max. output (ps/rpm) |
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Max. torque (Kg.m/rpm) |
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Intake |
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Open |
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Port |
(mm) |
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Close |
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timing |
Exhaust |
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Open |
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(mm) |
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Close |
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Valve clearance |
Intake |
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(cold) |
Exhaust |
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Idle speed (rpm) |
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Lubrication System |
Lubrication type |
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Oil pump type |
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Oil filter type |
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Oil capacity |
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Cooling |
Type |
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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 |
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Fuel capacity |
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Carburetor |
Type |
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Piston dia. (mm) |
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Venturi dia.(mm) |
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Throttle type |
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Electrical Equipment |
Ignition System |
Type |
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Spark plug gap |
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Ignition timing |
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Spark plug |
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Battery |
Capacity |
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Clutch |
Type |
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GearTransmission |
Type |
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System |
DrivePower |
Operating method |
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Type |
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1st gear |
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Reduction |
2nd gear |
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3rd gear |
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ratio |
4th gear |
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5th gear |
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Tire pressure |
Front |
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Device |
Moving |
(kg/cm²)(2 riders) |
Rear |
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Right |
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Turning angle |
Left |
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Front |
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Brake system type |
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Damping Device |
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Rear |
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Shock absorber |
Front |
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type |
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Rear |
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Frame type |
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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)
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Starting system |
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Type |
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Cylinder arrangement |
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Combustion chamber type |
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Valve train |
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Bore x stroke (mm) |
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Compression ratio |
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Compression pressure |
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(kg/cm²) |
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Engine |
Max. output (Ps/rpm) |
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Max. torque (Kg.m/rpm) |
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Intake |
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Open |
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Port |
(1mm) |
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Close |
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timing |
Exhaust |
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Open |
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(1mm) |
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Close |
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Valve clearance |
Intake |
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(cold) |
Exhaust |
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Idle speed (rpm) |
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Lubrication System |
Lubrication type |
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Oil pump type |
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Oil filter type |
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Oil capacity |
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Cooling |
Type |
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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
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Air cleaner type |
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SystemFuel |
Fuel capacity |
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Carburetor |
Type |
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Piston dia. (mm) |
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Venturi |
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dia.(mm) |
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Throttle type |
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Electrical Equipment |
Ignition System |
Type |
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Spark plug gap |
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Ignition timing |
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Spark plug |
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Battery |
Capacity |
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Moving |
Clutch |
Type |
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Transmission |
Type |
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Operating |
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method |
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Type |
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1st gear |
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Gear |
Reductio |
2nd gear |
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n |
3rd gear |
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ratio |
4th gear |
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5th gear |
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Tire pressure |
Front |
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(kg/cm²)(2 riders) |
Rear |
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Turning angle |
Left |
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Right |
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Brake system |
Front |
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Damping Device |
type |
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Rear |
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Shock absorber |
Front |
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type |
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Rear |
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Frame type |
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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 |
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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 |
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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 |
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Exhaust muffler joint lock nut |
2 |
6 |
0.8 1.2 |
Double end bolt |
Valve adjusting lock nut |
2 |
5 |
1.4 1.8 |
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Oil bolt |
1 |
12 |
2.0 3.0 |
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Cylinder bolt |
2 |
6 |
0.8 1.2 |
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A.C. generator bolt |
1 |
14 |
4.0 5.2 |
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Cylinder head cover bolt |
4 |
6 |
0.8 1.2 |
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Oil pump bolt |
2 |
6 |
0.7 1.1 |
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Oil filter lock nut |
1 |
16 |
1.5 3.0 |
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Rocker arm lock bolt |
3 |
8 |
1.5 2.0 |
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Cylinder head lock bolt |
1 |
8x79 |
1.5 2.0 |
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Cylinder bolt |
2 |
6x22 |
0.8 1.2 |
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Crankcase assembly bolt |
10 |
6 |
0.8 1.5 |
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Crankshaft damper bolt |
1 |
6x25 |
0.8 1.2 |
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Right crankcase cover bolt |
8 |
6 |
0.8 1.2 |
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Left crankcase cover bolt |
4 |
6 |
0.8 1.2 |
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A.C. generator coil lock bolt |
4 |
5 |
0.4 1.7 |
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Starter gear set plate bolt |
1 |
6 |
1.0 1.6 |
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Carburetor lock bolt |
2 |
6 |
0.8 1.2 |
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FRAME |
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Item |
Q‘ty |
Thread dia.(mm) |
Torque (kg-m) |
Remarks |
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Steering stem lock nut |
1 |
22 |
6.0 9.0 |
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Front axle nut |
1 |
14 |
5.5 7.0 |
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Rear axle nut |
1 |
16 |
6.0 8.0 |
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Rear shock absorber upper mount bolt |
2 |
10 |
3.0 4.0 |
|
Rear shock absorber lower mount bolt |
2 |
10 |
3.0 4.0 |
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Rear fork pivot nut |
1 |
12 |
5.5 7.0 |
|
Handlebar lock bolt |
4 |
6 |
6.0 9.0 |
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Rear driven gear bolt |
4 |
8 |
1.8 2.0 |
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Rear brake panel bolt |
1 |
8 |
1.8 2.5 |
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1-12
1. GENERAL INFORMATION
HIPSTER 125/150
SPECIAL TOOLS
Tool Name |
Tool No. |
Remarks |
Ref. Page |
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Flywheel puller |
E005 |
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Bearing puller 18mm |
E008 |
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Lock nut socket wrench |
E010 |
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Tappet adjuster |
E012 |
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Oil seat & bearing install |
E014 |
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Bearing puller 15mm |
E018 |
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Bearing puller 12mm |
E020 |
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Flywheel holder |
E021 |
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Crankshaf bearing puller |
E030 |
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Bearing puller 10mm |
E031 |
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Race cone install |
F005 |
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1-13
1. GENERAL INFORMATION
HIPSTER 125/150
LUBRICATION POINTS
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Engine Oil |
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Grease |
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Throttle Cable |
Clutch Cable |
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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 |
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Wire Harness |
Wire Connector |
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Fuel Filter |
||
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Ignition Coil
Fuel Tube
Ignition Switch
Taillight Wire
Connector
1-15
1. GENERAL INFORMATION |
HIPSTER 125/150 |
Negative Cable |
Battery Positive |
Starter Relay |
Cable |
Fuse Box
|
Starter Motor Wire |
Winker |
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Throttle Cable |
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Purge Control |
Vacuum Tube |
CDI Unit |
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Valve |
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Ignition Coil |
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A.I.C.V. |
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Wire |
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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
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Symptom |
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Inspection/Adjustment |
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Check if fuel reaches carburetor by loosening drain screw
Fuel reaches |
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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 |
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Weak or no spark |
|
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Test cylinder compression
Normal |
|
Low or no |
compression |
|
compression |
Start engine by follow-ing normal starting procedure
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Engine does not |
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Engine fires but |
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fire |
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does not start |
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Remove spark plug and |
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inspect again |
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Dry spark plug |
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Wet spark plug |
|
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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 |
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Incorrectly adjusted |
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Check carburetor gasket for air leaks
No air leak |
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Air leaks |
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Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground
Good spark |
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Weak or inter- |
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mittent spark |
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Check A.C. generator
Good |
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Faulty |
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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)
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Inspection/Adjustment |
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Symptom |
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Start engine and accelerate |
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lightly for observation |
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Engine speed |
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Engine speed does not |
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increases |
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increase sufficiently |
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Check ignition timing using |
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a timing light |
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Correct |
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Check valve clearance |
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Correct |
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Test cylinder compression |
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Normal |
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Abnormal |
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compression |
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compression |
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Check carburetor for |
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clogging |
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Not clogged |
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Clogged |
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Remove spark plug and |
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inspect |
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Plug not fouled or |
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Plug fouled or |
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discolored |
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discolored |
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Check crankcase for oil |
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level and condition |
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Correct and not |
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Incorrect or |
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contaminated |
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contaminated |
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Remove cylinder head oil |
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pipe bolt and inspect |
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Valve train lubricated |
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Valve train not |
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properly |
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lubricated properly |
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Check for engine overheating |
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Engine does not |
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Engine overheats |
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overheats |
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Rapidly accelerate or run at |
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high speed |
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Engine does not knock |
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Engine knocks |
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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 |
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Symptom |
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Check ignition timing
Correct |
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Incorrect |
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Check valve clearance
Correct |
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Incorrect |
Check fuel filter for fuel supply
Fuel flows freely |
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Fuel flow restricted |
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Check carburetor for clogged jets
Not clogged |
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Clogged |
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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 |
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Incorrect |
Cam timing gear aligning marks |
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not aligned |
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Check valve spring tension
Not weakened |
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Weak spring |
Faulty spring |
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1-21
1. GENERAL INFORMATION
HIPSTER 125/150
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Inspection/Adjustment |
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Symptom |
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Probable Cause |
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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 |
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Abnormal |
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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 |
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Symptom |
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Probable Cause |
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Replace with a new spark plug and inspect again
Weak or no spark |
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Good spark |
Faulty old spark plug |
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Check spark plug cap and ignition coil wire for looseness
Not loose |
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Loose |
Loose spark plug cap |
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Check CDI unit coupler for looseness
Normal |
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Abnormal |
Poorly connected coupler |
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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 |
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ENGINE |
: 2 6mm |
CHASSIS |
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Throttle grip free play |
Rear brake free play : 10 20mm |
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Spark plug gap |
: 0.6 0.7mm |
Brake fluid |
: DOT-3 |
Spark plug specification : DR8EA |
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Valve clearance : IN: 0.06mm |
Cold Engine: IN: 0.05mm |
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EX: 0.06mm |
EX: 0.05mm |
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Cylinder compression : 150cc: 13kg/cm² |
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125cc: 13kg/cm² |
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Ignition timing |
: 34.5±2°/4000rpm |
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Idle speed |
: 1600±100rpm |
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Engine oil capacity: |
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At disassembly : 1.0 liter |
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At change |
: 0.9 liter |
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TIRE PRESSURE |
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1 Rider |
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2 Riders |
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Front |
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1.75kg/cm² |
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1.75kg/cm² |
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Rear |
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2.0kg/cm² |
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2.25kg/cm² |
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TIRE SIZE: |
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Front : 3.00–18–4PR |
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Rear : 130/90–15–4PR |
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TORQUE VALUES |
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Front axle nut |
5.5 7.0kg-m |
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Rear axle nut |
6.0 8.0kg-m |
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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 |
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Regular Service Mileage (km) |
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Item |
first Ö |
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Ø |
1000 |
200 |
300 |
400 |
500 |
600 |
700 |
800 |
900 |
1000 1100 1200 |
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R |
New |
0 |
0 |
0 |
0 |
0 |
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0 |
0 |
0 |
0 |
0 |
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Engine oil |
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R |
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R |
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R |
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R |
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R |
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motorcycle |
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300km |
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Engine oil filter |
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C |
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C |
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C |
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screen |
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Fuel filter screen |
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R |
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Valve clearance |
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A |
New |
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A |
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A |
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A |
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motorcycle |
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300km |
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Carburetor |
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Air Cleaner |
Note 2,3 |
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R |
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R |
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R |
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Spark plug |
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Clean at every 3000km and replace if necessary |
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Brake system |
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Drive chain |
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A |
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A |
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A |
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Suspension |
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Nuts, bolts, fasteners |
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T |
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Tire |
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Steering head bearing |
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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. |
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Slide the dust boot out and adjust by |
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loosening the lock nut and turning the |
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adjusting nut. |
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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
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Wash |
Squeeze out |
Engine |
Squeeze out |
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oil |
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and dry |
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and dry |
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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