Kymco MO BW125, MO BW 150 Service Manual

1. GENERAL INFORMATION

1-0

Bet & Win 1 25 /1 50

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GENERAL INFORMATION

__________________________________________________________________________________

ENGINE SERIAL NUMBER--------------------------------------------- 1-1

SPECIFICATION---------------------------------------------------------- 1-2

SERVICE PRECAUTIONS----------------------------------------------- 1-4

TORQUE VALUES ------------------------------------------------------- 1-8

TOOLS --------------------------------------------------------------------- 1-9

LUBRICATION POINTS------------------------------------------------1-10

CABLE & HARNESS ROUTING----------------------------------------- 1-12

WIRING DIAGRAM-------------------------------------------------------------------1-17

TROUBLESHOOTING --------------------------------------------------1-18

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1. GENERAL INFORMATION

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SERIAL NUMBER

Location of Engine Serial Number

Location of Frame Serial Number

Vehicle Identification Serial Number

1. GENERAL INFORMATION

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SPECIFICATIONS

Name & Model No.

SH25CA Motorcycle Name & Type Overall length

1940mm

Overall width

750mm

Overall height

1145mm

Wheel base

1390mm

Engine type

Water cooled 4-stroke, OHC engine

Displacement

124cc

Fuel Used

92# nonleaded gasoline

Front wheel

54

Net weight (kg)

Rear wheel

75

Total

129

Front wheel

58.5

Gross weight(kg)

Rear wheel

79.5

Total

138

Front wheel

120/70-12 56J

Rear wheel

130/70-12 59J

Ground clearance

155mm

Perform

-

Braking distance (m)

30km/hr4.4m

ance

Min. turning radius

2300mm

Starting system

Starting motor &

Kick starter

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

O.H.C.

Bore x stroke (mm)

52.4 x 57.8

Compression ratio

10.6:1

Compression pressure (kg/cm_-rpm)

15

Max. output (kw/rpm)

8.4/8250

Max. torque (N.m/rpm)

9.9/6500

Intake

Open

BTDC 12°

Port

(1mm)

Close

ATDC 35°

timin g

Exhaust

Open

BDDC 28°

(1mm)

Close

0°

Valve

Intake

0.1

clearance (cold)

Exhaust

0.1

Idle speed (rpm)

1500rpm

Lubrication type

Forced pressure &

wet sump

Oil pump type

Inner/outer rotor

type

Oil filter type

Full-flow filtration

Oil capacity

1.1 liters

Cooling Type

Water cooling

Air cleaner type & No

Paper element, wet

Fuel capacity

10.6 liters

Type

VE

Piston dia.

22

Venturi dia.

26 equivalent

Throttle type

Butterfly type

Type

CDI

Ignition timing

BTDC 10°±1°

Contact breaker

Non-contact point

type

Spark plug

NGK

DPR7EA-9

Spark plug gap

0.9mm

Battery

Capacity

12V8AH

Clutch

Type

Dry multi-disc clutch

Type

Non-stage transmission

Operation

Automatic centrifugal

Type

Two-stage reduction

Reduction

1st

2.8~1.0

ratio

2nd

8.82

Front

Caster angle

Axle

Connecting rod

Tire pressure

Front

2.00

(kg/cm_)

Rear

2.25

Turning

Left

42.5°

angle

Right

42.5°

Brake system

Front

Disk brake

type

Rear

Disk brake

Suspension

Front

Telescope

type

Rear

Double swing

Shock absorber

Front

Telescope

type

Rear

Double swing

Frame type

Under bone

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Damping

Device

1. GENERAL INFORMATION

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SPECIFICATIONS

Name & Model No.

SH30CA Motorcycle Name & Type Overall length

1940mm

Overall width

750mm

Overall height

1145mm

Wheel base

1390mm

Engine type

Water cooled 4-stroke, OHC engine

Displacement

150cc

Fuel Used

92# nonleaded gasoline

Front wheel

54

Net weight (kg)

Rear wheel

75

Total

129

Front wheel

58.5

Gross weight(kg)

Rear wheel

79.5

Total

138

Front wheel

120/70-12 56J

Rear wheel

130/70-12 59J

Ground clearance

155mm

Perform

-

Braking distance (m)

30km/hr4.4m

ance

Min. turning radius

2300mm

Starting system

Starting motor &

kick starter

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

O.H.C.

Bore x stroke (mm)

57.4 x 57.8

Compression ratio

10.6:1

Compression pressure (kg/cm_-rpm)

15

Max. output (kw/rpm)

9.1/7500

Max. torque (N.m/rpm)

11.6/6500

Intake

Open

BTDC 12°

Port

(1mm)

Close

ATDC 35°

timin g

Exhaust

Open

BDDC 28°

(1mm)

Close

0°

Valve

Intake

0.1

clearance (cold)

Exhaust

0.1

Idle speed (rpm)

1500rpm

Lubrication type

Forced pressure &

wet sump

Oil pump type

Inner/outer rotor

type

Oil filter type

Full-flow filtration

Oil capacity

1.1 liters

Cooling Type

Water cooling

Air cleaner type & No

Paper element, wet

Fuel capacity

10.6 liters

Type

VE

Piston dia.

22

Venturi dia.

26 equivalent

Throttle type

Butterfly type

Type

CDI

Ignition timing

BTDC 10°±1°

Contact breaker

Non-contact point

type

Spark plug

NGK

DP7EA-9

Spark plug gap

0.9mm

Battery

Capacity

12V8AH

Clutch

Type

Dry multi-disc clutch

Type

Non-stage transmission

Operation

Automatic centrifugal

Type

Two-stage reduction

Reduction

1st

2.8~1.0

ratio

2nd

8.82

Front

Caster angle

Axle

Connecting rod

Tire pressure

Front

2.00

(kg/cm_)

Rear

2.25

Turning

Left

42.5°

angle

Right

42.5°

Brake system

Front

Disk brake

type

Rear

Disk brake

Suspension

Front

Telescope

type

Rear

Double swing

Shock absorber

Front

Telescope

type

Rear

Double swing

Frame type

Under bone

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Damping

Device

1. GENERAL INFORMATION

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SERVICE PRECAUTIONS

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

circlips, cotter pins, etc. when reassembling.

n When tightening bolts or nuts, begin with

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

n Use genuine parts and lubricants.

n When servicing the motorcycle, be sure to

use special tools for removal and installation.

n After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil before reassembly.

n Apply or add designated greases and

lubricants to the specified lubrication points.

n After reassembly, check all parts for

proper tightening and operation.

n When two persons work together, pay

attention to the mutual working safety.

n Disconnect the battery negative (-) terminal

before operation.

n When using a spanner or other tools, make

sure not to damage the motorcycle surface.

n After operation, check all connecting

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

n When connecting the battery, the positive

(+) terminal must be connected first.

n After connection, apply grease to the

battery terminals.

n Terminal caps shall be installed securely.

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n If the fuse is burned out, find the cause and

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

n After operation, terminal caps shall be

installed securely.

n When taking out the connector, the lock on

the connector shall be released before operation.

n Hold the connector body when connecting

or disconnecting it.

n Do not pull the connector wire.

n Check if any connector terminal is bending,

protruding or loose.

n The connector shall be inserted

completely.

n If the double connector has a lock, lock

it at the correct position.

n Check if there is any loose wire.

n Before connecting a terminal, check for

damaged terminal cover or loose negative terminal.

n Check the double connector cover for

proper coverage and installation.

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

coverage.

n Do not make the terminal cover opening

face up.

n 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.

Confirm Capacity

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n After clamping, check each wire to make

sure it is secure.

n Do not squeeze wires against the weld or

its clamp.

n After clamping, check each harness to make

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

n When fixing the wire harnesses, do not

make it contact the parts which will generate high heat.

n Route wire harnesses to avoid sharp edges

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

n Route wire harnesses passing through the

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

n Route harnesses so they are neither

pulled tight nor have excessive slack.

n Protect wires and harnesses with electrical

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

n When rubber protecting cover is used to

protect the wire harnesses, it shall be installed securely.

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

repair by wrapping it with protective tape or replace it.

n When installing other parts, do not press or

squeeze the wires.

Do not pull too tightð

No Contact

Do not press or squeeze the

1. GENERAL INFORMATION

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n After routing, check that the wire harnesses

are not twisted or kinked.

n 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.

n When a testing device is used, make sure to

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

n Be careful not to drop any parts.

n When rust is found on a terminal, remove

the rust with sand paper or equivalent before connecting.

n 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 lubrication.)

: Apply grease for lubrication.

: Transmission Gear Oil (90#)

: Use special tool.

: Caution

: Warning

Special

Engine Oil Grease

Gear Oil

＊

Do you understand the

Remove

1. GENERAL INFORMATION

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TORQUE VALUES

STANDARD TORQUE VALUES

Item

Torque (N-m)

Item

Torque (N-m)

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

4.9

9.8

21.6

34.3

53.9

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

3.9

8.8

11.8

26.5

39.2

Torque specifications listed below are for important fasteners.

ENGINE

Item

Q‘ty

Thread dia.(mm)

Torque (N-m)

Remarks

Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Exhaust muffler joint lock nut Cylinder head cap nut Valve adjusting lock nut

Cam chain tensioner slipper bolt

Oil bolt Clutch outer nut Clutch drive plate nut Flywheel nut Oil pump bolt Cylinder head cover bolt Spark plug Cam chain tensioner bolt Water pump impeller

2 2 1 2 4 2 1 1 1 1 1 2 4 1 1 1

8 8

30

8 8 5

6 12 12 12 14

5

6 10

6

8

21.6

14.7

8.8

21.6

8.8

12.7

53.9

3.9

11.8

8.8

13.7

Double end bolt Double end bolt Apply oil to

threads

Left hand threads

FRAME

Item

Q‘ty

Thread dia.(mm)

Torque (N-m)

Remarks

Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upp er bolt Rear shock absorber lower bolt Front shock absorber lock bolt Engine hanger bolt

1 1 1 2 2 4 1

10 12 14 10

8 10 12

44.1

58.8

88.2

29.4

24.5

53.9

U-nut U-nut U-nut

Kymco MO BW125, MO BW 150 Service Manual - chap 01 (info generali)