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SK25AA 2009
Service Manual
257 pgs19.89 Mb0

KYMCO Downtown 125i 2009, SK25AA 2009 Service Manual

DOWNTOWN 125i
All rights reserved. Any reproduction or
permission of KWANG YANG Motor Co., Ltd.
By KWANG YANG Motor Co., Ltd.
1st Edition, April 2009
unauthorized use without the written
is expressly prohibited.
T100-LFA7-A2
PREFACE
C C
DOWNTOWN 125i
TABLE OF CONTENTS
This Service Manual describes the technical features and servicing procedures for the KYMCO
Downtown 125i.
Section 1 contains the precautions for all operations stated in this manual. Read them carefully before any operation is started.
Section 2 is the removal/installation procedures for the frame covers which are subject to removal/installation frequency during maintenance and servicing operations.
Section 3 describes the inspection/ adjustment procedures, safety rules and service information for each part, starting from periodic maintenance.
Sections 5 to 11 give instructions for disassembly, assembly and adjustment of engine parts. Section 13-14 is the AFI system. Section 15 to 16 is the removal/ installation of chassis. Section 17 to 20 states the testing and measuring methods of 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.
QUALITY TECHNOLOGY DEPT.
EDUCATION SECTION
GENERAL INFORMATION EXHAUST MUFFLER/FRAME
COVERS INSPECTION/ADJUSTMENT LUBRICATION SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES
ENGINE
CYLINDER/PISTON DRIVE AND DRIVEN PULLEYS FINAL REDUCTION A.C. GENERATOR/STARTER
CLUTCH CRANKCASE/CRANKSHAFT COOLING SYSTEM Fi DIAGNOSTIC TOOL OPERATION FUEL INJECTION SYSTEM
CHASSIS
HANDLEBAR/FRONT WHEEL/FRONT BRAKE/FRONT SHOCK ABSORBER/STEERING STEM
REAR BRAKE/REAR FORK/REAR WHEEL/REAR SHOCK ABSORBER`
ELE
EQUIPMENT
BATTERY/CHARGING SYSTEM
TRI
IGNITION SYSTEM
AL
STARTING SYSTEM LIGHTS/METERS/SWITCHES
1 2
3 4 5 6 7
8 9
10
11 12
13 14
15
16
17 18 19 20
1. GENERAL INFORMATION
DOWNTOWN 125i
ENGINE SERIAL NUMBER SPECIFICATIONS SERVICE PRECAUTIONS TORQUE VALUES
SPECIAL TOOLS....................................
ENGINE SERIAL NUMBER
...................................
..................................
................... 1- 1
.....................
LUBRICATION POINTS..........................1-14
1-12
Location of Engine Serial Number
1
-1-
1-1
1. GENERAL INFORMATION
SPECIFICATIONS
Name DOWNTOWN125i Model No. SK25AA Overall length 2200mm Overall width 800 mm Overall height 1410 mm Wheel base 1542 mm
Engine type Displacement 124.8cc Fuel Used 92# nonleaded gasoline
Front wheel 68
Net weight (kg) Rear wheel 96
Total 164
Front wheel 70
Gross weight(kg) Rear wheel 104
Total 178
Tires
RR Ground clearance 140 mm Perform- Braking distance (m)
ance
Engine
Min. turning radius 2600mm
Starting system Type Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere Valve arrangement O.H.C.4V Bore x stroke (mm) 54 x 54.5 Compression ratio 11.7:1
Compression pressure (kg/cm²)
Max .horsepower (ps/rpm) 15/8750~9000
Max. torque (kg m/rpm) 1.17/8500~8750
Port timing
Valve Intake 0.10 mm
Front wheel 120/80-14
Rear wheel 150/70-13
Intake (1mm) Exhaust (1mm)
Open 8 °BTDC Close 31° BTDC Open 32° BTDC Close 6 °BTDC
O.H.C.
7.9m/30km/h
Starting motor
liquid cooled 4 stroke
15
DOWNTOWN 125i
Air cleaner type & No Paper element, wet
Fuel System
Fuel capacity 12.5 L
Throttle type
Ignition System
Electrical Equip.
Battery Capacity 12V10AH
Power Drive System
Clutch Type Dry multi-disc clutch
Transmis-
sion Gear
Reduction
Gear
Front Caster angle 28°
Moving Device
Axle
Tire pressure (kg/cm²)1 person
Turning Left 40? angle
Brake system type
Damping
Device
Suspension type
Frame type PIPE UNDER BONE
Type
Spark plug
Sparkpluggap 0.6～0.7mm
Type Non-stage transmission
Operation
Type Two-stage reduction
Reduction 1st ratio
Trail length 140mm
2nd
Front 2.0 Rear 2.25
Right 40?
Front Disk brake Rear
Front Telescope
Rear DOUBLE SWING
Butterfly type
ECU
NGK CR7E
Automatic centrifugal
type
0.83~2.2
10.41
Disk brake
clearance Exhaust 0.10 mm
Idle speed (rpm) 1850rpm
Lubrication
System
Lubrication type
Oil pump type Inner/outer rotor type Oil filter type Full-flow filtration
Oil capacity 1.2 L
Exchanging capacity 1.0 L
Cooling Type Liquid cooling
Forced pressure &
Wet sump
-2-
1. GENERAL INFORMATION
SERVICE PRECAUTIONS
Make sure to install new gasket, 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 specified torque diagonally.
DOWNTOWN 125i
-
Use genuine parts and lubricants.
When servicing the motorcycle, be sure to use special tools for removal and installation.
After diassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly.
-3-
1-3
1. GENERAL INFORMATION
Apply or add designated greases and lubricants to the specified lubrication points.
After reassembly, check all parts for proper tightening and operation.
DOWNTOWN 125i
When two person 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.
-4-
1. GENERAL INFORMATION
If the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity.
After operation, terminal caps shall be installed securely.
DOWNTOWN 125i
Confirm Capacity
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.
-5-
1-5
1. GENERAL INFORMATION
The connector shall be inserted completely.
DOWNTOWN 125i
If the double connector has a lock, lock it at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
Check the double connector cover for proper coverage and installation.
click
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 contactthe wireharnesses.
-6-
1. GENERAL INFORMATION
After clamping, check each wire to make sure it is secure.
Do not squeeze wires against the weld or its clamp
DOWNTOWN 125i
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.
No contact !
Route wire harnesses passing through the side of bolts and screws. Avoid the projected ends of bolts and screws.
-7-
1-7
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.
DOWNTOWN 125i
Do not pull too tight!
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.
Do not press or squeeze the wire.
-8-
1. GENERAL INFORMATION
After routing, check that the wire harnesses are not twisted or kinked.
Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
DOWNTOWN 125i
Do you understand the instrument? Is the instrument set correctly?
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.
Remove Rust !
-9-
1-9
1. GENERAL INFORMATION
Symbols :
The following symbols represent the servicing methods and cautions included in this service manual.
DOWNTOWN 125i
Engine Oil
Grease
Gear Oil
Special
: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
.
-10-
1. GENERAL INFORMATION
TORQUE VALUES
STANDAR TORQUE VALUES
Item Torque (kg -f m) Item Tor (kg -que f m)
DOWNTOWN 125i
5mm bolt, nut 6mm bolt, nut
8mm bolt, nut 10mm bolt, nut 12mm bolt, nut
Torque specifications listed below are for important fasteners.
ENGINE
Item Qty Thread dia.(mm) Torque (kgf-m) Remarks
Cylinder head bolt A Cylinder head bolt B
Oil filter screen cap O2 sensor
Cylinder head cover Tappet adjusting hole cap Cam chain set plate Engine oil drain bolt Clutch outer nut
Clutch drive plate nut Starter motor mounting bolt
Oil pump bolt Drive face nut Spark plug
A.C. Generator flywheel
Cam chain tensioner pivot
0.45~0.6
0.8~1.2
1.8~2.5
3.0~4.0
5.0~6.0
5mm screw 6mm screw, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut
6 6
30 12
6
30
6 12 12 28
6
6 12 10
12
6
0.45~0.6
0.7~1.1
1.0~1.4
2.4~3.0
3.0~4.5
0.7~1.1
0.7~1.1
2.0~3.0
0.7~1.1
0.8~0.9
1.0~2.0
1.0~1.4
2.0~3.0
5.0~6.0
5.0~6.0
0.8~1.2
0.7~1.1
5.5~6.5
1.0~1.4
5.0~6.0
0.8~1.2
FRAME
Item Qty Thread dia.(mm) Torque (kgf-m) Remarks
Steering stem lock nut Front axle Rear axle nut
Rear shock absorber upper bolt
Rear shock absorber lower bolt Muffler exh. Pipe
-11-
Bc1
14 16 10 10
8
6.0~6.5
1.5~2.5 11~13
3.5~4.5
3.5~4.5
1.8~2.0
U - nut U - nut
1. GENERAL INFORMATION
SPECIAL TOOLS
Tool Name Tool No.
Flywheel puller
DOWNTOWN 125i
Illustration
(Note: the special tools may differ
slightly from those shown in the figure of this manual.)
(Refer to the “STARTER CLUTCH” section in the chapter
10.)
Oilsealandbearing installer
Universal holder
(Refer to the “DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY” section in the chapter
8.)
Flywheel holder
(Refer to the “STARTER CLUTCH” section in the chapter
10.)
A120E00003
A120E00014
A120E00017
A120E00021
Clutch spring compressor
(Refer to the “DRIVE PULLEY, DRIVE BELT AND DRIVEN PULLEY” section in the chapter
8.)
Valve adjuster
(Refer to the “VA LV E CLEARANCE”sectioninthe
chapter 3.)
A120E00034
A120E00036
(Cont’d)
-12-
1. GENERAL INFORMATION
SPECIAL TOOLS
Tool Name Tool No.
Bearing puller A120E00037
Valve spring compressor
DOWNTOWN 125i
Illustration
(Note: the special tools may differ
slightly from those shown in the figure of this manual.)
(Refer to the “CYLINDER
HEAD” section in the chapter 6.)
Lock nut wrench
(Refer to the “STEERING STEM” section in the chapter 15.)
Lock nut wrench
(Refer to the “STEERING STEM” section in the chapter 15.)
Bottom Ball Race
Remove
Cone Race Remove
(Refer to the “STEERING STEM” section in the chapter 15.)
special tool/ Top Ball
special tool
A120E00040
A120F00023
A120F00002
A120F00009
Bottom Ball Race
Install
Top Ball Cone Race
Install
(Refer to the “STEERING STEM” section in the chapter 15.)
-13-
special tool
special tool
A120F00019
1-13
1. GENERAL INFORMATION
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
DOWNTOWN 125i
Valve guide/valve stem movable part Cam lobes Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod/piston pin hole Connecting rod big end Crankshaft R/L side oil seal Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O-ring face Oil seal lip
Genuine KYMCO Engine Oil (SAE15W-40) API , SJ Engine Oil
Starter idle gear
Friction spring movable part/shaft movable part
Shaft movable grooved part
A.C. generator connector
Transmission case breather tube
High-temperature resistant grease
Adhesive
1-14
-14-
2
. EXHAUST MUFFLER/FRAME COVERS
DOWNTOWN 125i
2
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
2
EXHAUST MUFFLER/FRAME COVERS
__________________________________________________________________________________
SERVICE INFORMATION------------------------------------------------ 2- 1 TROUBLESHOOTING----------------------------------------------------- 2- 1 FASTENER REMOVAL AND REINSTALLATION------------------ 2- 2 FRAME COVERS REMOVAL/INSTALLATION--------------------- 2- 3 EXHAUST MUFFLER ----------------------------------------------------- 2-14
2-0
2
. EXHAUST MUFFLER/FRAME COVERS
DOWNTOWN 125i
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• When removing frame covers, use care not to pull them by force because the cover joint claws may be damaged.
• Make sure to route cables and harnesses according to the Cable & Harness Routing.
TORQUE VALUES
Exhaust muffler pipe nuts 1.8~2.2 kgf-m Exhaust muffler brake /RR Frok 3.2~3.8 kgf-m
RR/Engine case 3.0~4.0 kgf-m
TROUBLESHOOTING
Noisy exhaust muffler
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
Lack of power
• Caved exhaust muffler
• Clogged exhaust muffler
• Exhaust muffler air leaks
2-1
2
. EXHAUST MUFFLER/FRAME COVERS
FASTENER REMOVAL AND REINSTALLATION
REMOVAL
Depress the head of fastener center piece {. Pull out the fastener.
INSTALLATION
Let the center piece stick out toward the head so that the pawls | close.
Insert the fastener into the installation hole.
DOWNTOWN 125i
＊
To prevent the pawl | from damage, insert the fastener all the way into the installation hole
Push in the head of center piece until it becomes flush with the fastener outside face.
2-2
2
r
. EXHAUST MUFFLER/FRAME COVERS
FRAME COVERS REMOVAL/ INSTALLATION
SEAT
Unlock the seat with the ignition key. Open the seat.
Remove the two nuts and the seat.
Installation is in the reverse order of removal.
DOWNTOWN 125i
LUGGAGE BOX
Unlock the seat with the ignition key. Open the seat.
Remove four bolts, and the fastener on the right side of luggage box, then lift luggage box.
Disconnect the luggage box light connector, then remove the luggage box.
Installation is in the reverse order of removal.
Luggage Box Light Connecto
2-3
2
r
. EXHAUST MUFFLER/FRAME COVERS
DOWNTOWN 125i
CENTER COVER
Remove the luggage box.
Remove the center cover.
＊
During removal, do not pull the joint claws forcedly to avoid damage.
Installation is in the reverse order of removal.
Center Cove
Remove four bolts and , then remove the rear carrier.
2-4
2
. EXHAUST MUFFLER/FRAME COVERS
Installation is in the reverse order of removal.
DOWNTOWN 125i
UPPER/LOWER HANDLEBAR COVER
Remove the four screws. then remove upper handlebar cover.
Remove the four screws, then remove the bottom handlebar cover.
Disconnect the throttle cable refer to the “THROTTLE BODY /TPS” section , then pull the throttle cable out from the lower cover. Remove the lower cover.
Installation is in the reverse order of removal.
2-5
2
. EXHAUST MUFFLER/FRAME COVERS
WINDSHIELD/WINDSHIELD GARNISH
Remove five bolts and windshield garnish.
DOWNTOWN 125i
2-6
2
. EXHAUST MUFFLER/FRAME COVERS
FRONT CENTER COVER
Remove the windshield Remove four screws, then remove the front
center cover. Remove the front cover.
Installation is in the reverse order of removal.
FRONT COVER
Remove the small front cover(black) screw
DOWNTOWN 125i
Remove the small front cover(black) Remove two nuts.
Remove eight screws from the inner cover. Remove the front cover
2-7
2
. EXHAUST MUFFLER/FRAME COVERS
Disconnect the headlight/position light connect and right/left turn signal light connectors.
Installation is in the reverse order of removal.
FRONT FENDER
DOWNTOWN 125i
Remove four screws. screws and front fender. Installation is in the reverse order of removal.
RIGHT/LEFT FOOT SKIRT
Remove the six screws attaching to the right or left skirt.
＊
During removal, do not pull the joint claws forcedly to avoid damage.
Installation is in the reverse order of removal.
2-8
2
. EXHAUST MUFFLER/FRAME COVERS
DOWNTOWN 125i
FRONT LOWER COVER
Remove the front cover Remove the foot skirt
Remove seven screws and front lower cover.
Installation is in the reverse order of removal.
REAR FENDER
Remove the body cover and then the rear fender .
Installation is in the reverse order of removal.
BODY COVER
Remove the rear center cover. Remove the right and left foot skirts
Remove the rear carrier.
Remove six screws and two nuts then remove the body cover.
2-9
2
r
. EXHAUST MUFFLER/FRAME COVERS
DOWNTOWN 125i
Disconnect the taillight connector.
Installation is in the reverse order of removal.
TIRE FENDER
Remove the body cover .
Remove four bolts attaching to the tire fender
Taillight Connecto
Installation is in the reverse order of removal.
FLOORBOARD
Remove the body cover Remove the right /left skirt
Remove two screws.
2-10
2
. EXHAUST MUFFLER/FRAME COVERS
Remove eight bolts, then remove the floorboard.
DOWNTOWN 125i
UNDER COVER
Remove four bolts Remove the under cover.
2-11
2
. EXHAUST MUFFLER/FRAME COVERS
Remove the fuel tank cap cover.
Installation is in the reverse order of removal.
Speedometer Wires
METER PANEL
DOWNTOWN 125i
Disconnect the speedometer wires. Disconnect the DC power connectors.
Remove one screws Remove the ignition key garnish Remove three screws from the inner cover,
then remove the handler panel.
Installation is in the reverse order of removal.
DC power Connectors
2-12
2
. EXHAUST MUFFLER/FRAME COVERS
INNER COVER
Remove the front cover . Remove the front lower cover . Remove the floorboard
Remove four bolts and front glove box one screw.
DOWNTOWN 125i
(1)
Remove two fastener bolts then remove the fuel tank fill cap. Remove the inner cover
(3)
(4)
(2)
(2)
(5)
2-13
(6)
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