KYMCO Downtown 125i Manuel utilisateur
DOWNTOWN 125i
By KWANG YANG Motor Co., Ltd.
1st Edition, April 2009
All rights reserved. Any reproduction or
unauthorized use without the written
permission of KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T100-LFA7-A2
DOWNTOWN 125i
PREFACE
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.
KWANG YANG MOTOR CO., LTD.
QUALITY TECHNOLOGY DEPT.
EDUCATION SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
EXHAUST MUFFLER/FRAME
COVERS
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/VALVES
6
CYLINDER/PISTON
7
DRIVE AND DRIVEN PULLEYS
8
FINAL REDUCTION
9
A.C. GENERATOR/STARTER
CLUTCH
10
CRANKCASE/CRANKSHAFT
11
COOLING SYSTEM
12
Fi DIAGNOSTIC TOOL OPERATION
13
FUEL INJECTION SYSTEM
14
HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/STEERING
STEM
15
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
16
BATTERY/CHARGING SYSTEM
17
IGNITION SYSTEM
18
STARTING SYSTEM
19
LIGHTS/METERS/SWITCHES
20
The information and contents
included in this manual may be
different from the motorcycle in case
specifications are changed.
CHASSIS ELE
C
TRI
C
AL
EQUIPMENT
ENGINE
1
ENGINE SERIAL NUMBER ................... 1- 1
Location of Engine Serial Number
ENGINE SERIAL NUMBER
1-1
1. GENERAL INFORMATION
-1-
SPECIFICATIONS
SERVICE PRECAUTIONS
TORQUE VALUES
SPECIAL TOOLS....................................1-12
...................................
.....................
..................................
LUBRICATION POINTS..........................1-14
DOWNTOWN 125i
1. GENERAL INFORMATION
SPECIFICATIONS
-2-
Name DOWNTOWN125i
Model No. SK25AA
Overall length 2200mm
Overall width 800 mm
Overall height 1410 mm
Wheel base 1542 mm
Engine type O.H.C.
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
Front wheel 120/80-14
Rear wheel 150/70-13
RR Ground clearance 140 mm
Perform- Braking distance (m) 7.9m/30km/h
ance Min. turning radius 2600mm
Starting system Starting motor
Type liquid cooled 4 stroke
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)15
Max .horsepower (ps/rpm) 15/8750~9000
Max. torque (kg m/rpm) 1.17/8500~8750
Intake Open 8 °BTDC
Port (1mm) Close 31° BTDC
timing Exhaust Open 32° BTDC
(1mm) Close 6 °BTDC
Valve Intake 0.10 mm
clearance Exhaust 0.10 mm
Idle speed (rpm) 1850rpm
Lubrication type Forced pressure &
Wet sump
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
Tires
Engine
Lubrication
System
Air cleaner type & No Paper element, wet
Fuel capacity 12.5 L
Throttle type Butterfly type
Type ECU
Spark plug NGK CR7E
Sparkpluggap 0.6～0.7mm
Battery Capacity 12V10AH
Clutch Type Dry multi-disc clutch
Type Non-stage transmission
Operation Automatic centrifugal
type
Type Two-stage reduction
Reduction 1st 0.83~2.2
ratio 2nd 10.41
Front Caster angle 28°
Axle Trail length 140mm
Tire pressure Front 2.0
(kg/cm²)1
person Rear 2.25
Turning Left 40?
angle Right 40?
Brake system Front Disk brake
type Rear Disk brake
Front Telescope
Suspension
type Rear DOUBLE SWING
Frame type PIPE UNDER BONE
Reduction
Gear
Transmis-
sion Gear
Fuel System Power Drive System
Electrical Equip.
Ignition System
Moving Device Damping
Device
DOWNTOWN 125i
-
1-3
SERVICE PRECAUTIONS
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to specified torque
diagonally.
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.
Make sure to install new gasket, O-rings, circlips,
cotter pins, etc. When reassembling.
.
1. GENERAL INFORMATION
-3-
DOWNTOWN 125i
1. GENERAL INFORMATION
Disconnect the battery negative (-) terminal
before operation.
-4-
Apply or add designated greases and
lubricants to the specified lubrication points.
After reassembly, check all parts for proper
tightening and operation.
When two person work together, pay attention
to the mutual working safety.
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.
DOWNTOWN 125i
1-5
Confirm
Capacity
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.
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.
1. GENERAL INFORMATION
-5-
DOWNTOWN 125i
click
If the double connector has a lock, lock it
at the correct position.
The connector shall be inserted completely.
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.
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.
1. GENERAL INFORMATION
-6-
DOWNTOWN 125i
1-7
No contact !
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.
1. GENERAL INFORMATION
-7-
DOWNTOWN 125i
Do not pull
too tight!
Do not press or
squeeze the wire.
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.
1. GENERAL INFORMATION
-8-
DOWNTOWN 125i
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