DOWNTOWN125i.pdf

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DOWNTOWN 125i
By KWANG YANG Motor Co., Ltd.
1st Edition, Dec 2009
All rights reserved. Any reproduction or
unauthorized use without the written
permission of KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T300-SK25AA-A1
DOWNTOWN
125i
PREFACE
This Service Manual describes the
technical features and servicing
procedures
for
the
KYMCO
Downtown
i.
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 12 give instructions for
disassembly,
assembly
and
adjustment of engine parts. Section 13
is the AFI system. Section 14 to 15 is
the removal/ installation of chassis.
Section 16 to 19 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.
TABLE OF CONTENTS
GENERAL INFORMATION
EXHAUST MUFFLER/FRAME
COVERS
INSPECTION/ADJUSTMENT
LUBRICATION SYSTEM
1
2
3
4
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/VALVES
ENGINE
CHASSIS
ELECTRICAL
EQUIPMENT
6
7
8
9
10
11
12
13
CYLINDER/PISTON
DRIVE AND DRIVEN PULLEYS/V-
BELT
FINAL REDUCTION
A.C. GENERATOR/STARTER
CLUTCH
CRANKCASE/CRANKSHAFT
COOLING SYSTEM
FUEL INJECTION SYSTEM
STEERING HANDLEBAR/FRONT
14
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK
REAR BRAKE/REAR FORK/REAR
15
WHEEL/REAR SHOCK ABSORBER`
BATTERY/CHARGING SYSTEM
IGNITION SYSTEM
STARTING SYSTEM
LIGHTS SWITCHES / FUEL PUMP
16
17
18
19
KWANG YANG MOTOR CO., LTD.
QUALITY TECHNOLOGY DEPT.
EDUCATION SECTION
1. GENERAL INFORMATION
1
DOWNTOWN
125i
________________________________________________________________________________
1
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
GENERAL INFORMATION
________________________________________________________________________________
SERIAL NUMBER ------------------------------------------------------------------------------------ 1-1
SPECIFICATION ------------------------------------------------------------------------------------- 1-2
SERVICE PRECAUTIONS ------------------------------------------------------------------------- 1-3
TORQUE VALUES ----------------------------------------------------------------------------------- 1-4
SPECIAL TOOLS ------------------------------------------------------------------------------------- 1-6
LUBRICATION POINTS ---------------------------------------------------------------------------- 1-7
CABLE & HARNESS ROUTING--------------------------------------------------------------------- 1-8
1-0
1. GENERAL INFORMATION
SERIAL NUMBER
DOWNTOWN
125i
Location of Frame Serial Number
(inside luggage box)
Location of Vehicle Identification
Number (VIN)
Location of Engine Serial Number
1-1
1. GENERAL INFORMATION
SPECIFICATIONS
Air cleaner type & No
Fuel capacity
Fuel System
DOWNTOWN 125i
Paper element, wet
12.5 L
Name
Model No.
Overall length
Overall width
Overall height
Wheel base
Engine type
Displacement
Fuel Used
Front wheel
Net weight (kg) Rear wheel
Total
Front wheel
Gross weight
(kg)
Rear wheel
Total
Front wheel
Tires
Rear wheel
RR Ground clearance
Perform- Braking distance (m)
ance
Min. turning radius
Starting system
Type
Cylinder arrangement
Combustion chamber type
Valve arrangement
Bore x stroke (mm)
Compression ratio
Compression pressure
(kg/cm²)
Max .horsepower (ps/rpm)
DOWNTOWN125i
SK25AA
2200mm
800 mm
1410 mm
1542 mm
O.H.C.
124.8cc
92# nonleaded gasoline
Throttle type
Ignition System
Butterfly type
Type
Spark plug
ECU
NGK CR7E
Electrical Equip.
68
96
164
70
104
178
120/80-14
150/70-13
140 mm
7.9m/30km/h
2600mm
Starting motor
liquid cooled 4 stroke
Spark plug gap
0.6�½�0.7mm
Battery
Capacity
12V10AH
Clutch Type
Dry multi-disc clutch
Transmis-
sion Gear
Single cylinder
Semi-sphere
O.H.C.4V
54 x 54.5
11.7:1
15
15/8750~9000
1.17/8500~8750
8 °BTDC
31° BTDC
32° BTDC
6 °BTDC
0.10 mm
Reduction 1st
ratio
2nd
Front Caster angle
Axle
Trail length
Front
Tire pressure
(kg/cm²) 1
Rear
person
Turning
Left
angle
Right
Front
Brake system
type
Rear
Moving Device
Damping
Device
Power Drive System
Type
Operation
Type
Non-stage transmission
Automatic centrifugal
type
Two-stage reduction
0.83~2.2
10.41
28°
Reduction
Gear
140mm
2.0
2.25
40?
40?
Disk brake
Disk brake
Telescope
DOUBLE SWING
PIPE UNDER BONE
Front
Suspension
type
Rear
Engine
Max. torque (kg m/rpm)
Intake
Open
Close
Port (1mm)
timing Exhaust
Open
(1mm)
Close
Valve
Intake
clearance
Exhaust
Idle speed (rpm)
Lubrication
System
Frame type
0.10 mm
1850rpm
Forced pressure &
Lubrication type
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
-2-

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