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2. ECU Engine Control Unit Use DC 8 16V electric power There s a program inside to receive data from several sensors calculate and to control fuel pump injector inductive ignition coil and ABV 32 pin totally Roll sensor Use DC 8 16V electric power When vehicles are tilted over 65 degree it will send inform the ECU to cut fuel supply and ignition for safety Fuel pump Use DC 8 16V electric power Supply fuel equip pressure regulator to keep at 3 0 bar stable pressure it s the source of injector pressure and equip a filter to avoid the impurity get in Inductive ignition coil Use DC 8 16V electric power Produce 20 kV to ignition spark plug Injector Use DC 8 16V electric power To inject the fuel the quantity is fixed and ECU control the time of injection ABV Air Bypass Valve Use DC 8 16V electric power ECU according to the engine running condition to compensate flash air into inlet pipe by opening the air
3. 1 Ls IS e e a new 1 the 1 1 n I 2s un heck 1f th It of is broken 1 1 ENT Cis IS C C 76 1 NSOT 1 1ICation zi After repairing trouble you should clear the failure code or sq ECU When you maintain this vehicle next time it will show again and you get confuse four ECU Engine Control Unit Voltage inspection Outlook checking MAP content edition Issue no LFA i Performance confirmed FUEL PUMP Standard 8 16 V Battery volt T MAP Manifold Temperature Pressure Sensor Standard 101 3 3 kpa TPS Throttle Position Sensor Standard Idle 0 voltage 0 23V 0 05 Throttle fully 90 over voltage 3 27V over WTS Water Temperature Sensor Standard 540 25 V Standard 20 C 68 F 2 075t10 k Standard 20 C 68 F 10 6 15 9
4. 1 CELP 3 1 or Fi diagnostic tool 2 and pc software 3 Update 5042 version 2 COMPONENT EXAMINE Diagnostic Tool Connector f i in n gu Jue gt Sm Hip TET H no is There are 3 kinds of priority grade let PRIORITY LAMP ACTION _ user to know what kind of trouble was CR Priority grade 1 w 2 Priority grade 2 Priority grade 3 You read the failure code below lt x i If vehicle got more than one failure code the CELP will be shown from lower number failure code and then show the other higher number one alter four seconds All the failure codes would be shown repeatedly t t t 8 5 Di n e m m m D 3 B 8 a E 5 I zs O E n E I n TT in 2 3 1 05 1 050505050505 3 1 05050505 3 NENNEN imma 9 3 I i 1st Code 23 2nd Code 12 KEY ON B lamp on for test BE amp on for tens lamp on for unities s lamp off
5. 11 2 IROUBLESHOOTING u ueteri oa eurn eee 11 2 CRANKCASE SEPARATION 11 3 CRANKSHAFT 11 4 CRANKCASE ASSEMBLY Yu uu 22 11 5 11 0 GQ KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 125i SCHEMATIC DRAWING 96001 06032 91255 KHE7 nara GP 96100 60020 96100 62030 96001 06025 X7 95701 08012 9 91202 LEB1 0 9052A 94301 08140 96001 06085 94301 10160 96001 06032 95701 06025 11 1 GQ KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS e This section covers crankcase separation to service the crankshaft The engine must be removed for this operation e When separating the crankcase never use a driver to pry the crankcase mating surfaces apart forcedly to prevent damaging the mating surfaces e When installing the crankcase do not use an iron hammer to tap it e following parts must be removed before separating the crankcase Cylinder head Cylinder piston Drive and driven pulley A C generator starter clutch Rear wheel rear shock absorber Starter motor Oil pump SPECIFICATIONS Unit mm Lo Bem 2 Standard Connecting rod big end side clearance 0 15 0 35 Crankshaft Connecting rod big end radial clearance 0 0 008 p j TORQUE VALUES Crankcase bolt
6. HANDLEBAR SWITCH LUGGAGE BOX LIGHT SWITCH 20 9 20 0 GQ KYMCO 20 LIGHTS METERS SWITCHES DPOWNIOWN 1750 _ SERVICE INFORMATION GENERAL A halogen head light bulb becomes very hot while the head light 15 and remains for a while after it is turned off Be sure to let it cool down before servicing e Note the following when replacing the halogen headlight bulb Wear clean gloves while replacing the bulb Do not put finger prints on headlight bulb as they may create hot spots on the bulb and cause it to fail TM f you touch the bulb with your bare hands clean it with a cloth moistened with alcohol to prevent its early failure Be sure to install the dust cover after replacing the bulb e Check the battery condition before performing any inspection that requires proper battery voltage e A continuity test can be made with the switches installed on the scooter e Route the wires and cables properly after servicing each component 20 1 dC KYMCO 20 LIGHTS METERS SWITCHES DOWNTOWN125 i BULB REPLACEMENT POSITION LIGHT Remove the front cover refer to the COVERS REMOVAL INSTALLATION section in the chapter 2 Remove the bulb socket 1 Remove the bulb 2 and replace with a new one Installation is in the reverse order of removal 2 20 2
7. pude eei ien 6 5 CAMSHAFT 222226228 acess tao u 6 8 versa nassau se 6 13 6 0 GQ KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 125i SCHEMATIC DRAWING 96001 06014 39301 94111 06800 9 225 ary 1621 55 16201 e 0 5 O en 14711 37720 37750 9600 94301 14453 14721 90033 GFY6 900 9000B X4 e 14781X8 GQ KYMCO 6 CYLINDER HEAD VALVES DOWNTOWNUS SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder head can be serviced with the engine installed the frame Coolant in the radiator and water jacket must be drained first e When assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts and valve arm sliding surfaces for initial lubrication e The valve rocker arms are lubricated by engine oil through the cylinder head engine oil passages Clean and unclog the oil passages before assembling the cylinder head e After disassembly clean the removed parts and dry them with compressed air before inspection e After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal SPECIFICATIONS Unit mm ER Ive el L IN 1112 Cylin
8. Install the camshaft holder with the mark face exhaust valve side e Apply engine oil to the threads of the cylinder head cap nuts e Diagonally tighten the cylinder head cap nuts in 2 3 times 6 5 KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 125i DISASSEMBLY Take out the valve rocker arm shafts Remove the valve rocker arms rbi la NA Rocker Shafts INSPECTION Camshaft Holder Inspect the camshaft holder valve rocker arms and rocker arm shafts for wear or damage X If the valve rocker arm contact surface 15 worn check each cam lobe for wear or damage Rocker Arm Shafts Rocker Arm Bore Inspect the rocker arm bore cam lobe contact surface and adjuster surface for wear pitting scratches blue discoloration If any defects are found replace the rocker arm shaft with a new one then inspect lubrication system Adjuster Surface Contact Surface 6 6 KYMCO Measure I D of each valve rocker arm Service Limits IN 10 1 mm EX 10 1 mm Measure each rocker arm shaft O D Service Limits IN 9 9 mm EX 9 9 mm Measure arm to shaft clearance Replace as a set if out of specification Service limits 0 1 mm ASSEMBLY Rocker Arm Shafts Apply engine oil to the rocker arms and rocker arm shafts Install the rocker arms and shafts into camshaft holder gt e Install the exhaust valve rocker arm shaft o
9. KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i INSTALLATION Replace the gasket with new ones Install the exhaust muffler and three mounting bolt but do not tighten them Install and tighten the two exhaust pipe joint nuts to the specified torque Torque 20 Nem 2 kgf m Tighten the three mounting bolts Torque 35 Nem 3 5 kgfem Gasket Remove the coolant tank cover Installation 15 In the reverse order of removal 2 15 GQ KYMCO 3 INSPECTION ADJUSTMENT DOWN TOWN 125i INSPECTION ADJUSTMENT SERVICE INFORMA TION tinent tene Bed MAINTENANCE SCHE DUI 222222222 AE 22 FUEL LINE EUEF L 3 4 VHBOTILEOPERATIONS u u us 3 4 BN D a suma LL asss 3 5 IPANSNISSIONNSDE dodenus cis bue uu 3 11 AJI C L ANNE pupa T 3 12 SPARK u sc Ses aa 3 13 VALVE CLEARANCE die 3 14 S D gt sete ee 3217 CYLINDER 65 3 16 u UEM UE 3 16 CRUTCH SHOE WE A icra ates cients 3 17 se 3 17 eee MU E 3 18 BRAKE FLUID esac sites cheese eee ete cee 3 20 DEAKEDAD 3 20 NUISBOLIS IASTENEBS 3 01 WHEBES jp ce i ee ne 3 01 STEERING uu 2 02 SHOT S
10. gt Woe d P S Rear Axle Nut Bolt Collar Bolts 16 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER DOWNTOWN 1251 REAR WHEEL de 0 REMOVAL Remove the exhaust muffler Remove the rear brake caliper Remove the rear fork Remove the rear axle collar Remove the rear wheel Rear Brake Disk Rear Axle Collar INSPECTION Measure the rear wheel rim runout INSTALLATION The installation sequence is the reverse of removal Torque Rear shock absorber lower mount bolt 35 45N m Rear axle nut 120 N m REAR SHOCK ABSORBER REMOVAL Remove the met in box and carrier Remove the body cover center cover and rear fender A together Remove the right left rear shock absorber upper and lower mount bolts Remove the right and left rear shock absorbers 16 7 16 REAR BRAKE REAR FORK REAR A YMCO WHEEL REAR SHOCK ABSORBER POWNTOWN 125 INSTALLATION Install the rear shock absorbers the reverse order of removal Torque Upper Mount Bolt 40 N m Lower Mount Bolt 40 N m Suspension Each shock absorber on your scooter has 5 spring preload adjustment positions for different T load or riding conditions Use a pin spanner to adjust the rear shock spring preload Position 1 is for light loads and smooth road conditions Position 3 to 5 increase spring preload for a stiffer rear suspension and can be used when the scooteris
11. 13 2 KYMCO 13 Fi DIAGNOSTIC TOOL OPERATION DOWN TOWN 125 Press the Enter button to check the DTC number Press the Enter button i B WE www E i J i a m jd i LISTE grs Vit 2 JAL a E 1 uy H i Press the Enter button Display what s DTC number on this DTC List Referto DTC summary list on chapter 5 Press the Enter button and then turn to the previous page 13 3 KYMCO 13 Fi DIAGNOSTIC TOOL OPERATION powN TOWN 125 Press the UP button Press the Enter button and then turn to the previous page Press the UP button Press the Enter button and then turn to the first page 13 4 KYMCO 13 Fi DIAGNOSTIC TOOL OPERATION powN TOWN 125 DTC CLEAR PROCEDURE Choose Load DTC Press Down button Press the Enter button The DTC indicator 1s lighting at that time Clearing DTC completed until the DTC indicator is off 13 5 KYMCO 13 Fi DIAGNOSTIC TOOL OPERATION powN TOWN 125 DATA ANALYSIS Choose Data Analyze Press Enter button to enter page 01 setpoint and battery voltage Referto standard specifications on page 18 9 Press the Down button to enter page 02 The figure includes TPS position TPI idle adapted voltage and TPI WOT adapted Throttle grip fully opened Referto standard specifications on page 18 9 Press Down button
12. eie 15 11 FRONT ERAKI DAT 15 15 BRAKE DISC INSPECTION 15 17 FRONT SHOCK 15 18 STEERING 15 19 15 0 15 HANDLEBAR FRONT WHEEL FRONT FRONT SHOCK ABSORBER STEERING STEM SERVICE INFORMATION GENERAL INSTRUCTIONS GQ KYMCO Downtown 125i e Remove the motorcycle frame covers before removing the front wheel steering handlebar front shock absorber and front fork Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down e During servicing keep oil or grease off the brake pads and brake disk SPECIFICATIONS Item Axle shaft runout Unit mm in Standard Brake disk thickness 3 5 4 2 0 14 0 168 3 Brake disk runout TORQUE VALUES Handlebar lock nut Steering stem lock nut Steering stem pinch bolt Front axle Master cylinder reservoir cover screw Master cylinder holder bolt Brake lever pivot bolt Brake lever pivot nut Brake light switch screw Brake caliper mounting bolt Brake caliper bleed screw Brake hose oil bolt SPECIAL TOOLS Lock nut wrench 12 2 45 Nem 4 5 70 Nem 7 0kgfem 27 Nem 2 7 kgfem 20 Nem 2 0 kgfem 1 6Nem 0 16 kgfem 12 Nem 1 2 kgfem 2 Nem 0 2 kgfem 10 Nem 1 kgfem Nem 0 1 kgfem 35 3 5 kgfem ALOC bolt
13. Oil capacity At disassembly 0 13 liter At change 0 12 liter Install and tighten the oil check bolt Drain Bolt 3 jg Torque 0 8 1 2kgf m Start the engine and check for oil leaks Oil Filler GQ KYMCO IO A C GENERATOR STARTER CLUTCH DOWNTOWN 125i A C GENERATOR STARTER CLUTCH SCHEMATIC cen cee 10 1 SERVICER INFORMATION cresce aE 10 2 TROUBLESHOOTING Zur 10 2 AP TERN A VOR eee cerca 10 3 ARTER EO I 10 6 10 0 GQ KYMCO IO A C GENERATOR STARTER CLUTCH DOWNTOWN 125i SCHEMATIC DRAWING 96001 06022 X3 96001 06035 96001 06120 X7 94301 08140 197 s t 96001 06030 94301 08140 EIS 4 lt 11394 94301 08140 90428 19232 94510 14000 31100 m 9660008015 9110172 gt 91101 au 4 18 n i 96600 08015 10 10 1 GQ KYMCO IO A C GENERATOR STARTER CLUTCH DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS e All servicing operations and inspections in this section can be made with the engine installed e Drain the coolant before removing the right crankcase cover e Be careful not to drain the coolant when the engine temperature 15 high Perform this operation when the engine 15 cold e Drain the coolant into a clean container e Drain the
14. SPECIFICATIONS Unit mm Outer rotor to pump body clearance 0 15 0 2 MEME Rotor end to pump body clearance 0 04 0 09 ERE ENGINE OIL Engine Oil Capacity Recommended Oil SAEI5W40 API SJ or SM TROUBLESHOOTING Oil level too low Poor lubrication pressure e Natural oil consumption e Oil level too low e leaks e Clogged oil filter or oil passage e Worn piston rings e Faulty oil pump e Worn valve guide e Worn valve guide seal Oil contamination e Oil not changed often enough e Faulty cylinder head gasket e Loose cylinder head bolts KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 125i OIL PUMP REMOVAL Remove the flywheel and driven gear refer to the STARTER CLUTCH section in the chapter 10 Remove the bolt and then oil separator cover When removing and installing the oil pump use care not to allow dust or dirt to enter the engine e Oil Separator Cover Pry the snap ring off and remove the oil pump driven gear then remove the oil pump drive chain A Ring E Pump Driven Gear Oil Pump Remove the two oil separator bolts to remove the oil pump Oil Separator Bolt KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 125i Arrow Mark INSTALLATION Install the oil pump and oil separator and tighten the two bolts Make sure the pump shaft rotates freely and arrow on the oil pump 15 upside Install the pump drive chain
15. 2 0kg cm 2 25 kg cm Rear 3 21 GQ KYMCO 3 INSPECTION ADJUSTMENT DOWN TOWN 125i STEERING HANDLEBAR Raise the front wheel off the ground and check that the steering handlebar rotates freely If the handlebar moves unevenly binds or has vertical movement adjust the steering head bearing SUSPENSION Check the action of the front rear shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn Replace the engine hanger bushings if there 1s any looseness Rear suspension adjustment Each shock absorber 1 has 5 adjustment positions for different load or riding conditions Use a pin spanner 2 to adjust the rear shocks Always adjust the shock absorber position in sequence 1 2 3 4 5 or 5 4 3 2 1 Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber Position 1 is for light loads and smooth road conditions Positions 3 to 5 increase spring preload for a stiffer rear suspension and can be used when the scooter is heavily loaded Be certain to adjust both shock absorbers to the same position 3 22 INSPECTION ADJUSTMENT SIDE STAND Perform the following maintenance in accordance with the maintenance schedule Functional check Check the spring for damage or loss of ten
16. KYMCO 20 LIGHTS METERS SWITCHES DOWNTOWN HEADLIGHT 1 A halogen headlight bulb becomes very hot while the headlight is ON and remain for a while after it is turned OFF Be sure to let it cool down before servicing Remove the front cover refer to the COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the headlight cover Disconnect the headlight connector 1 from the headlight bulb 2 Install a new bulb in the headlight case Install the headlight and connect the headlight connector 20 3 KYMCO 20 LIGHTS METERS SWITCHES DOWNTOWN125 i FRONT TURN SIGNAL LIGHT 0 Remove the front cover refer to the COVERS REMOVAL INSTALLATION section in the chapter 2 Turn the bulb socket 1 then remove the front turn signal light Push and turn the bulb counterclockwise to remove it then replace with a new one Installation is in the reverse order of removal TAILLIGHT BRAKE LIGHT REAR TURN SIGNAL LIGHT Remove the seat and met in then remove the light bulb socket KYMCO 20 LIGHTS METERS SWITCHES DOWNTOWN _ Rear turn signal light Push and turn the bulb counterclockwise to remove it then replace with a new one Installation 1s In the reverse order of removal Taillight Brake light Push and turn the bulb counterclockwise to remove it then replace with a new one Installation 1s In the reverse order o
17. Use the special tool to install spring and clutch then install and tighten the nut to the specified torque Torque 5 5 6 5m 55 65N m Special tool Clutch Spring Compressor A120E00034 Clutch spring compressor 8 16 GQ KYMCO 9 FINAL REDUCTION DOWNTOWN 125 i FINAL REDUCTION SCHEMATIC DRA WING s ssssssss1suscspapss1usasspspasasssucqapapashussqa 9 1 SERVICE INFORMATION AR 9 2 TROUBLESHOOTING 9 2 FINAL REDUCTION zs 9 3 BEARING BL PEACI MI Nasua 9 7 9 0 DOWNTOWN 125i KYMCO 9 FINAL REDUCTION SCHEMATIC DRAWING 96100 LFE2 9 91202 LFE2 96100 63030 96100 62020 9 1 GQ KYMCO 9 FINAL REDUCTION DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS e The servicing operations of this section can be made with the engine installed e When replacing the drive shaft use a special tool to hold the bearing inner race for this operation SPECIFICATIONS Specified Oil SAE 908 Oil Capacity At disassembly 0 13 At change 0 12 liter TORQUE VALUES Transmission case cover bolt 1 0 1 4kgf m SPECIAL TOOLS Oil seal and bearing installer 120 00014 Bearing puller A120E00037 TROUBLESHOOTING Engine starts but motorcycle won t move e Damaged transmission e Seized or burnt transmission Abnormal noise e Worn seized or chipped gea
18. 1 side 2 Engine side Rear fork bolt speed sensor cable 02 sensor Rear carrier Front axle nut Rear axle nut Rear cushion upper lower bolt KYMCO 1 GENERAL INFORMATION Downtown 125i SPECIAL TOOLS Performance _ Flywheel Puller 120 00003 A C generator flywheel removal E s s Tappet Adjuster A120E00012 Tappet adjustment Oil Seal amp Bearing A120E00014 Oil seal amp bearing installing Installer Flywheel Holder A120E00021 A C generator flywheel holding 41 Nut amp Fitting A120E00028 Clutch disassembly amp assembly Thread Protector A120E00029 Protecting the crankshaft s thread Valve Cotter Installer A120E00051 Valve cotter installation Clutch Spring A120E00053 Compressor Shaft Collar Puller A120E00088 Bearing crankcase removal Shaft Collar Driver A120E00091 Bearing crankcase removal Shaft Collar Installer A120E00092 Bearing crankcase installation A120E00093 Bearing removal Lock Nut Socket Wrench A120F00002 Steering stem removal or installation Electric Repair Kit A120F00032 Fuel injection system diagnosis KYMCO 1 GENERAL INFORMATION DOWNTOWN 1251 LUBRICATION POINTS FRAME The following is the lubrication points for the frame Use grease for parts not listed Apply engine oil or grease to cables and movable parts not specified It will avoid abnormal noise and damage the durability of the motorc
19. 1 095 1 093 1 091 1 088 1 085 1 082 1 079 1 076 1 073 1 070 1 067 COOLANT MIXTURE WITH ANTI RUST AND ANTI FREEZING EFFECTS 206 48505 306 1 2 9505 1 406 550 1 50 0 0 0 00 00 00 sc 05484 Cautions for Using Coolant e Use coolant of specified mixing rate The mixing rate of 425cc KYMCO SIGMA coolant concentrate 975cc distilled water 1s 30 e Do not mix coolant concentrate of different brands e Do not drink the coolant which 15 poisonous e The freezing point of coolant mixture shall be 5 Clower than the freezing point of the riding area 12 2 GQ KYMCO 12 COOLING SYSTEM Downtown 1251 COOLING SYSTEM TESTING RADIATOR CAP INSPECTION Removing the radiator cap while the engine 15 hot can cause the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap Remove the radiator cap 1 Pressure test the radiator cap Replace the radiator cap if it does not hold pressure or if relief pressure 15 too high or too low It must hold the specified pressure for at least six seconds Before installing the cap in the tester wet the sealing surface Radiator Cap Relief Pressure Radiator Cap 90 kPa 0 9 kg cm 12 8 psi Pressurize the radiator engine and hoses and check for leaks Excessive pressure can damage the cooling system components Do not exceed 105 kPa
20. 20 LIGHTS METERS SWITCHES DOWNTOWN125 i Left handlebar switch Disconnect the left handlebar switch Dimmer Switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wires as follows WINKER SW HORN SW HO I PUSH COLORIBRIL Horn Switch Turn Signal light Switch DIMMER SW Passing Switch PASSING SW 20 8 GQ KYMCO 20 LIGHTS METERS SWITCHES PDOWNIOWN 125 LUGGAGE BOX LIGHT SWITCH INSPECTION Remove the luggage box refer to the COVERS REMOVALDL INSTALLATION section in the chapter 2 Disconnect the luggage box light switch connector 2 and check the luggage box light switch 1 for continuity between the switch terminals There should be no continuity with the luggage box light switch pushed and there should be continuity with the luggage box light switch 1s released 20 9 KYMCO 20 LIGHTS METERS SWITCHES DOWNTOWN125 i FUEL PUMP REMOVAL Remove the seat and met in Remove the center cover Remove the fuel pump connector Be sure to relieve the fuel pressure before removing fuel pump or fuel hose Remove the 6 nuts 1 and fuel unit connectors 2 then remove the fuel hose 3 Remove the fuel pump 4 Check the fuel pump O ring 5 If was damage Replace new one KYMCO 20 LIGHTS METERS SWITCHES pow 1291 INSPECTION Connect the fu
21. Charging current LOX5 10H 5 2 p 17 2 GQ KYMCO 17 BATTERY CHARGING SYSTEM DOWNTOWN125i TROUBLESHOOTING No power e Dead battery e Disconnected battery cable e Fuse burned out e Faulty ignition switch Low power e Weak battery e Loose battery connection e Charging system failure e Faulty regulator rectifier 17 3 Intermittent power e Loose battery cable connection e Loose charging system connection e Loose connection or short circuit in 1gnition system Charging system failure e Loose broken or shorted wire or connector e Faulty regulator rectifier e Faulty A C generator GQ KYMCO 17 BATTERY CHARGING SYSTEM DOWNTOWN 125i BATTERY REMOVAL INSTALLATION The battery 15 1n the battery box below seat Remove the seat 2 Remove the met in box 3 Remove the four screws and then remove the battery retainer 2 4 Pull battery out to expose the terminal leads Disconnect the negative terminal lead 3 from the battery first then disconnect the positive terminal lead 4 6 Remove the battery from the battery box Battery installation Install in the reverse order of the removal When install the battery first connect the positive cable and then negative cable to avoid short circuit 17 4 GQ KYMCO 17 BATTERY CHARGING SYSTEM DOWNTOWNI125i VOLTAGE INSPECTION Remove the battery cover last
22. KYMCO INSPECTION ADJUSTMENT DOWN TOWN 125i AIR CLEANER The air cleaner should be serviced at regular intervals Service more frequently when riding in unusually wet or dusty areas Air cleaner element replacement Remove the screws from the air cleaner cover then remove air cleaner cover 2 Remove screws from the air cleaner element then remove and discard this air cleaner element 4 The new air cleaner element installation 1s in the reverse order of removal Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model Using the wrong KYMCO air cleaner element or a non K YMCO air cleaner element which is not of equivalent quality may cause premature engine wear or performance problems gt m M amp d 3 12 3 INSPECTION ADJUSTMENT SPARK PLUG Remove the spark plug cap and spark plug Check the spark plug for wear and fouling deposits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug DOWNTOWN 125 i NGK CR7E Measure the spark plug gap Spark Plug Gap 0 0 0 7 mm When installing first screw in the spark plug by hand and then tighten it with a spark plug wrench Torque 0 9 kgf m 9 N m 3 13 KYMCO DOWN TOWN 125i Cracks 4 Damage Deformation Gap Wear Fouling 0 6 0 7mm Deposits KYMCO INSPECTION ADJUS
23. 1 05 kg cm Cap Tester 14 9 psi Repair or replace components if the system will not hold the specified pressure for at least six seconds 12 3 12 COOLING SYSTEM COOLANT REPLACEMENT PREPARATION e The effectiveness of coolant decreases with the accumulation of rest or if there is a change in the mixing proportion during usage Therefore for best performance change the coolant regularly as specified he maintenance schedule e Mix only distilled low mineral water with the antifreeze Recommended mixture 1 1 Distilled water and antifreeze REPLACEMENT AIR BLEEDING Remove the front cover refer to the 4 FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 When filling the system or reserve tank with coolant checking the coolant level place the scooter in a vertical position on a flat level surface Remove the radiator cap 1 Remove the drain bolt 2 and drain the coolant from the system KYMCO Downtown 1251 AHTIFREEZE SOLUTION ETHYLENE GLYCOL BASE LOW MINERAL OR SOLUTION DISTILLED WATER 7 gt MM bs NT 744 EH Tp lt 12 4 12 COOLING SYSTEM Remove the screw 3 and reserve tank lid 4 Remove the reserve tank cap 5 and drain the coolant from the reserve tank Reinstall and tighten the drain bolt securely Fill the reserve tank to the upper level line 6 12 5
24. 2 then remove the caliper Remove the brake pads Always replace the brake pads in pairs to ensure even disc pressure 15 15 KYMCO Downtown 125i 1S HANDLEBAR FRONT WHEELFRONTERAkg KYMCO Install new pads so that their ends rest on the pad retainer on the brake properly Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper Install the front caliper onto the fork leg and then install and tighten the new two caliper mounting bolts to the specified torque Torque 35 N m 3 5 kgf m Tighten 1 pad pins to the specified torque Torque 18 N m 1 8 kgf m 13 Ibf ft 15 16 15 HANDLEBAR FRONT WHEEL FRONT BRAKE KYMCO FRONT SHOCK ABSORBER STEERING STEM Downtown 1291 BRAKE DISC INSPECTION Visually inspect the brake disc for damage or cracks Measure the brake disc thickness Service limits 3 mm 0 12 in Replace the brake disc if the smallest measurement 1s less than the service limit Measure the brake disc warpage Service limits 0 3 mm 0 012 in 15 17 15 HANDLEBAR FRONT WHEEL FRONTBRAkg KYMCO FRONT SHOCK ABSORBER REMOVAL Remove the front cover and front fender refer to the FRAME CVOERS REMOVAL INSTALLATION section in the chapter 2 Remove the front brake caliper refer to the FRONT BRAKE section in this chapter Remove the front wheel refer to the FRO
25. burning scratches or abnormal stem wear If any defects are found replace the valve with a new one Check valve movement in the guide Measure each valve stem O D Measure each valve guide I D Subtract each valve stem O D from the corresponding guide I D to obtain the stem to guide clearance If the stem to guide clearance exceeds the service limits replace the cylinder head is necessary Valve spring Measure the free length of the inner and outer valve springs 6 12 GQ KYMCO 6 CYLINDER HEAD VALVES POWNTOWNUS Cylinder head Check the spark plug hole and valve areas for cracks Check the cylinder head for warpage with a straight edge and feeler gauge ASSEMBLY Install the valve spring seats and oil seal sure to install new oil seal Lubricate each valve with engine oil and insert the valves into the valve guides Install the valve springs and retainers Compress the valve springs using the valve spring compressor then install the valve cotters K When assembling a valve spring compressor must be used e Install the cotters with the pointed ends facing down from the upper side of the cylinder head Special tool Valve Spring Compressor A120E00040 Plastic Hammer Tap the valve stems gently with a plastic hammer for 2 3 times to firmly seat the cotters Be careful not to damage the valves 6 13 GQ KYMCO 7 CYLINDER PISTON D
26. crankshaft into the left crankcase e Avoid damaging the oil seal e Apply grease to the lip of the oil seal Install the two dowel pins and a new gasket Place the right crankcase over the crankshaft and onto the left crankcase X Install the right crankcase squarely and do not tap it with an iron or plastic hammer Install and tighten the right and left crankcase attaching bolts Torque 1 kgf m 11 6 KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 125i Cam Chain Tensioner Slipper Install the cam chain Install the cam chain tensioner slipper Install and tighten the cam chain tensioner slipper bolt Torque 1 0kgf m 11 7 GQ KYMCO 12 COOLINGSYSTEM Downtowni25i COOLING SYSTEM SERVICE IN TORMA TON ere 12 1 TROUBILESHOO LING eres 12 1 COOLING SYSTEM ES Gece u uu eect 19 3 COOLANT REPLACEMENT cesta 12 4 RADIATOR E 123 se 12 9 FANMOLORS WII OH constare tete 12 10 WATERPOMP ua luu u 12 11 WATER TEMPERATURE SENSOR 12 16 JI KO T nue ee ee UU RE EE 12 18 12 0 GQ KYMCO 12 COOLING SYSTEM Downtown 1251 SERVICE INFORMATION GENERAL INSTRUCTIONS e water pump must be serviced after removing the engine Other cooling system service can be done with the engine installed in the frame e engine must be cool before servicing the cooling system W
27. removal of starter motor can be accomplished with the engine installed e For the starter clutch removal refer to the chapter 10 e After the starter clutch is installed be sure to add the engine oil and coolant and then bleed air from the cooling system TORQUE VALUES starter motor mounting bolt kgf m 10 N m TROUBLESHOOTING Starter motor won t turn e Fuse burned out e Weak battery e Faulty ignition switch e Faulty starter clutch e Faulty front or rear stop switch e Faulty starter relay e Poorly connected broken or shorted wire e Faulty starter motor Lack of power e Weak battery e Loose wire or connection e Foreign matter stuck in starter motor gear Starter motor rotates but engine does not start e Faulty starter pinion e Starter motor rotates reversely e Weak battery 19 2 KYMCO 19 STARTING SYSTEM DOWNTOWN 125 i START MOTOR INSPECTION Disconnect the start motor cable 2 from the start MAG 1 Connect the start motor cable directly to the battery positive terminal 3 If the start motor does not turn the starter motor 15 faulty REMOVAL Turn the ignition switch turned to OFF Release the rubber cap 1 and remove the terminal screw 2 to disconnect the start motor cable from the start motor Remove the two mounting bolts 3 then remove the start motor 19 3 dC KYMCO 19 STARTING SYSTEM DOWNTOWN 125 i INSTALLATION Coat a new O
28. replace with a new one 5 5N m 0 55 kgfem 35 Nem 3 5 kgfem 120 00002 Oil seal and bearing installer 120 00014 Bearing piller Lock nut wrench 15 1 A120E00037 A120F00023 15 HANDLEBAR FRONT WHEEL FRONTBRAKE FRONT SHOCK ABSORBER STEERING STEM TROUBLESHOOTING Hard steering heavy e Excessively tightened steering stem top cone race e Broken steering balls e Insufficient tire pressure Steers to one side or does not track straight e Uneven front shock absorbers e Bent front fork e Bent front axle or uneven tire Poor brake performance e Worn brake pads e Contaminated brake pad surface e Deformed brake disk e Air in brake system e Deteriorated brake fluid e Worn brake master cylinder piston oil seal e Clogged brake fluid line e Unevenly worn brake caliper GQ KYMCO Downtown 1251 Front wheel wobbling e Bent rim e front axle e Bent spoke plate e Faulty tire e Improperly tightened axle nut Soft front shock absorber e Weak shock springs e Insufficient damper oil Front shock absorber noise e Slider bending e Loose fork fasteners e Lack of lubrication 15 2 I5 HANDLEBAR FRONT WHEELIFRONT BRAKE KYMCO FRONT SHOCK ABSORBER STEERING STEM Downtown 1251 HANDLEBAR REMOVAL Remove the lower handlebar cover and front cover refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Remove the two bolts 1 and disconnect the brake light
29. the special tool Special tool Bearing puller A120E00037 Remove the distance collar 4 from wheel 15 9 15 HANDLEBAR FRONT WHEEL FRONTBRAKE C KYMCO Remove the front wheel bearing 5 by using the special tool Special tool Bearing puller A120E00037 ASSEMBLY Install the front wheel bearing 5 by using the special tool Special tool Bearing installer A120E00014 Install the distance collar Install the front wheel bearing 5 by using the special tool Special tool Bearing installer A120E00014 Apply grease to the collar then install the collar onto the wheel D 7 4 15 HANDLEBAR FRONT WHEEL FRONT dO KYMCO FRONT BRAKE FLUID Check Brake fluid Brake hose Cracks wear damage Replace Apply the brake lever several times Fluid leakage Replace Brake hose clamp Loosen Tighten FLUID REPLACEMENT AIR BLEEDING gt e A contaminated brake disc or pad reduces stopping power Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent e Do not allow foreign material to enter the system when filling the reservoir e Avoid spilling brake fluid on painted plastic or rubber parts Place a rag over these parts whenever the system 1s serviced Once the hydraulic system has been opened or if the brake feels spongy the system must bled When using a commercially ava
30. Check that the O ring 1s in good condition 3 9 GQ KYMCO DOWN TOWN 125i KYMCO INSPECTION ADJUSTMENT DOWN TOWN 125i 5 Install the new oil filter K Make sure the rubber seal on the oil filter facing the left crankcase 6 Install the spring O ring and cap Cap bolt torque 12 N m 1 2 kgf m 7 Fill the crankcase with the recommended grade oil and install the oil filler cap Oil capacity after draining 1 0 liter 8 Start the engine and let it idle for 2 3 minutes 9 Stop the engine and check that the oil level opring is at the upper level mark on the oil filler cap dipstick with the scooter upright on firm level ground Make sure there are no oil leaks 3 10 KYMCO J INSPECTION ADJUSTMENT U DOWNTOWN1 25 TRANSMISSION OIL Oil change 1 Place the scooter in its center stand 2 Place a drain pan under the drain bolt 1 3 Remove the transmission oil drain bolt 4 Remove the transmission oil filler bolt 2 slowly turn the rear wheel and drain the oil After draining the oil completely install the oil drain bolt with a new sealing washer and tighten it Torque 13 N m 1 3 kgf m 5 Fill the transmission case with recommended oil Recommended transmission oil SAE 90 Oil capacity at draining 0 12 liter 6 Install the transmission oil filler bolt with a new sealing washer and tighten it 2 Torque 13 N m 1 3 kgf m 3 11 dC
31. Install the driveshaft Driveshaft Final Gear Shaft Final Gear 9 5 KYMCO 9 FINAL REDUCTION POWN OWNDSI Install new gasket Install the two dowel pins Install the transmission case cover Install and tighten the nine bolts to the specified torque in a crisscross pattern in 2 or 3 steps Torque 1 0 1 4kgf m Fill the transmission case with the specified oil refer to the TRANSMISSION OIL section in the chapter 3 9 6 KYMCO 9 FINAL REDUCTION DOWNTOWN 125i BEARING REPLACEMENT TRANSMISSION CASE COVER Remove the transmission case cover Remove the transmission case cover bearings by using the special tool Special tool Bearing puller 120 00037 Install the new bearings or new oil seal into the transmission case cover by using the special tool Special tool Oil seal and bearing installer A120E00014 TRANSMISSION CASE Remove the all transmission gears refer to the FINAL REDUCTION REMOVAL INSPECTION INSTALLATION section in this chapter Remove the transmission case bearings by using the special tool Special tool Bearing puller 120 00037 KYMCO 9 FINAL REDUCTION POWN OWNUSI Install the new bearings or new oil seal into the transmission case by using the special tool Special tool Oil seal and bearing installer A120E00014 After installation fill the transmission case with the specified oil Specified gear oil SAE90
32. KYMCO Downtown 1251 3 5 dC KYMCO 12 COOLING SYSTEM Downtown 125i Fill the system with the recommended coolant through the filler opening up to the filler neck 1 Bleed air from the system as follow 1 Start the engine and let it idle for 2 3 minutes 2 Snap the throttle three to four times to bleed air from the system 3 Stop the engine and add coolant to the proper level if necessary Reinstall the radiator cap 4 Check the level of coolant in the reserve 1 tank and fill to the upper level if it 1s low 12 6 KYMCO 12 COOLING SYSTEM Downtown 1251 2 RADIATOR REMOVAL Drain the coolant see page 12 5 Disconnect the siphon hose 1 and air bleed hose 2 Remove the nut 3 3 1 5 Loosen the hose bands then disconnect the output radiator hose 4 and input radiator hose 5 from the radiator Disconnect the fan motor switch connectors 6 Disconnect the fan motor connector 7 12 7 KYMCO 12 COOLING SYSTEM Downtown 125i Remove the three nuts 10 and then remove the radiator from frame INSTALLATION Installation is in the reverse order of removal Refill the coolant refer to the COOLANT REPLACEMENT section in this chapter 12 8 KYMCO 12 COOLING SYSTEM Downtown 1251 FAN MOTOR REMOVAL Remove the radiator refer to the RADIATOR section in this chapter Remove the three mounting bolt
33. Worn cam chain tensioner e Leaking cylinder head gasket e Worn camshaft and rocker arm e Warped or cracked cylinder head e Poorly installed spark plug Compression too high e Excessive carbon build up in combustion chamber 6 3 C KYMCO 6 CYLINDER HEAD VALVES DOWNIOWNUSI CYLINDER HEAD COVER REMOVAL Remove the four bolts 2 then remove the cylinder head cover INSTALLATION Install a new cylinder head cover O ring and install the cylinder head cover sure to install the O ring into the groove properly Install and tighten the cylinder head cover bolts to the specified torque in a crisscross pattern Torque 0 8 0 9kgf m KYMCO CAMSHAFT HOLDER REMOVAL Turn the A C generator fly wheel so that the T mark on the flywheel aligns with the index mark on the crankcase Hold the round hole on the camshaft gear facing up and location is the top dead center On the compression stroke Remove the two bolts attaching cam chain tensioner and tensioner Remove the four cap nuts and cylinder 2 bolts washers from camshaft holder and cylinder 2 bolts then remove the cam shaft Bolt Remove the camshaft gear and holder Bolt INSTALLATION Install the camshaft gear Holder bolt and holder washers and nuts Tighten the four cylinder head nuts to the specified torque Torque 0 7 1 1 kgf m Holder nuts 1 0 1 4 kgf m Cam shaft set plate 1 8 2 2 kgf m Cylinder head M8X1 25
34. and driven gear then set the snap ring securely on the pump shaft snap Ring Install the oil separator cover properly Fit the tab of the separator cover into the slit in the separator KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 125i DISASSEMBLY Remove the screw and disassemble the oil pump as shown Pump Cover Outer Rotor Inner Rotor Scre Pump Body Dowel Pin Pump Shaft INSPECTION Pump Body Outer Rotor Measure the pump body to outer rotor clearance dC KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 125i Outer Rotor Inner Rotor Measure the inner rotor to outer rotor clearance Measure the rotor end to pump body clearance Pump Body Rotor End ASSEMBLY Dowel Pin Pump Body Install the outer rotor inner rotor and pump shaft into the pump body Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor Install the dowel pin There is one punch mark on the surface of the inner rotor and outer rotor Outer Rotor Inner Rotor Pump Shaft The mark 15 upside 4 6 GQ KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 125i ENGINE REMOVAL INSTALLATION SERVICE 5 1 ENGINE REMOVAL INSTALLATION 5 2 5 8 5 0 GQ KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS
35. bypass valve For making stable idle r p m It location in the ECU David OU CPS Crank Position Sensor To detect flywheel let the ECU to judge and calculate the engine r p m crank position T MAP Temperature Manifold Air Pressure sensor Use DC 5V which ECU provide It location in the ECU Measure and provide gave ECU en
36. engine oil into a clean container before removing the right crankcase cover e When the right crankcase cover 15 installed fill with the recommended engine oil and coolant Then bleed air from the water Jacket e Refer to chapter 17 for A C generator inspection SPECIFICATIONS Engine oil SAE 10W 40 API SJ Over Oil capacity at change 1 0 liter Coolant distilled water coolant concentrate Coolant capacity 0 87L SPECIAL TOOLS Flywheel puller A120E00003 Flywheel holder A120E00021 TORQUE VALUES Flywheel nut 5 0 6 0 kgf m TROUBLESHOOTING Refer to page chapter 17 for A C generator troubleshooting Starter motor rotates but engine does not start e Faulty starter clutch e Starter motor rotates reversely e Weak battery 10 2 KYMCO 10 GENERATOR STARTER CLUTCH DOWNTOWNUSi ALTERNATOR STATOR REMOVAL Drain the engine oil refer to the ENGINE section in the chapter 3 Disconnect the alternator stator connectors refer to the chapter 17 Remove the 10 bolts from the right crankcase cover and then remove the cover Remove the two dowel pins and gasket Gasket Stator Remove the two pulse coil mount screws Remove the three stator mount bolts grommet and the stator from the right crankcase cover Pulser Coil 10 3 KYMCO IO A C GENERATOR STARTER CLUTCH DOWNTOWN 125i INSPECTION Check the stator and pulse coil for damage Stator INSTA
37. kgf m Cam chain tensioner slipper bolt 1 0 kgf m TROUBLESHOOTING Excessive engine noise e Excessive bearing play e Excessive crankpin bearing play e Worn piston pin and piston pin hole 11 2 KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 125i CRANKCASE SEPARATION Remove the two right crankcase attaching bolts Remove the left crankcase bolts Left Crankcase Right Crankcase Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase Never use a driver to pry the crankcase mating surfaces apart Remove the gasket and dowel pins Left Crankcase Remove the crankshaft from the left Crankshaft crankcase Left Crankcase 11 3 KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 125i Oil Seal Remove the oil seal from the left crankcase Left Crankcase CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Measure the connecting rod small end I D 11 4 dC KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 125i Measure the crankshaft runout Measure the crankshaft bearing play Radial CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces Avoid damaging the crankcase mating surfaces Install a new oil seal into the left crankcase dos Left Crankease 11 5 KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 125i Place the left crankcase down and install the
38. part of the antifreeze solution Water that 1s high in mineral content or salt may be harmful to the aluminum engine Using coolant with silicate inhibitors may cause premature wear of water pump seals or blockage of radiator passages Using tap water may cause engine damage The factory provides a 50 50 solution of antifreeze and distilled water in this scooter This coolant solution is recommended for most operating temperatures and provides good corrosion protection A higher concentration of antifreeze decreases the cooling system performance and 1s recommended only when additional protection against freezing 15 needed concentration of less than 40 60 40 antifreeze will not provide proper corrosion protection During freezing temperatures 3 18 GQ KYMCO 3 INSPECTION ADJUSTMENT DOWN TOWN 1251 check the cooling system frequently and add higher concentrations of antifreeze up to a maximum of 60 antifreeze if required 3 19 INSPECTION ADJUSTMENT BRAKE FLUID Brake fluid level With the scooter in an upright position check the front and rear fluid level It should be above the lower level mark If the level 1s at or below the lower level mark L check the brake pads for wear Worn pads should be replaced If the pads are not worn have your brake system inspected for leaks The recommended brake fluid is DOT 4 brake fluid from a sealed container or an equivalent Other checks M
39. ring 1 with engine oil and install it into the start motor groove Install the starter motor into the crankcase Install the two mounting bolts and engine ground cable then tighten the bolts securely Connect the start motor cable to motor terminal with the terminal screw and tighten it securely 19 4 KYMCO 19 STARTING SYSTEM DOWNTOWN 125 i START RELAY INSPECTION Release the rubber cap 1 and remove the nut 2 then disconnect the start motor cable Turn the ignition switch to Squeeze and hold the brake lever fully then push the starter switch The coil is normal if the start MAG switch clicks Release the rubber caps 1 and remove the nuts 2 then disconnect the start motor cable battery positive cable and harness wire Disconnect the start MAG switch connector 3 and then remove start MAG Connect a fully charged 12 V battery positive wire to the relay switch Yellow Red wire terminal and negative wire to the Green Yellow wire terminal There should be continuity between the cable terminals while the battery 1s connected and no continuity when the battery 15 disconnected 19 5 GQ KYMCO 20 LIGHTS METERS SWITCHES DOWNTOWN125 i LIGHTS METERS SWITCHES SERVICE INFORMATION BULB REPLACEMENT BRAKE LIGHT SWITCH IGNITION SWITCH
40. sudden surge of current may blow out the fuse the tester Specified current leakage 5 mA max If current leakage exceeds the specified value shorted circuit 15 likely Locate the short by disconnecting connections one by one and measuring the current 17 6 KYMCO 17 BATTERY CHARGING SYSTEM DOWNTOWN125i CHARGING VOLTAGE INSPECTION Be sure that the battery is in good condition before performing this test Do not disconnect the battery or any cable In the charging system without first switching off the ignition switch Failure to follow this precaution can damage the tester or electrical components Start the engine and warm it up to the operating temperature stop the engine Connect the multimeter between the positive and negative terminals of the battery To prevent short make absolutely certain which are the positive and negative terminals or cable With the headlight on and turned to the high beam position restart the engine Measure the voltage on the multimeter when the engine runs at 5000 rpm Standard Measured battery voltage page 17 5 Measure charging voltage see above 15 5 V 17 7 KYMCO 17 BATTERY CHARGING SYSTEM DOWNTOWN 125i REGULATOR RECTIFIER WIRE HARNESS INSPECTION Remove the luggage box refer to the COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the regulator rectifier connectors Chec
41. to enter page 03 The figure includes engine working temperature atmosphere pressure and manifold pressure Referto standard specifications on page 18 9 Press Down button to enter page 04 13 6 KYMCO 13 Fi DIAGNOSTIC TOOL OPERATION powN TOWN 125 The figure includes fuel injector interval 1gnition advance angle and ABV angle Referto standard specifications on page 18 9 Press Down button to enter page 05 The figure includes O2 sensor voltage O2 heater working condition and O2 correction Referto standard specifications on page 18 9 Press Down button to enter page 06 s a 4 The figure includes rollover voltage Referto standard specifications on page 18 9 Press Down button to enter page 07 The figure includes ECU counter hours Press the UP button to the first page 13 7 KYMCO 13 Fi DIAGNOSTIC TOOL OPERATION powN TOWN 125 ADJUST Need to make TPI ABV reset to operate after changing new ECU and clean THROTTLE BODY and changing the engine department product let ECU set up and set up initially Choose Adjust Press the Enter button to TPI ABV Reset Press the Enter button Please key switch off then key switch on Completed the TPI ABV reset operate 13 8 KYMCO 13 Fi DIAGNOSTIC TOOL OPERATION powN TOWN 125 Diagnostic Standard Specifications EF AO 4 919
42. 4 If required add the specified oil up to the upper level mark Do not overfill Engine oil capacity At disassembly 5 Reinstall the oil filler cap dipstick Check 236 for oil leaks At change Let the engine and exhaust system cool 1 01 before working in those areas Engine oil level check Check the engine oil level each day before riding the scooter The level must be maintained between the upper and lower level marks on the oil filler cap dipstick 1 Start the engine and let it idle for a few minutes 3 5 GQ KYMCO INSPECTION ADJUSTMENT DOWN TOWN 125i Engine oil replacement Engine oil quality 1s the chief factor affecting engine service life Change the engine oil as specified in the maintenance schedule When running in very dusty conditions oil changes should be performed more frequently than specified the maintenance schedule Please dispose of used engine oil in a manner that 15 compatible with the environment We suggest you take it in a sealed container to your local recycling center or service station for reclamation Do not throw it 1n the trash or pour it on the ground or down a drain Used engine oil may cause skin cancer if repeatedly left 1n contact with the skin for prolonged periods Although this 1s unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil
43. ASE COVER section in this chapter Use the special tool to hold the drive pulley then remove the nut and ratchet Special tool Universal holder A120E00017 Remove the drive pulley face and washer Hold the clutch outer with the universal holder and remove the clutch outer nut Special tool Universal Holder A120E00017 Remove the clutch outer driven pulley assembly and drive belt together KYMCO DOWNTOWN 125i Nut Ratchet 4 1 2 m 1 Y zi Y y J x l Universal Holder Nut Universal Holder Clutch Outer Driven Pulley Assembly Drive Belt 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i Remove the movable drive face assembly Movable Drive Face Assembly Drive belt inspection Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Use specified genuine parts for replacement Clutch out inspection Inspect the clutch outer for wear or damage Measure the clutch outer I D 8 6 8 DRIVE AND DRIVEN PULLEYS KICK STARTER INSTALLATION Apply lubricant to the drive face boss inner surface then install the movable drive face assembly Install the clutch outer onto the driven pulley assembly Compress the driven pulley assembly by hand then install the drive belt into the driven pulley assembly K e The drive belt should be installed so that the arrow
44. Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining 3 6 INSPECTION ADJUSTMENT m Remove the oil filler cap dipstick 1 from the right crankcase cover Place a container under the left crankcase Remove the oil drain plug 2 to drain the oil Reinstall the drain plug and tighten the drain plug to specification Oil drain plug torque 25 N m 2 5 kgf m Fill the crankcase with the recommended grade oil and install the oil fill cap Oil capacity after draining 1 0 liter Start the engine and let it idle for 2 3 minutes Stop the engine and check that the oil level is at the upper level mark on the oil filler cap dipstick with the scooter upright on firm level ground Make sure there are no oil leaks Let the engine and exhaust system cool before working in those areas 3 7 GQ KYMCO DOWN TOWN 125i INSPECTION ADJUSTMENT strainer screen clean Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining Let the engine and exhaust system cool before working in those areas Remove the oil filler cap dipstick 1 from the right crankcase cover 2 Place a drain pan under the crankcase and remove the oil strainer screen cap 2 The spring 3 and oil strainer scree
45. Diagnostic Report LFA7 Customer Eng Num Date of production repair Mileage Reason of repair maintenance breakdown x __ Eo uaaaevs sonwaeve 1 2 ver J _ 4 G enviontemp 2 C C EnsneTemp Coting evine 2 S Atom Pressure Kpa _ S throttle Position vene C f 5 5 5 S Inoue Position v 023v 2005 2327 WIDLETeefdly rmaewemco 925045 E Bat Vote J o isCAdpMen T 5 Cut Out switch vot V 04 144V 37 47V Qver65 25 Pp injection duration ms 16 276 80 90 8 9 C 2 S fignDwellduration msy 19 26m cas T Engine Temp CO gt E 02 sensor V o y jO2smsorheser Yesn Yes So 02 sensorcorret Jo pu cows 94 126 Engine wamupio80 907C gt 140 The scooter with exchang engine oil and clean throttly body ABVAngDurMech mE gt 80 The scooter must clean throttly body 48 60kps 80 90 C injection duration ms f 16 27m 80900 4 4 8 m Advance 5 j8o9vC SS fignDwellduration ms 19 26ms Batt
46. GENERAL INFORMATION KYMCO DOWNTOWN 125i SPECIFICATIONS Engine type O H C Front wheel 68 Rear wheel 96 Total 164 178 140 mm 7 9m 30km h ance 2600mm Starting motor Compression pressure kg cm 15 8750 9000 1 17 8500 8750 8 BTDC Port 1mm Close 31 BTDC timing Exhaust 32 BTDC 1mm 6 BTDC Valve 0 10 mm clearance 0 10 mm Idle speed rpm 1850rpm Inner outer rotor type Full flow filtration 1 21 Exchanging capacity LOL Cooling Type Liquid cooling Tires liquid cooled 4 stroke Single cylinder Semi sphere O H C 4V 54 x 54 5 11 7 1 215 lt cleaner type amp No Fuel capacity Throttle type Spark plug Spark plug gap 0 6 0 7mm I2VI0AH Type Dry multi disc clutch Non stage transmission Operation Automatic centrifugal type Two stage reduction Reduction 0 83 2 2 ratio 10 41 Front 28 Axle Trail length 140mm Paper element wet 12 5L 84 on Butterfly type ECU NGK CR7E dinbg eorgoo q lt UONIUS STUISUBL 84 wN uononpoy Tire pressure kg cm 1 Disk brake Disk brake Front DOUBLE SWING PIPE UNDER BONE Telescope 1 GENERAL INFORMATION Symbols The following symbols represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use Engine
47. HO INAWdINOA 1 21412313 STARTING SYSTEM LIGHTS SWITCHES FUEL PUMP 1 dO KYMCO DOWNTOWN 125i TABLE OF CONTENTS GENERAL INFORMATION EXHAUST MUFFLER FRAME COVERS DRIVE AND DRIVEN PULLEYS V BELT FINAL REDUCTION A C GENERATOR STARTER CLUTCH CRANKCASE CRANKSHAFT COOLING SYSTEM FUEL INJECTION SYSTEM STEERING HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER FRONT FORK 1 s s s REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER BATTERY CHARGING SYSTEM 1 IGNITION SYSTEM GQ KYMCO 1 GENERAL INFORMATION DOWNTOWN 125i GENERAL INFORMATION SERIAL NUMBER i395 eee ce ore te eia io uae ocio eaa eet atia sere eee acai 1 1 SPECIFICATION 1 2 SERVICE 5 1 3 TO DE SIL tU A E LL 1 4 SPECIAL 5 1 6 LUBRICATION POINTS 1 7 CABLE S HARNESS ROUTING 25 ee 1 8 dC KYMCO 1 GENERAL INFORMATION DOWNTOWN 125i SERIAL NUMBER Location of Frame Serial Number inside luggage box Location of Vehicle Identification Number VIN Location of Engine Serial Number 1 1 1
48. IGNITION SYSTEM DOWNTOWN 125 i IGNITION PULSE GENERATOR INSPECTION Remove the luggage box refer to the COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the ignition pulse generator connector 1 Measure the ignition pulse generator resistance between the Green White wire and Blue Yellow wire Standard 96 144Q 20 C 68 F 18 5 KYMCO 18 IGNITION SYSTEM DOWNTOWN 125i IGNITION COIL REMOVAL INSTALLATION Remove the luggage box refer to the COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the spark plug cap from the spark plug 1 Disconnect the ignition coil primary connector 2 Remove the two bolts 3 and the ignition coil 4 Installation is in the reverse order of removal 18 6 GQ KYMCO 19 STARTING SYSTEM DOWNTOWN 125 i STARTING SYSTEM STAPTINGSYSTENEIAYQUS Scenes ee ea 19 1 S u 19 1 SER VICE INFORMA TION cscs conce cece 19 2 TROUBLESHOOTING 19 2 STARTER eel sae 19 3 STARTER RELAY 19 5 19 0 19 STARTING SYSTEM STARTING SYSTEM LAYOUT Batte c Start MAG m m Ni i gd Na I 19 1 KYMCO DOWNTOWN 125i Start motor 19 STARTING SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS C KYMCO DOWNTOWN 125i e
49. ION SYSTEM DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch 1s and current 15 present e When servicing the ignition system always follow the steps in the troubleshooting e The ignition timing cannot be adjusted since the ignition control module 15 factory preset e The ignition control module or ECU may be damaged if dropped Also if the connector 15 disconnected when current 1s flowing the excessive voltage may damage the ignition control module or ECU Always turn off the ignition switch before servicing e A faulty ignition system is often related to poor connections Check those connections before proceeding Make sure the battery is adequately charged Using the starter motor with a weak battery results in a Slower engine cranking speed as well as no spark at the spark plug e Use a spark plug of the correct heat range Using spark plug with an incorrect heat range can damage the engine e See chapter 10 for ignition pulse generator removal installation e See chapter 14 for ECU removal installation inspection e See section 20 for those components Ignition switch Engine stop switch SPECIFICATIONS CR7E Spark plug Spark plug gap 0 6 0 7mm Ignition timing 18 2 GQ KYMCO 18 IGNITION SYSTEM DOWNTOWN 125 i TROUBLESHOOTING LOW PEAK VOLTAGE e Cranking spee
50. LLATION Install the stator and tighten the stator mount bolts to the specified torque Torque kgf m Apply sealant to the grommet seating surface and install it to the cover groove properly Install the pulse coil and tighten mount screws securely Pulser Coil Clean the mating surfaces of the right crankcase and cover Gasket Gasket Dowel Pins 10 4 KYMCO 10 GENERATOR STARTER CLUTCH DOWNTOWNUSi Install the dowel pins and gasket Install the right crankcase cover and tighten the bolts a crisscross pattern in 2 or 3 steps 10 5 KYMCO 10 GENERATOR STARTER CLUTCH DOWNTOWN 125i STARTER CLUTCH REMVOAL Remove the right crankcase cover refer to the ALTERNATOR STATOR section in this chapter Hold the flywheel with a special tool and remove the flywheel nut Special tool Flywheel holder A120E00021 Remove the flywheel driven gear by using the special tool Special tool Flywheel puller A120E00003 Remove the reduction gear shaft and reduction gear Reduction Gear 10 6 KYMCO IO A C GENERATOR STARTER CLUTCH DOWNTOWN 125i Starter Driven Gear Remove the starter driven gear INSPECTION Install the driven gear into the flywheel Check the operation of the sprag clutch by turning the driven gear You should be able to turn the driven gear clockwise smoothly but the gear should not turn cou
51. Lock nut wrench A120F00023 15 19 15 HANDLEBAR FRONT WHEEL FRONTBRAKE KYMCO Inspect the ball races cone races and steel balls for wear or damage Replace if necessary Remove the top balls Remove the upper ball race by using a chisel if necessary Remove the bottom balls Remove the bottom ball race by using a pipe if necessary Remove the bottom cone race by using a chisel if necessary Be careful not to damage the steering stem m Z Bottom Balls Bottom Cone Race 15 20 15 HANDLEBAR FRONT WHEEL FRONT BRAKE KYMCO INSTALLATION Install the new bottom cone race onto the steering stem Install the new upper and bottom ball races into the frame Apply grease to the top and bottom ball races and install new steel balls on the top ball race and new steel balls on the bottom ball race Install the steering stem Apply grease to the top cone race and install it Tighten the top cone race and then turn the steering stem right and left several times to make steel balls contact each other closely Check that the steering stem rotates freely without vertical play Lock nut wrench A120F00023 Install the steering stem lock nut and tighten it to the specified torque by using the special tool while holding the top cone race Torque 7 kgf m 70 N m Special tool Lock nut wrench A120F00002 15 21 1S HANDLEBAR FRONT WHEELFRONTBERAkg KYMCO Top B
52. NT WHEEL section in this chapter Remove the speed wheel sensor bolt 1 and then remove the brake hose guide from right front shock absorber Remove the speedometer cable guide from left front shock absorber Remove the two mounting bolts 2 and then remove the right front shock absorber Remove the two mounting bolts 3 and then remove the left front shock absorber INSTALLATION Installation is in the reverse order of removal Tighten the shock absorber mounting bolt to the specified torque Torque 3 2 kgf m 32 N m 23 Ibf ft INSPECTION Inspect the following items and replace if necessary eFront shock absorber tube bending damage Or wear eWeak front shock absorber spring eDamper and damper rod bending eOil seal damage or wear 15 16 15 HANDLEBAR FRONT WHEEL FRONT BRAKE KYMCO STEERING STEM REMOVAL Remove the steering handlebar refer to the HANDLEBAR section in this chapter Remove the front shock absorber refer to the FRONT SHOCK ABSORBER section in this chapter Remove the front brake hose and speed wheel Sensor connector 1 from the guide Hold the steering stem top cone race and remove the steering stem lock nut by using the special tool Special tool Lock nut wrench A120F00002 Remove the top cone race and washer remove the steering stem Be careful not to lose the steel balls 26 on top race and 19 on bottom race
53. O DOWNTOWN 125i KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 125i Loosen the rear axle nut Support the scooter securely on its main stand Remove the three bolts 1 from rear brake hose clamps Remove the two bolts 2 then remove the rear brake caliper 2 1 Disconnect the alternator connector 3 Disconnect the ignition pulse generator connector 4 a G Release the rubber cap and remove the terminal screw 5 to disconnect the start motor cable from the start motor 5 3 KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 125i Remove the bolts 6 and engine ground cable Remove the spark plug cap 9 5 4 KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 125i Disconnect the lower radiator hose 10 from lower radiator pipe Remove the right and left rear shock absorber lower mount bolts 11 GQ KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 125i Remove the engine mount nut 12 Pull out the engine mount bolt Remove the engine from the frame At removing the engine be careful not to catch your hand or finger between the engine hanger and crankcase KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 125i INSTALLATION Installation 1s in the reverse order of removal Tighten the engine mounting bolt nut to the specified torque Torque 5 kgf m 50 N m Tighten the right and left rear shock absorber lower mount bo
54. O2 SENSOR Standard 20 C 68 F 6 7 9 5 0 1 ON ROLL SENSOR Standard E Y d m es n x KYMCO DiagnosticReport DOWNTOWN 125 I SF Customer Eng No Production Service Date Date Reason of repair maintenance breakdown Mileage Item CU No Hardware Ver oftware Ver alibration Ver Model Name Active Occurred lt 7 2 6 History Air Temp C enviren temp 2 C ngine Temp Coiling Atom Pressure Kpa 1013 3kPa hrtlePostinp OO EP o 0 hrottle Position PIIdleMean V Battery Volt V Idle speed setpoint rpm SCAdapMean ut Out switch volt V dojgoursu 1002 1850 100 rpm 50 62 1 6 2 7ms 3 20 BTDC 1 9 2 6 ms environ temp 2 C gt 80 C 0 1 20 0 4 1 2 1409 1850 100 rpm 50 62 1 6 2 7ms 3 20 BTDC 1 9 2 6 ms environ temp 2 gt 80 C 1V E 20 0 4 1 2 1409 ngineSpeed IDLE rpm MAPSample kPa njection duration ms gn Advance 2 gn Dwell duration ms Air Temp C ngine Temp O2 sensor voltage V lt un O2 sensor heater Yes no O2 sensor correct DLE CO ABVAngDurMech 2 OuSu ngi
55. OWNTOWN 125i CYLINDER PISTON SCHEMATIC 7 1 SERVICE INFORMATION 9 VROUBLESEOO PING i 7 3 CYLINDER AND PISTON 7 4 7 0 GQ KYMCO 7 CYLINDER PISTON POWNIOWNES SCHEMATIC DRAWING 90005 KEC8 90001 di 90001 Y 91306 C KYMCO 7 CYLINDER PISTON DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder and piston can be serviced with the engine installed the frame e When installing the cylinder use a new cylinder gasket and make sure that the dowel pins are correctly installed e After disassembly clean the removed parts and dry them with compressed air before inspection SPECIFICATIONS Unit mm Em UL Cynder OPO ee Ring o groove fap 0015 005 _ Top Ring end gap Second 010 0285 02 07 pistonring 199200 ros 3235 DT 125 9mm from bottom of skirt PisonpinholeLD 15090 15008 PistompinO D ts 0 002 0 014 NENNEN ConnectingrodsmallendLD bore 15016 1504 _ 7 2 GQ KYMCO TROUBLESHOOTING e When hard starting or poor performance at low speed occurs check the crankcase breather for
56. Oil designated engine oil for lubrication din Grease Apply grease for lubrication Transmission Gear Oil 90 Use special tool gt Caution Warning GQ KYMCO DOWNTOWN 125i KYMCO 1 GENERAL INFORMATION DOWNTOWN 125i TORQUE VALUES STANDARD TORQUE VALUES 5mm bolt nut omm screw 6mm bolt nut 6mm screw SH bolt 0 7 1 1 amp mm bolt nut 6mm flange bolt nut 1 0 1 4 10mm bolt nut emm flange bolt nut 2 4 3 0 12mm bolt nut 10mm flange bolt nut 3 0 4 5 ENGINE Cylinder head stud bolt 1 Stud bolt Inlet pipe side 2 Stud bolt EX pipe side Cylinder head stud nut Right crankcase cover bolt Left crankcase cover bolt Bolt B stud 10 180 Valve adjusting lock nut Cam sprocket bolt Transmission oil check drain bolt Engine oil drain bolt Clutch outer nut otarter motor mounting bolt Mission case bolt Drive face nut Drive plate comp Cam chain tensioner bolt Cam chain tensioner pivot Oneway clutch bolt ACG flywheel nut opark plug Water pump impeller Double end bolt Double end bolt 04 Bo enun Apply oil to thread Apply oil to thread Apply oil to thread Apply thread lock Left thread KYMCO 1 GENERAL INFORMATION DOWNTOWN 125i TORQUE VALUES FRAME Steering 1 Stem lock nut 2 Handle post bolt 3 Bridge bolt 4 Race nut head Brake 1 Front Rear caliper bolt 2 Brake hose bolt 3 Disk bolt Engine hanger
57. RY 0 A 80 T QE Dee 3 23 3 0 GQ KYMCO SERVICE INFORMATION GENERAL N WARNING eBefore running the engine make sure that the working area is well ventilated Never run the engine in a closed area The exhaust contains poisonous carbon monoxide gas which may cause death to people eGasoline is extremely flammable and is explosive under some conditions The working area must be well ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area SPECIFICATIONS Throttle grip free play 2 6 mm Spark plug DOWNTOWN125 1 CR7E Spark plug gap 0 6 0 7 mm Valve clearance IN 0 1 mm EX 0 1 mm Idle speed 1850 rpm Cylinder compression 15 kgf cm 2 Engine oil capacity At disassembly 1 2 L At change 1 0L Gear oil capacity At disassembly 0 13 L At change 0 121 Coolant capacity Reserve tank capacity 0 49 liter Radiator capacity 0 87 liter Ignition timing ECU control Bia 1 Rider 75 kg 2 Riders 150 kg Front 2 0 kgf cm 2 Okgf cm Rear 2 25 kgf cm 2 25 kgf cm TIRE SPECIFICATION Front 120 80 14 Rear 150 70 13 3 1 GQ KYMCO INSPECTION ADJUSTMENT DOWN TOWN 125i TORQUE VALUES Front axle 2 0 kgf m Rear axle nut 12 kgf m MAINTENANCE SCHEDULE Perform the pre ride inspection at each scheduled maintenance period This interval should be judged by odometer reading or months whichever
58. S TIRES i GQ KYMCO 3 INSPECTION ADJUSTMENT DOWN TOWN 125i FUEL LINE FUEL FILTER Check the fuel lines and replace any parts which show signs of deterioration damage or leakage THROTTLE OPERATION Check the throttle grip for smooth movement Measure the throttle grip free play Free Play 2 6 mm 2 6mm 0 08 0 24 in Major adjustment of the throttle grip free play 16 made with the adjusting nut at the carburetor side Adjust by loosening the lock nut turning the adjusting nut KYMCO 3 INSPECTION ADJUSTMENT DOWN TOWN 1 25 Minor adjustment is made with the adjusting nut at the throttle grip side Slide the rubber cover 1 out and adjust by loosening the lock nut 3 and turning the adjusting nut 2 ENGINE OIL Engine oil recommendation 2 Stop the engine and put the scooter on its center stand on level ground Use a premium quality 4 stroke motor oil to 99 ensure longer service life of your scooter Use After a few minutes remove the oil filler cap dipstick wipe it clean and reinsert the ony oils ud rated SJ under the API oil filler cap dipstick without screwing it service classification The recommended in Remove the oil filler cap dipstick The viscosity is SAE 10W 40 If a SAE 10W 40 oil level should be between the upper and a lower marks on the oil filler cap dipstick motor oil is not available select an alternative according to the right chart
59. SYSTEM Downtown 1251 Impeller Left Hand Threads Install the impeller onto the water pump shaft Torque 1 2 kgf m 12 N m 9 Ibf ft The impeller has left hand threads Dowel Pins Install the two dowel pins and a new gasket Gasket Water Pump Cover Install the water pump cover and tighten the 4 bolts Torque kgf m 10 N m 7 Ibf ft 12 15 12 COOLING SYSTEM WATER TEMPERATURE SENSOR METER S COOLANT TEMPERATURE GAUGE REMOVAL Remove the luggage box refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Drain the coolant refer to the COOLANT REPLACEMENT section in this chapter Disconnect the water temperature sensor connectors 1 Remove the water temperature sensor 2 from thermostat INSPECTION Connect the water temperature sensor to the ohmmeter and dip it in oil contained in a pan which 15 placed on an electric heater Gradually raise oil temperature while reading the thermometer in the pan and the ohmmeter connected If the resistance measured 15 out of specification replace the temperature gauge with a new one 50C 123 9 4789 Q 100 C 26 2930 e Handle the water temperature sensor carefully as it 1s vulnerable to impact e Do not allow the water temperature sensor and the thermometer to come in contact with the bottom of the pan Sensor KYMCO Downtown 1251 12 16 GQ KYMCO 12 COOLING SYSTEM Dow
60. TMENT DOWN TOWN 125i VALVE CLEARANCE e Inspect and adjust valve clearance while the engine is cold below 35 Remove the four bolts then remove cylinder head cover Remove the timing hole cap and O ring Remove the crankshaft hole cap and O ring Turn the A C generator flywheel clockwise to the top dead center TDC on the compression stroke so that the mark on the flywheel aligns with the index mark on the left crankcase cover The punch mark the camshaft should face upward as shown If the punch mark on the camshaft are facing downward turn the crankshaft clockwise one full turn 360 and the punch mark are facing upward 3 14 GQ KYMCO 3 INSPECTION ADJUSTMENT DOWN TOWN 1251 Adjust by loosening the valve adjusting screw lock nut and turning the adjusting screw until there is a slight drag on the thickness gauge Valve Clearance IN 0 1 mm EX 0 1 mm Apply oil to the valve adjusting screw lock nut threads and seating surface Hold the adjusting screw and tighten the lock nut to the specified torque Torque 0 9 kgf m 9 N m Special tool Valve adjuster AI20E00036 After tightening the lock nut recheck the valve clearance Install the removed parts the reverse order of removal IDLE SPEED gt e It is not necessary to adjust idle speed for DOWNTOWN 1251 The throttle body 15 factory pre set do not loosen or tighten the painted bolts and s
61. TON Inspect the exhaust side and intake side chain guides Wear Damage Replace INSTALLATION Piston ring Carefully install the piston rings into the piston ring grooves with the markings facing up Be careful not to damage the piston and rings Do not confuse the top and second rings To install the oil ring install the oil ring then install the side rails Stagger the piston ring end gaps 120 degrees apart from each other Stagger the side rail end gaps as shown GQ KYMCO DOWNTOWN 125i Intake Side Guide Exhaust Side Guide Side Rail Oil Ring Side Rail 7 8 KYMCO 7 CYLINDER PISTON POWNIOWNES Cylinder Piston Clean any gasket material from the cylinder mating surfaces of the crankcase and oil passage Apply engine oil to the piston pin Apply engine oil to the connecting rod small end and piston pin hole Install the piston with the IN mark face intake side and piston pin Place a clean shop towel over the crankcase prevent the clip from falling into the crankcase Install the new pin clip Make sure that the piston pin clips are seated securely Do not align the piston pin clip end gap with the piston cut out Install the dowel pins and gasket 7 9 KYMCO 7 CYLINDER PISTON DOWNTOWN 125i Apply engine oil to the cylinder wall piston and piston ring outer surfaces Pass the cam chain thro
62. Technical Data 80 82 C 176 Begins to open 180 F Full open 90 C 198 F Valve lift 3 5 mm 0 14 in minimum e Do not let the thermostat touch the pan as it will give a false reading e Replace the thermostat if the valve stays open at room temperature e Test the thermostat after it is opened for about 5 minutes and holds the temperature at 70 ASSEMBLY Thermostat assembly is in the reverse order of disassembly Thermostat Housing 12 20 KYMCO 13 Fi DIAGNOSTIC TOOL OPERATION powN TOWN 125 F1 Diagnostic Tool Operation nstructions Part No 3620A LEB2 E00 ECU Version agg BS DIC Inspect DATA Analyze D AdJust i KEY FUNCTION 1 Model No DATA Analyze 2 Down Button 9 DTC Inspect 8 DTC indicator Failure codes ECU Version 4 Enter or Exit Power indicator 6 UP Button 7 Adjust TPI and ABV reset function KYMCO 13 Fi DIAGNOSTIC TOOL OPERATION powN TOWN 125 Fi diagnostic tool Outlook DTC Inspection Precedure DTC Clear Procedure Data Analysis 13 1 KYMCO 13 Fi DIAGNOSTIC TOOL OPERATION powN TOWN 125 DTC INSPECTION PROCEDURE Connect Fi diagnostic tool with the connector of harness wire located beside the Battery Press the Enter button Check the software version Press the Enter button and then turn to the first page Press the Down button to enter the DTC Inspect
63. able drive face splines for wear cracks or damage Check ramp plate for cracks or damage Check the movable drive face and drive pulley face cracks or damage 9 10 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i DRIVE PULLEY ASSEMBLY Clean the movable drive face drive pulley face weight rollers slide pieces ramp plate and drive face boss Remove any excess grease Install the weight rollers X The direction of all weight rollers is the same The thin side 15 towards to clockwise Weight Roller Install the slide pieces and ramp plate 8 11 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i Install the drive face boss Boss 9 12 8 DRIVE AND DRIVEN PULLEYS KYMCO __ STARTER Q 4 DOWNTOWNUSi DRIVEN PULLEY DISASSEMBLY Hold the clutch driven pulley assembly with the clutch spring compressor Be sure to use a clutch spring compressor to avoid spring damage Special tool Lock Nut Wrench Clutch Spring Compressor A120E00034 Set the tool in a vise and remove the clutch drive plate nut Clutch spring compressor Remove the clutch 8 13 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i Remove the spring Remove the spring collar on the movable driven face Remove the three guide pins rollers then remove the movable driven face Remove the need
64. ake sure there are no fluid leaks Check for deterioration or cracks the hoses and fittings BRAKE PAD WEAR Brake pad wear depends upon the severity of usage the type of riding and road conditions Generally the pads will wear faster on wet and dirty roads Inspect the pads at each regular maintenance interval Front brake Check the cutout in each pad If either pad 15 worn to the cutout replace both pads as a set See your KYMCO dealer for this service Rear brake Check the cutout in each pad If either pad 15 worn to the cutout replace both pads as a set See your KYMCO dealer for this service KYMCO DOWN TOWN 125i GQ KYMCO 3 INSPECTION ADJUSTMENT DOWN TOWN 125 NUTS BOLTS FASTENERS Check all important chassis nuts and bolts for looseness Tighten them to their specified torque values if any looseness is found WHEELS TIRES Tire pressure Insufficient air pressure in the tires not only hastens tire wear but also seriously affects the stability of the scooter Under inflated tires make smooth cornering difficult and overinflated tires decrease the amount of tire in contact with the ground which can lead to skids and loss of control Be sure that the tire pressure 15 within the specified limits at all times Tire pressure should only be adjusted when the tires are cold Cold inflation tire pressure lc Rider 75 kg 2 Riders 150 kg 2 0kg cm 2 25 kg cm ront
65. all Cone Race Remove special tool Bottom Ball Race Remove special tool 120 000 Bottom Ball Top Ball Cone Race Install special tool Install special tool 120 FOO0019 15 22 16 REAR BRAKE REAR FORK REAR REARBRAKE REAR FORK REAR REARSHOCK ABSORBER SCHEMATIC DRAWING 16 1 SERVICE INFORMATION 16 2 TROUBLESHOOTING 16 2 REAR 16 3 REAR 16 6 REAR WHEEL 16 7 REAR SHOCK 5 16 7 16 0 16 REAR BRAKE REAR FORK REAR KYMCO SCHEMATIC DRAWING 95801 10040 99801 10040 95801 10040 X2 x 90302 LLB1 43156 95801 10075 X2 52000 42600 42312 90305 90122 1 7 16 1 16 REAR BRAKE REAR FORK REAR KYMCO SERVICE INFORMATION GENERAL INSTRUCTIONS e When performing the services stated in this section the engi
66. comes first I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE The following maintenance schedule specifies all maintenance required to keep your scooter in peak operating condition Maintenance work should be performed in accordance with standards and specifications of KYMCO by properly trained and equipped technicians Your KYMCO dealer meets all of these requirements Should be serviced by your KYMCO dealer unless the owner has the proper tools and service data and 1s mechanically qualified In the interest of safety we recommend these items be serviced only by your KYMCO dealer KYMCO recommends that your KYMCO dealer should road test your scooter after each periodic maintenance 15 carried out KYMCO 3 INSPECTION ADJUSTMENT DOWN TOWN 1 25 MAINTENANCE SCHEDULE WHICHEVER COMES ODOMETER READING NOTE 1 FIRST 1000 T3 8 L7 S REFER 1000 mi 0 2 0 6 1 8 3 4 2 5 4 6 6 TO NOTE MONTH lale 24 30 PAGE AIR CLEANER 2 SPARK PLUGS THROTTLE OPERATION VALVE CLEARANCE FUEL LINE CRANKCASE BREATHER ENGINE OIL ENGINE OIL STRAINER SCHEEN ENGINE IDLE SPEED TRANSMISSION OIL DRIVE BELT WHICHEVER COMES ODOMETER READING NOTE 1 FIRST X1000kmo3 1 3 5 7 9 tt nEFER X 1000 0 2 0 6 1 8 3 4 2 5 4 6 6 TO 18 24 3 BRAKE FLUID NOTE 6 HEADLIGHT AIM NUTS BOLTS FASTENERS WHEEL
67. crews of throttle body Loosening or tightening them can cause throttle and idle and valve synchronization failure Idle Speed DOWNTOWN1251 16504100 rpm 3 15 KYMCO 3 INSPECTION ADJUSTMENT DOWN TOWN 125i CYLINDER COMPRESSION Warm up the engine before compression test Remove the center cover and spark plug cap Remove the spark plug Insert a compression gauge Open the throttle valve fully and push the starter button to test the compression Compression Downtown1251 15 kgf cm If the compression 1s low check for the following Leaky valves Valve clearance to small Leaking cylinder head gasket Worn pistons Worn piston cylinder If the compression 15 high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head DRIVE BELT Remove the left crankcase cover Inspect the drive belt for cracks or excessive wear Replace the drive belt with a new one if necessary and in accordance with the Maintenance Schedule 3 16 KYMCO 3 INSPECTION ADJUSTMENT DOWN TOWN 1251 CLUTCH SHOE WEAR Start the engine and check the clutch operation by increasing the engine speed gradually If the scooter tends to creep or the engine stalls check the clutch shoes for wear and replace if necessary refer to the DRIVE PULLEY DRIVE BELT AND DRIVEN PULLEY section in the chapter 8 Horizontally Adjusting Screw HEADLIGHT AIM Remove th
68. d 1s too low battery 1s undercharged e Poorly connected connectors or an open circuit in the ignition system e Faulty ignition coil e Faulty ignition control module NO PEAK VOLTAGE Short circuit in engine stop switch or ignition switch wire Faulty engine stop switch or ignition switch Loose or poorly connected ignition control module connectors Open circuit or poor connection in ground wire of the ignition control module Faulty ignition pulse generator Faulty ignition control module PEAK VOLTAGE IS NORMAL BUT NO SPARK JUMPS AT THE PLUG e Faulty spark plug or leaking ignition coil secondary current e Faulty ignition coil 18 3 KYMCO 18 IGNITION SYSTEM DOWNTOWN 125i IGNITION COIL INSPECTION P P IGNITION COIL PRIMARY PEAK VOLTAGE Remove the center cover refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 7 Check cylinder compression and check that the spark plug 1 15 installed correctly in the cylinder Disconnect the spark plug cap 2 from the 1 2 spark plug Turn the ignition switch to and engine stop switch ON and side stand is up Connect the multimeter probe to the black wire and the multimeter to the body ground Check for initial voltage at this time The battery voltage should be measured If the initial voltage cannot be measured check the power supply circuit 18 4 dC KYMCO 18
69. dO KYMCO 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 is expressly prohibited T300 SK25AA A1 PREFACE This Service Manual describes the technical features and servicin rocedures for the KYMC owntown oection 1 contains the precautions for all operations stated in this manual Head them carefully before 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 oection 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 KWANG YANG MOTOR CO LTD QUALITY TECHNOLOGY DEPT EDUCATION SECTION SISSV
70. der head Downtown l5kg cm2 compression pressure 1251 Cylinder head warpage 25 965 Camshaft D11251 EX 25810 m height IN 10 0 10 015 EX 10 0 10 015 Valve rocker arm I D Valve rocker arm shaft IN 9 972 9 987 O D EX 19 972 90 987 4975 4970 Valve stem O D N S58 212 4 a 220 2 IN 50 5012 Valve guide I D EX i 0 9 TE Valve stem to guide IN 0 010 0 037 COO O clearance EX 0 030 0 057 IEEE NN TORQUE VALUES Cylinder head cover bolt 0 8 0 9 kgf m Tensioner mounting bolt 0 9 kgf m Tensioner sealing bolt 0 9 kgf m Cylinder head cap nut 2 kgf m Apply engine oil to threads Cylinder head bolt 0 7 1 1 kgf m GQ KYMCO 6 CYLINDER HEAD VALVES POWNTOWNUS SPECIAL TOOLS Valve spring compressor 120 00040 TROUBLESHOOTING e poor cylinder head operation can be diagnosed by a compression test or by tracing engine top end noises Poor performance at idle speed White smoke from exhaust muffler e Compression too low e Worn valve stem or valve guide e Damaged valve stem oil seal Compression too low e ncorrect valve clearance adjustment Abnormal noise e Burned or bend valves e Incorrect valve clearance adjustment e Incorrect valve timing e Sticking valve or broken valve spring e Broken valve spring e Damaged or worn camshaft e Poor valve and seat contact e
71. der of removal REAR SPOILER REAR SPOILER STAY Unlock the seat with the ignition key Open the seat Remove the three bolts Remove the bolt covers and bolts then remove the rear spoiler KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i Installation is in the reverse order of removal UPPER LOWER HANDLEBAR COVER Remove the 4 screws then remove upper handlebar cover Remove the 4 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 dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i WINDSHIELD WINDSHIELD GARNISH Remove the 5 bolts and windshield garnish Installation is in the reverse order of removal 2 EXHAUST MUFFLER FRAME COVERS FRONT METER VISOR Remove the windshield see page 2 6 Remove the front cover Remove4 screws then remove the front meter visor Installation 1s the reverse order of removal FRONT COVER Remove the small front cover black screw Remove the small front cover black Remove the two nuts Remove the 8 screws from the inner cover Remove the front cover 2 7 KYMCO DOWNTOWN 125i KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i Disconnect the headlight position light connect and right left tur
72. e A floor Jack or other adjustable support 15 required to support and maneuver the engine careful not to damage the scooter body cables and wires during engine removal e Use shop towels to protect the scooter body during engine removal e Drain the coolant before removing the engine e After the engine 15 installed fill the cooling system with coolant and be sure to bleed air from the water Jacket Start the engine to check for coolant leaks e Before removing the engine the rear brake caliper must be removed first Be careful not to bend or twist the brake fluid tube SPECIFICATIONS Engine oil capacity at disassembly 1 2L 1 27 US qt at change 1 0 L 1 06 US qt Coolant capacity Radiator capacity 0 87 liter Reserve tank capacity 0 49 liter TORQUE VALUES Engine hanger Engine side 5 kgf m 50 N m Engine hanger Frame side 6 5 kgf m 65 N m 5 ENGINE REMOVAL INSTALLATION ENGINE REMOVAL INSTALLATION REMOVAL Remove the air cleaner Disconnect the ECU connector A Disconnect the O2 heater O2 sensor connector Disconnect the throttle cable B Remove a bolt from fuel hose guide C Disconnect the fuel hose D from fuel injector Disconnect the WTS connector E from WITS Disconnect the coolant temperature sensor connector F from coolant temperature sensor Disconnect the fuel injector connector G Disconnect the output water hose H Disconnect the air bleed hose I C KYMC
73. e cover and replace the mechanical seal Water Pump Outlet Hose WATER PUMP IMPELLER REMOVAL Drain the coolant see page 12 5 Remove the coolant inlet hose and outlet hose Inlet Hose 12 11 GQ KYMCO 12 COOLING SYSTEM Downtown 125i Remove the four bolts and the water pump Bolts Water Pump Cover cover gasket and 2 dowel pins Remove the water pump Impeller The impeller has left hand threads Inspect the mechanical water seal and seal Seal Washer Porcelain Mechanical Seal washer for wear or damage KYMCO 12 COOLING SYSTEM Downtown 125 i WATER PUMP SHAFT REMOVAL Disconnect the water hose from the right crankcase cover Remove the 5 bolts attaching the water pump assembly Remove the water pump assembly gasket and dowel pins Remove the water pump shaft clip and water pump shaft 12 13 KYMCO 12 COOLING SYSTEM Downtown 125i Install the dowel pins and a new gasket and then install the water pump assembly to the right crankcase cover Tighten the 5 bolts to secure the water pump assembly Water Pump Assembly NEP Ey L When Installing the water pump assembly aligning the groove on the water pump shaft with the tab on the oil pump shaft WATER PUMP IMPELLER INSTALLATION When the mechanical seal 1s replaced a new seal washer must be installed to the impeller KYMCO 12 COOLING
74. e front cover Place the scooter on a level surface Adjust the headlight beam adjuster A clockwise rotation moves the beam up and counterclockwise rotation moves the beam down Adjust the headlight beam horizontally by turning the horizontal beam adjuster A clockwise rotation moves the beam toward the right side of the rider Vertically Adjusting Screw 3 17 GQ KYMCO INSPECTION ADJUSTMENT DOWN TOWN 125i COOLANT Inspection The reserve tank 1s under footboard left Check the coolant level through the inspection window 1 at the front lower cover while the engine 15 at the normal operating temperature with the scooter in an upright position If the coolant level is below the LOWER level mark 3 remove screw 4 and reserve tank lid 5 and reserve tank cap 6 and add coolant mixture until it reaches the upper level mark 2 Always add coolant to the reserve tank Do not attempt to add coolant by removing the radiator cap If the reserve tank is empty or if coolant loss is excessive check for leaks and see your KYMCO dealer for repair 5 Coolant recommendation The owner must properly maintain the 4 coolant to prevent freezing overheating and corrosion use only high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum 1 engines See antifreeze container label Use only low mineral drinking water or distilled water as a
75. el unit wire connectors and turn the ignition switch ON Before performing the following test operate the turn signals to determine that the battery circuit 15 normal Check the fuel meter for correct indication by sn i E moving the fuel unit float up and down Display Much Full Less Empty Display Apply e to The fuel meter is normal if it operates as above indicated If not check for poorly connected terminals or shorted wires Measure the resistance between the Yellow White and Blue White terminals of the fuel unit connector Standard at 20 C 68 F Float at full position About1100 Q Float at empty position About100 Q INSTALLATION Installation is in the reverse order of removal 20 11 KYMCO 20 LIGHTS METERS SWITCHES DOWNTOWN125 i SIDE STAND SWITCH INSPECTION Remove the luggage box refer to the COVERS REMOVAL INSTALLATION section in the chapter 2 Side stand switch 1s located on side stand Disconnect the side stand switch connector 1 There should be continuity between the Yellow Green and Green with the side stand retracted There should be continuity between the Yellow Black and Green with the side stand applied REMOVAL Disconnect the side stand switch connector Remove the bolt 1 and side stand switch from the side stand INSTALLATION Installs the side stand switch aligning the groove on the switch with the pi
76. elength Sid SSCS Driven face O D 33 965 33 985 Movable driven face I D 34 34 025 MEE Weight roller O D 17 920 18 080 TORQUE VALUES Drive face nut 5 5 6 5 kgf m Clutch outer nut 5 0 6 0 kgf m Clutch plate comp 5 0 6 0 kgf m SPECIAL TOOLS Universal holder A120E00017 Clutch spring compressor A120E00034 8 DRIVE AND DRIVEN PULLEYS KICK STARTER TROUBLESHOOTING Engine starts but motorcycle won t move e Worn drive belt e Broken ramp plate e Worn or damaged clutch lining e Broken driven face spring Engine stalls or motorcycle creeps e Broken clutch weight spring GQ KYMCO DOWNTOWN 125i Lack of power e Worn drive belt e Weak driven face spring e Worn weight roller e Faulty driven face 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i LEFT CRANKCASE COVER REMOVAL Remove the 10 left crankcase cover bolts and then remove the left crankcase cover Remove the gasket and dowel pins Dowel Pins INSTALLATION No Install the dowel pins and gasket SAT A Install the left crankcase cover X Do not pull out the kick starter spindle Press in the kick starter spindle when installing the left crankcase cover Install and tighten the 10 bolts diagonally to specified torque 8 DRIVE AND DRIVEN PULLEYS KICK STARTER DRIVE PULLEY DRIVE BELT AND DRIVEN PULLEY REMOVAL Remove the left crankcase cover refer to the LEFT CRANKC
77. ery Volt V 14V 19 21ms12V25 26ms P o gt Esmee ceo 2 forsensorvolage ov LLL fO2sensorheater vesino ves 8 fO2sensorcomect 0 00000 22 Engine warm up to 80 90 mM OW H AzI gt 140 The scooter with exchang engine oil and clean throttly body ABV AngDurMech lt 1402 gt 80 The scooter must clean throttly body Repair description Repair Process Report ID Report Version DEC 11 2008 13 9 DOWN TOWN 125 FUEL PUMP INDUCTIVE IGNITION COIL KEY OFF
78. esume its voltage after it 1s recharged but its voltage decreases suddenly and then increases when a load 1s added e When a battery 1s overcharged some symptoms can be found If there 1s a short circuit inside the battery no voltage 1s produced on the battery terminals If the rectifier won t operate the voltage will become too high and shorten the battery service life e f a battery 1s not used for a long time it will discharge by itself and should be recharged every 3 months e A new battery filled with electrolyte will generate voltage within a certain time and it should be recharged when the capacity 1s insufficient Recharging a new battery will prolong its service life e nspect the charging system according to the sequence specified 1n the Troubleshooting e Do not disconnect and soon reconnect the power of any electrical equipment because the electronic parts the regulator rectifier will be damaged Turn off the ignition switch before operation e t is not necessary to check the MF battery electrolyte or fill with distilled water e Check the load of the whole charging system e Do not quick charge the battery Quick charging should only be done in an emergency e Remove the battery from the motorcycle for charging e When replacing the battery do not use a traditional battery e When charging check the voltage with an electric tester SPECIFICATIONS Standard Capacity Voltage Fully charged 20 C Undercharged
79. f removal Bulb 20 5 KYMCO 20 LIGHTS METERS SWITCHES DOWNTOWN125 i BRAKE LIGHT SWITCH Remove the upper handlebar cover refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect front or rear light switch connectors and check for continuity between the switch terminals 1 There should be continuity with the front or rear brake lever squeezed and there should be no continuity with the front or rear brake lever 1s released IGNITION SWITCH INSPECTION Remove the front cover refer to the COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the ignition switch connector 2 and check the ignition switch 1 for continuity at the switch side connector terminals Continuity should exist between the color code wires as follows COMB SW 20 6 GQ KYMCO HANDLEBAR SWITCH INSPECTION Remove the front cover refer to the Engine Stop Switch FRAME COVERS REMOVAL INSTALLATION section the chapter 2 Right handlebar switch Disconnect the right handlebar switch connector and check for continuity at switch side connector terminals Continuity should exist between the color code wires as follows A PO TL HL ps 0 STARTER SW ENGINE STOP SW G F PUSH OTO RN COLOR 20 7 KYMCO
80. gine intake temperature and air pressure TPS Throttle Position Sensor Use DC which ECU provide To detect how 77 4 much the throttle to be opened Help injector and ignition make correct control WTS Water Temperature Sensor Use DC 5V which ECU provide To detect engine temperature O2 Oxygen sensor Use DC 8 16V which ECU provide Locate on forward end to detect the thickness of oxygen let ECU decide to increase or decrease the fuel injection The sensor can t work until the exhaust temperature over 350 centigrade There s a heater inside when turning on the switch it will heat the sensor to working temperature Down town 1251 Inductive ignition coil Fuel pump ECU Fuel injector WTS sensor sensor ABV TPS Roll sensor CPS 02 02 HT sensor TPS ABV T MAP sensor Manifold and air pressure T MAP sensor Temperature Before maintaining injection vehicles you have to notice something as follow 1 Never to dismantle the wire of batte while engine is running or the ECU will 2 Never dismantle the ECU while engine is running or the ECU will be destroyed 3 Be sure to use the anti interfere spark plug 4 Be sure to relieve the fuel pressure before removing fuel pump or fuel hose
81. gs are noisy or have excessive play KYMCO DOWNTOWN 125i KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 125i INSTALLATION Punch Marks Turn the A C generator flywheel so that the mark on the flywheel aligns with the index mark on the crankcase Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the cam chain over the camshaft gear h l Round Hole Cam shaft Install the rocker arms shafts bolt Bolt Install the camshaft gear Camshaft Gear 6 10 GQ KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN isi Valve Spring Compressor DISASSEMBLY Remove the valve spring cotters retainers springs spring seats oil seals and valves using a valve spring compressor e Be sure to compress the valve springs with a valve spring compressor e Mark all disassembled parts to ensure correct reassembly Special tool Valve Spring Compressor A120E00040 Valves e 00 e 9 00 e D a 14777 SS a e 12209 NS QS 14751 3 44771 14781X8 9 y dU 6 11 GQ KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 2 INSPECTION Combustion Chamber Remove carbon deposits from the exhaust port and combustion chamber Be careful not to damage the cylinder head mating surface Valve Valve guide Inspect each valve for bending
82. heavily loaded Be certain to adjust both shock absorbers to the same spring preload positions Standard spring preload position 3 A CAUTION Always adjust the shock absorber pre load position in sequence 1 2 3 4 5 or 5 4 3 2 1 Attempting to adjust directly from 1 to 5 or 5 to 1 may damage the shock absorber 16 8 GQ KYMCO 17 BATTERY CHARGING SYSTEM DOWNTOWN 125i BATTERY CHARGING SYSTEM CHARGING SY SIENI AN OU 17 1 CHARGING CIRC UU 17 1 SERVICE INFORMA TION Eu tc a cece 17 2 TROUBLE SHOOTING O uuu 17 3 BATI Resear ae 17 4 CHARGING SYSTEM 17 6 REGULA TOR RECTIPIER accus teens 17 8 17 0 KYMCO 17 BATTERY CHARGING SYSTEM DOWNTOWN125i CHARGING SYSTEM LAYOUT y a EEE REGULATOR RECTIFIER d gt 2 4 ACG 17 1 GQ KYMCO 17 BATTERY CHARGING SYSTEM DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS gt The battery electrolyte sulfuric acid 1s poisonous and may seriously damage the skin and eyes Avoid contact with skin eyes or clothing In case of contact flush with water and get prompt medical attention e The battery can be charged and discharged repeatedly If a discharged battery 1s not used for a long time its service life will be shortened Generally the capacity of a battery will decrease after it is used for 2 3 years capacity decreased battery will r
83. hen the coolant temperature is over 100 C never remove the radiator cap to release the pressure because the boiling coolant may cause danger e Avoid spilling coolant on painted surfaces because the coolant will corrode the painted surfaces Wash off any spilled coolant with fresh water as soon as possible e After servicing the system check for leaks with a cooling system tester SPECIAL TOOL Mechanical seal driver TORQUE VALUES Water pump impeller 1 2 kgf m 12 N m 9 Left hand threads Water pump cover bolt kgf m 10 N m 7 TROUBLESHOOTING Engine temperature too high Coolant leaks e Faulty temperature gauge or thermosensor e Faulty pump mechanical water seal e Faulty radiator cap e Deteriorated O rings e Faulty thermostat e Damaged or deteriorated water hoses e nsufficient coolant e Passages blocked in hoses or water Jacket e Clogged radiator fins e Passages blocked in radiator e Faulty water pump Temperature gauge pointer does not register the correct coolant temperature e Faulty temperature gauge or thermosensor e Faulty thermostat 12 1 GQ KYMCO 12 COOLING SYSTEM Downtown 125 i SPECIFICATIONS Radiator cap relief pressure 90 kPa 0 9 12 8 psi 80 82 C 176 180 F Thermostat temperature Full open 909 198 F Valve lift 13 5 mm 0 14 in minimum Coolant capacity Radiator and engine 10 87 Reservetank 00 49 liter COOLANT GRAVITY
84. ilable brake bleeder follow the manufacturer s operating instructions 15 11 1S HANDLEBAR FRONT WHEELFRONTBERAkg KYMCO Brake fluid draining Make sure that the master cylinder parallel to the ground before removing the reservoir Remove two screws 1 Remove the reservoir cover diaphragm plate and diaphragm Connect a bleed hose to the bleed valve 15 12 15 HANDLEBAR FRONT WHEEL FRONT BRAKE KYMCO Loosen the bleed valve and pump the brake lever Stop operating the brake when no more fluid flows out of the bleed valve Brake fluid filling Air bleeding Do not mix different types of fluid since they are not compatible Fill the master cylinder with DOT 4 brake fluid to the upper level Connect a commercially available brake bleeder to the front caliper bleed valve Check the fluid level often while bleeding the brake to prevent air from being pumped into the system When using a brake bleeding tool follow the manufacture s operating instructions gt If air enters the bleeder from around the bleed valve threads seal the threads with teflon tape Pump the brake bleeder and loosen the front caliper bleed valve Add fluid when the fluid level in the master cylinder Is low to prevent drawing air into the system Repeat the above procedures until no air bubbles appear in the plastic hose Close the front caliper bleed valve and operate the front bra
85. k the connectors for loose contacts of corroded terminals Battery line Measure the voltage between the Red White wire terminal and ground There should be battery voltage at all times GQ KYMCO 17 BATTERY CHARGING SYSTEM DOWNTOWN125i Ground line Check the continuity between the Green wire terminal and ground There should be continuity at all times Charging coil line Measure the resistance between each Yellow wire terminals Standard 0 4 0 6 20 C 68 F Disconnect the regulator rectifier connector Check for continuity between each Yellow wire terminal regulator rectifier side and ground There should be no continuity 17 9 KYMCO 17 BATTERY CHARGING SYSTEM DOWNTOWN 125i 3 2 REMOVAL INSTALLATION Remove the side body cover refer to the COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the regulator rectifier connectors Remove the two bolts 2 regulator rectifier 3 Installation is in the reverse order of removal 17 10 GQ KYMCO 18 IGNITION SYSTEM DOWNTOWN 125i IGNITION SYSTEM IGNITION SYSTEM LAY OU T 18 1 SERVICE INFORMATION S u annie been iore aee nate 18 2 TROUBLESHOOTING tentent 18 3 IGNITION COM INSPECTION u ll uae u u u 18 4 18 0 GQ KYMCO 18 IGNITION SYSTEM DOWNTOWN 125 i IGNITION SYSTEM LAYOUT Roll sensor 18 1 GQ KYMCO 18 IGNIT
86. ke fluid tube use shop towels to cover plastic parts and coated surfaces to avoid damage Bolts Brake Caliper INSPECTION Brake Disk Inspect the brake pads and brake disk Measure the brake disk thickness Visually check the brake pad thickness DISASSEMBLY Remove two brake pads dowel pins and three bolts from the brake caliper Brake pads Remove the brake pads 16 3 16 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER POWNTOWN 125 Compressed Air Remove the piston from the brake caliper If necessary use com pressed air to squeeze out the piston through the brake fluid inlet opening and placeatowel under thecaliperto avoid contamination caused by the removed piston Check the piston cy linder for scratches wear and replace if necessary Push the piston oil seal outward to remove it Clean the oil seal groove with brake fluid Be careful not to damage the piston surface Check the piston for scratches or wear Measure the piston O D with a micrometer gauge Check the caliper cy linder for scratches or wear and measure the cylinder bore 16 4 16 REAR BRAKE REAR FORK REAR KYMCO WHEEL REAR SHOCK ABSORBER DOWNTOWN 225i ASSEMBLY Clean all removed parts Apply silicon grease to the piston and oil seal Lubricate the brake caliper linder inside wall with brake fluid Install the brake caliper piston with grooved side facing
87. ke lever If 1t still spongy bleed the system again 15 13 15 HANDLEBAR FRONT WHEELIFRONTBRAKE KYMCO If the brake bleeder is not available perform the following procedure Pump up the system pressure with the brake lever until these are not air bubbles in the fluid flowing out of the reservoir small hole and lever resistance is felt Pump the brake lever several times then squeeze the brake lever all the way and loosen the bleed valve 1 4 turn Wait several seconds and close the bleed valve Do not release the brake lever until the bleed valve has been closed 2 Release the brake lever slowly until the bleed valve has been closed Add fluid when the fluid level in the master cylinder Ts gt gt ae e is low to prevent drawing air into the 2042 w system 27 4 3 Repeat the steps 1 2 until there are no air bubbles in the bleed hose After bleeding air completely tighten the bleed valve to the specified torque Torque 6 Nem 0 6 kgfem 4 3 Fill the reservoir to the casting ledge with DOT 4 brake fluid to the upper level Install the diaphragm set plate and reservoir cover and tighten the screws to the specified torque Torque 2 Nem 0 2 kgfem 1 1 15 14 15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM FRONT BRAKE PAD BRAKE PAD REPLACEMENT Remove the pad pins 1 Remove the two caliper mounting bolts
88. le bearing from driven face Remove the snap ring then remove the bearing from driven face Guide Pins Rollers Needle Bearing Dust Seal w spring Collar snap Ring Bearing Driven Face Movable Driven Face Dust Seal Spring 9 14 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i DRIVEN PULLEY INSPECTION Grooves Check the driven pulley for smooth operation If any scratches or damage 15 found then replace as a set Check the torque cam grooves for wear or damage Check guide pins and rollers for wear or damage If any scratches or damage 15 found then E replace as a set Guide Pins Check the spring for damage Measure the spring free length em Check the clutch shoe for heat damage Measure the clutch shoe thickness 8 15 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i DRIVEN PULLEY ASSEMBLY Clean any oil from the drive belt sliding surfaces on the driven face Apply grease Filling 12 g of grease to driven face inner side Apply grease to lips of the new dust seals and install into the movable driven face Coat new O rings with grease and install them into the movable driven face grooves Install the movable driven face onto the driven face Install the guide rollers and guide roller pins Filling 5 g of grease to each guide groove Install the guide pins rollers Apply grease l Lock Nut Wrench Install spring collar
89. lts to the specified torque Torque 4 0kgf m 40N m Install the rear brake caliper and tighten the mount bolts to the specified torque Torque 3 2 kgf m 32 N m 23 Ibf ft After installation inspect and adjust the following e Throttle grip free play e Fill the cooling system with coolant and start the engine to bleed air from the system API ABV Reset KYMCO 5 ENGINE REMOVAL INSTALLATION DOWNTOWN 125i ENGINE HANGER EMOVAL Be careful to put the engine down Remove the engine mount nut 1 Pull the engine mount bolt 2 out Remove the left engine hanger mount bolt 3 Remove the right engine hanger mount bolt and collar 4 Remove the engine from frame INSTALLATION Installation 1s in the reverse order of removal Tighten the engine hanger mount bolts to the specified torque engine side Torque 5 kgf m 50 N m Tighten the engine mount bolt nut to the specified torque frame side Torque 5 kgf m 50 N m 36 Ibf ft GQ KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 125i CYLINDER HEAD VALVES 6 SCHEMATIC DRAWING 6 1 6 2 TROUBLESHOOTING 6 3 C YEINDERTIEADICGOYVY EE 2 ee 6 4
90. n side of camshaft holder and the exhaust rocker arm shaft is shorter 2 z e Clean the intake valve rocker arm shaft Valve Rocker Arms off any grease before installation e Align the cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder KYMCO 6 CYLINDER HEAD VALVES DOWNTOWN 125i CAMSHAFT Tensioner Sealing Bolt REMOVAL Turn the A C generator flywheel so that the mark on the flywheel aligns with the index mark on the crankcase Hold the round hole on the camshaft gear facing up and the location 15 the top dead center on the compression stroke Remove the tensioner sealing bolt and spring d Remove the two bolts from cam chain Round Hole tensioner and then remove the tensioner and gasket Remove the camshaft holder refer to the CAMSHAFT HOLDER section in this chapter Remove the camshaft gear and holder Camshaft Bolt Remove camshaft from the cam chain r tiza ele 6 5 6 CYLINDER HEAD VALVES INSPECTION Camshaft Inspect camshaft lobes for pitting scratches blue discoloration Measure the cam lobe height Service Limits DT 125 IN 25 57 mm EX 25 4 mm Camshaft Bearings If any defects are found replace the camshaft with a new one then inspect lubrication system Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearin
91. n 4 will come out when the drain plug 15 removed Let the engine oil drain out 3 Clean the oil strainer screen 4 Check that the oil strainer screen sealing rubber and drain plug O ring are in good condition 5 Install the oil strainer screen spring and oil strainer screen cap Oil strainer screen cap torque 15N m 1 5 kgf m 5 Fill the crankcase with the recommended grade oil and install the oil filler cap Oil capacity after draining 1 0 liter 6 Start the engine and let it idle for 2 3 minutes 7 Stop the engine and check that the oil level is at the upper level mark on the oil filler cap dipstick with the scooter upright on firm level ground Make sure there are no oil leaks KYMCO DOWN TOWN 125i INSPECTION ADJUSTMENT Oil filter replacement Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining Let the engine and exhaust system cool before working in those areas Remove the oil filler cap dipstick 1 from the right crankcase cover 2 Place a drain pan under the crankcase Remove three bolts and then remove the oil filter cap 2 and O ring 3 The spring 4 will come out when the filter cap 15 removed Let the engine oil drain out 3 Remove and discard the oil filter 5 Do not remain the rubber seal on the oil filter in the oil filter housing 4
92. n on the side stand stay Install and tighten the side stand switch bolt securely Connect the side stand switch connector 20 12 GQ KYMCO 20 LIGHTS METERS SWITCHES PDOWNIOWN 125 HORN INSPECTION Remove the front cover refer to the COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the horn connectors 1 from the horn Connect a 12 V battery to the horn terminals The horn is normal if it sounds when the 12 V battery 1s connected across the horn terminals REMOVAL INSTALLATION Disconnect the horn connectors from the horn Remove the bolt 2 and horn Installation is in the reverse order of removal
93. n signal light connectors Installation is in the reverse order of removal FRONT FENDER Remove the 4 screws and front fender Installation is in the reverse order of removal RIGHT LEFT FOOT SKIRT Kick the button and make the passenger footpeg out Remove the 6 screws and right or left foot skirt During removal do not pull the joint claws forcedly to avoid damage Installation is in the reverse order of removal dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i FRONT LOWER COVER Remove the front cover see page 2 8 Remove the foot skirt see page 2 9 Remove the 7 screws and front lower cover Installation is in the reverse order of removal REAR FENDER Remove the body cover then remove the rear fender Installation is in the reverse order of removal BODY COVER Remove the center cover see page 2 5 Remove the right and left foot skirts see page 2 9 Remove the rear spoiler and rear spoiler stay E see page 2 5 Remove the 6 screws and 2 nuts then remove the body cover 2 9 KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i e Rear Combination Light Connector Disconnect the rear combination light pu cu connector po j Installation is in the reverse order of removal REAR COMBINATION LIGHT UNDER COVER Remove body cover see page 2 10 Remove the 4 bolts and rear combination light under cover Installation is in the
94. ne and exhaust muffler must be cold to avoid scalding e During servicing keep oil or grease off the brake pads and brake disk SPECIFICATIONS Standard mm Rear wheel rim runout Rear brake disk thickness x 40 Rear brake disk runout __ Rear brake master cylinder I D 27 00 i Rear brake master cylinder piston O D 26 95 TORQUE VALUES Exhaust muffler lock bolt 35 N m 4 kgf m Exhaust muffler pipe nut 20 N m 2 kgf m Rear axle nut 120 N m 12 kgf m Rear shock absorber lower mount bolt 40N m 4 Rear shock absorber upper mount 40 4 kgfem Rear brake caliper holder bolt 27 N m 2 7 kgfem TROUBLESHOOTING Rear wheel wobbling Poor brake performance e Bent rim e Air in brake system e Faulty tire e Deteriorated brake fluid e Axle not tightened properly e Contaminated brake pad surface e Worn brake pads Soft rear shock absorber e Clogged brake fluid line e Weak shock absorber spring e Deformed brake disk e Damper oil leaks e Unequal worn brake caliper Rear wheel noise e Worn rear wheel axle bearings e Worn rear fork bearings e Deformed rear fork 16 2 16 REAR BRAKE REAR FORK REAR KYMCO REAR BRAKE Fluid Tube Bolt REAR BRAKE CALIPER REMOVAL First remove the exhaust muffler Remove the rear brake fluid tube bolt and disconnect the brake fluid tube Remove two bolts attaching the rear brake caliper Remove the rear brake caliper gt When removing the bra
95. neSpeed IDLE rpm MAPSample kPa njection duration ms gn Advance gn Dwell duration ms Air Temp C ngine Temp O2 sensor voltage V 0 lt un O2 sensor correct DLE ABVAngDurMech ourdug rri n D 22 2 e lt L B Repair description Repair Process Report ID Report Version DEC 11 2008 STEP 1 Disconnect the fuel pump relay or fuel pump connector STEP 2 switch on Start the engine still engine stop Never adjust screws 23 25 timing of cleaning throttle body 180 140 After replacing throttle body or engine overhauled It will change the efficiency of air intake so must be do the No Oo process i 15 HANDLEBAR FRONT WHEELIFRONTBRAKE iC KYMCO HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM SERVICE INFORMA TION eno coca ees uu uu L 15 1 TPOUBEESHOOTJING u u cesar eect tee ces 15 2 HANDLEBAR uen ues 15 4 FERONT u a u ss 15 7 FRONT BRAKE L l
96. nterclockwise Remove the starter driven gear by turning the driven gear Starter Driven Gear Check the starter driven gear teeth for wear or damage Measure the starter driven gear boss O D Measure the starter driven gear bushing I D Starter Idle Gear Check the starter reduction gear teeth and shaft for wear or damage Shaft 10 7 KYMCO 10 GENERATOR STARTER CLUTCH DOWNTOWN 125i INSTALLATION Starter Driven Gear Install the starter driven gear onto the crankshaft Apply oil to the starter reduction gear shaft Install the starter reduction gear and shaft to the right crankcase Flywheel Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel Before installation check and make sure that the Inside of the flywheel 15 not contaminated Key Groove 10 5 KYMCO 10 GENERATOR STARTER CLUTCH DOWNTOWNEUSi Nut Hold the flywheel with the special tool and tighten the flywheel nut Torque 5 0 6 0 kgf m Special tool Flywheel holder A120E00021 Install the dowel pins and gasket Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 or 3 steps 10 9 GQ KYMCO 11 CRANKCASE CRANKSHAFT DOWNTOWN 125i CRANKCASE CRANKSHAFT SCHEMATIC DRAWING emer cce 11 1 SERVICE INFORMATION
97. ntown 1251 INSTALLATION With thread lock applied to the threaded part tighten the water temperature sensor Torque 0 8 kgf m 8 N m 5 8 Connect the sensor connectors After the water temperature sensor has been installed fill coolant and perform air bleeding refer to the COOLANT REPLACEMENT section in this chapter 12 17 KYMCO 12 COOLING SYSTEM Downtown 1251 THERMOSTAT THERMOSTAT REMOVAL REMOVAL Drain the coolant refer to the COOLANT REPLACEMENT section in this chapter Remove the luggage box refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the water hose 1 from the thermostat housing Remove the mounting bolt 2 and the thermostat housing from the cylinder head INSTALLATION The installation sequence 15 the reverse of removal After the water thermostat has been installed fill coolant and perform air bleeding refer to the COOLANT REPLACEMENT section in this chapter 12 16 12 COOLING SYSTEM DISASSEMBLY Remove the two bolts and separate the thermostat housing halves Remove the thermostat from the thermostat housing 12 19 KYMCO Downtown 125 i Bolts A Thermostat Thermostat KYMCO 12 COOLING SYSTEM Downtown 125i INSPECTION Thermostat Suspend the thermostat in a pan of water over a burner and gradually raise the water temperature to check its operation
98. ooves without catching Push the ring until the outer surface of the piston ring 15 nearly flush with the piston and measure the ring to groove clearance Insert each piston ring into the bottom of the cylinder squarely Use the piston head to push each piston ring Into the cylinder Measure the piston ring end gap 7 5 GQ KYMCO 7 CYLINDER PISTON DOWNTOWN 125i Piston Piston pin Measure the piston O D at the point A from the bottom and 90 to the piston pin hole Calculate the cylinder to piston clearance Measure the piston pin hole Take the maximum reading to determine the I D Measure the piston pin O D at piston and connecting rod sliding areas Measure the piston to piston pin clearance KYMCO 7 CYLINDER PISTON DOWNTOWN 125i Cylinder Check the cylinder for warpage with a uuu DU TE MN Ll straight edge and feeler gauge in the directions shown Check the cylinder wall for wear or damage Measure and record the cylinder I D at three levels in an X and Y axis Take the maximum reading to determine the cylinder wear Calculate the piston to cylinder clearance Take a maximum reading to determine the clearance Calculate the taper and out of round at three levels in an X and Y axis Take the maximum reading to determine them Measure the connecting rod small end I D Calculate the connecting rod to piston pin clearance 7 7 7 CYLINDER PIS
99. out gt Install the piston with its outer end protruding 3 5mm beyond the brake caliper Install the two spring plates onto the groove of the caliper Spring Plate Make sure the spring plate next to the brake pad dowel pin orientation Install two brake pads and brake pad dowel pin Brake pads 16 5 16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER Fluid Tube Bolt INSTALLATION Install the brake caliper to rear fork and tighten the two bolts Torque 27 N m Connect the brake fluid tube to the brake caliper and install fluid tube bolt copper washers and tighten the fluid tube bolt Fill the brake reservoir with the specified brake fluid and bleed air from the brake system When installing the brake fluid tube be sure to install the two copper sealing washers REAR FORK REMOVAL Remove the exhaust muffler Remove the rear brake caliper Remove the right rear shock absorber lower mount bolt Remove the rear axle nut and remove the collar Remove the rear fork The installation sequenceis the reverse of removal Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub i 72 TX NW X d N Y lt 3 1 W l qa s 4 KYMCO DOWNTOWN 125i
100. page Measure the battery voltage using a commercially available digital multimeter Voltage 20 C 68 C Fully charged 13 13 2 V Under charged below 12 3 V BATTERY CHARGING Remove the battery ERY Connect the charger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal Turn the power ON OFF at the chatger not at the battery terminals Charging current time Standard 1 0 5 10 hours Quick 10 A 0 5 hours Quick charging should only be done in an emergency slow charging 15 preferred For battery charging do not exceed the charging current and time specified on the battery Using excessive current or extending the charging time may damage the battery 17 5 KYMCO 17 BATTERY CHARGING SYSTEM DOWNTOWN 125i CHARGING SYSTEM INSPECTION Remove the battery cover see page 17 4 CURRENT LEAKAGE TEST Turn the ignition switch OFF disconnect the negative cable from the battery Connect the ammeter probe to the negative cable and the ammeter probe to the battery terminal With the ignition switch OFF check for current leakage When measuring current using a tester set it to a high range and then bring the range down to an appropriate level Current flow higher than the range selected may blow out the fuse in the tester While measuring current do not turn the ignition switch ON A
101. reverse order of removal FLOORBOARD Remove the body cover see page 2 10 Remove the front lower cover see page 2 10 Remove the 1 screws Right KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i Remove the 8 bolts then remove the floorboard UNDER COVER Remove the four bolts and side stand stop rubber Remove the under cover 2 11 KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i remove the fuel tank cap cover Installation is in the reverse order of removal Speedometer Cable METER PANEL Disconnect the speedometer cable Disconnect the DC power connectors Remove the 1 screws Remove the ignition key garnish Remove the 3 screws from the inner cover then remove the handler panel Installation is in the reverse order of removal 2 12 dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i INNER COVER Remove the front cover see page 2 8 Remove the front lower cover see page 2 10 Remove the floorboard see page 2 11 Remove the 4 bolts and front glove box 1 screw Remove the 2 PO bolts then remove The fuel tank fill cap Remove the inner cover 2 13 KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i EXHAUST MUFFLER REMOVAL Disconnect the O2 heater O2 sensor connector Remove the two exhaust pipe joint nuts Remove three muffler mount bolts and muffler and gasket 2 14
102. rs e Worn bearing Oil leaks e Oil level too high e Worn or damaged oil seal KYMCO 9 FINAL REDUCTION DOWNTOWN 125 i FINAL REDUCTION REMOVAL Drain the transmission gear oil into a clean container refer to the TRANSMISSION section in the chapter 3 Remove the driven pulley refer to the DRIVE PULLEY DRIVE BELT AND DRIVEN PULLEY section in the chapter 8 Remove the nine bolts from the transmission case cover then remove the transmission case cover Countershaft Gasket Final gear Remove the dowel pins and gasket Remove the final gear and shaft then remove the countershaft Drive shaft Dowel Pins KYMCO 9 FINAL REDUCTION DOWNTOWNUST INSPECTION Inspect the countershaft and gear fcr wear or damage Inspect the final gear and final gear shaft for wear damage or seizure Check the driveshaft for wear or damage Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage 9 4 dC KYMCO 9 FINAL REDUCTION DOWNTOWN 125 i Drive Shaft Bearing Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage s Final Shaft Bearing Countershaft Bearing Final Gear Shaft Bearing Drive Shaft Bearing Countershaft Bearing INSTALLATION Countershaft Install the final gear and final gear shaft Install the Countershaft
103. s 1 and then remove the fan motor 2 INSPECTION Battery Check the fan motor to operate using an available battery INSTALLATION Installation is in the reveres order of removal Fan Motor 12 9 QC KYMCO 12 COOLING SYSTEM Downtown 125i FAN MOTOR SWITCH REMOVAL 1 Disconnect fan motor switch connectors refer to the RADIATOR section in this chapter Remove the fan motor switch 1 INSPECTION Place the fan motor switch in oil contained in a pan as shown and raise the oil temperature gradually to check for the temperature at which the switch starts to operate If the switch operating temperature 1s not within the specified range replace the switch with a new one OFFON Over 88 929 ON OFF Lower 88 929 e Handle the cooling fan motor switch carefully as it 15 vulnerable to impact e Do not allow the cooling fan motor switch cand the thermometer eto come in contact with the bottom of the pan INSTALLATION Fit the new O ring Tighten the cooling fan motor switch to specified torque Torque 1 8 kgf m 18 N m 13 Ibf ft e Replace the O ring a new one e Do not coat grease to the O ring 12 10 dC KYMCO 12 COOLING SYSTEM Downtown 125 i Right Crankcase Cover WATER PUMP MECHANICAL SEAL WATER SEAL INSPECTION Inspect the telltale hole for signs of mechanical seal coolant leakage If the mechanical seal 1s leaking remove the right crankcas
104. s on the drive belt periphery point in the normal turning direction 1f the drive belt has arrow mark e The drive belt contact surface of the driven face should be thoroughly cleaned Install the driven pulley assembly clutch outer and drive belt together Use the special tool to hold clutch outer then tighten the nut to the specified torque Torque 5 0 6 0kgf m 50 60N m Special tool Universal holder A120E00017 KYMCO DOWNTOWN 125i Boss Movable Drive Face Assembly Clutch Outer Driven Pulley Assembly O yA Drive Belt Nut Universal Holder 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i Nut Ratchet Install the drive pulley face and ratchet Use the special tool to hold drive pulley face then tighten the nut to the specified torque Torque 5 5 6 5 kgf m 55 65 N m Special tool Universal holder A120E00017 Drive Pulley Face Universal Holder 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i DRIVE PULLEY DISASSEMBLY Remove the drive face boss Boss Ramp Plate Remove the ramp plate Remove the six weight rollers Weight Roller 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i DRIVE PULLEY INSPECTION Weight rollers Check each roller for wear or damage Measure outside diameter Movable drive face Slide pieces Drive pulley face Check the mov
105. sion and the side stand assembly for freedom of movement Check the side stand ignition cut off system 1 Place the scooter on its center stand 2 Put the side stand up and start the engine 3 Lower the side stand The engine should stop as you put the side stand down If the side stand system does not operate as described see your KYMCO dealer for service 3 23 KYMCO DOWN TOWN 125i Side stand up Side stand down GQ KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 125i LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 4 1 SERVICEINEORBMATIOQN S a uu u uuu 4 2 TROUBLESHOOTING uu 4 2 uuu 4 3 4 0 GQ KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 125i LUBRICATION SYSTEM DIAGRAM Rocker Arm Shaft Crankshaft E Strainer c creen Pump Oil Filter Screen 4 1 C KYMCO 4 LUBRICATION SYSTEM DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS e The maintenance of lubrication system can be performed with the engine installed the frame e Drain the coolant before starting any operations e Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line e Do not attempt to disassemble the oil pump The oil pump must be replaced as a set when it reaches its service limit e After the oil pump 15 installed check each part for oil leaks
106. st muffler joint air leaks Lack of power e Caved exhaust muffler e Clogged exhaust muffler e Exhaust muffler air leaks GQ KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i 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 pawls Q close Insert the fastener into the installation hole To prevent the pawl 2 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 dC KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i 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 LUGGAGE BOX Unlock the seat with the ignition key Open the seat Remove the screw and four bolts then lift luggage box Luggage Box Light Connector N Disconnect the luggage box light connector then remove the luggage box Installation is in the reverse order of removal KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i Center Cover CENTER COVER Remove the luggage box see page 2 4 Remove the center cover During removal do not pull the joint claws forcedly to avoid damage Installation is in the reverse or
107. switch wire 2 then remove the rear brake master cylinder Remove the two bolts 3 and disconnect the brake light switch wire 4 then remove the front brake master cylinder Remove the inner cover refer to the COVERS 2 4 REMOVAL INSTALLATION section in the chapter 2 0 7 5 Remove the handlebar lock nut 5 and take out the bolt 6 Remove the handlebar and collar 7 15 3 ISHANDLEBAR FRONT WHEEL FRONTBRAKg KYMCO INSTALLATION Install the handlebar onto the steering stem and install the handlebar collar lock nut and bolt Tighten the bolt to the specified torque Torque 4 5 kgf m 45 N m 32 Ibf ft Install the front and rear master cylinders and connect the brake light switch wires refer to the BRAKE MASTER CYLINDER section in this chapter and chapter 15 Adjust the throttle grip free play to the specified range of 2 6 mm 0 08 0 24 in 15 HANDLEBAR FRONT WHEEL FRONT BRAKE KYMCO FRONT SHOCK ABSORBER STEERING STEM Downtown 1251 DISASSEMBLY Remove the two screws 1 from right handlebar switch Disconnect the throttle cable 2 from the throttle grip Remove the right handlebar switch Remove the two screws 3 and then remove the left handlebar switch 15 5 1S HANDLEBAR FRONT WHEELFRONTERAkg KYMCO ASSEMBLY Install the left handlebar switch Alien the pin on the left handlebar switch with the hole on
108. the handlebar Install and tighten the two screws securely Install the right handlebar switch Align the pin on the right handlebar switch with the hole on the handlebar Lubricate the throttle grip front end with grease and then connect the throttle cable to the throttle grip Install and tighten the two screws 15 6 15 HANDLEBAR FRONT WHEEL FRONTBRAKg KYMCO FRONT WHEEL REMOVAL Jack the scooter front wheel off the ground Remove the bolt 1 then pull out the axle 2 And 3 Remove the front wheel and collar Axle runoutn inspection Set the axle in V blocks and measure the runout using a dial gauge The actual runout is 1 2 of the total indicator reading Service Limit 0 2 mm 0 008 in Wheel rim inspection Check the wheel rim runout 15 7 15 HANDLEBAR FRONT WHEEL FRONTBRAKE C KYMCO Apply grease to the collar 1 then install the collar onto the wheel Install the speedometer speed wheel sensor 15 5 I5 HANDLEBAR FRONT WHEELIFRONT BRAKE KYMCO FRONT SHOCK ABSORBER STEERING STEM Downtown 1251 DISASSEMBLY Remove the side collar 1 and dust seal 2 Turn the inner race of each bearing with your finger to see if they turn smoothly and quietly Also check if the outer race fits tightly in the hub Replace the bearings if the races do not turn smoothly quietly or if they fit loosely in the hub Remove the front wheel bearing 3 by using
109. ugh the cylinder and install the cylinder over the piston Be careful not to damage the piston rings and cylinder walls Install the cylinder head and camshaft holder has installed refer to the CYLINDER HEAD section in the chapter 6 Connect the water hose 7 10 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i DRIVE AND DRIVEN PULLEYS SCHBMATIC DR ANM IN SE 8 1 5 0 TROUBLESHOOTING ua cene ceu 8 3 LEFT ERANKCASI COVER z 8 4 DRIVE PULLEY DRIVE BELT AND DRIVEN PULLEY 8 5 9 0 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i SCHEMATIC DRAWING 94050 12080 Sa 193903 35260 X9 8 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS e The drive pulley clutch and driven pulley can be serviced with the engine installed e Avoid getting grease and oil on the drive belt and pulley faces Remove any oil or grease from them to minimize the slipping of drive belt and drive pulley SPECIFICATIONS Unit mm x Standard Movable drive face bushing I D 24 011 24 052 __ Drive face collar 23 960 23 974 vs Clutch lining thickness 4 ee Clutch outer LD 130 130 2 MEE Driven face spring fe
110. white smoke If white smoke is found it means that the piston rings are worn stuck or broken Compression too low or uneven compression Excessive smoke from exhaust muffler e Worn or damaged cylinder and piston rings e Worn or damaged piston rings e Worn stuck or broken piston rings e Worn or damaged cylinder and piston Compression too high Abnormal noisy piston e Excessive carbon build up in combustion e Worn cylinder piston and piston rings chamber or on piston head e Worn piston pin hole and piston pin e Incorrectly installed piston 7 3 KYMCO 7 CYLINDER PISTON DOWNTOWN 125i CYLINDER AND PISTON REMOVAL Remove the cylinder head refer to CYLINDER HEAD section in the chapter 6 Remove the water hose from the cylinder Remove the cylinder Remove the cylinder gasket 4 and dowel pins 3 Clean any gasket material from the cylinder surface Remove the piston pin clip Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Press the piston out of the piston remove the piston GQ KYMCO Spread each piston ring and remove it by lifting up at a point opposite the gap Do not damage the piston ring by spreading the ends too far Clean carbon deposits from the piston ring grooves INSPECTION Piston ring Inspect the piston rings for movement by rotating the rings The rings should be able to move in their gr
111. ycle k Ki a P m 2 4 j Sot a gt w j UU Grease Grease Side stand pivot Rear wheel axle amp nut Front wheel axle amp nut amp Main stand pivot KYMCO 1 GENERAL INFORMATION DOWNTOWN 125i CABLE amp HARNESS ROUTING Tilt Switch Speedometer Radiator Filler Cap Lo Beam Relay Ignition Switch Hi Beam Relay Winker Relay Horn KYMCO 1 GENERAL INFORMATION DOWNTOWN 125i Ignition Coil Output Voltage Connector Coolant Reserve Tank GQ KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i 2 EXHAUST MUFFLER FRAME COVERS SCHEMATIC eer SERVICE INFORMA TION senden E Ls 2 2 IPOUBLESHOO TING taces duse 220 FASTENER REMOVAL AND REINSTALLATION 2 3 FRAME COVERS REMOVAL INSTALLATION 2 4 EXHAUST MUEEDE Reste dehinc etae aee cedet 2 15 2 0 GQ KYMCO 2 EXHAUST MUFFLER FRAME COVERS DOWNTOWN 125i SERVICE INFORMATION GENERAL INSTRUCTIONS e When removing frame covers use care not to pull them by force because the cover Joint claws may be damaged e Make sure to route cables and harnesses according to the Cable amp 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 e Damaged exhaust muffler e Exhau

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