Kymco MO P125, MO P 150 Service Manual - chap 17 (imp elettrico)

17. LIGHTS/INSTRUMENTS/SWITCHES

17-0

PEO PLE 12 5/ 15 0

17

LIGHTS/INSTRUMENTS/SWITCHES

ELECTRICAL EQUIPMENT LAYOUT ........................................ 17-1

SERVICE INFORMATION........................................................ 17-2

TROUBLESHOOTING.............................................................. 17-2

HEADLIGHT ............................................................................ 17-3

FRONT TURN SIGNAL LIGHT ................................................ 17-3

POSITION/REAR TURN SIGNAL LIGHT..................................... 17-3

IGNITION SWITCH.................................................................. 17-4

HANDLEBAR SWITCH ............................................................ 17-4

STOP SWITCH ......................................................................... 17-6

HORN ....................................................................................... 17-6

FUEL GAUGE........................................................................... 17-6

FUEL UNIT............................................................................... 17-6

AUTO BYSTARTER.................................................................. 17-7

INSTRUMENTS ........................................................................ 17-8

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17. LIGHTS/INSTRUMENTS/SWITCHES

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PEO PLE 125/15 0

Turn Signal Switch

Stop Switches

Horn Button

ELECTRICAL EQUIPMENT LAYOUT

Headlight
Dimmer Switch

Fuel Unit

Starter Button

Ignition Switch

Auto Bystarter

Headlight Switch

Auto
Bystarter

Horn

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SERVICE INFORMATION

GENERAL INSTRUCTIONS

• An electric tester is needed to measure or test the electric equipment.

• Be sure to use fuses and bulbs of the same specifications to avoid damage of electrical equipment.

• After installation of each switch, a continuity check must be performed. A continuity check can

usually be made without removing the part from the motorcycle.

TROUBLESHOOTING

Lights do not come on and horn does not Engine starts but stalls during idling

sound when ignition switch is “ON”

•Faulty auto bystarter

• Faulty ignition switch • Faulty auto bystarter resistor

• Fuse burned out • Poorly connected or broken wire

• Weak battery • Clogged carburetor

• Burned bulb

• Faulty switch

• Faulty horn

• Poorly connected, broken or shorted wire

Fuel gauge pointer does not register

Fuel gauge pointer does not move correctly

• Faulty fuel gauge • Faulty fuel gauge

• Faulty fuel unit • Faulty fuel unit

• Poorly connected, broken or shorted wire • Faulty fuel unit float

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HEADLIGHT

BULB REPLACEMENT

Remove the handlebar front cover. (!2)
Remove the rubber boot from the bulb socket.
Remove the bulb socket by turning it counter­clockwise.
Remove the bulb for replacement.
Install a new bulb, aligning the groove on the
bulb socket with the tab on the bulb.
Install the bulb socket.
Install the rubber boot.
Install the front cover. (!2)

HEADLIGHT REMOVAL

Remove the handlebar front cover. (!2)
Remove the two screws attaching the
headlight.
Remove the headlight unit.
Remove adjust the headlight beam bolt.
The installation sequence is the reverse of
removal.
After installation, adjust the headlight beam.
(!3-9)

FRONT TURN SIGNAL LIGHT

Remove the turn signal bulb shell screw. (!2)
Remove the front turn signal bulb socket and
replace the bulb.
The installation sequence is the reverse of
removal.

POSITION LIGHT/REAR TURN
SIGNAL LIGHT

BULB REPLACEMENT

Remove the bulb shell screw.
The installation sequence is the reverse of
removal.

Screw

Bulb Socket
Rubber Boot

Screws

Turn Signal Bulb Shell

Position Light Shell

Bolt

17. LIGHTS/INSTRUMENTS/SWITCHES

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IGNITION SWITCH

INSPECTION

Remove the front cover. (!2-4)
Disconnect the ignition switch wire coupler.
Check for continuity between the wire
terminals.

Replacement

Remove the two mounting bolts to remove
the ignition switch holder.
Remove the two screws to remove the
ignition switch for replacement.

HANDLEBAR SWITCHES

HEADLIGHT SWITCH INSPECTION

Remove the handlebar front and rear covers.
(!2-4)
Disconnect the headlight switch wire
couplers. Check for continuity between the
wire terminals.

Ignition Switch Coupler

Ignition Switch Bolts

Headlight Switch

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STARTER SWITCH

HORN SWITCH

TURN SIGNAL SWITCH

DIMMER SWITCH

Horn Button

Turn Signal Switch

Starter Switch

Dimmer Switch

Headlight Switch

Sky

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STOP SWITCH

INSPECTION

Remove the handlebar front cover. (!2)
Disconnect the front stop switch wire
coupler.
Check for continuity between the wire
terminals when the front brake lever is
applied. The switch is normal if there is
continuity.

HORN INSPECTION

Remove the front cover. (!2)
Disconnect the horn wire coupler.
The horn is normal if it sounds when a 12V
battery is connected across the horn wire
terminals.

FUEL GAUGE

INSPECTION

Remove the rear right side cover. (!2)
Disconnect the fuel gauge wire connector.
Turn the ignition switch ON.
Connect the green and yellow/white wires and
the fuel gauge needle should move from E to
F.
Connect the green and blue/white wires and
the fuel gauge needle should move from F to
E.

FUEL UNIT

REMOVAL

Remove the met-in box. (!2)
Remove the rear right side cover. (!2)
Disconnect the fuel unit wire connector.
Remove the fuel unit.

Fuel Unit Connector

Be careful not to bend or damage the fuel
unit float arm.

＊

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INSPECTION

Measure the resistance between the fuel unit
wire terminals with the float at upper and
lower positions.

RESISTANCES Unit: W

Float

Color

Upper

Lower

G_ Y/W

26_ 38

450_ 550

G_ L/W

450_ 550

26_ 38

Y/W_ L/W

450_ 550

450_ 550

The installation sequence is the reverse of
removal.

AUTO BYSTARTER

AUTO BYSTARTER INSPECTION

Remove the rear right side cover. (!2)
Disconnect the auto bystarter wire connector.
Measure the resistance between the yellow
and green/black wire terminals.

Resistance: 10W max.

RESISTOR INSPECTION

Remove the front cover. (!2)
Disconnect the green/black and green wires
and measuring the resistance between the wire
terminals.

Resistance: 5W max.
If the needle remains at “•”, it indicates that

the resistor is faulty and must be replaced.

• Install the fuel unit by aligning the

groove on the fuel unit with the tab on
the fuel tank.

Perform this operation when the engine
is cold.

＊

Auto Bystarter

Auto Bystarter Resistor

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INSTRUMENTS

BULB REPLACEMENT

Remove the front cover. (!2)
Remove the bulb socket and replace the bulb.
The installation sequence is the reverse of
removal.

INSTRUMENTS REPLACEMENT

Remove the handlebar front cover. (!2)
Remove the handlebar rear cover. (!2)
Disconnect the right and left handlebar
switches wire couplers.
Disconnect the speedometer cable.
Remove the instrument bulb sockets
Disconnect the three fuel gauge wires.
Remove the instrument wire clamp screw.

Remove the three screws attaching the
instruments to the handlebar rear cover.
Remove the instruments.

ASSEMBLY/INSTALLATION

The assembly and installation sequence is the
reverse of removal.

Clamp

Bulb Socket

Speedometer Cable

Bulb Socket

Screws

Instruments

Fuel Gauge Wires

Dimmer/
Passing Wires

Lighting/
Start Wires

Stop Light
Wires

Turn Signal
Wires

Clamp

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DISASSEMBLY

Remove the screws to disassemble the instruments.