SUPER8
50/125
DRIVER'S MANUAL
KWANG YANG MOTOR CO.,LTD.
KWANG YANG MOTOR CO.,LTD.
KWANG YANG MOTOR CO.,LTD.
NO.35 Wan Hsing Street, San Min District
NO.35 Wan Hsing Street, San Min District
Kaohsiung, Taiwan, Republic of PROC
Kaohsiung, Taiwan, Republic of PROC
Telephone : 886-7-3822526
Telephone : 886-7-3822526
FAX : 886-7-3950021
FAX : 886-7-3950021
Dear KYMCO Scooter Users:
Thank you for purchasing this KYMCO scooter and welcome to the
family of KYMCO scooter riders. To enjoy safer and more pleasant
riding, become thoroughly familiar with this owner's manual before you
ride the scooter. You safety depends not only on your own alertness
and familiarity with the scooter but also the scooter mechanical
condition. A pre-ride inspection before every outing and regular
maintenance are essential. The quality of each KYMCO scooter is
guaranteed.
Note: 1. The information and specifications stated in this manual are for
reference only and subject to change without notice.
2. When starting the engine, the battery must be installed to
facilitate starting and increase the engine performance.
TABLE OF CONTENTS
1.PRECAUTIONS FOR A SAFE RIDING
2.PARTS LOCATION
FRAME NUMBER
ENGINE NUMBERKEY NUMBER
3.OPERATION INSTRUCTIONS
IGNITION SWITCH/STEERING HANDLEBAR LOCK
ELECTRIC STARTER BUTTONHEADLIGHT SWITCH
HEADLIGHT DIMMER SWITCH/PASSING SIGNAL SWITCH
HORN BUTTON/TURN SIGNAL SWITCH
SEAT LOCK/MET-IN BOX
HELMET HOLDER
INSTRUMENTS AND INDACATORS
4.PRE-RIDE INSPECTION
ADVANCE INSPECTIONENGINE OIL LEVEL INSPECTION/REFILLING
BACK STEP USE
TIRE INSPECTION
1 1
3 3
7 7
8 8
9 9
9 9
10 10
11 11
12 12
1313
1313
1414
1616
1616
1818
19 19
FUEL LEVEL INSPECTION/REFILLING
STEERING HANDLEBARINSTRUMENT LIGHTS INSPECTION
BRAKE FLUID LEVEL INSPECTION
BRAKE PAD WEARBRAKE SHOE WEAR
BRAKE LEVER FREE PLAY INSPECTION & ADJUSTMENT
HORN/LIGHT INSPECTION
FRONT/REAR SHOCK ABSORBER INSPECTIONBRAKE PERFORMANCE
INSPECTIONBACK MIRROR ANGLE CHECKLICENSE PLATE CHECK
REFLECTOR CHECKPREVIOUS ABNORMAL PARTS INSPECTION
LUBRICATION POINT CHECK
TABLE OF CONTENTS
21 21
22 22
23 23
24 24
25 25
27 27
28 28
5.ENGINE STARTING METHODS
6.NORMAL RIDING METHOD
7.PRECAUTIONS FOR RIDING
8.HOW TO STOP RIDING
9.EASY MAINTENANCE
AIR CLEANER CLEANING & REPLACEMENT
APPEARANCE CLEANING
29 29
33 33
35 35
3939
4141
4141
4343
TABLE OF CONTENTS
BATTERY
FUSE CHANGE
TRANSMISSION GEAR OIL
SPARK PLUG INSPECTION
BRAKE FLUID LEVEL INSPECTION/REFILLINGRUBBER COVER
INSPECTION FOR WIRE AND CABLE
10.IMPORTANT NOTICES
10.IMPORTANT NOTICES
POLLUTION-FREE PERIODIC MAINTENANCE SCHEDULE
SPECIFICATIONS
11.KYMCO CLEAN AIR SYSTEM (FOR EURO 2)
44 44
46 46
48 48
49 49
50 50
51 51
52 52
53 53
54 54
1.PRECAUTIONS FOR A SAFE RIDING
(1) CLOTHES
To relax and wear comfortable clothes are the main
points for a safe riding.
To observe traffic laws, keep a cool mind, relax and be
careful will provide you a safe riding.
(1) Wear helmet and fasten it tightly.
(2) Have the clothes well-arranged. Fasten shirt cuffs
and keep them from hooking the brake lever.
(3) Wear low-heeled shoes for a safe riding.
(4) When riding, use both hands to grasp the handlebar.
it is very dangerous to hold the handlebar with one
hand.
CAUTION:
A scooter rider should not wear loose or too long
clothes to avoid danger.
During riding or 10 minutes after the scooter is
stopped, do not touch the exhaust muffler to avoid
scalding.
When parking the scooter, keep it away from dry
lawn or inflammables to avoid danger.
(4)
(2)
(1)
(3)
⌒1⌒
(2) RIDING METHOD
The safety of two-wheel vehicles is influenced by sitting
position. The rider should sit on the central part of the
seat cushion. If the rider sits on the rear part of the seat,
the load of front wheel will decrease. As a result, the
handlebar will swing and cause danger to the rider.
When making a turn, it will be easier for the rider to
steer the scooter by leaning the body inward slightly.
The scooter will lose its balance if the rider fails to
keep his body leaning inward.
When riding on a damaged or macadam road. Slow
down the speed and hold the handlebar tightly.
(3) CARRYING GOODS
Keep a good sitting posture to operate the scooter
properly.
The feel of the handlebar will be different when carrying
goods on the scooter. Overloading may cause the
handlebar to swing. Avoid riding with overload.
(1) Max. loading capacity of the met-in box is 10kg.
(2) Max. loading capacity of the rear carrier is 5kg.
⌒2⌒
(1)
(2)
2. PARTS LOCATION
(1) Headlight switch (P.10)/
Electric starter button (P.10)
(2) Tun right signal indicator light
(P.15)
(3) Speedometer (P.14)
(4) Tun left signal indicator light (P.15)
(5) Headlight dimmer switch (P.11)/
Passing signal switch (P.11)/Turn
signal switch (P.12)/Horn
button(P.12)
(2)(3)(4)(5) (1)
⌒3⌒
(1) Seat lock (P.13)
(2) Fuel fill cap (P.21)
(3) Met-in box (P.13)
(4) Helmet holder (P.13)
(5) Center hook
(6) Side stand
(7) Main stand
(8) Kickstarter pedal (P.32)
(9) Air cleaner housing (P.41)
(3)(4)(5)
(6) (7) (8) (9)
(1)
(2)
⌒4⌒
(1) Ignition switch (P.9)
(2) Helmet holder (P.13)
(3) Engine oil tank cap (P.16)
(3)
(2)
(1)
⌒5⌒
(1) Low oil level indicator (P.15)
(2) Rear brake lever (P.25)
(3) Battery (P.44)/Fuse (P.46)
(4)
Throttle grip
(5)
Front brake lever
(6) High beam indicator light (P.25)
(3) (1)
(2)
⌒6⌒
(4)
(5)
(6)
FRAME NUMBER
The read frame number, please remove the cover on
inner cover with a flat head screwdriver.
Always check that the frame number stamped on
your scooter is the same written in document and
warranty scooter is the same written in document
and warranty card.
Please write down your frame number in place below.
FRAME NUMBER:
ENGINE NUMBER
The engine number is stamped on right engine case.
Please write down your engine number in place
below.
ENGINE NUMBER:
KEY NUMBER
The key number (1) will be needed when you order
replacement part. Record the number for your
reference.
KEY NUMBER:
(1)
⌒8⌒
3. OPERATION INSTRUCTIONS
(1) IGNITION SWITCH/STEERING HANDLEBAR LOCK
(1) ON : At this position, power is connected to start
the engine. The key cannot be taken out.
(2) OFF : At this position, power is cut off and the
engine stops. The key can be taken out.
(3) LOCK : At this position, the steering handlebar is
locked. The key can be taken out
Locking Method
Turn the steering handlebar left to the full and then push
and turn the ignition switch key left to the "LOCK"
position the handlebar can be locked.
Unlocking Method
Turn the ignition switch key right to the"OFF" and the
"LOCK" is released automatically.
CAUTION:
After locking, turn the handlebar gently to make
sure that it is locked.
Do not turn the ignition switch to the"LOCK"
position during riding, otherwise the handlebar
will be out of control and cause accidents.
Don't park your scooter at a place to hinder the
traffic.
(2)
(3)
(1)
⌒9⌒
(2) ELECTRIC STARTER BUTTON " "
To start the engine, first turn on the ignition switch
"ON "and then push the electric starter button. At
this time, be sure to fully apply the front or rear brake
lever in order to connect the power.
CAUTION:
During engine running, do not push the electric
starter button to avoid engine damage.
Turn the headlight switch off and turn signal
switch off before using the electric starter button.
Release the electric starter button immediately
after the engine is started.
(3) HEADLIGHT SWITCH
At this position, the position light, headlight,
instrument lights and taillight turn off together.
At this position, the position light, instrument lights
and taillight light turn on.
At this position, the position light, headlight,
instrument lights and taillight light all turn on.
⌒10⌒⌒10⌒
(4) HEADLIGHT DIMMER SWITCH/PASSING
SIGNAL SWITCH
(1)
Switch to this position for using high beam.
(2)
When riding in downtown area or there is a
car coming from the opposite direction, use
low beam to avoid affecting the visibility of
coming cars.
CAUTION:
This indicator light comes on when the long
distance light is turned on.
(2)
(1)
PAS
SING
PASSING
When passing, if there are cars coming
from the opposite direction, press and
release the PASSING switch and the
headlight will wink to warn the coming
cars.
⌒11⌒
PA
SS
IN
G
(5) HORN BUTTON " "/TURN SIGNAL SWITCH
When the ignition switch key is turned the"ON"
position, push the horn button and it will sound.
Move the turn signal switch to (1) For turning to the
right. (2) For turning to the left. (3) Push the turn
signal switch button to release it.
(4) Horn Button.
The horn and turn signal switch do not work when the
ignition switch is the"OFF".
CAUTION:
The turn signal light will not release automatically.
Be sure to reset it after use; otherwise it may
affect the traffic safety.
(2)
(3)
(4)
PAS
S
ING
(1)
⌒12⌒
(6) SEAT LOCK/MET-IN BOX
Unlock the seat and put the helmet in the MET-IN box.
Unlocking Method
Stop the engin and turn the ignition switch to the "OFF"
position. Insert the ignition switch key into the seat lock
and turn it clockwise..
To lock the seat, push on it until it lock automatically.
Make sure the seat is secure before riding.
CAUTION:
Never put the key inside the seat cushion to lock
the seat.
(7) HELMET HOLDER
1.Open the seat with the ignition switch key and lift up the
seat.
2.Put the helmet retaining ring into the helmet holder.
3.Put down the seat and it will lock automatically.
Take out the helmet in the reserve order of the above
steps.
CAUTION:
When riding, wear the helmet and do not retain it
on the scooter; the helmet may interfere with safe
operation and result in loss of control.
⌒13⌒
(8) INSTRUMENTS AND INDACATORS
(1) FUEL GAUGE: The fuel gauge is to show the
volume of gasoline in the fuel tank. If the fuel
gauge pointer is at the "E" area, the fuel is
insufficient. Refill 92# or 95# nonleaded gasoline
as early as possible.
(2) SPEEDOMETER (km/hour): The riding speed is
indicated by km/hour.
(3) SPEEDOMETER (mph): The riding speed is
indicated by mph.
(4) ODOMETER: The total riding mileage is
indicated by kilometer. The figure in black and
white is an unit of 100m.
(5) CLOCK METER: It displays time and date which
can be adjusted manually.
(6) ADJUST KEY: They are used to correct time and
date.
(5)
(3)
(6)
(2)(4)
(1)
⌒14⌒
(7) TURN SIGNAL INDICATOR LIGHT(LEFT): When
the turn signal switch is operated, this indicator
light will wink.
(8) LOW OIL LEVER INDICATOR: When the ignition
switch is "ON", it is normal if the low oil lever
indicator light comes on for several seconds and
then goes out. If the light does not go out, it means
that the 2-stroke engine oil is insufficient. Please
refill with the specified engine oil.
(9) HIGH BEAM INDICATOR LIGHT: This indicator
light comes on when the long distance light is
turned on.
(10) TURN SIGNAL INDICATOR LIGHT(RIGHT):
When the turn signal switch is operated, this
indicator light will wink.
(7)(7) (8)(8)
(9)(9)
(10)(10)
⌒15⌒
4. PRE-RIDE INSPECTION
(1) ADVANCE INSPECTION
Get into a good habit of inspection before riding. For the
sake of safety and to prevent vehicle damage and traffic
accidents, the pre-ride inspection is absolutely required.
CAUTION:
Be sure to perform inspection and maintenance
for your new scooter after it is ridden for 300km.
(2) ENGINE OIL LEVEL INSPECTION/REFILLING
:
When the low oil level indicator lights, it means the oil
level in the oil tank is low; stop the engine and fill the oil
tank as soon as possible.
To fill, lift the seat (page 13), remove the cap (1) from
the oil tank.
(1)
⌒16⌒
Fill with the recommended oil up to the upper level
mark (2).
Oil recommendation:
Use KYMCO 2-stroke oil or its equivalent.
CAUTION:
If the low oil level indicator comes on while riding,
stop riding and shut the engine off. Fill the oil tank
to the upper level mark with the recommended oil .
Continuing to ride with a low oil level may lead to
engine failure that could result in an accident.
If the engine has been run after the low oil level
indicator has come on, the scooter must be taken
to an authorized KYMCO dealer for inspection and
bleeding of the oil system. Failure to do this will
result in serious engine damage.
The use of improper oils may cause excessive
and/or premature carbon build-up in the engine
and exhaust system, resulting in loss of power
and possible engine damage.
When filling, do not let dirt or other foreign
materials enter the tank.
(2)
⌒17⌒
(3) BACK STEP USE
1. When using it, pull the back steps lever
butteon,to back steps lever flick.
2.When not using it, push the back steps
lever,comeback it to original position.
⌒18⌒
(4) TIRE INSPECTION
1.Tire Pressure Check
Check if the tire pressure is normal when the tire is in
contact with level ground.
If there is any abnormal condition, check the tire
pressure with a tire pressure gauge.
Measure the tire pressure under room temperature.
The tire pressure must not overpass 2.50kg/cm
2
NORMAL PRESSURE(1 Rider / 2 Riders )
Front Wheel
Rear Wheel
1.5/2.0 kgf/cm
1.75/2.25 kgf/cm
2
2
⌒19⌒
2. Cracks & damage
Check the tire-contact area for crack or damage.
3. Abnormal wear
Check the tire-contact area for abnormal wear.
4. Foreign objects of metal piece & gravel
Check the tires and tire-contact area for imbedded
objects of metal piece and gravel.
5. Depth of tire groove
If the tire is worn to the wear limit indication mark,
Replace it with a new one.
CAUTION:
Abnormal tire pressure, crack, damage and
abnormal wear will cause unsteady handlebar and
result in tire break.
If the tire has cracks or is worn to the wear limit
indication mark, replace it with a new one.
4.
5.
5.
2.
3.
2.
⌒20⌒
(5) FUEL LEVEL INSPECTION/REFILLING
Check if the fuel is sufficient.
If the fuel gauge pointer is at "E" grid, refill #92 or #95
nonleaded gasoline as soon as possible.
Refilling Method
1.Lift the seat (page 13), then remove the fuel fill cap
(1) by turning it counterclockwise.
2.After refueling, be sure to tighten the fuel fill cap
firmly by turning it clockwise. Make sure that the allow
marks (2) on the fuel fill cap and fuel tank is aligned.
CAUTION:
Use unleaded fuel only because it produces fewer
engine and spark plug deposits and extends the life of
the exhaust system.
Do not overfill the tank (there should be not fuel in the
filler neck (3) after refueling, make sure the fuel fill cap
is closed securely.
(2)
(1)
(3)
⌒21⌒
(6) STEERING HANDLEBAR
Visually inspect the steering handlebar for damage.
Apply the front brake and move the handlebar upward
and downward to check for abnormal noise.
Move the steering handlebar upward, downward,
rightward and leftward to check for any loose parts.
Check if the handlebar rotates freely.
If any abnormal condition is found, go to your scooter
dealer or for inspection.
(7) INSTRUMENT LIGHTS INSPECTION
Check the turn signal indicator lights and high beam
indicator light for proper operation.
Check the speedometer for proper operation.
Check the fuel gauge for proper operation.
Check the low oil lever indicator light for proper
operation.
⌒22⌒
(8) BRAKE FLUID LEVEL INSPECTION
Check if the fluid level is below the lower level mark
through the inspection window.
CAUTION:
As the brake pads wear, brake fluid level drops,
automatically compensating for wear. There are
no adjustments to perform, but fluid level and pad
wear must be inspected periodically. The system
must be inspected frequently to ensure there are
no fluid leaks.
If the brake lever travel become excessive and the
brake pads are not worn beyond the recommended
limit, There is probably air in the brake system and
it must be bled. See your authorized KYMCO dealer
for this service.
To prevent damage to the brake system, use only
fluid from a sealed container. Never allow
contaminants (dirt, water, etc.) to enter the brake
fluid reservoir.
Brake fluid can damage paint and plastic, so
handle the fluid with care. When adding brake
fluid, be sure the reservoir is horizontal before
removing the cover to prevent accidental spilling.
Use only DOT 4 brake fluid from a sealed container.
⌒23⌒
(9) BRAKE PAD WEAR
Check the wear indicator mark on each pad.
If either pad is worn to the wear indicator mark, replace both
pads as a set. See your authorized KYMCO dealer for this
service.
(10) BRAKE SHOE WEAR
The rear brake is equipped with a brake wear indicator.
When the brake is applied, an arrow mark (1) attached to
the brake arm moves toward a reference mark (2) on the
brake panel. If the arrow mark aligns with the reference
mark on full application of the brake, the brake shoes
must be replaced. See your authorized KYMCO dealer
for this service.
⌒24⌒
(2)
(1)
(11) BRAKE LEVER FREE PLAY INSPECTION &
ADJUSTMENT
The rear brake lever free play should be adjusted to
10~20mm (0.4~0.8 in) at the tip of the brake lever. If the
free play is incorrect, adjust as follows:
Place the scooter on its main stand.
Turn the adjusting nut in direction (A) to decrease play,
and in direction (B) to increase play.
Turn the adjusting nut on the brake hub in direction
(A) to decrease play, and in direction (B) to
increase play.
1~2cm
(A)
(B)
(1)
⌒25⌒
CAUTION:
Make sure the cut-out on the adjusting nut (2) is
seated on the brake arm pin (1) after making final
free play adjustment.
⌒26⌒
(1)
(2)
(12) HORN/LIGHTS INSPECTION
Turn the ignition switch to the "ON" position and push
the horn button to check if it sounds.
Headlight/Taillight Inspection:
Start the engine and turn on the headlight switch to
check if the headlight and taillight are good and check
the light shells for dirt and damage.
Stoplight Inspection:
Apply the front and rear brake levers respectively to
check if the stoplight is good. And also check the stop
light shell for dirt and damage.
Turn Signal Light Inspection:
Operate the turn signal switch to make sure whether
the right/left front and rear turn signal lights can wink
and buzz. Also check the light shells for dirt and damage.
(1)Headlight (2)Taillight/ Stoplight (3)Turn signal light
(4)Horn button
CAUTION:
Replace any dirty or damaged lights with new
ones to avoid danger during riding.
(3)
(1)
(2)
A
S
SINGP
⌒27⌒
(13) FRONT/REAR SHOCK ABSORBER INSPECTION
Check the condition of the front/rear shock absorbers
by pressing down on the handlebar and seat several
times.
(14) BRAKE PERFORMANCE INSPECTION
Fully apply the front and rear brake levers and move
the scooter forward to see if the braking effect is
good.
(15) BACK MIRROR ANGLE CHECK
Sit on the scooter uprightly and make a viewing
test of the rear mirror angle.
(16) LICENSE PLATE CHECK
Check the license plate for dirt and damage, then
tighten it.
(17) REFLECTOR CHECK
Check the reflector for dirt and damage.
(18) PREVIOUS ABNORMAL PARTS INSPECTION
Make sure that the previous abnormal parts are
repaired.
(19) LUBRICATION POINT CHECK
Visually check if all motorcycle lubrication points are
lubricated properly.
⌒28⌒
Oil
5. ENGINE STARTING METHODS
(1) TURN THE IGNITION SWITCH "ON"
Unlock the steering handlebar.
Turn the ignition switch to the "ON" position.
CAUTION:
Check the gasoline volume and engine oil level
before starting the engine.
Be sure to erect the main stand while starting the
engine and side stand is up.
Before starting the engine, the side stand shall be
kicked up to secure safety.
(2) LOCK THE REAR WHEEL
Apply the brake lever to connect the power for
starting.
CAUTION:
In order to prevent the scooter from rushing out at
high speed, make sure to lock the rear wheel.
If free play of the rear brake lever is incorrect, the
rear wheel cannot be braked and it will cause
danger easily.
⌒29⌒
(3) USE THE ELECTRIC STARTER BUTTON
Push the electric starter button without rotating the
throttle grip.
If the engine fails to start after the electric starter button
is pressed for 3~4 seconds when it is warm, rotate the
throttle grip for 1/8~1/4 turn to facilitate starting.
When the scooter is not used for a long time or the
fuel tank is empty, if the engine is still hard to start after
the fuel tank is refilled with gasoline, slightly turn the
throttle grip and push the electric starter button for
several times to start the engine.
In order to avoid battery overcharge, do not push the
starter button more than 5 seconds.
If the engine does not start after the electric starter
button is pushed for 5 seconds, wait for more than 5
seconds and then push the button again.
1/8~1/4
⌒30⌒
CAUTION:
Don't push the electric starter button while the
engine is running; otherwise the engine will be
damaged.
When starting the engine, the rear brake lever
must be applied to connect power and the
stoplight will come on when power is connected.
⌒31⌒
(4) START WITH THE KICK PEDAL
1.Place the scooter on its main stand on level ground.
2.Depress the kick pedal with force.
When the engine is cold and does not start after the kick
pedal is depressed for 3~4 times, rotate the throttle grip
for 1/8~1/4 turn to facilitate starting.
Warm up the engine for a little while (about 2°3 minutes)
after cold start.
After the engine is started, do not accelerate suddenly
and keep riding at low speed to prolong the engine
service life.
CAUTION:
After the engine is started, the kick pedal must be
returned to its original position.
The exhaust contains poisonous carbon monoxide
which is harmful to human body. Never run the
engine in a closed area.
Turn off all light switches before starting the
scooter.
1/8~1/4
⌒32⌒
6. NORMAL RIDING METHOD
(1) STARTING THE ENGINE
Start the engine by referring to the starting methods
specified in Section 5.
CAUTION:
Keep your finger away from the button immediately
after the engine is started to avoid engine damage.
The rear brake lever should be kept at the braking
position before riding.
(2) REBOUND THE MAIN STAND
Keep the rear brake lever at braking position and
push the scooter forward, then the main stand will
rebound automatically.
CAUTION:
After starting the engine and before moving, do not
turn the throttle grip to increase the engine rpm.
⌒33⌒
(3) CORRECT SITTING POSITION
Ride astride on the scooter from the left side and
sit upright. Touch the ground with left foot to avoid
slipping.
CAUTION:
The rider must wear helmet, gloves and goggles.
Do not wear any clothes which will affect riding
safety.
(4) ROTATE THE THROTTLE GRIP
Release the rear brake lever and slowly rotate the
throttle grip, then the scooter will move smoothly.
CAUTION:
After the rear wheel brake lever is released, do not
rotate the throttle grip suddenly to prevent the
scooter from rushing out.
During riding, do not accelerate or decelerate
rapidly and suddenly to save fuel and prolong the
scooter life.
⌒34⌒
7. PRECAUTIONS FOR RIDING
(1) CORRECT RIDING
Before moving, turn on the turn signal light and make
sure whether the rear side is safe.
Do not rush into the car lanes and always keep the
scooter to the right side to avoid danger.
CAUTION:
Moderate riding will prolong the engine service
life. The clutch linings are worn more quickly
when often ridden at low speed.
(2) SPEED CONTROL
The speed is controlled by the throttle grip.
(1) ROTATE:
The speed will become faster. Don't be hasty to
accelerate.
When riding on an ascending road, rotate the throttle
grip gradually to increase the horse power.
(2) RESTORE:
The speed will become slower. Restore the throttle
grip quickly.
CAUTION:
Apply the brake level while restoring the throttle
grip. This will shorten the time required to slow
down.
⌒35⌒
(2)
(1)
(3) PROPER RIDING WILL PROLONG THE ENGINE
LIFE
For a new scooter, keep the speed below 30km per
hour within the first 1000km of riding.
Avoid sudden acceleration and long-time riding at high
speed.
In hot weather, the engine overheats easily at long-time
idling. Stop the engine in this case.
CAUTION:
Moderate riding will prolong the engine life.
(4) APPLY BOTH FRONT AND REAR BRAKE
LEVELS WHEN BRAKING
First restore the throttle grip to the closed position and
then pull the brake levers tight.
The best way to brake the scooter is to pull the brake
levers "slowly" at the beginning, then pull them tight.
CAUTION:
Apply single brake lever will cause the scooter to
slip.
During riding, never brake the scooter suddenly.
It may cause the scooter to slip and could be very
dangerous.
⌒36⌒
30KM
(5) DO NOT MAKE SUDDEN STOP OR SHARP TURN
Sudden stop and sharp turn are the main causes for
slipping and could be very dangerous.
In rainy days the road is slippery. Sudden stop will
cause the scooter to slip. Be careful to avoid
danger.
When approaching a corner or turn, close the throttle
fully, and slow the scooter down by applying both front
and rear brakes at the same time.
After completing the turn, open the throttle gradually to
accelerate the scooter.
⌒37⌒
(6) BE MORE CAREFUL WHILE RIDING IN RAINY
DAYS
A longer braking distance is required in rainy days
than in sunny days. Be sure to slow down and brake
the scooter slowly as soon as possible.
When riding on a descending road, restore the throttle
grip to closed position and slow down by making
intermittent braking.
CAUTION:
A longer braking distance is required in rainy
days. Be sure to slow down and brake the scooter
slowly as soon as possible.
⌒38⌒
8. HOW TO STOP RIDING
(1) WHILE GO NEAR THE PARKING PLACE
Turn on the turn signal light in advance. Watch out
vehicles coming behind or aside and stop the scooter
to the right side slowly.
Restore the throttle grip to closed position and apply
the front and rear brake levels as soon as possible.
At this moment, the stoplight will come on to warn the
vehicles coming behind.
(2) WHILE THE SCOOTER IS COMPLETELY
STOPPED
Return the turn signal switch to its original position.
Turn the ignition switch key to the "OFF" position to
stop the engine.
CAUTION:
During riding, never operate the ignition switch key.
When the ignition switch key is turned to the"OFF"
position, the electric system does not work which
may result in traffic accident. Turn off the ignition
switch key after the scooter is fully stopped.
⌒39⌒
(3) PARKING
Place the scooter on its main stand on level ground
and do not hinder the traffic.
Stand on the left side and grip the handlebar straight
with left hand and the side rod or rear carrier with
right hand. Then, step down the main stand evenly
with right foot and pull the scooter backward by
force with right hand.
CAUTION:
The scooter may easily fall down if it is parked on
an uneven ground.
(4) HANDLEBAR
After parking, be sure to lock the steering handlebar
and take out the key to prevent pilferage. (Refer to P.9)
CAUTION:
Don't park your scooter at a place to hinder the
traffic.
The temperature of engine and exhaust muffler is
very high. Be careful to avoid scalding.
Park the scooter at a safe place and be sure to take
out the key to prevent pilferage.
⌒40⌒
9. EASY MAINTENANCE
(1) AIR CLEANER CLEANING & REPLACEMENT
1.Remove the air filter case cover by removing the 7
screws.
2.Remove the air cleaner (1).
(1)
⌒41⌒
3.Wash the air cleaner gently but thoroughly in solvent.
4.Squeeze the excess solvent out of the cleaner and let it
dry.
CAUTION:
Never use petrol or low flash point solvents for
cleaning the air cleaner.
A fire or explosion could result.
Do not twist the air cleaner when squeezing it.
5.Inspect the element. If damaged, replace it.
6.Soak the air cleaner in gear oil (SAE80~90) until
saturated, then squeeze out the excess oil.
7.For installation, reverse the removal procedures.
CAUTION:
The air cleaner should be wet but not dripping.
⌒42⌒
(2) APPEARANCE CLEANING
Often wipe clean the scooter appearance to
prevent accumulated dust affecting the function of
components.
CAUTION:
If a scooter is not used for a long time, check the
operation of each part and replace lubricants
before riding. Ride the scooter only after its
performance is confirmed.
When waxing the scooter, make sure that the
ingredients of the wax will not damage the paint
of the scooter.
⌒43⌒
(3) BATTERY
Battery remove
1. Make sure the ignition switch is OFF.
2. Remove the screw (1).
3. remove the battery cover (2) .
(2)
(1)
4. Disconnect the negative (-) terminal lead (1) from the
battery first, then disconnect the positive (+) terminal
lead (2).
5. Remove the battery.
⌒44⌒
(2)
(1)
This model adopts the battery which needs no refilling
of distilled water.
When cleaning the terminals, remove the screws
attaching the battery cover on the footboard and then
open the battery cover.
When battery terminals are corroded, take out the
battery for cleaning.
After cleaning, apply a thin coat of grease or vaseline
to battery terminals and then install the battery.
CAUTION:
Never open the closed-type battery electrolyte cap.
If the scooter will not be used for a long time, the
battery will discharge electricity by itself. Remove
the battery and put it in a cool place after it is fully
charged to prevent electricity leakage.
If the scooter will not be used for a long time,
remove the negative (-) terminal.
Do not smoke or allow flames or sparks near the
battery while removing and installing it.
Turn off the ignition switch before removal or
installation.
The negative (-) terminal shall be removed first
and the positive (+) terminal shall be installed first.
Tighten the loose terminal nuts securely.
⌒45⌒
Battery Charger
(4) FUSE REPLACEMENT
(1)
(2)
When frequent fuse failure occurs, it usually indicates a
short circuit or an overload in the electrical system. See
your authorized KYMCO dealer for repair.
The fuse holder (1) is located in a compartment under
the battery cover.
The specified fuses are: 7A/7A/10A
The spare fuse (2) is on the battery compartment.
CAUTION:
To prevent accidental short-circuiting, turn off the
ignition switch before checking or replacing a fuse.
Fuse replace:
1. Remove the battery cover, by removing the screw.
(See page 44)
2. Open the fuse holders (1) and lift out the fuse with
the clips (2).
(2)
(2)
(1)
(1)
⌒46⌒
(1)
(2)
3. Slide the old fuse out of the clips and discard it.
4. Slide the clips (2) onto the ends of the new fuse,
push them back into the fuse holder (1), and close
the fuse holder.
The spare fuse is on the battery compartment.
CAUTION:
Do not pry the clips open to get a fuse out; you
could bend them and cause poor contact with the
new fuse. A loose fuse could cause damage to the
electrical system and even start a fire.
After replacing the fuse, be sure return the fuse
holder to its original location
⌒47⌒
(5) TRANSMISSION GEAR OIL
Transmission oil measurement:
1.Place the scooter on its main stand on level ground.
After the engine stops for 2~3 minutes.
Remove the oil filler bolt (1) and check the oil level (2).
2.
3.Add fluid of the specified type and amoumt through the
fluid filler hole with a measuring glass,or the transmission
fluid will be over filled probably.
Recommended Gear Oil: SAE #90
Capacity / Exchanging Capacity: 0.12L / 0.09 L
CAUTION:
After refilling, use a rag to wipe clean.
Excess or insufficient gear oil will affect the engine
performance.
Never use gear oil of different brand or inferior
quality which may result in engine breakdown.
Change gear oil at first 300km and then change at
every 4000km. Add specified gear oil whenever it is
necessary.
(2)
(2)
(1)(1)
⌒48⌒
(6) SPARK PLUG INSPECTION
Check the spark plug side electrodes for wear.
Fouling deposits on spark plug electrodes and big gap
may result in weak spark.
Spark Plug Removal:
1.Remove the spark plug with a spark plug remover.
2.The installation sequence is the reverse of removal.
Spark Plug Cleaning:
1.It is better to remove spark plug deposits with a spark
plug cleaner.
2.If a spark plug cleaner is not available, clean with a
wire brush.
The side electrode gap is 0.6°0.7mm.
Specified Spark Plug: NGK-BR8HSA
(1) Decarbonizing Fouling Deposits (2) Gap
(3) Wear (4) Crack/Damage
CAUTION:
Clean the spark plug at every 2000km and replace it
with a new one at every 5000km or when the center
electrode is burned out.
First screw in the spark plug with fingers and then
tighten with a spark plug wrench.
Use unspecified spark plug may damage the engine.
(3)
(1)
(2)
(4)
⌒49⌒
(7) BRAKE FLUID LEVEL INSPECTION /REFILLING
Add recommended brake fluid DOT 4 into the tank until
the fluid level reaches the upper limit and then put on
the cover and tighten the screws.
Recommended Brake Fluid: DOT 4
CAUTION:
Do not mix brake fluid of different brands. It may
cause brake failure and is very dangerous. When
refilling brake fluid, use towels to cover and
protect the painted and coated surfaces. (Replace
at 10000km or every year.)
(8) RUBBER COVER INSPECTION FOR WIRE AND
CABLE
The cable cores are protected by the rubber cover
outside the connector. Check the rubber cover
frequently for proper installation.
When washing the scooter, do not flush the rubber
cover directly or brush it. Use a wet rag to wipe off dirt
and dust.
Rubber Cover
Check Points
(2)
(1)
⌒50⌒
10. IMPORTANT NOTICES
(1) WHEN THE ENGINE FAILS TO START OR STOPS
DURING RIDING
Is the gasoline enough?
If the fuel gauge pointer is at the red line, refill #92 or
#95
nonleaded gasoline.
Is the way to start the engine correct?
Is there any other faulty parts?
(2) IN CASE OF BREAKDOWN
For any trouble occurred during riding, go to a KYMCO
distributor or service station for inspection.
CAUTION:
For the sake of safety and to prevent vehicle
damage and save your precious time, the pre-ride
inspection is absolutely required. Please read this
User's Manual carefully and get into a good habit
of inspection before riding.
⌒51⌒
(3) POLLUTION-FREE PERIODIC MAINTENANCE SCHEDULE
In order to have a safe riding, maintain good performance, prolong the scooter service life and
reduce pollution, make sure to perform the periodic inspection and maintenance.
I: Inspect and clean, lubricate, refill, repair or replace if necessary.
A: Adjust C: Clean R: Replace T: Tighten
Item
Engine Oil
Engine Oil Strainer
Gear Oil
Cooling Water
Spark Plug
Valve Clearance
Carburetor
Drive Belt
Drive Chain
Air Cleaner
Battery Electrolyte
Fuel Filter Screen
Brake System
Clutch Lever Free Play
Bolts & Nuts
Tire Pressure
Motor Oil Strainer
Engine Oil Pump
2Stroke
4Stroke
300
1000
R R R R R R R
C C C C
Replace at every 10000 km or once a year it at every 5000 km.
Clean ( C ) at every 2000km and replace ( R ) at every 5000 km.
A A A
A A A A A A A
T T T
I I I I
Regular Service Mileage (KM)
3000
5000
7000
RRR
9000
11000
13000
R
A
I
II
I I
A A A AAAA
R
RR
III
IIIII
R
I
I I I I I I
I I I I I I I
R
The above items are applicable to different models. Perform suitable items for each model.
When exceeding the listed mileage, perform maintenance according to the listed intervals.
The air cleaner requires more frequent cleaning or replacing when ridden in unusually dusty areas.
I
II
Daily Preride
Inspection
I
I
I
I
I
⌒52⌒
(4) SPECIFICATIONS
Engine Type
Displacement (cc)
Bore x Stroke (mm)
Compression Ratio
Max. Horsepower
(ps/rpm)
Max. Torque
(kg.m/rpm)
Tire Size
Transmission Type Non-stage transmission
Clutch
Ignition Fuse
Starting System
Idle Speed
2-stroke single
cylinder
49.5 745 mm
39x41.4
7.2
Speed limited
type: 2.6/6500
Speed limited
type: 0.42/6000
FR:120/70-14
RR:120/80-14
Dry Multi-Disc Clutch Fuel Tank Capacity
C.D.I.
Starting motor &
kick starter
1850 rpm
Overall Length
Overall Width
Overall Height
Dry Weight
Wheel Base
Spark Plug
Fuel Type
Engine Oil Tank Capacity
Gear Oil Type
Capacity/Change
Battery
2040 mm
1240 mm
112 kg
1350 mm
NGK-BR8HSA
#92 or 95 nonleaded
gasoline
1.1 liter
6.0 liter
7A/7A/10A
SAE 90#
0.12 L/0.09 L
12V6AH
⌒53⌒
11.KYMCO CLEAN AIR SYSTEM (FOR EURO 2)
The KYMCO Clean Air System is a secondary air suction system that helps the exhaust gases to
burn more completely. When the spent fuel charge is released into the exhaust system, it is still
hot enough to burn. The system allows extra air into the exhaust system so that the spent fuel
charge can continue to burn. This continued burning action tends to burn up a great deal of the
normally unburned gases, as well as changing a significant portion of the poisonous carbon
monoxide into harmless carbon dioxide.
The spent fu el cha rge
Secondary air ho se
Cylin der
Reed valve
⌒54⌒
Fresh air
Secondary air cle aner
Cata ly tic conv erte r
KWANG YANG MOTOR CO.,LTD.
NO.35 Wan Hsing Street, San Min District
Kaohsiung, Taiwan, Republic of China
Telephone : 886-7-3822526
FAX : 886-7-3950021
By KWANG YANG Motor Co., Ltd.
First Edition, Jan 2004
All rights reserved. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
4121-LBD5-U00
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