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1. 12 6 HYDRAULIC BRAKE 12 8 FRONT SHOCK ABSORBER 12 13 STEERING HANDLEBAR 12 16 STEERING STEM 12 17 12 0 12 FRONT WHEEL FRONT BRAKE QC KYMCO SUSPENSION SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS Remove the motorcycle frame covers before removing front wheel Jack the motorcycle front wheel off the ground and be careful to prevent the motorcycle from falling down During servicing keep oil or grease off the brake drum and brake linings Contaminated brake disk or brake pads reduce stopping power Clean the contaminated brake disk with high performance brake degreaser and replace the brake pads Do not use brake fluid for cleaning Bleed air from the brake system if the brake system is removed or the brake is soft Do not allow any foreign matters to enter the brake system when filling it with brake fluid Brake fluid will damage painted surfaces and plastic parts When servicing the brake system use shop towels to cover and protect rubber plastic parts and coated surfaces Wipe off any spilled brake fluid with a clean shop towel e Inspect the brake system before riding SPECIFICATIONS Standard mm Axle shaft runout
2. ss 9 3 CLOTCH DRIVEN PULL BY BS 9 7 9 IMO RSA Re Roe L LL 9 13 9 DRIVE AND DRIVEN PULLEYS QC KYMCO KICK STARTER MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS e The drive pulley clutch and driven pulley can be serviced with the engine installed 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 Clutch lining thickness s TORQUE VALUES Drive face nut 5 5kg m Clutch outer nut 5 5kg m Clutch drive plate nut 5 5kg m SPECIAL TOOLS Universal holder Clutch spring compressor Driver handle A Lock nut wrench 39mm Outer driver 32x35mm Bearing driver Pilot 20mm Bearing driver TROUBLESHOOTING Engine starts but motorcycle won t move Lack of power e Worn drive belt e Worn drive belt e Broken ramp plate e Weak driven face spring e Worn or damaged clutch lining e Worn weight roller e Broken driven face spring Fouled drive face Engine stalls or motorcycle creeps e Broken clutch weight spring 9 1 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER MOVIE SYSTEM REMOVAL Loosen the drive belt air tube band screw Screw Cable Clamp Left Crankcase Cover Remove the left crankcase cover bolts and left crankcase cover Remove the seal rubber and dowel pins INSTALLATION Ins
3. This Service Manual describes technical features and servicing procedures for the KYMCO MOVIE SYSTEM 125 150 Section 1 contains the precautions for all operations stated in this manual Read them carefully before starting any operation Section 2 is the removal installation procedures for the frame covers which are subject to higher 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 4 through 17 give instructions for disassembly assembly and inspection of engine chassis frame and 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 OVERSEAS SALES DEPARTMENT OVERSEAS SERVICE SECTION TABLE OF CONTENTS SISSVHO HNIONH BATTERY CHARGING SYSTEM A C GENERATOR GNITION SYSTEM TARTING SYSTEM IGHTS INSTRUMENTS SWITCHES 1 IVOBLLOT TH gt 6 1 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM GENERAL INFORMATION SERIAL NUMBER ES 151 SPECIFICATIONS
4. Bearings Brake Cam Anchor Pin G Front Shock Absorber Lower Main Stand Pivot Rear Wheel BEL T Mount Bushings Pivot 1 16 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM CABLE amp HARNESS ROUTING Front Brake Reservoir Front Stop Switch Wire Rear Stop Switch Wire Front Brake Fluid Tube N Throttle Cable X E Ignition Switch Rear Brake Cable Instrument Cable Speedometer Cable Front Brake Fluid Tube Regulator Rectifier w Buzzer Horn 1 17 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM Regulator Rectifier Wire Harness Speedometer Cable Throttle Cable Front Brake Fluid Tube Rear Brake Cable 1 18 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM Battery Cable CDI Unit Ground Battery Cable Wire Harness CDI Unit Fuse Reserve Fuse 1 19 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM A C Generator Wire Throttle Cable Fuel Tube Auto Bystarter Wire Fuel Valve Vacuum A Tube Ignition Coil Vacuum Tee Crankcase Breather Tube 1 20 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM Fuel Unit Fuel Tube Carburetor Vacuum Tube Starter Relay Throttle Cable Auto Bystarter Wire Crankcase Breather Wire Harness Starter Relay Starter Motor Wire Tube Fuel Unit Vacuum Tee Auto Bystarter 1 21 MOVIE SYSTEM KYMCO 1 GENERAL INFORMATION WIRING DIAGRAM TEAD LIGHT 12V 35W 35W POSITION LIGT
5. etas 25 SERVICE PRECAUTIONS L ss 1 3 TORQUE VALUES 1 11 GBRCEAROGOES EE 1 12 LUBRICATION POINTS eds 1 13 CABLE S HARNESS ROUTING 014 1 15 WIRING DIAG ES 1 20 TROUBLESHOOTING 1 21 1 0 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM SERIAL NUMBER SD25GB SD25GC Vehicle Identification Serial Number Location of Frame Serial Number 1 1 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM SPECIFICATIONS SD25GB SD25GC Jockey 125 5 5 liters 1745 Overall width mm 690 140 24 equivalent 1220 Butterfly type HC CDI 124 6 13 BTDC 1700rpm 92 nonleaded gasoline Non contact point type NGK CR7HSA Gross weight kg Spark plug gap 0 6 0 7mm 109 5 12V8AH 100 90 10 Dry multi disc clutch 100 90 10 Non stage transmission Ground clearance mm Operation Automatic centrifugal type Reduction atio 84 ond Io aTndre Spark plug eornoo q Ulo s S uonrus IS 90 m p uo SIULISUBT 1090 NO nN uro SAS 7 9m Initial speed Perform Braking distance m uem Iti dehy 1866 Two stage reduction system r 2nd 8 615 Type Gaso ine 200 Front Cylinder arrangement Single cylinder Trail length Combustion chamber type Tire pressure O H C chai
6. motor Cable Starter Motor Cable Front Cover Remove the waterproof rubber jacket and disconnect the starter motor cable connector DISASSEMBLY Remove two starter motor case screws front cover motor case and other parts Case Screws Motor Case INSPECTION Commutator Inspect the removed parts for wear damage or discoloration and replace if necessary Clean the commutator if there is metal powder between the segments Check for continuity between pairs of the commutator segments and there should be continuity Also make a continuity check between individual commutator segments and the armature shaft There should be no continuity STARTER MOTOR CASE CONTINUITY KYMCO 16 STARTING SYSTEM MOVIE SYSTEM CHECK Check to confirm that there is no continuity between the starter motor wire terminal and the motor front cover Also check for the continuity between the wire terminal and each brush Replace if necessary m di Wire Terminal Measure the length of the brushes Service Limit 8 5mm replace if below Check for continuity between the brushes If there is continuity replace with new ones Check if the needle bearing in the front cover turns freely and has no excessive Bearing play Replace if necessary Check the dust seal for wear or damage Dust Seal 16 4 KYMCO 16 STARTING SYSTEM MOVIE SYSTEM ASSEMBLY Commuta
7. 7 10 7 0 KYMCO 7 CYLINDER HEAD VALVES MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS e The cylinder head can be serviced with the engine installed in the frame e When assembling apply molybdenum disulfide grease or engine oil to the valve guide movable parts valve arm and camshaft sliding surfaces for initial lubrication e The camshaft is 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 Standard mm Service Limit O N OR E _ Cylinder head compression pressure 13kg cm 2 Cylinder head warpage ps 29 803 29 40 Camshaft cam height EX 29 5637 29 16 Valve arm O N 10 000 10 015 10 10 EX 10 000 10 015 10 10 Valve rocker arm shaft IN 9 972 9 087 O D 9 972 9 987 RENS 2975 4590 4 955 4 970 5 000 5 012 5 000 5 012 Valve stem to guide 0 010 0 037 clearance 0 030 0 057 KYMCO 7 CYLINDER HEAD VALVES MOVIE SYSTEM TOROUE VALUES Cylinder head nut 2 0kg m Apply engine oil to threads Valve clearance adjusting nut 0 9kg m Apply engine oil to threads Stud bolt 0 9 1 1kg m SPECIAL TOOLS Valve spring compressor
8. CDI unit Measure the resistance between the terminals using the electric tester e Due to the semiconductor in circuit it is necessary to use a specified tester for accurate testing Use of an improper tester in an improper range may give false readings e Use a Sanwa Electric Tester or Kowa Electric Tester Black Yellow Blue Black e In this table Needle swings then returns indicates that there is a charging current applied to a condenser The needle will then remain at unless the condenser is discharged Unit Blue Black Blue Green Probe Black Yellow Yellow ie 1 20 60 Black wn CDI Unit IGNITION COIL REMOVAL 15 4 KYMCO 15 IGNITION SYSTEM MOVIE SYSTEM Remove the frame body cover Remove the spark plug cap Disconnect the ignition coil wires and remove the ignition coil bolt and ignition coil INSPECTION CONTINUITY TEST This test is to inspect the continuity of ignition coil Measure the resistance between the ignition coil primary coil terminals Resistance 0 1 1 00 20 Measure the secondary coil resistances with and without the spark plug cap Resistances with plug cap 7 12 0 20 without plug cap 3 5 20 Correctly operate the tester following the manufacturer s instructions 1 Turn the ignition coil tester changeover switch to 12V and connect the ignition coil to the tester 2 Turn the tester power switch
9. EE GO 1 22 1 GENERAL INFORMATION TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment Check if fuel reaches i carburetor by loosening coe drain screw Fuel does not reach carburetor Fuel reaches carburetor Remove spark plug and t install it into spark Plug cap to test spark by ae connecting it to engine i ground x Test cylinder i compression cwm follow ing normal starting procedure Remove spark plug and inspect again Dry spark plug Wet spark plug 1 23 KYMCO MOVIE SYSTEM Probable Cause Empty fuel tank logged fuel line between fuel tank and carburetor logged float oil passage logged fuel tank cap breather hole Faulty auto fuel valve Faulty charging system Faulty spark plug Fouled spark plug Faulty CDI unit Faulty pulser coil Broken or shorted ignition coil Broken or shorted exciter coil Faulty ignition switch Weak or dead battery aulty starter clutch Valve clearance too small proper valve and seat contact Worn cylinder piston and piston rings eaking cylinder head gasket Seized valve Improper valve timing Faulty auto bystarter Air leaking through intake pipe Incorrect ignition timing Incorrectly adjusted pilot screw Flooded carburetor Faulty auto bystarter Throttle valve excessively open KYMCO 1 GENERAL INF
10. ENGINE HANGER BRACKET REMOVAL Remove the ignition coil from the engine hanger Remove the engine hanger bracket bolt and nut Remove the engine hanger bracket Br ake Adjusting Nut Inspect the engine hanger bushings and v KYMCO 6 ENGINE REMOVAL INSTALLATION MOVIE SYSTEM stopper rubbers for wear or damage ENGINE HANGER BRACKET INSTALLATION Install the engine hanger bracket to the engine Install the engine hanger bracket bolt and tighten the nut ENGINE INSTALLATION Engine Mounting Bolt Install the engine and tighten the engine mounting bolt Torque 7 0kg m Tighten the rear shock absorber upper mount bolt Torque 4 0kg m Install the removed parts in the reverse order of removal Route the wires and cables properly After installation inspect and adjust the following Throttle grip free play Rear brake adjustment Bushings Stopper Rubbers 6 4 7 CYLINDER HEAD VALVES KYMCO MOVIE SYSTEM CYLINDER HEAD VALVES SERVICE INFORMATION gs TROUBLESHOOTING 7 2 CAMSHAET REMOVA 73 CYLINDER HEAD REMOV AL sie os 7 6 CYLINDER HEAD DISASSEMBLY 159 CYLINDER HEAD ASSEMBLY 7 8 CYLINDER HEAD INSTALLATION 7 9 CAMSBHAFDINSPADIDCATION
11. 10 4 10 0 KYMCO 10 FINAL REDUCTION MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS When replacing the drive shaft use a special tool to hold the bearing inner race for this operation SPECIFICATIONS Specified Oil GEAR OIL SAE 90 Oil Capacity At change 0 2 liter At disassembly 0 18 liter TORQUE VALUES Transmission case cover bolt 1 2kg m SPECIAL TOOLS Driver handle A Outer driver 32x35mm Outer driver 37x40mm Outer driver 42x47mm Pilot 15mm Pilot 17mm Pilot 20mm Crankcase assembly tool Assembly shaft Assembly collar TROUBLESHOOTING Engine starts but motorcycle won t move e Damaged transmission e Seized or burnt transmission Oil leaks Oil level too high e Worn or damaged oil seal FINAL REDUCTION DISASSEMBLY Remove the exhaust muffler 10 1 KYMCO 10 FINAL REDUCTION MOVIE SYSTEM Remove the rear wheel Remove the rear brake cable Remove the left crankcase cover Remove the clutch driven pulley Drain the transmission gear oil into a clean container Remove the transmission case cover attaching bolts Bolts Remove the transmission case cover Dowel Pin Drive Shaft Remove the gasket and dowel pins Remove the final gear and countershaft Final Gear Countershaft Dowel Pin FINAL REDUCTION INSPECTION Inspect the countershaft and gear for wear or damage Countershaft Inspect the final gear and final shaft for
12. Check each piston cylinder for scratches or wear and replace if necessary Compressed Air Piston Oil Seals Push the piston oil seals outward to remove them Clean each oil seal groove with brake fluid Be careful not to damage the piston surface Check each piston for scratches or wear Measure each piston O D with a micrometer gauge Service Limit 25 33mm Check each caliper cylinder for scratches or wear and measure the cylinder bore Service Limit 25 46mm ASSEMBLY C 1 12 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION MOVIE SYSTEM Clean all removed parts Apply silicon grease to pistons and oil seals Lubricate the brake caliper cylinder inside wall with brake fluid Install the brake caliper piston with grooved side facing out Install the piston with its outer end protruding 3 5mm beyond the brake caliper cylinder Wipe off excessive brake fluid with a clean shop towel Apply silicon grease to the brake caliper seat pin and caliper inside Install the brake caliper seat INSTALLATION Install the brake caliper and tighten the two bolts Torque 2 9 3 5kg m Connect the brake fluid tube to the brake caliper and tighten the fluid tube bolt Torque 2 5 3 5kg m Fill the brake reservoir with recommended brake fluid and bleed air from the brake system 2 Fluid Tube Mount Bolts FRONT SHOCK ABSORBER REMOVAL Remove the fro
13. Starter Button Starter Motor STARTING CIRCUIT R Fusels5A Ignition Switch B L Rear Stop Switch ICE Ed Front Stop Switch Starter Button Starter Motor i KYMCO 16 STARTING SYSTEM MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS e The removal of starter motor can be accomplished with the engine installed For the starter clutch removal refer to Section 4 SPECIFICATIONS Standard mm Service Limit mm TORQUE VALUES Starter clutch cover socket bolt 1 2kg m Starter clutch lock nut 9 5kg m SPECIAL TOOLS Lock nut wrench Universal holder TROUBLESHOOTING Starter motor won t turn Lack of power e Fuse burned out e Weak battery e Weak battery e Loose wire or connection Faulty ignition switch e Foreign matter stuck in starter motor e Faulty starter clutch or gear e Faulty front or rear stop switch e Faulty starter relay Starter motor rotates but engine does Poorly connected broken or shorted wire not start e Faulty starter motor e Faulty starter clutch e Starter motor rotates reversely e Weak battery STARTER MOTOR 16 2 KYMCO 16 STARTING SYSTEM MOVIE SYSTEM REMOVAL Before removing the starter motor turn the ignition switch OFF and remove the battery ground Then turn on the ignition switch and push the starter button to see if the starter motor operates properly Remove the two starter motor mounting bolts
14. Tensioner Screw Turn the flywheel counterclockwise so that Camshaft Gear the T mark on the flywheel ahgns with the index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke Cylinder Head Cover 7 3 KYMCO 7 CYLINDER HEAD VALVES MOVIE SYSTEM Remove two cylinder head bolts Remove the four cylinder head nuts and washers Diagonally loosen the cylinder head nuts in 2 or 3 times Remove the camshaft holder and dowel Camshaft Holder pins Remove the camshaft gear from the cam chain and remove the camshaft CAMSHAFT INSPECTION Check each cam lobe for wear or damage Measure the cam lobe height Service Limits IN 29 40mm replace if below EX 29 16mm replace if below Nut Bolt 7 4 KYMCO 7 CYLINDER HEAD VALVES SYSTEM Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play CAMSHAFT HOLDER DISASSEMBLY Take out the valve rocker arm shafts using a 5mm bolt Remove the valve rocker arms Rocker Arm Rocker Arm Shaft 5mm Bolt CAMSHAFT HOLDER INSPECTION Camshaft Holder Inspect the camshaft holder valve rocker arms and rocker arm shafts for wear or damage If the valve rocker arm contact surface is worn check each cam lobe for wear or damage Rocker Arm Shafts Measure the I D of each
15. e After the carburetor is removed plug the intake manifold side with a clean shop towel to prevent foreign matters from entering e Remove the vacuum diaphragm before cleaning the carburetor air and fuel passages with compressed air to avoid damaging the vacuum diaphragm e When the motorcycle is not used for over one month drain the residual gasoline from the float chamber to avoid erratic idling and clogged slow jet due to deteriorated fuel SPECIFICATIONS Pilot screw opening Throttle grip free play Pilot screw opening 24 234 5 1 5 FUEL SYSTEM TROUBLESHOOTING Engine is hard to start e No spark at plug Compression too low e No fuel to carburetor Clogged fuel filter Restricted fuel line Faulty float valve Incorrectly adjusted float level Engine flooded with fuel Clogged air cleaner Fuel overflowing e Intake air leak e Contaminated fuel e Faulty auto bystarter Clogged idle system or auto bystarter passages Rich mixture e Faulty auto bystarter e Faulty float valve Float level too high Clogged air jets e Dirty air cleaner e Flooded carburetor Backfiring at deceleration Improper air cut off valve operation e Lean mixture in idle system KYMCO MOVIE SYSTEM Misfiring during acceleration e Faulty ignition system e Lean mixture Engine idles roughly stalls or runs poorly e Clogged fuel system Ignition malfunction e Rich or lean mixture
16. 9mm from bottom of skit 8 2 KYMCO 8 CYLINDER PISTON MOVIE SYSTEM CYLINDER REMOVAL _ Remove cylinder head Remove the cam chain guide Remove the cylinder base bolts Remove the cylinder Remove the cylinder gasket and dowel pins Clean any gasket material from the cylinder i j Surface PISTON REMOVAL 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 pin out of the piston and remove the piston Piston Rings Piston 8 3 KYMCO 8 CYLINDER PISTON MOVIE SYSTEM Inspect piston piston and piston rings Remove the piston rings Take care not to damage or break the piston rings during removal Clean carbon deposits from the piston ring grooves Install the piston rings onto the piston and measure the piston ring to groove clearance Service Limits Top 0 09mm replace if over 2nd 0 09mm replace if over Remove the piston rings and insert each piston ring into the cylinder bottom Use the piston head to push each piston ring into the cylinder Measure the piston ring end gap Service Limit 0 5mm replace if over Measure the piston pin hole I D Service Limit 15 04mm replace if over 8 4 KYMCO 8 CYLINDER PISTON MOVIE SYSTEM Measure the piston pin O D Service Limit 14 96mm replace if below Measure the piston O
17. Be sure to set the vacuum diaphragm lip into the groove on the carburetor e When installing the air cut off valve cover make sure that the vacuum diaphragm is properly installed VACUUM CHAMBER DISASSEMBLY Remove the two vacuum chamber cover screws and the cover Remove the spring and vacuum diaphragm piston 5 5 Spring Vacuum Diaphragm Air Cut off valve Cover Screws Spring 1 Vacuum Diaphragm Piston KYMCO 5 FUEL SYSTEM MOVIE SYSTEM Push the needle holder in and turn it left to remove the needle holder Remove the spring and jet needle from the piston Be careful not to damage the vacuum diaphragm INSPECTION Jet Needle Inspect the needle for stepped wear Inspect the vacuum piston for wear or damage Inspect the diaphragm for deterioration and tears Vacuum Diaphragm Vacuum Chamber Cover ASSEMBLY Install the vacuum piston diaphragm in the carburetor body and align the tab on the diaphragm with the groove in the carburetor body Install the spring Install the vacuum chamber cover and tighten it with the two screws Be careful not to damage the diaphragm Hold the vacuum piston while tightening the vacuum chamber cover Vacuum Diaphragm Screws FLOAT CHAMBER DISASSEMBLY Remove the four float chamber screws and the float chamber Float Chamber 5 6 KYMCO 5 FUEL SYSTEM MOVIE SYSTEM Remove the float pin
18. Remove the A C generator wire set plate Remove the pulser coil bolts Remove the A C generator wire rubber sleeve and pulser coil from the right crankcase Remove the two bolts and A C generator stator 14 BATTERY CHARGING SYSTEM Q KYMCO A C GENERATOR MOVIE SYSTEM Bolts INSTALLATION Install the A C generator stator and pulser coil onto the right crankcase Tighten the stator and pulser coil bolts L A Torques Pulser Coil 0 5kg m 6 Stator 0 9kg m di gt MEI amp Bolts Install the A C generator wire rubber sleeve and A C generator wire set plate Connect the A C generator wire connector mi Clean the taper hole in the flywheel off any burrs and dirt Install the woodruff key in the crankshaft keyway C gt NN 4 lt Y Y UIT e Install the flywheel onto the crankshaft with the flywheel hole aligned with the crankshaft woodruff key The inside of the flywheel is magnetic Make sure that there is no bolt or nut before installation 14 9 A C Generator Wire Connector wr 4 e ZA 14 BATTERY CHARGING SYSTEM O KYMCO A C GENERATOR MOVIE SYSTEM Hold the flywheel with the universal holder and tighten the flywheel nut Torque 5 5kg m Universal Holder Install the cooling fan Torque 0 9kg m Install the fan cover Install the rear right side cover Fan Cover 14 10 14
19. Remove the met in box Remove the rear right side cover Disconnect the fuel unit wire connector Remove the fuel unit Be careful not to bend or damage the KYMCO 17 LIGHTS INSTRUMENTS SWITCHES MOVIE SYSTEM Fuel Unit Connector INSPECTION Measure the resistance between the fuel unit wire terminals with the float at upper and lower positions RESISTANCES Unit Q GYW The installation sequence is the reverse of removal e nstall the fuel unit by aligning the groove on the fuel unit with the tab on the fuel tank e Align the arrow on the fuel unit retainer with the arrow on the fuel tank AUTO BYSTARTER AUTO BYSTARTER INSPECTION Remove the rear right side cover Disconnect the auto bystarter wire connector Measure the resistance between the yellow and green black wire terminals Resistance 100 max Perform this operation when the engine is cold INSTRUMENTS BULB REPLACEMENT Remove the front cover Remove the bulb socket and replace the bulb The installation sequence is the reverse of removal 17 7 Auto Bystater Connector Instruments KYMCO 17 LIGHTS INSTRUMENTS SWITCHES MOVIE SYSTEM Bulb Socket Switch Couplers Bulb Socket Switch Couplers INSTRUMENTS REPLACEMENT Remove the handlebar front cover Remove the handlebar rear cover Disconnect the right and left handlebar switches wire couplers Disconnect the speedometer cable
20. 0 12mm Inner Rotor Measure the rotor end to pump body clearance Service Limit 0 2mm 4 4 KYMCO 4 LUBRICATION SYSTEM MOVIE SYSTEM ASSEMBLY Outer Rotor Inner Rotor Install 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 Install the pump cover by aligning the hole in the cover with the dowel pin Dowel Pin Pump Cover Screw Tighten the screw to secure the pump cover Make sure that the pump shaft rotates freely without binding Oil Pump INSTALLATION Install the oil pump into crankcase Install the oil pump with the arrow on the pump body facing up and fill the oil pump with engine oil before installation After the oil pump is installed tighten two mounting bolts Install the pump driven gear and drive chain by aligning the pump driven gear with the cutout in the pump shaft Install and tighten the pump driven gear nut Torque 1 0kg m Pump Driven Gear 4 5 KYMCO 4 LUBRICATION SYSTEM MOVIE SYSTEM Install the oil separator cover and tighten the bolts Install the starter idle gear and starter clutch Install the gasket and dowel pins Starter Clutch Gasket Install the right crankcase cover and tighten Right Crankcase Cover the nine bolts E Torque 0 9kg m Diagonally tighten the bolts i
21. Avoid the projected ends of bolts and screws B Route wire harnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws 1 9 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM Route harnesses so they are neither pulled tight nor have excessive slack Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner E When rubber protecting cover is used to protect the wire harnesses it shall be installed securely E Do not break the sheath of wire W If a wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it B When installing other parts do not press or squeeze the wires 1 10 1 GENERAL INFORMATION KYMCO MOVIE SYSTEM After routing check that the wire harnesses are not twisted or kinked B Wire harnesses routed along with handlebar should not be pulled tight have excessive slack or interfere with adjacent or surrounding parts in all steering positions B When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions Be careful not to drop any parts B When rust is found on a terminal remove the rust with sand paper or equivalent before connecting 1 11 emove Rusf KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM B Symbols The fo
22. Axle shaftrunout o 0 2 Ax 0 20 Front brake drum LD Front brake lining thickness Front shock absorber spring free length Brake disk runout 030 Brake master cylinder piston O D 12 657 12 684 12 64 Brake caliper piston O D 25 335 25 368 25 330 Brake caliper cylinder 25 40 25 45 25 460 TORQUE VALUES Steering stem bolt 4 0 5 0kg m Brake caliper bleed valve 0 6kg m Steering stem lock nut 8 0 12 0kg m Brake fluid tube bolt 2 5 3 5kg m Steering top cone race 0 5 1 3kg m Brake pad pin bolt 1 5 2 0kg m Front shock absorber 2 0 2 5kg m brake caliper bolt 2 9 3 5kg m Front axle nut 6 0kg m Brake master cylinder bolt 1 0 1 4kg m 12 1 12 FRONT WHEEL FRONT BRAKE FRONT SUSPENSION SPECIAL TOOLS Lock nut wrench Lock nut wrench Outer driver 28x30mm Rear shock absorber attachment Shock absorber compressor Ball race remover Pliers close TROUBLESHOOTING Hard steering heavy Excessively tightened steering stem top cone race e Broken steering balls 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 Incorrectly adjusted brake Worn brake linings e Contaminated brake lining surface Worn brake shoes at cam contacting area e Worn brake drum Poorly connected brake arm Poor brake performance Disk Brake e Air in
23. LUBRICATION POINTS ENGINE Valve guide valve stem movable part eGenuine KYMCO Engine Oil SAE15W 40 Cam lobes e API SG Engine Oil Valve rocker arm friction surface Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings Cylinder inside wall Connecting rod piston pin hole Connecting rod big end Crankshaft right side oil seal Crankshaft one way clutch movable part Oil pump drive chain Starter reduction gear engaging part Countershaft gear engaging part Final gear engaging part Bearing movable part O ring face Oil seal lip Starter idle gear Friction spring movable part shaft movable part High temperature resistant grease Shaft movable grooved part Starter spindle movable part Starter one way clutch threads Thread locking agent A C generator connector Adhesive Transmission case breather tube 1 15 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM FRAME The following is the lubrication points for the frame Use general purpose grease for parts not listed Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle T ain Grease Engine Oil Front Brake Lever Front Brake Cable Pivot Speedometer Cable Throttle Cable Grease Seat Lock Engine Rear Brake Cable Grease fae E Speedometer Gear Front Wheel
24. float and float valve Float Float Valve INSPECTION Inspect the float valve and valve seat for damage or clogging Inspect the float valve and valve seat contact area for stepped wear or contamination Worn or contaminated float valve and valve seat must be replaced because it will result in float level too high due to incomplete airtightness Remove the main jet needle jet holder needle jet slow jet and pilot screw Be careful not to damage the fuel jets and pilot screw Before removing turn the pilot screw in and carefully count the number of turns until it seats lightly and then make a note of this Do not force the pilot screw against its seat to avoid seat damage Pilot Screw Needle Jet Holder Main Jet Clean the removed fuel jets with detergent oil and blow them open with compressed air Blow compressed air through all passages of the carburetor body Also remove and clean the vacuum chamber and air cut off valve 5 7 KYMCO 5 FUEL SYSTEM MOVIE SYSTEM ASSEMBLY Install the slow jet needle jet needle jet holder main jet and pilot screw Needle Jet Slow Jet Return the pilot screw to the original position as noted during removal Standard Opening 3 12 turns Install the float valve float and float pin Pilot Screw Needle Jet Holder Main Jet Float Valve FLOAT LEVEL INSPECTION e Check the operation of the float valve and float before float level inspe
25. the bottom of the engine to drain the engine oil thoroughly Oil Filter Screen Cap After the oil has been completely drained check the filter screen O ring for damage and replace if necessary Install the oil filter screen spring and filter screen cap Torque 1 5kg m Fill with the specified SAE1SW40 API SG engine oil to the proper level Oil Capacity At disassembly 0 90 liter At change 0 80 liter Check for oil leaks and then start the engine and let it idle for few minutes Recheck the oil level Bolts Pulser Coil OIL PUMP y y REMOVAL Remove the A C generator flywheel Remove the nine right crankcase cover bolts and the right crankcase cover Stator Right Crankcase Cover 4 2 4 LUBRICATION SYSTEM Remove the gasket and dowel pins Remove the starter idle gear and starter clutch Remove the two bolts and oil separator Remove oil pump driven gear nut to remove the oil pump driven gear and drive chain Remove the two oil pump mounting bolts and the oil pump 4 3 Oil Pump Nut KYMCO MOVIE SYSTEM KYMCO 4 LUBRICATION SYSTEM MOVIE SYSTEM S DISASSEMBLY Remove screw disassemble oil pump Pump Body INSPECTION pump body to outer rotor clearance Service Limit 0 12mm Pump Body Measure the inner rotor to outer rotor Outer Rotor clearance Service Limit
26. 1 0kg m Install the brake arm return spring Install the brake arm pin Connect the brake cable and install the adjusting nut Install the rear wheel Adjust the rear brake lever free play uU Adjusting Nut Brake Arm Pin Wear Indicator Plate Punch Mark 13 4 13 REAR WHEEL REAR QC KYMCO REAR SUSPENSION MOVIE SYSTEM REAR SHOCK ABSORBER B gt PJP REMOVAL Remove the frame body cover Remove the air cleaner case Bolt Remove the rear shock absorber upper and lower mount bolts Remove the rear shock absorber DISASSEMBLY Install the rear shock absorber compressor as the figure shown Install the rear shock absorber lower joint into the rear shock absorber compressor Compress the rear shock absorber spring Loosen the lower joint lock nut Lock Nut Rear Shock Absorber Compressor Remove the lower joint Remove the lock nut rubber and damper 13 REAR WHEEL REAR BRAKE QC KYMCO REAR SUSPENSION MOVIE SYSTEM INSPECTION Inspect the damper rod for bending or damage Inspect the damper for oil leaks Inspect the damper rubber for deterioration or damage Damper Damper Rod Rubber Measure the front shock absorber spring free length Service Limit 220mm replace if below ASSEMBLY Assemble the rear shock absorbers in the reverse order of disassembly Install the shock absorber spring with loosely wound coils facing down e Apply locking agent to the
27. 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION MOVIE SYSTEM and disconnect the throttle cable from the throttle pipe Remove the throttle pipe from the handlebar Throttle Seat Remove the steering stem lock bolt collar Nut nut and the handlebar STEERING STEM REMOVAL Remove the steering stem lock nut Special Steering Stem Lock Nut Wrench Lock Nut wrench Remove the top cone race Be careful not to lose the steel balls 26 on top race and 19 on bottom race e Clean the openings of frame covers with clean shop towels Remove the front fork Throttle Pipe BOTTOM CONE RACE REPLACEMENT 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION MOVIE SYSTEM Remove the bottom cone race using a Be careful not to steering stem and front fork Drive a new bottom cone race into place with a proper driver Bottom Cone Race BALL RACE REPLACEMENT Drive out the top and bottom ball races Ball Race Remover Outer Driver 37x40mm Drive new top and bottom ball races into the steering head using the outer driver Special Outer Driver 37x40mm INSTALLATION Apply grease to the top and bottom ball races and install 26 steel balls on the top ball race and 19 steel balls on the bottom ball race Apply grease to the ball races and install the front fork Apply grease to the top cone race and install f it 12 18 12 FRONT
28. Contaminated fuel e Intake air leak Incorrect idle speed Incorrectly adjusted pilot screw Clogged idle system or auto bystarter passages Incorrectly adjusted float level Lean mixture Clogged fuel jets e Faulty float valve Float level too low Clogged fuel system e Intake air leak e Improper vacuum piston operation e Improper throttle operation 5 2 KYMCO 5 FUEL SYSTEM MOVIE SYSTEM CARBURETOR REMOVAL Remove the frame body cover Disconnect the auto bystarter wire connector Auto Bystarter Wire Loosen the drain screw and drain the fuel from the float chamber Disconnect the fuel tube and vacuum tube at the carburetor Fuel Tube Vacuum Tube Air Cleaner Connecting rent Adjusting Nut Loosen the throttle cable adjusting nut and Jupe me EE lock nut and disconnect the throttle cable from the carburetor Loosen the carburetor intake manifold band and air cleaner connecting tube band screws and then remove the carburetor AUTO BYSTARTER OPERATION INSPECTION Measure the resistance between the auto bystarter wire terminals Resistance 100 max 10 minutes minimum after stopping the engine If the reading is not within the limit replace the auto bystarter with a new one 5 3 5 FUEL SYSTEM Connect a hose to the fuel enriching circuit of the carburetor Connect the auto bystarter yellow wire to the positive terminal of a battery and
29. D Take measurement at 9mm from the bottom and 90 to the piston pin hole Service Limit 52 3mm replace if below Measure the piston to piston pin clearance Service Limit 0 02mm replace if over CYLINDER INSPECTION Inspect the cylinder bore for wear or damage Measure the cylinder I D at three levels of top middle and bottom at 90 to the piston pin in both X and Y directions Service Limit 52 50mm repair or replace if over Measure the cylinder to piston clearance Service Limit 0 1mm repair or replace if over The true roundness is the difference between the values measured in X and Y directions The cylindricity difference between the values measured at the three levels is subject to the maximum value calculated Service Limits True Roundness 0 05mm repair or replace if over Cylindricity 0 05mm repair or replace if over 8 5 KYMCO 8 CYLINDER PISTON MOVIE SYSTEM Inspect the top of the cylinder for warpage Service Limit 0 05mm repair or replace if Over Measure connecting small end Service Limit 15 06mm replace if over PISTON RING INSTALLATION Install the piston rings onto the piston Apply engine oll to each piston ring e Be careful not to damage or break the piston and piston rings e All rings should be installed with the markings facing up 2 e After installing rings they should rotate freely without s
30. Valve seat cutter 24 5mm 45 IN EX Valve seat cutter 25mm Plane cutter 32 IN Valve seat cutter 22mm Plane cutter 32 EX Valve seat cutter 26mm Plane cutter 60 IN EX Cutter clip 5mm Valve spring compressor attachment Valve wrench Valve guide driver Valve guide reamer TROUBLESHOOTING e The 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 Damaged valve stem seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment ncorrect valve timing e Sticking valve or broken valve spring e Broken valve spring Damaged or worn camshaft Poor valve and seat contact e Worn cam chain guide e Leaking cylinder head gasket e Worn camshaft and rocker arm Warped or cracked cylinder head Poorly installed spark plug Compression too high Excessive carbon build up in combustion chamber 7 2 KYMCO 7 CYLINDER HEAD VALVES MOVIE SYSTEM CAMSHAFT REMOVAL Remove the center cover Remove the four cylinder head cover bolts to remove the cylinder head cover Remove the two nuts attaching the secondary air inlet tube Remove the cam chain tensioner cap screw O ring and the O ring Turn the cam chain tensioner screw clockwise to tighten it
31. brake system e Deteriorated brake fluid e Contaminated brake pads and brake disk Worn brake pads e Worn brake master cylinder piston oil seal Clogged brake fluid line e Deformed brake disk Unevenly worn brake caliper KYMCO MOVIE SYSTEM Driver handle A Outer driver 37x40mm Pilot 10mm Bearing remover Bearing remover head 10mm Damper compressor Front wheel wobbling e Bent rim e Excessive wheel bearing play Bent spoke plate e Faulty tire Improperly tightened axle nut Soft front shock absorber e Weak shock springs Insufficient damper oil Front shock absorber noise e Slider bending e Loose fork fasteners e Lack of lubrication 12 2 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION MOVIE SYSTEM FRONT WHEEL REMOVAL Jack the motorcycle front wheel off the ground Remove the speedometer cable set screw and disconnect the speedometer cable Remove the front brake cable Screw Front Brake Cable Remove the front axle nut and pull out the axle Remove the front wheel Remove the front brake panel Axle Shaft Axle Nut INSPECTION AXLE RUNOUT Set the axle in V blocks and measure the runout using a dial gauge The actual runout is 12 of the total indicator reading Service Limit 0 2mm replace if over WHEEL RIM Check the wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over Spee
32. contact flush with water and get prompt medical attention The battery can be charged and discharged repeatedly If a discharged battery is not used for a long time its service life will be shortened Generally the capacity of a battery will decrease after itis used for 2 3 years capacity decreased battery will resume its voltage after it 15 recharged but its voltage decreases suddenly and then increases when a load is added e When a battery is overcharged some symptoms can be found If there is a short circuit inside the battery no voltage is 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 is not used for a long time it will discharge by itself and should be recharged every 3 months A new battery filled with electrolyte will generate voltage within a certain time and it should be recharged when the capacity is insufficient Recharging a new battery will prolong its service life e Inspect the charging system according to the sequence specified in the Troubleshooting Do not disconnect and soon reconnect the power of any electrical equipment because the electronic parts in the regulator rectifier will be damaged Turn off the ignition switch before operation e It is not necessary to check the MF battery electrolyte or fill with distilled water Check the load of the whole charging system Do not quick charge the ba
33. cup lips facing the correct direction Install the main piston spring and snap ring Install the rubber cover Install the brake lever Master Cylinder Spring 12 10 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION MOVIE SYSTEM Place the brake master cylinder on the handlebar and install the holder with the up mark facing up Also align the punch mark with the holder joint seam First tighten the upper bolt and then tighten the lower bolt Torque 1 0 1 4kg m Up Mark Install the brake fluid tube with the attaching bolt and two sealing washers Install the handlebar covers Connect the front and rear stop switch wire connectors Fill the brake reservoir with recommended brake fluid to the upper limit and bleed air according to the method stated in page 12 8 BRAKE CALIPER FRONT REMOVAL Remove the brake caliper and brake pad springs Place a clean container under the brake caliper and disconnect the brake fluid pipe from the caliper Do not spill brake fluid on any coated surfaces DISASSEMBLY Remove the brake caliper seat from the brake caliper Fluid Tube Bolt Punch Mark Remove the pistons from the brake caliper 12 FRONT WHEEL FRONT BRAKE O KYMCO FRONT SUSPENSION MOVIE SYSTEM If necessary use compressed air to squeeze out the pistons through the brake fluid inlet opening and place a shop towel under the caliper to avoid contamination caused by the removed pistons
34. green wire to the negative terminal Wait 5 minutes and blow the hose with mouth or vacuum pump If the passage is blocked the auto bystarter is normal Disconnect the auto bystarter from the battery Wait 30 minutes and blow the hose with mouth or vacuum pump If air can be blown into the hose the auto bystarter is normal REMOVAL Remove the set plate screws and set plate Remove the auto bystarter from the carburetor AUTO BYSTARTER INSPECTION Check the auto bystarter valve and needle for nicks wear or damage If any faulty part is found replace the auto bystarter as a set INSTALLATION Insert the auto bystarter into the carburetor body until it bottoms Position the set plate into the groove in the auto bystarter and tighten the screws Be sure to install the auto bystarter and set plate properly e Install the set plate with its bottom face facing down KYMCO MOVIE SYSTEM Adopter Auto Bystarter Set Plate Screws Bystarter Valve Bystarter Needle Auto Bystarter Set Plate Screws 5 4 5 FUEL SYSTEM KYMCO MOVIE SYSTEM AIR CUT OFF VALVE DISASSEMBLY Disconnect the vacuum tube from the air cut off valve Remove the two screws to remove the air cut off valve cover spring and vacuum diaphragm ASSEMBLY Install the vacuum diaphragm onto the carburetor Install the spring and air cut off valve cover and then tighten the two screws
35. lock nut threads and tighten the lock nut Tighten the lock nut Torque 3 5 4 8kg m INSTALLATION Install the rear shock absorber First install the upper mount bolt and then the lower mount bolts and tighten them Install the air cleaner case and tighten the two bolts Install the frame body cover Torque Upper Mount Bolt 4 0kg m Lower Mount Bolt 2 5kg m Lower Mount Bolt 13 6 14 BATTERY CHARGING SYSTEM A C GENERATOR KYMCO MOVIE SYSTEM BATTER CHARGING SYSTEM GENERATOR SERVICE INFORMATION 14 2 TROUBLESHOOTING seat 14 3 BATTERY REMOY 14 4 CHARGING aiii ies 14 5 REGULATOR BECTIPIBR lll 14 6 GENERATOR CHARGING COIL 14 7 AC GENERATOR 14 7 14 0 KYMCO MOVIE SYSTEM Regulator Rectifier 14 BATTERY CHARGING SYSTEM A C GENERATOR Ignition Switch Battery A C Generator CHARGING CIRCUIT 12 VSAH Handlebar switches Rectifier II 14 1 14 BATTERY CHARGING SYSTEM O KYMCO A C GENERATOR MOVIE SYSTEM SERVICE INFORMATIONN GENERAL INSTRUCTIONS The battery electrolyte sulfuric acid is poisonous and may seriously damage the skin and eyes Avoid contact with skin eyes or clothing Incase of
36. the intake and exhaust cam lobes down and install the camshaft onto 2 a p d 4 4 the cylinder head Install the cam chain over the camshaft gear Round Hole Punch Marks Install the dowel pins Dowel Pins 2 Install the camshaft holder washers nuts on cylinder head Tighten the four cylinder head nuts and two bolts Torque Cylinder head nut 2 0kg m Apply engine oil to the threads of the cylinder head nuts e Diagonally tighten the cylinder head nuts in 2 3 times Adjust the valve clearance Turn the cam chain tensioner screw counter clockwise to release it Tensioner Screw Cam Chain Camshaft Gear 7 10 KYMCO 7 CYLINDER HEAD VALVES MOVIE SYSTEM Apply engine oil to a new O ring and install it Tighten the cam chain tensioner cap screw Be sure to install the O ring into the groove properly Install a new cylinder head cover O ring and install the cylinder head cover Install and tighten the cylinder head cover bolts Be sure to install the O ring into the groove properly Cylinder Head Cover KYMCO 8 CYLINDER PISTON MOVIE SYSTEM CYLINDER PISTON SERVICE INFORMATION 2225 6 Lp 8 1 TROUBLESHOOTING 8 1 CYLINDER REMOVAT 8 2 PISTON REMOV AE 8 2 PISTON INSTALLATION 8 6 CYLI
37. valve rocker arm Service Limits IN 10 10mm replace if over US EX 10 10mm replace if gt Measure each rocker arm shaft O D Service Limits IN 9 91mm replace if over EX 9 91mm replace if over KYMCO 7 CYLINDER HEAD VALVES MOVIE SYSTEM YLINDER HEAD REMOVE Remove the camshaft Remove the carburetor Remove the exhaust muffler Remove the carburetor intake manifold Remove the cooling fan cover Remove the engine cover bolts and screws Separate the engine cover joint claws Intake Manifold Remove the cylinder head Remove the dowel pins and cylinder head Bolts gasket Remove the cam chain guide POSSEM OU diras Remove all gasket material from cylinder mating surface e Avoid damaging the cylinder mating surface Be careful not to drop any gasket material into the engine KYMCO 7 CYLINDER HEAD VALVES MOVIE SYSTEM CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters retainers springs spring seats and valve stem seals 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 Valve Spring Compressor Valve Spring Compressor Attachment Remove carbon deposits from the combustion chamber Clean off any gasket material from the cylinder head mating surface Be careful not to damage the cylinder head m
38. 0 300 400 500 600 0 0 0 0 0 0 0 0 0 0 0 Be Em n i ei el e Engine oil motorcycle 300km Engine oil filter C Screen 300km Vasa A al al _ _ OA RUN Sparkplug atever 3000km and replace gmkessem prp E ET pw Suspension jr T jr L li Netus 1 bcd Se Eq m In interest of safety we recommend these items should be serviced only by an authorized KYMCO motorcycle dealer Note 1 For higher odometer readings repeat at the frequency interval established here 2 Service more frequently when riding in dusty or rainy areas 3 Service more frequently when riding in rain or at full throttle KYMCO 3 IISPECTION ADJUSTMENT MOVIE SYSTEM Fuel Line FUEL LINE Remove the met in box Check the fuel lines and replace any parts which show signs of deterioration damage or leakage Do not smoke or allow flames or sparks in your working area THROTTLE OPERATION Check the throttle grip for smooth movement Measure the throttle grip free play Free Play 2 6mm Major adjustment of the throttle grip free play is made at the carburetor side Adjust by loosening the lock nut and turning the adjusting nut Adjusting Nut Lock Nut M
39. 80 Reinstall the oil check bolt and check for oil leaks Torque 1 2kg m 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 Drive Belt 3 7 KYMCO 3 IISPECTION ADJUSTMENT MOVIE SYSTEM Punch Mark BRAKE SHOE apes Replace the brake shoes if the arrow on the wear indicator plate aligns with the punch mark on the brake panel when the brake is fully applied BRAKE SYSTEM FRONT BRAKE Measure the front brake lever free play Free Play 10 20mm If the free play do not fall within the limit adjust by turning the adjusting nut Adjusting Nut REAR BRAKE Measure the rear brake lever free play Free Play 10 20mm 3 8 KYMCO 3 IISPECTION ADJUSTMENT MOVIE SYSTEM Adjusting Nut If the free play do not fall within the limit adjust by turning adjusting nut HEADLIGHT AIM Turn the ignition switch ON and start the engine Turn on the headlight switch Adjust the headlight aim by turning the headlight aim adjusting screw Adjusting Screw SUSPENSION FRONT Fully apply the front brake lever and check the action of the front shock absorbers by compressing them several times Check the entire shock absorber assembly for oil leaks looseness or damage REAR Check the action of the rear shock absorber by compressing
40. BATTERY CHARGING SYSTEM KYMCO A C GENERATOR MOVIE SYSTEM 14 11 KYMCO 15 IGNITION SYSTEM MOVIE SYSTEM IGNITION SYSTEM SERVICE INFORMATION 15 2 TROUBLESHOOTING 15 3 CDI UNIT INSPECTION EE 15 4 deu 15 5 PULSER aera eee ete 15 6 15 0 KYMCO 15 IGNITION SYSTEM MOVIE SYSTEM Ignition Switch CDI Unit A C Generator Pulser Coil IGNITION CIRCUIT Ignition Switch L Y GB Y Battery 12V8AH Generator 15 1 KYMCO 15 IGNITION SYSTEM MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS e Check the ignition system according to the sequence specified in the Troubleshooting e The ignition system adopts CDI unit and the ignition timing cannot be adjusted e If the timing is incorrect inspect the CDI unit and A C generator and replace any faulty parts Inspect the CDI unit with a CDI tester e Loose connector and poor wire connection are the main causes of faulty ignition system Check each connector before operation e Use of spark plug with improper heat range is the main cause of poor engine performance e The inspections in this section are focused on maximum voltage The inspection of ignition coil resistance is also described in this section e Inspect the ignition switch according to the conti
41. CH 1 3 3 4 5 8 8 17 15 13 13 14 10 11 12 13 14 15 16 QN A WO N N 16 1 ON N CA ON N ON N 1 1 1 1 N N N WN STARTER MOTOR STARTER RELAY STEERING HANDLEBAR STEERING HYDRAULIC STEERING STEM STOP SWITCHES SUSPENSION THROTTLE OPERATION TORQUE VALUES TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING VACUUM CHAMBER VALVE CLEARANCE WHEELS TIRES WIRING DIAGRAM 16 16 3 12 12 17 nm OQ t A WO N KF COO Q SO OO Q tA A N KYMCO MOVIE SYSTEM 3 5 10 16 17 6 9 3 KYMCO KvMco TECHNICAL INFORMATION Model ALL MODEL For EURO 2 Date 8 JAN 04 Subject KYMCO Clean Air System For EURO 2 NO KTI 04002 KYMCO Clean Air System For EURO 2 The KYMCO Clean Air System is a secondary air suction system that helps the exhaust gases to burn more completely When the spent fuel charge is released into the exhaust system it is still hot enough to burn The system allows extra air into the exhaust system so that the spent fuel charge can continue to burn This continued burning action tends to burn up a great deal of the normally unburned gases as well as changing a significa
42. G SYSTEM STARTER RELAY GROUND CIRCUIT INSPECTION Disconnect the starter relay wire connector Check for continuity between the yellow red wire terminal and ground There should be continuity when the starter button is depressed If there is no continuity check the starter button for continuity and inspect the wire OPERATION TEST Connect the electric tester to the starter relay larger terminals that connect to the battery positive cable and the starter motor cable Connect a fully charged battery across the starter relay yellow red and green yellow wire terminals Check for continuity between the starter relay large terminals The relay is normal if there is continuity INSTALLATION Connect the starter motor cable connector and properly install the waterproof rubber jacket Check the O ring for wear or damage and replace if necessary Apply grease to the O ring and install the starter motor Tighten the two mounting bolts The starter motor cable connector must be installed properly STARTER CLUTCH REMOVAL Remove the A C generator Remove the right crankcase cover KYMCO MOVIE SYSTEM Yellow Red Wire Starter Relay Starter Motor Cable KYMCO 16 STARTING SYSTEM MOVIE SYSTEM Lock Nut Remove the starter clutch lock nut Lock Nut Wrench Note that the lock nut is left threaded Remove the starter clutch Remove the starter idle gear and shaft Lock Nut
43. ION SYSTEM MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS e The maintenance of lubrication system can be performed with the engine installed in the frame e Use care when removing and installing the oil pump not to allow dust and foreign matters to enter the engine and oil line 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 is installed check each part for oil leaks SPECIFICATIONS 2 44 22 O a pump Rotor end to pump body clearance 0 05 0 10 TROUBLESHOOTING Oil level too low Poor lubrication pressure e Natural oil consumption Oil level too low e Oil leaks Clogged oil filter or oil passages Worn or poorly installed piston rings e Not use the specified oil e Worn valve guide or seal 4 1 KYMCO 4 LUBRICATION SYSTEM MOVIE SYSTEM Lower Level ENGINE OIL OIL FILTER OIL LEVEL e Place the motorcycle upright on level ground for engine oil level check eRun the engine for 2 3 minutes and check the oil level after the engine is stopped for 2 3 minutes Remove the oil dipstick and check the oil level with the oil dipstick If the level is near the lower level fill to the Oil Dipstick Upper Level upper level with the specified engine oil OIL CHANGE The engine oil will drain more easily while the engine is warm Remove the oil filter screen cap located on
44. N GENERAL NWARNING 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 ENGINE Throttle grip free play 2 6mm Spark plug gap 0 6 0 7mm Spark plug Standard NGK CR7HSA Valve clearance IN 0 12mm EX 0 12mm Idle speed 1700x100rpm Engine oil capacity At disassembly 0 9 liter At change 0 8 liter Gear oil capacity At disassembly 200cc At change 180cc Cylinder compression 13kg cm 2 Ignition timing BTDC 13 3 1700 100 CHASSIS Front brake free play 10 20mm Rear brake free play 10 20mm TIRE PRESSURE a 2 00kg cm 2 2 25kg cm 2 TIRE SIZE Front 100 90 10 Rear 100 90 10 TORQUE VALUES Front axle nut 6 0kg m Rear axle nut 11 0kg m 3 1 KYMCO 3 INSPECTION ADJUSTMENT SYSTEM MAINTENANCE SCHEDULE Perform periodic maintenance at each scheduled maintenance period I Inspect and Clean Adjust Lubricate or Replace if necessary A Adjust Clean R Replace Tighten Whichever Regular Service Mileage km comes first gt M 1000 20
45. NDER INSTALLATION 8 6 8 0 8 CYLINDER PISTON SERVICE INFORMATION GENERAL INSTRUCTIONS KYMCO MOVIE SYSTEM The cylinder and piston be serviced with the engine installed in frame e After disassembly clean the removed parts and dry them with compressed air before inspection TROUBLESHOOTING e When hard starting or poor performance at low speed occurs check the crankcase breather for white smoke If white smoke is found it means that the piston rings are worn stuck or broken Compression too low or uneven compression Worn stuck or broken piston rings e Worn or damaged cylinder and piston Compression too high Excessive carbon build up in combustion chamber or on piston head 8 1 Excessive smoke from exhaust muffler e Worn or damaged piston rings e Worn or damaged cylinder and piston Abnormal noisy piston e Worn cylinder piston and piston rings Worn piston pin hole and piston pin KYMCO 8 CYLINDER PISTON MOVIE SYSTEM SPECIFICATIONS Movie 125 Standard mm 52400 52 410 52 50 Ring to groove Second Top Piston Second piston ring Olsideril __ 0207 Piston O D measuring position 9mm from bottom of skirt Movie 150 Standard mm 57400 57 410 57 50 Ring to groove Top clearance Second Top 0 5 Piston Ring end gap Second piston ring Olsideril 0207 Piston O D measuring position
46. ON and check the spark from the watch window Good Normal and continuous spark Faulty Weak or intermittent spark Ignition Coil 4 PULSER COIL INSPECTION KYMCO 15 IGNITION SYSTEM MOVIE SYSTEM This test is performed with the stator installed in the engine Remove the frame body cover Disconnect the A C generator connector Measure the pulser coil resistance between the blue yellow and green wire terminals Resistance 50 1500 20 A C generator removal IGNITION TIMING INSPECTION The CDI unit is not adjustable the ignition timing is incorrect inspect the CDI unit pulser coil and A C generator and replace any faulty parts Remove the timing hole cap Warm up the engine and check the ignition timing with a timing light When the engine is running at 1700rpm the ignition timing is correct if the mark aligns with the index mark within 3 Ignition Timing 13 BTDC 1700rpm 15 6 KYMCO 16 STARTING SYSTEM MOVIE SYSTEM STARTING SYSTEM SERVICE 16 2 TROUBLESHOOTING 16 2 STARTER MOTOR 16 3 STARTER REE 16 5 STARTER CLUTCH 16 6 16 0 16 1 16 STARTING SYSTEM QC KYMCO MOVIE SYSTEM Stop Switches Starter Relay
47. ORMATION MOVIE SYSTEM ENGINE LACKS POWER lee aa Probable Cause i Start engine and accelerate lightly for t observation Clogged air cleaner Restricted fuel flow Clogged fuel tank cap breather hole Engine speed does not logged exhaust muffler increase sufficiently Faulty auto bystarter Split carburetor vacuum piston diaphragm Faulty auto fuel valve Faulty CDI unit Correct timing Incorrect timing Faulty pulser coil x Check ignition timing using a timing light Check Valve clearance Improper valve clearance Worn valve seat valve stem too protruding mproper valve and seat contact Normal Abnormal Worn cylinder and piston rings compression compression Leaking cylinder head gasket Improper valve timing gt Not clogged Clogged carburetor jets Remove spark plug and mu inspect Plug not fouled or Plug fouled or ouled spark plug discolored discolored Incorrect heat range plug Remove oil dipstick and check oil level and conditio Oil level too high Oil level too low Oil not changed logged oil pipe Faulty oil pump Worn cylinder and piston rings Mixture too lean Poor quality fuel Excessive carbon buildup in combustion chamber Ignition timing too early Rapidly accelerate or run at high speed xcessive carbon build up in combustion chamber Poor quality fuel lutch slipping Engine doe
48. OVIE SYSTEM CYLINDER REMOVAL DRIVE BELT DRIVE PULLEY ENGINE INSTALLATION ENGINE OIL OIL FILTER ENGINE REMOVAL EXHAUST MUFFLER REMOVAL FINAL REDUCTION ASSEMBLY FINAL REDUCTION DISASSEMBLY FINAL REDUCTION GEAR OIL FINAL REDUCTION INSPECTION FLOAT CHAMBER FRAME COVERS FRONT BRAKE FRONT SHOCK ABSORBER FRONT TURN SIGNAL LIGHT FRONT WHEEL FUEL GAUGE FUEL LINE FUEL TANK FUEL UNIT FUEL UNIT HANDLEBAR SWITCHES HEADLIGHT AIM HEADLIGHT HORN HYDRAULIC BRAKE IGNITION COIL IGNITION SWITCH IGNITION TIMING INSTRUMENTS KICK STARTER LEFT CRANKCASE COVER 8 2 3 7 9 3 6 4 4 2 6 2 2 5 10 4 10 2 455 10 2 5 6 2 2 12 6 12 13 17 3 12 3 17 6 3 3 5 10 17 6 5 11 17 4 3 9 1 3 17 6 12 8 15 5 17 4 3 6 17 8 9 13 9 2 LUBRICATION POINTS MAINTENANCE SCHEDULE NUTS BOLTS FASTENERS OIL PUMP PILOT SCREW ADJUSTMENT PISTON INSTALLATION PISTON REMOVAL POSITION REAR TURN SIGNAL LIGHT PULSER COIL REAR SHOCK ABSORBER REAR WHEEL REGULATOR RECTIFIER SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE INFORMATION SERVICE PRECAUTIONS SPARK PLUG SPECIAL TOOLS SPECIFICATIONS STARTER CLUT
49. Rear shock absorber lower mount bolt Speedometer cable set screw Front shock absorber tube bolt Front shock absorber upper mount bolt Front shock absorber lower mount bolt Front shock absorber hex bolt Rear shock absorber lower Joint lock nut 1 13 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM SPECIAL TOOLS Valve adjuster Valve guide driver Valve guide reamer Valve spring compressor Lock nut wrench 39mm Bearing driver Bearing driver Bearing remover 12mm Remover set 12mm Remover head 12mm Remover shaft Remover weight Bearing remover set 15mm Bearing driver Driver handle Driver weight Clutch spring compressor Outer extension Crankshaft assembly tool Crankshaft assembly collar Crankshaft assembly shaft Attachment Lock nut wrench Lock nut wrench Ball race remover extension Ball race remover Spring compressor Spring compressor attachment Spring compressor attachment Spring compressor attachment Lock nut wrench Driver outer extension Float level gauge Valve spring compressor Valve seat cutter 24 5mm 45 Valve seat cutter 25mm Plane cutter 32 IN Valve seat cutter 22mm Plane cutter 32 EX Valve seat cutter 26mm Plane cutter 60 IN EX Cutter clip 5mm Universal holder Outer driver 32x35mm Outer driver 37x40mm Outer driver 42x47mm Bearing remover shaft Bearing remover head 12mm Flywheel puller 1 14 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM
50. Rear wheel Rear brake drum I D Rear brake lining thickness Rear shock absorber spring free length TORQUE VALUES Rear axle nut 11 0 13 0kg m Rear shock absorber upper mount bolt 4 0kg m Rear shock absorber lower mount 2 5kg m Exhaust muffler joint lock nut 1 2kg m Exhaust muffler lock bolt 3 5kg m Brake arm bolt 1 0kg m TROUBLESHOOTING Rear wheel wobbling Poor brake performance e Bent rim e Brake not adjusted properly e Faulty tire Worn brake linings e Axle not tightened properly Worn brake shoes at cam contacting area Soft rear shock absorber Worn brake cam e Weak shock absorber spring e Worn brake drum e Faulty damper 13 1 13 REAR WHEEL REAR KYMCO REAR SUSPENSION MOVIE SYSTEM REAR WHEEL 2 REMOVAL Remove the exhaust muffler joint lock nuts and exhaust muffler lock bolts Remove the exhaust muffler Remove the rear axle nut to remove the rear wheel INSPECTION Measure the rear wheel rim runout Service Limits Radial 2 0mm replace if over Axial 2 0mm replace if over If the rim runout exceeds the specified service limits check the final shaft bearing for excessive play and the final shaft for bending Inspect the rear wheel and wheel rim for runout INSTALLATION Install the rear wheel and apply SAE30 engine oil to the axle shaft threads Then tighten the rear axle nut Torque 11 0 13 0kg m Install the exhaust muffler Tighten the exhaust m
51. Remove the cylinder head cover Turn the flywheel counterclockwise so that the mark on the flywheel aligns with the index mark on the crankcase to bring the round hole on the camshaft gear facing up to the top dead center on the compression stroke Inspect and adjust the valve clearance Valve Clearance IN 0 12mm EX 0 12mm Loosen the lock nut and adjust by turning the adjusting nut Valve Wrench e Check the valve clearance again after the lock nut is tightened CARBURETOR IDLE SPEED e The engine must be warm for accurate idle speed inspection and adjustment Remove the inspection cover Warm up the engine before this operation Start the engine and connect a tachometer Turn the throttle stop screw to obtain the specified idle speed Idle Speed 1700 100rpm When the engine misses or run erratic adjust the pilot screw 3 5 KYMCO 3 IISPECTION ADJUSTMENT MOVIE SYSTEM Timing Hole Cap IGNITION TIMING The CDI unit is not adjustable If the ignition timing is incorrect check the ignition system Remove the rear right side cover Remove the timing hole cap Check the ignition timing with a timing light When the engine is running at idle speed the ignition timing is correct if the mark on the flywheel aligns with the index mark on the crankcase Also use a timing light to check the advance Raise the engine speed to 5 000rpm and the index mark on the crankcase shoul
52. Remove the instrument bulb sockets Disconnect the three fuel gauge wires Remove the instrument wire clamp screw Fuel Gauge Wires Clamp Speedometer Cable Handlebar Rear Cover Remove the three screws attaching the instruments to the handlebar rear cover Remove the instruments DISASSEMBLY Remove the screws to disassemble the instruments ASSEMBLY INSTALLATION The assembly and installation sequence is the reverse of removal KYMCO 17 LIGHTS INSTRUMENTS SWITCHES MOVIE SYSTEM Fuel Gauge Wires Clamp 17 9 A C GENERATOR CHARGING COIL A C GENERATOR AERIAL NUMBER AIR CLEANER AIR CLEANER AIR CUT OFF VALVE AUTO BYSTARTER AUTO BYSTARTER AUTO FUEL VALVE BATTERY BEAR BRAKE BEARING REPLACEMENT BRAKE SHOE BRAKE SYSTEM CABLE amp HARNESS ROUTING CAMSHAFT INSTALLATION CAMSHAFT REMOVAL CARBURETOR IDLE SPEED CARBURETOR INSTALLATION CARBURETOR REMOVAL CDI UNIT INSPECTION CHARGING SYSTEM LAYOUT CHARGING SYSTEM CLUTCH DRIVEN PULLEY CRANKCASE ASSEMBLY CRANKCASE INSPECTION CRANKCASE SEPARATION CYLINDER COMPRESSION CYLINDER HEAD ASSEMBLY CYLINDER HEAD DISASSEMBLY CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOVAL CYLINDER INSTALLATION 14 14 nN 17 14 13 10 N N 15 14 14 11 11 11 N N WwW 7 7 4 15 10 1 QU Q 1 1 ON ON N ON N KYMCO M
53. WHEEL FRONT BRAKE FRONT SUSPENSION 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 Install the steering stem lock nut and tighten it while holding the top cone race Torque 8 0 12 0kg m Install the front wheel HANDLEBAR INSTALLATION Install the handlebar onto the steering stem tube and then install and tighten the bolt Torque 4 5kg m Install the front wheel Install the brake levers Install the handlebar covers KYMCO MOVIE SYSTEM Top Cone Race Steering Stem Lock Nut Wrench Collar 13 REAR WHEEL REAR BRAKE KYMCO SUSPENSION MOVIE SYSTEM REAR WHEEL REAR BRAKE SUSPENSION SERVICE INFORMATION 13 1 TROUBLESHOOTING 13 1 REAR WHEEL 13 2 REAR 13 2 REAR SHOCK ABSORBER 13 5 13 0 13 WHEEL REAR BRAKE KYMCO REAR SUSPENSION MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS During servicing keep oil or grease off the brake drum and brake linings SPECIFICATIONS Standard mm Rim runout
54. Wrench INSPECTION Inspect the operation of the starter drive gear when it is assembled on the clutch The starter drive gear should turn clockwise freely and should not turn counterclockwise STARTER CLUTCH DISASSEMBLY Inspect the starter drive gear for wear or damage and replace if necessary Measure the starter drive gear I D Service Limit 32 06mm replace if over Inspect the needle bearing for wear or damage and replace if necessary Starter Drive Gear Needle Bearing Clutch Body CLUTCH BODY DISASSEMBLY Remove the rollers plungers and springs e from the clutch body Inspect the clutch body for wear or damage and replace if necessary Inspect each roller and plunger for wear or damage and check for weak spring Replace if necessary Spring Roller 16 7 16 STARTING SYSTEM Measure the clutch cover O D Service Limit 27 94mm replace if over Measure the starter idle gear I D Service Limit 10 05mm replace if over Measure the starter idle gear shaft O D Service Limit 9 94mm replace if below ASSEMBLY Install the springs plungers and rollers onto the clutch body Install the clutch cover by aligning the clutch cover anchor pin with the hole in the clutch body Apply locking agent to the threads of the clutch cover bolts and tighten them Torque 1 2kg m Apply engine oil to the needle bearing and starter drive gear and then install them to the clutch body INSTALLATION Install the s
55. allation sequence is the reverse of removal i Wire Connectors Handlebar Rear Cover FLOOR BOARD REMOVAL CDI Unit Remove the battery cover Remove the battery cables Remove the battery Remove the CDI unit 2 5 a lt When removing first disconnect the battery negative cable and then the positive cable e When installing first connect the positive cable and then the negative cable Battery KYMCO 2 FRAME COVERS EXHAUST MUFFLER MOVIE SYSTEM Remove the rear right and left side covers Remove the frame body cover Remove the front right and left side covers Remove the four bolts attaching the floor board Remove the screw on the bottom of the battery case Remove the floor board The installation sequence is the reverse of removal Floor Board FRONT TOOL BOX REMOVAL Front Tool Box Remove the bolt attaching the front tool box Remove the front tool box The installation sequence is the reverse of removal BOTTOM COVER REMOVAL Remove the four bolts attaching the bottom cover Remove the bottom cover The installation sequence is the reverse of removal When installing the edge of the bottom cover must be insert into the front side covers EXHAUST MUFFLER REMOVAL Remove the two exhaust muffler joint lock nuts Remove the two exhaust muffler lock bolts to remove the exhaust muffler Remove the exhaust muffler jo
56. alve clearance valve seat Empty fuel tank logged fuel tube or filter logged Fuel tank cap breather hole Faulty auto fuel valve Clean and unclog Cam aligning marks not aligne Faulty spring 1 26 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment Probable Cause O Start engine and test limit voltage of PURA x m terminals Normal voltage Voltage does not Dead battery Faulty battery Measure resistance between AC generator RE terminals Faulty A C generator coil Resistance too high Broken yellow wire m Loose connector Connect battery wire ito regulator rectifier icoupler red wire and g battery wire to engine ground and test voltage Normal voltage No voltage Broken red wire Check regulator rectifier coupler for loose x connection BM EE Eni connected coupe 22 7 generator Overcharging Inspection Adjustment Probable Cause O Connect battery wire ito regulator rectifier coupler green wire and battery wire to engine ground and test voltage Battery has voltage with ignition switch Battery has no Mo with ignition Broken green wire switc Check regulator rectifier co
57. andard 5 10 hours Quick 30 minutes After charging Open circuit voltage 12 8V min 14 4 14 BATTERY CHARGING SYSTEIM A C GENERATOR CHARGING SYSTEM SHORT CIRCUIT TEST Disconnect the ground wire from the battery and connect an ammeter across the battery negative terminal and the ground wire Turn the ignition switch OFF and check for short circuit Connect the electric tester positive 4 terminal to ground wire and the tester negative terminal to the battery negative terminal If any abnormality is found check the ignition switch and wire harness for short circuit CURRENT TEST This inspection must be performed with an electric tester when the battery is fully charged Warm up the engine for inspection Connect the electric tester across the battery terminals Disconnect the red wire from the fuse terminal and connect an ammeter between the red wire lead and the fuse terminal as shown Attach a tachometer to the engine Start the engine and gradually increase the engine speed to measure the limit voltage and current Limit Voltage Current 13 5 15 5V 0 5A max 5000rpm max If the limit voltage is not within the specified range check the regulator rectifier LIGHTING SYSTEM LIMIT VOLTAGE INSPECTION Remove the front cover Measure the voltage with the electric tester in the DC range Limit Voltage 12 14V 5000rpm If the limit voltage is not within the speci
58. ating surface INSPECTION 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 Service Limit 0 05mm repair or replace if over VALVE SPRING FREE LENGTH Measure the free length of the inner and outer valve springs Service Limits Inner 32 3mm replace if below Outer 35 0mm replace if below 7 7 Valve Spring Compressor KYMCO 7 CYLINDER HEAD VALVES MOVIE SYSTEM VALVE VALVE GUIDE Inspect each valve for bending burning scratches or abnormal stem wear Check valve movement in the guide Measure each valve stem O D Service Limits IN 4 90mm replace if below EX 4 90mm replace if below Measure each valve guide I D Service Limits IN 5 03mm replace if over EX 5 03mm replace if over Subtract each valve stem O D from the corresponding guide I D to obtain the stem to guide clearance Service Limits IN 0 08mm replace if over EX 0 10mm replace if over If the stem to guide clearance exceeds the service limits replace the cylinder head as necessary CYLINDER HEAD ASSEMBLY Install the valve spring seats and valve stem seals Be sure to install new valve stem seals Lubricate each valve stem 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
59. body cables and wires during engine removal e Use shop towels to protect the motorcycle body during engine removal e Parts requiring engine removal for servicing Crankcase Crankshaft 6 1 6 ENGINE REMOVAL INSTALLATION ENGINE REMOVAL Disconnect the battery negative cable Remove the frame body cover Disconnect the engine negative cable Disconnect the spark plug high tension wire Disconnect the auto bystarter wire connector Disconnect the starter motor cable from the starter relay Remove the spark plug cap and disconnect the ignition coil wire from the set plate Disconnect the fuel tube at the carburetor side Disconnect the auto fuel valve vacuum tube from the tee tube Disconnect the throttle cable from the carburetor Loosen the drive belt air cleaner connecting tube band screw and remove the connecting tube KYMCO MOVIE SYSTEM Auto Bystarter Wire Connector Starter Relay Starter Motor Cable Ignition Coil Wire Vacuum Tube Fuel Tube 6 2 KYMCO 6 ENGINE REMOVAL INSTALLATION MOVIE SYSTEM Remove the air cleaner bolts Remove the rear brake adjusting nut connecting pin and rear brake cable Rear Shock Absorber Lower Mount Bolt Remove the rear shock absorber lower X mount bolt Remove the four A C generator cooling fan cover bolts and cooling fan cover Remove the engine mounting bolt and pull out the engine with the engine hanger bracket backward
60. ch Weights Shoes pins PE MEA Install the clutch weights shoes and clutch springs onto the drive plate Install the retainer plate and secure with the circlips Drive Plate Retainer Plate Seal Movable Driven Face CLUTCH DRIVEN PULLEY ASSEMBLY Clean the driven pulley faces and remove any grease from them Install the oil seal onto the moveable driven face Apply grease to the O rings and install them onto the moveable driven face 9 11 9 DRIVE AND DRIVEN PULLEYS dC KYMCO KICK STARTER MOVIE SYSTEM nstall the movable driven face onto the driven face Apply grease to the guide rollers and guide roller pins and then install them into the holes of the driven face Install the seal collar Remove any excessive grease Be sure to clean the driven face off any grease de Driven Face Movable Driven Face Set the driven pulley assembly driven face spring and clutch assembly onto the clutch spring compressor Align the flat surface of the driven face with the flat on the clutch drive plate Clutch Spring Compressor Compress the clutch spring compressor and install the drive plate nut Set the clutch spring compressor in a vise and tighten the drive plate nut to the specified torque Torque 5 5kg m Be sure to use a clutch spring compressor to avoid spring damage Special Clutch Spring Compressor Lock Nut Wrench Outer Driver 32x35mm INSTALLATION Install the clu
61. clockwise and remove the fuel unit Do not bend the fuel unit float arm otherwise the fuel unit metering values will be incorrect INSTALLATION Inspect the fuel unit gasket for damage Install the fuel unit by aligning the groove in the fuel unit with the tab on the fuel tank 5 11 KYMCO 5 FUEL SYSTEM MOVIE SYSTEM The installation sequence is the reverse of removal Retainer Retainer Install the fuel unit retainer and turn the retainer clockwise to secure it Make sure that the arrow on the retainer is aligned with the arrow on the fuel tank Connect the fuel unit wire connector AIR CLEANER Loosen the air cleaner connecting tube band screw Disconnect the transmission case breather tube from the air cleaner case Remove the two bolts and air cleaner case E 9 Z s Air Cleaner Case KYMCO 6 ENGINE REMOVAL INSTALLATION MOVIE SYSTEM ENGINE REMOVAL INSTALLATION 6 SERVICE INFORMATION 6 1 ENGINE REMOVAL 6 2 ENGINE INSTA LATION in uuu 6 4 6 0 KYMCO 6 ENGINE REMOVAL INSTALLATION MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS A floor jack or other adjustable support is required to support and maneuver the engine careful not to damage the motorcycle
62. cotters e 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 Valve Spring Compressor Valve Spring Compressor Attachment Valve Spring Compressor Attachment 7 8 KYMCO 7 CYLINDER HEAD VALVES MOVIE SYSTEM 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 Dowel Pins CYLINDER HEAD INSTALLATION Tighten the four stud bolts Install the dowel pins and a new cylinder head gasket Install the cam chain guide Torque Stud Bolts 0 7 1 1kg m Install the cylinder head Cylinder Head Camshaft Holder CAMSHAFT HOLDER ASSEMBLY Install the exhaust valve rocker arm to the EX mark side of the camshaft holder Install the intake valve rocker arm and the rocker arm shafts e Align the cutout on the front end of the intake valve rocker arm shaft with the bolt of the camshaft holder e Align the cross cutout on the exhaust valve rocker arm shaft with the bolt of the camshaft holder Valve Rocker Arm CAMSHAFT INSTALLATION KYMCO 7 CYLINDER HEAD VALVES MOVIE SYSTEM Turn the 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
63. ction e Measure the float level by placing the float level gauge on the float chamber face parallel with the main jet Measure the float level Float Level 17 5mm Special Float Level Gauge CARBURETOR INSTALLATION Tighten the drain screw Install the carburetor onto the intake manifold aligning the tab on the carburetor with the cutout in the intake manifold Tighten the band screw Install the air cleaner connecting tube and tighten the band screw Connect the throttle cable to the throttle wheel on the carburetor KYMCO 5 FUEL SYSTEM MOVIE SYSTEM lightly and back it out to the specification given Standard Opening 3 turns Connecting Tube Band Connect the fuel tube and vacuum tube to Vacuum Tube the carburetor Connect the auto bystarter wire connector Perform the following inspections and adjustments Throttle grip free play Carburetor idle speed PILOT SCREW ADJUSTMENT ADJUSTMENT e The pilot screw is factory pre set and no adjustment is necessary During carburetor disassembly note the number of turns of the pilot screw and use as a reference when reinstalling it Place the motorcycle on its main stand on level ground for this operation Pilot Screw A tachometer must be used when adjusting the engine speed Turn the pilot screw clockwise until it seats 5 9 KYMCO 5 FUEL SYSTEM MOVIE SYSTEM x CAUTION Do not force the pilot screw against i
64. d be aligned with the advance mark on the flywheel CYLINDER COMPRESSION Warm up the engine before compression test Remove the met in box and frame center cover Remove the spark plug Insert a compression gauge Open the throttle valve fully and push the starter button to test the compression Compression 13kg cm If the compression is low check for the following Leaky valves Valve clearance to small Leaking cylinder head gasket Worn piston rings Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head QC KYMCO 3 IISPECTION ADJUSTMENT MOVIE SYSTEM Oil Check Bolt Sealing Washer FINAL REDUCTION GEAR OIL OIL LEVEL CHECK Place the motorcycle on its main stand on level ground for oil level check Stop the engine and remove the oil check bolt The oil level shall be at the oil check bolt hole If the oil level is low add the recommended oll to the proper level Recommended Oil GEAR OIL SAE90 Check Bolt Hole Install the oil check bolt Make sure that the sealing washer 15 in good condition OIL CHANGE Remove the oil check bolt Remove the oil drain bolt and drain the oil thoroughly Install the oil drain bolt Torque 1 0kg m Make sure that the sealing washer is in good condition Fill with the recommended oil Oil Capacity At disassembly 200cc At change 1
65. dometer Cable FRONT WHEEL BEARING 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION MOVIE SYSTEM Remove the side collar and dust seal Dust Seal 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 Wheel Bearing Bearing Remover BEARING REPLACEMENT Remove the front wheel bearings and distance collar Bearing Remover Bearing Remover Head 12mm Pack all bearing cavities with grease Drive left bearing Install the distance collar Drive in the right bearing e Do not allow the bearings to tilt while driving them in e Drive in the bearing squarely with the sealed end facing out Special Outer driver 32x35mm Driver handle A Pilot 12mm Side Collar Apply grease to a new dust seal lip and 12 4 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION MOVIE SYSTEM install the dust seal Install the side collar Dust Seal INSTALLATION Apply grease to the brake panel dust seal lip Apply grease to the speedometer gear engaging and sliding parts Install the brake panel by aligning the speedometer retaining pawls with the hub cutouts If not aligned the retaining pawl will be deformed when the axle nut is tightened Af
66. e removed for this operation e The following parts must be removed before separating the crankcase Cylinder head gt Section 7 Cylinder piston Section 8 Drive and driven pulleys Section 9 A C generator Section 14 Carburetor air cleaner Section 4 wheel rear shock absorber c Section 13 Starter motor gt Section 16 Oil pump Section 4 SPECIFICATIONS tem Standard mm Service Limit Connecting rod big end side clearance 0 10 0 35 Crankshaft Connecting rod big end radial clearance 0 0 008 Imma o TOROUE VALUES Crankcase bolt 0 9kg m Cam chain tensioner slipper bolt 1 0kg m Cam chain 0 9kg m SPECIAL TOOL Gear remover TROUBLESHOOTING Excessive engine noise e Excessive bearing play Excessive crankpin bearing play CRANKCASE SEPARATION Remove the two crankcase attaching bolts 11 1 Crankcase Bolts KYMCO 11 CRANKCASE CRANKSHAFT MOVIE SYSTEM Separate the left and right crankcase halves Do not damage the crankcase gasket surface Remove the gasket and dowel pins Remove the crankshaft and cam chain from the left crankcase Clean off all gasket material from the crankcase mating surfaces Avoid damaging the crankcase mating surfaces Remove the oil seal from the right crankcase Check the oil seal lip for wear or deterioration 11 2 11 CRANKCASE CRANKSHAFT The installation seq
67. emove the frame body cover FRAME CENTER COVER REMOVAL Remove the two screws on the bottom of the frame center cover Remove the frame center cover FRONT SIDE COVERS REMOVAL Remove the front cover Remove the bolt and five screws attaching each of the front right and left side covers Remove the front side covers by pulling them outward The installation sequence is the reverse of removal FRONT COVER REMOVAL Remove the three bolts on the front of the front cover Remove the six screws that combine the front cover with the front tool box Remove the front cover and disconnect the turn signal light wire connector The installation sequence is the reverse of removal 2 3 KYMCO MOVIE SYSTEM Frame Body Cover Frame Center Cover Screws Front Side Cover Screws Front Cover Bolt Screws Back KYMCO 2 FRAME COVERS EXHAUST MUFFLER MOVIE SYSTEM HANDLEBAR FRONT REAR COVER Handlebar Front Cover Handlebar Rear Cover REMOVAL HANDLEBAR REAR COVER REMOVAL Remove the right and left rearview mirrors Remove the handlebar rear cover bolt Disconnect all of the wire connectors couplers and the speedometer cable Remove the handlebar rear cover During removal be careful not to damage the joint claws Screws Speedometer Cable HANDLEBAR FRONT COVER REMOVAL Remove the two screws attaching the handlebar front cover Remove the handlebar front cover The inst
68. er rod and then install them into the front shock absorber tube Install the shock absorber spring onto the front shock absorber tube and tighten the lock bolt on the top Install the front shock absorber spring with the closely wound coils facing down Set the front shock absorber in a vise Insert the shock absorber tube into the shock absorber and tighten the hex bolt Apply locking agent to the washer and install it together with the hex bolt Torque 1 5 3 0kg m Add engine oil into the front shock absorber Specified Oil SS S Oil Capacity 553 Shock Absorber Tube Front Shock Absorber Hex Bolt Washer Install the circlip 12 15 12 FRONT WHEEL FRONT BRAKE qo KYMCO FRONT SUSPENSION OVIE SYSTEM Install the dust boot Dust Boot INSTALLATION Mount Bolts Install the front shock absorbers onto the S steering stem Install and tighten the front shock absorber upper mount bolts Tighten the lower mount bolts Align the upper mount bolt hole with the groove on the front fork Install the front wheel STEERING HANDLEBAR Bolts Bolts REMOVAL Remove the handlebar covers Remove the rear brake lever holder bolt to remove the holder Remove the front brake master cylinder holder bolts to remove the brake master cylinder Brake Master Cylinder Rear Brake Lever Throttle Pipe Remove the throttle seat screw Screw Remove the throttle seat from the handlebar 12 16
69. fied range check the regulator rectifier PERFORMANCE TEST Perform this test with a fully charged battery 14 5 KYMCO MOVIE SYSTEM 14 BATTERY CHARGING SYSTEM O KYMCO A C GENERATOR MOVIE SYSTEM YY are not within the specifications in the table REGULATOR RECTIFIER MAIN HARNESS CIRCUIT INSPECTION Remove front cover Remove regulator rectifier 5P coupler and check for continuity between the wire harness terminals according to the following lim ie Colo Between battery red Battery has and engine ground voltage Between ground green WE and engine ground Continuity exists Between lighting wire and engine ground Remove the resistor Battery has coupler and auto voltage bystarter coupler and turn the lighting switch OFF for inspection Between charging coil generator pink and engine ground coil has resistance REGULATOR RECTIFIER INSPECTION If the main harness terminals are normal check the regulator rectifier coupler for loose connection and measure the resistances between the regulator rectifier terminals Do not touch the tester probes with your finger because human body has resistance e Use the following specified testers for accurate testing Use of an improper tester in an improper range may give Red Yellow false readings Kowa Electric Tester Sanwa Electric Tester Kowa Electric Tester 5 e Proper ra
70. g the groove on the bulb socket with the tab on the bulb Install the bulb socket Install the rubber boot Install the front cover Rubber Boot Bulb Socket HEADLIGHT REMOVAL Remove the front cover Remove the six screws attaching the headlight Remove the headlight The installation sequence is the reverse of removal After installation adjust the headlight beam FRONT TURN SIGNAL LIGHT Remove the front cover Remove the front turn signal bulb socket and replace the bulb The installation sequence is the reverse of removal POSITION LIGHT REAR TURN SIGNAL LIGHT BULB REPLACEMENT Remove the rear cover Remove the two screws to remove the position light rear turn signal light shell Remove the bulb sockets and replace the bulb The installation sequence is the reverse of removal 17 3 17 LIGHTS INSTRUMENTS SWITCHES Screws IGNITION SWITCH INSPECTION Remove the front cover Disconnect the ignition switch wire coupler Check for continuity between the wire terminals o mer we E To _ s ogg loc KR E E Replacement Remove the two mounting bolts to remove the ignition switch holder Remove the two screws to remove the ignition switch for replacement HANDLEBAR SWITCHES HEADLIGHT SWITCH INSPECTION Remove the handlebar front and rear covers Disconnect the headlight switch wire couplers Check for continuity between the wire ter
71. inor adjustment is made with the adjusting nut at the throttle grip side Slide the rubber cover out and adjust by loosening the lock nut and turning the adjusting nut Adjusting Nut Lock Nut 3 3 KYMCO 3 IISPECTION ADJUSTMENT MOVIE SYSTEM AIR CLEANER AIR CLEANER REPLACEMENT Remove the rear side covers Remove the five air cleaner case cover screws and the cover Remove the air cleaner element by removing the two screws Check the element and replace it if it is excessively dirty or damaged Air Cleaner Case Cover Air Cleaner Element CHANGE INTERVAL More frequent replacement is required when riding in unusually dusty or rainy areas e The air cleaner element has a viscous type paper element Do not clean it with fuel Be sure to install the air cleaner element and cover securely SPARK PLUG Remove the 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 NGK CR7HSA Measure the spark plug gap Spark Plug Gap 0 6 0 7mm When installing first screw in the spark plug by hand and then tighten it with a spark plug wrench Washer Deformation Cracks Damage 3 4 KYMCO 3 IISPECTION ADJUSTMENT MOVIE SYSTEM Cylinder Head Cover VALVE CLEARANCE Inspect and adjust valve clearance while the engine is cold below 35 Remove the center cover
72. int packing collar When installing first install the exhaust muffler packing collar onto the engine and then install the exhaust muffler Torques Exhaust muffler lock bolt 3 5kg m Exhaust muffler joint lock nut 1 2kg m Be sure to install a new exhaust muffler packing collar 2 5 KYMCO 3 INSPECTION ADJUSTMENT SYSTEM INSPECTION ADJUSTMENT SERVICE INFORMATION MAINTENANCE SCHEDULE 3 2 BU LPN mene re ae d It LLL 348 THROTTLE OPERATION 4 2 AIR CLEANER E 3 4 3 4 VALVE CLEARANCE e 3 5 CARBURETOR IDLE SPEED 3 5 IGNETION TIMING SSES n tasu 3 6 CYLINDER COMPRESSION 3 6 FINAL REDUCTION GEAR SE 424 DRIVE BELI case 327 LL E E 3 8 BRAKE SYSTEM cesse lee ee 3 8 HEADLIGHT AIM S 3 9 IN IJN 3 9 NUTS IBOLTS PASTENBRS 3 10 WEBELSAEIBES 3 10 STEERING HANDIER A Rice edente 3 10 3 0 KYMCO 3 INSPECTION ADJUSTMENT MOVIE SYSTEM SERVICE INFORMATIO
73. isk thickness Service Limit 3 0mm Measure the brake disk runout Service Limit 0 3mm BRAKE MASTER CYLINDER Bos REMOVAL First drain the brake fluid from the hydraulic brake system e When servicing brake system use shop towels to cover rubber and plastic parts and coated surfaces to avoid being contaminated by brake fluid e When removing the brake fluid tube bolt be sure to plug the tube end to avoid brake fluid leakage DISASSEMBLY Remove the piston rubber cover and snap ring from the brake master cylinder Brake Pads 12 9 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION MOVIE SYSTEM Remove the rubber cover main piston and spring from the brake master cylinder Clean the inside of the master cylinder and brake reservoir with brake fluid Main Piston Snap Ring rubber cover INSPECTION Measure the brake master cylinder I D Inspect the master cylinder for scratches or cracks Service Limit 12 75mm Measure the brake master cylinder piston O D Service Limit 12 64mm Before assembly inspect the Ist and 2nd rubber cups for wear or damage ASSEMBLY Before assembly apply brake fluid to all removed parts Install the spring together with the Ist rubber cup e During assembly the main piston and spring must be installed as a unit without exchange e When assembling the piston soak the cups in brake fluid for a while e Install the cups with the
74. it 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 3 9 KYMCO 3 IISPECTION ADJUSTMENT MOVIE SYSTEM 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 Check the tires for cuts imbedded nails or other damages Check the tire pressure Tire pressure should be checked when tires are cold TIRE PRESSURE p ome ome 1 75kg cm 2 1 75kg cm 2 2 00kg cm 2 2 25kg cm 2 TIRE SIZE Front 100 90 10 Rear 100 90 10 Check the front axle nut for looseness Check the rear axle nut for looseness If the axle nuts are loose tighten them to the Front Axle Nut specified torques Torques Front 6 0kg m Rear 11 0kg m 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 3 10 KYMCO 4 LUBRICATION SYSTEM MOVIE SYSTEM LUBRICATION SYSTEM SERVICE INFORMA TION tates 4 1 TROUBLESHOOTING tee 4 1 ENGINE OIL OIE 4 2 CT PUMP eem una suma RI eiue 4 2 KYMCO 4 LUBRICAT
75. iven face spring free length Service Limit 147 6mm replace if below Check the driven face for wear or damage Measure the driven face O D Service Limit 33 94mm replace if below Guide Roller Guide Roller Pin 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER MOVIE SYSTEM eck the movable driven face for wear or damage Measure the movable driven face I D Service Limit 34 06mm replace if DRIVEN PULLEY FACE BEARING REPLACEMENT Drive the inner needle bearing out of the driven pulley face Discard the removed bearing and replace with a new one Inner Bearing Remove the drive the outer bearing out of the driven face Discard the removed bearing and replace with a new one Apply grease to the outer bearing Drive a new outer bearing into the driven face with the sealed end facing up Special Bearing Driver Outer Bearing Apply grease to the driven face bore areas Pack all bearing cavities with 9 9 5g grease Specified grease Heat resistance 2309 9 10 9 DRIVE AND DRIVEN PULLEYS QC KYMCO KICK STARTER MOVIE SYSTEM Tress anew needle bearing into the n face Bearing Driver Pilot 20mm CLUTCH DISASSEMBLY Remove the circlips and retainer plate to disassemble the clutch Keep grease off the clutch linings Circlip CLUTCH ASSEMBLY Clutch Lining Retainer Plate Install the damper rubbers on the drive plate Circlip Springs Clut
76. kg m Exhaust muffler joint lock nut 1 2kg m TROUBLESHOOTING Noisy exhaust muffler e Damaged exhaust muffler e Exhaust muffler joint air leaks Lack of power e Caved exhaust muffler e Exhaust muffler air leaks e Clogged exhaust muffler 2 1 KYMCO 2 FRAME COVERS EXHAUST MUFFLER MOVIE SYSTEM FRAME COVERS REAR HAND GRIP REMOVAL Remove the three bolts attaching the rear hand grip Remove the rear hand grip The installation sequence is the reverse of removal FRAME REAR COVER REMOVAL Remove the two screws attaching the frame rear cover Remove the frame rear cover The installation sequence is the reverse of removal Screws REAR SIDE COVERS REMOVAL Rear Side Cover Remove the two screws on the rear end of each of the rear right and left side covers Remove the one bolt on the front end of each of the rear right and left side covers Remove the rear right and left side covers by pulling them backward The installation sequence is the reverse of removal During removal do not pull the joint claws forcedly to avoid damage Remove the two bolts and nuts attaching the met in box Remove the met in box The installation sequence is the reverse of removal Bolt Screws Seat Met in Box Bolts Nut 2 FRAME COVERS EXHAUST MUFFLER Remove fuel tank Remove the six screws inside the frame body cover on the joint between the floor board and the frame body cover R
77. l Apply engine oil to the felt seal and install it to the brake panel Install the wear indicator plate on the brake cam by aligning the tooth on the plate with the groove on the brake cam Return Spring Hole Install the brake arm on the brake cam by Brake Arm aligning the punch marks on the brake arm x and brake Install and tighten brake arm bolt Torque 1 0kg m 7 Apply grease to brake panel collar install it into the brake panel Apply grease to the speedometer gear and then install it into the brake panel Install the brake shoe springs to the brake shoes and then install the brake shoes into the brake panel INSTALLATION Install the brake panel onto the front wheel Install the front wheel Adjust front brake play PE Brake Shoe Springs Brake Shoe Z Felt Seal Wear Indicator Plate 12 7 12 FRONT WHEEL FRONT BRAKE QC KYMCO FRONT SUSPENSION MOVIE SYSTEM HYDRAULIC BRAKE FRONT BRAKE BRAKE FLUID REPLACEMENT AIR BLEEDING Check the brake fluid level on level ground e When operating the brake lever the brake reservoir cap must be tightened securely to avoid splash of brake fluid e When servicing the brake system use shop towels to cover plastic parts and coated surfaces to avoid damage caused by splash of brake fluid Lower Limit BRAKE FLUID BLEEDING Front Brake Caliper In order to avoid s
78. llowing symbols represent the servicing methods and cautions included in this service manual t Apply engine oil to the specified points Use designated engine oil for Engine Oil lubrication m Apply lubrication Transmission Gear Oil 908 Special Use special tool Caution V Warning 512 3 10 12 3 1 12 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM TORQUE VALUES STANDARD TORQUE VALUES Torque kg m Torque kg m 5mm bolt nut 5mm screw 6mm bolt nut 6mm screw Smm nut 6mm flange nut 10mm nut 8mm flange bolt nut 12mm bolt nut 10mm flange bolt nut Torque specifications listed below are for important fasteners ENGINE Item Q ty Thread dia mm Torque kg m Remarks y q 8 Cylinder head bolt A Double end bolt Cylinder head bolt B Oil filter screen cap Exhaust muffler joint lock nut Cylinder head nut Valve adjusting lock nut Cam chain tensioner slipper bolt Oil bolt Clutch outer nut Clutch drive plate nut Drive face seal cover bolt Starter clutch cap bolt Drive face nut Spark plug Starter clutch lock nut Cam chain tensioner screw gt oo Double end bolt Left hand threads Q Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upper mount bolt
79. minals me etl _ KYMCO MOVIE SYSTEM Ignition Switch Holder Headlight Switch White Blue Black Black Brown 17 4 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES MOVIE SYSTEM E Es STARTER SWITCH Headlight Switch Yellow Red Green Starter Switch HORN SWITCH oe Ls j Horn Button TURN SIGNAL SWITCH Orange Light Gray Blue Turn Signal Switch Dimmer Switch DIMMER SWITCH Pass Black White PASS White Blue Blue KYMCO 17 LIGHTS INSTRUMENTS SWITCHES MOVIE SYSTEM STOP SWITCH INSPECTION Remove the handlebar front cover Disconnect the front stop switch wire coupler Check for continuity between the wire terminals when the front brake lever is applied The switch is normal if there is continuity HORN INSPECTION Remove the front cover Disconnect the horn wire coupler The horn is normal if it sounds when a 12V battery is connected across the horn wire terminals FUEL GAUGE INSPECTION Remove the rear right side cover Disconnect the fuel gauge wire connector Turn the ignition switch ON Connect the green and yellow white wires and the fuel gauge needle should move from EtoF Connect the green and blue white wires and the fuel gauge needle should move from F to E FUEL UNIT REMOVAL
80. n 2 3 times Stator Bolts Pulser Coil 4 6 KYMCO 5 FUEL SYSTEM MOVIE SYSTEM FUEL SYSTEM SERVICE INFORMATION uuu au L uu eue 5 1 TROUBLESHOOTING 5 2 CARBURETOR a 2 5 3 AUTO BYSTARTER 5 3 AIR CUT OFF VALVE se 5 5 WACUUM CHAMBER eco 5 5 FLOAT CHAMBER z det 5 6 CARBURETOR INSTALLATION 5 8 PILOT SCREW ADJUSTMENT 5 9 1 5 10 SOTO TORIL VALNE 5 11 FUEL UNIT 5 5 11 es 5 12 5 0 KYMCO 5 FUEL SYSTEM MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS Gasoline is very dangerous When working with gasoline keep sparks and flames away from the working area Gasoline is extremely flammable and is explosive under certain conditions Be sure to work in a well ventilated area e When disassembling the carburetor be sure to service the vacuum piston and float chamber Do not bend or twist control cables Damaged control cables will not operate smoothly e When disassembling fuel system parts note the locations of O rings Replace them with new ones during assembly Before float chamber disassembly loosen the drain screw to drain the residual gasoline into a clean container
81. n drive kale ooc5 Bore x stroke mm 52 4 x 57 8 kg 2 00 2 25 Turning Left 45 gt IMAI SUIAOIA type torque kg 099 6800 Telescope Intake Mam Por Idmm 1mm fr ume cold mm wet sump Full flow filtration 54 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM SPECIFICATIONS 7 5 liters VE 928 nonleaded gasoline Front wheel 44 NGK Spark plu CR7HSA 5 Total park plug gap 0 6 0 7mm urojs g l0jomnque eornoo q Ulo s S uonrus 48 119 12V8AH senso TS Perform 5 30km h 1 rider Min turning radius m Dry multi disc clutch a Non stage transmission Operation Automatic centrifugal type Two stage reduction Starting motor amp Reduction 2 64 kick starter rati 2nd Type Gasoline 4 stroke u x Front Cylinder arrangement Single cylinder 2 Trail length Combustion chamber 15 chain drive ee kg cm 2 00 2 25 TS 2D N uo SIUISUUEI 1090 uro SAS gt gt eu Tuming 45 kg cm Brake system type s mr fimm i 1mm 6 9 ATDC cold mm Lubrication type Forced pressure amp wet sump IMAI SUIAOIA ura SA uoneorqn T Oil pump type Inner outer rotor type Oil filter type Full flow filtra
82. nge for testing Use range for Sanwa Tester Use X10002 range Kowa Tester e f the dry battery in the tester is weak the readings will be incorrect In this case check the dry battery e The Kowa tester readings are 100 times the actual values Be careful during testing Replace the regulator rectifier if the 14 BATTERY CHARGING SYSTEM Q KYMCO A C GENERATOR MOVIE SYSTEM A C GENERATOR CHARGING COIL The inspection of A C generator charging coil can be made with the engine installed INSPECTION Disconnect the A C generator 2P connector Measure the resistance between the A C generator pink wire and engine ground with an electric tester Standard 0 2 1 2Q at 20 Replace the A C generator charging coil if the reading is not within the specifications A C GENERATOR REMOVAL Remove the rear right side cover Remove the four bolts attaching the cooling fan cover to remove the fan cover Remove the cooling fan by removing the four cooling fan attaching bolts 14 7 14 BATTERY CHARGING SYSTEM O KYMCO A C GENERATOR MOVIE SYSTEM Cooling Fan Hold the flywheel with an universal holder Remove the flywheel nut Universal Holder Universal Holder Remove the A C generator flywheel using the flywheel puller Remove the woodruff key Special Flywheel Puller Remove the A C generator wire connector Flywheel Puller A C Generator Wire Connector
83. nnector the lock on the connector shall be released before operation YT E Hold the connector body when connecting or disconnecting it E Do not pull the connector wire B Check if any connector terminal is bending protruding or loose 1 7 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM B The connector shall be inserted completely mH X W If the double connector has a lock Snapping lock it at the correct position B Check if there is any loose wire Before connecting a terminal check X for damaged terminal cover or loose Q negative terminal B Check the double connector cover for proper coverage and installation B Insert the terminal completely E Check the terminal cover for proper coverage E Do not make the terminal cover opening face up Secure wire harnesses to the frame with their respective wire bands at the Q X X designated locations Tighten the bands so that only the insulated surfaces contact the wire harnesses 1 8 1 GENERAL INFORMATION KYMCO MOVIE SYSTEM After clamping check each wire to make sure it is secure Do not squeeze wires against the weld or its clamp B After clamping check each harness to make sure that it is not interfering with any moving or sliding parts B When fixing the wire harnesses do not make it contact the parts which will generate high heat Bi Route wire harnesses to avoid sharp edges or corners
84. nt cover Remove the front inner fender Remove the front wheel Remove the front shock absorber upper mount bolts Loosen the lower mount bolts to remove the front shock absorbers Shock Absorbers DISASSEMBLY Remove the dust boot 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION MOVIE SYSTEM Remove circlip Dust B Set the front shock absorber in a vise ESE POO Remove the damper rod hex bolt and Washer Bolt copper washer Pull out the front shock absorber tube Set the front shock absorber tube in a vise Remove the lock bolt on the front shock absorber tube e When holding the shock absorber tube place a shop towel to protect it and do apply too much force e Place a container under the front shock absorber to drain the engine oil from Shock Absorber Tube Take out the front shock absorber spring Front Shock Absorber damper and damper spring Damper Shock Absorber Tube Damper Shock Absorber Spring Spring Circlip INSPECTION 12 14 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION MOVIE SYSTEM Inspect the following items and replace if necessary eFront shock absorber tube bending or damage eWeak front shock absorber spring eDamper and damper rod bending eOil seal damage or wear Measure the front shock absorber spring free length Service Limits Right 251mm Left 251mm ASSEMBLY Install the damper spring onto the damp
85. nt portion of the poisonous carbon monoxide into harmless carbon dioxide Secondary Air Suction System Diagram 4 stroke Air cleaner Carburetor Fresh air Inlet pipe Vacuum tube Secondary air pipe Air suction valve Secondary air cleaner Fresh air 1 2 KYMCO KvMco TECHNICAL INFORMATION Model ALL MODEL For EURO 2 Date 8 JAN 04 Subject KYMCO Clean Air System For EURO 2 NO KTI 04002 Secondary Air Suction System Diagram 2 stroke Secondary air hose lt x Fresh air Cylinder The spent fuel charge Reed valve Secondary air cleaner Catalytic converter 2 2
86. nuity table specified in page 20 3 e Inspect the spark plug referring to Section 3 Remove the A C generator and pulser coil referring to Section 10 SPECIFICATIONS Item Spark plug Hot type lu c Spark plug gap Ignition timing mark 13 BTDC 1 700 100rpm Full advance 27 BTDC 5 000 100rpm Ignition coil resistance 20 Secondary Pulser coil resistance 20 Ignition coil primary side max voltage Pulser coil max voltage TESTING INSTRUMENT Kowa Electric Tester or commercially available electric tester with resistance over 15 2 KYMCO 15 IGNITION SYSTEM MOVIE SYSTEM TROUBLESHOOTING High voltage too low No high voltage e Weak battery or low engine speed e Faulty ignition switch e Loose ignition system connection e Faulty CDI unit e Faulty CDI unit Poorly connected or broken CDI ground wire e Faulty ignition coil eDead battery or faulty regulator rectifier e Faulty pulser coil e Faulty ignition coil connector Normal high voltage but no spark at plug e Faulty pulser coil e Faulty spark plug e Electric leakage in ignition secondary circuit e Faulty ignition coil Good spark at plug but engine start e Faulty CDI unit or incorrect ignition timing Improperly tightened generator flywheel CDI UNIT INSPECTION Remove the two battery cover screws Disconnect the CDI coupler and remove the 15 3 KYMCO 15 IGNITION SYSTEM MOVIE SYSTEM
87. pilling brake fluid connect a transparent hose to the bleed valve Spilled brake fluid on brake pads or brake disk reduces stopping power Clean the brake pads and brake disk with a high performance brake degreaser Fully apply the brake lever and then loosen the brake caliper bleed valve to drain the brake fluid until there is no air bubbles in Bleed Valve the brake fluid Then tighten the bleed valve Repeat these steps until the brake system 15 free of air BRAKE FLUID REFILLING Add DOT 3 brake fluid to the brake reservoir e When bleeding be careful not to allow air in the brake reservoir flowing into the brake system e When using a brake bleeder follow the manufacturer s instructions e Never use dirty or unspecified brake fluid or mix different brake fluids Brake Pad Pins be cause it will damage the brake Make sure to bleed air from the brake system BRAKE PAD DISK REPLACEMENT The brake pads must be replaced as a set to ensure the balance of the brake disk Remove the two bolts attaching the brake caliper Remove the brake caliper Remove the brake pad pin to remove the Front Brake Caliper brake pads Upper Limit 12 8 12 FRONT WHEEL FRONT BRAKE QC KYMCO FRONT SUSPENSION MOVIE SYSTEM Install the brake pads in the reverse order of removal Tighten the brake pad pin bolt Torque 1 5 2 0kg m Keep grease or oil off the brake pads to avoid brake failure BRAKE DISK Measure the brake d
88. r Remove the drive pulley and drive belt Hold the clutch outer with the universal holder and remove the clutch outer nut Universal Holder Remove the clutch outer Universal Holder INSPECTION Inspect the clutch outer for wear or damage Measure the clutch outer Service Limit 125 5mm replace if over Drive Pulley Face 9 DRIVE AND DRIVEN PULLEYS dC KYMCO KICK STARTER MOVIE SYSTEM Check the clutch shoes Tor wear or damage Measure the clutch lining thickness Service Limit 1 5mm replace if below CLUTCH DRIVEN PULLEY Clutch Driven Pulley DISASSEMBLY e 7 Hold clutch driven pulley assembly with Clutch Spring Compressor the clutch spring compressor Be sure to use a clutch spring compressor to avoid spring damage Special Clutch Spring Compressor Outer Driver 32x35mm Set the clutch spring compressor in a vise and remove the clutch drive plate nut Lock Nut Wrench 39mm Lock Nut Wrench Loosen the clutch spring compressor and disassemble the clutch driven pulley assembly Remove the seal collar 9 8 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER MOVIE SYSTEM Pull out the guide roller pins and guide rollers Remove movable driven face T from the driven face Movable Driven Face O ring Remove the oil seal from the movable Oil Seal driven face INSPECTION Measure the dr
89. r Measure the movable drive face bushing 9 4 9 DRIVE AND DRIVEN PULLEYS QC KYMCO KICK STARTER MOVIE SYSTEM Service Limit 24 06mm replace if over Check the drive pulley collar for wear or damage Measure the O D of the drive pulley collar sliding surface Service Limit 23 94mm replace if below 4 ASSEMBLY Install the weight rollers into the movable drive face Install the ramp plate Ramp Plate 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER MOVIE SYSTEM nsert the drive pulley collar 1nto the movable drive face INSTALLATION Install the movable drive face onto the crankshaft Lay the drive belt on the driven pulley Set the drive belt on the drive pulley collar Drive Belt 9 6 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER MOVIE SYSTEM nstall the drive pulley face starting ratchet and drive face nut e When installing the drive pulley face compress it to let the drive belt move downward to the lowest position so that the drive pulley can be tightened e Install the starting ratchet by aligning the starting ratchet teeth with the crankshaft teeth Drive Face Nut Starting Ratchet Hold the drive pulley with the universal 1 Fully holder and tighten the drive face nut Torque 5 5kg m Special Universal Holder Do not get oil or grease on the drive belt or pulley faces CLUTCH DRIVEN PULLEY Remove the left crankcase cove
90. r pins etc when reassembling B When tightening bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally E Use genuine parts and lubricants B When servicing the motorcycle be sure to use special tools for removal and installation B After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly ow 1 5 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM E Apply or add designated greases and lubricants to the specified lubrication points B After reassembly check all parts for proper tightening and operation B When two persons work together pay attention to the mutual working safety E Disconnect the battery negative terminal before operation B When using a spanner or other tools make sure not to damage the motorcycle surface After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive terminal must be connected first B After connection apply grease to the battery terminals B Terminal caps shall be installed securely KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM E If the fuse is burned out find the cause and repair it Replace it with a new one according to the specified capacity After operation terminal caps shall be installed securely B When taking out the co
91. s gt ie b gt 4 l y m Uu 17 1 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS e An electric tester is needed to measure or test the electric equipment Be sure to use fuses and bulbs of the same specifications to avoid damage of electrical equipment e After installation of each switch a continuity check must be performed continuity check usually be made without removing the part from the motorcycle TROUBLESHOOTING Lights do not come on and horn does not Engine starts but stalls during idling sound when ignition switch is ON eFaulty auto bystarter e Faulty ignition switch e Faulty auto bystarter resistor e Fuse burned out Poorly connected or broken wire e Weak battery Clogged carburetor e Burned bulb e Faulty switch e Faulty horn Poorly connected broken or shorted wire Fuel gauge pointer does not register Fuel gauge pointer does not move correctly e Faulty fuel gauge e Faulty fuel gauge e Faulty fuel unit e Faulty fuel unit Poorly connected broken or shorted wire e Faulty fuel unit float 17 2 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES MOVIE SYSTEM HEADLIGHT BULB REPLACEMENT Remove the front cover Remove the rubber boot from the bulb socket Remove the bulb socket by turning it counter clockwise Remove the bulb for replacement Install a new bulb alignin
92. s not knock Engine knocks ixture too lean TU Ignition timing too early 1 24 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause Check ignition timing aulty CDI unit Faulty pulser coil Correct timing Incorrect timing Check carburetor pilot i screw adjustment 1xture too rich turn screw out ixture too lean turn screw in Correctly adjusted Incorrectly adjusted Check carburetor gasket Deteriorated O ring arburetor not securely tightened Damaged insulator rubber Broken vacuum tube Remove spark plug and install it into spark plug to test spark i connecting it to engine Faulty or fouled spark plug Faulty CDI unit aulty generator aulty ignition coil Broken or shorted spark plug wire aulty ignition switch Weak or inter mittent spark Good spark Check air cut off valve aulty air cut off valve Damaged vacuum tube logged or damaged air vent hole 1 25 1 GENERAL INFORMATION KYMCO MOVIE SYSTEM POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Check ignition timing Correct timing Incorrect timing iens fuel supply Check carburetor jets for clogging 1 E aa i tension Probable Cause aulty CDI unit aulty pulser coil Improperly adjusted v
93. tall the dowel pins and seal rubber Install the left crankcase cover and tighten the left crankcase cover bolts Install the cable clamp to the specified location and tighten bolt i Air Tube Band Install the drive belt air tube and tighten the 9 2 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER MOVIE SYSTEM tube band screw Tube Band Screw DRIVE PULLEY Starting Ratchet REMOVAL Remove the left crankcase cover Hold the drive pulley using an universal holder and remove the drive face nut and starting ratchet Remove the drive pulley face Universal Holder Drive Pulley Face Hold the clutch outer with the universal holder and remove the clutch outer nut Remove the clutch driven pulley and drive belt Drive Belt INSPECTION Check the drive belt for cracks separation or abnormal or excessive wear Measure the drive belt width Service Limit 19 0mm replace if below Use specified genuine parts for replace ment Intake Cover Remove the movable drive face assembly 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER MOVIE SYSTEM emove the drive pulley collar Ss Movable Drive Face Assembly DISASSEMBLY Ramp Plate Remove the ramp plate Remove the weight rollers Weight Roller INSPECTION Check each weight roller for wear or damage Measure each weight roller O D Service Limit 17 4mm replace if below Drive Pulley Colla
94. tarter clutch onto the crankshaft Apply engine oil to the starter idle gear and shaft and then install them Hold the starter drive gear with the universal holder and tighten the starter clutch lock nut Torque 9 5kg m Universal Holder Note that the lock nut 15 left threaded Install the right crankcase cover KYMCO MOVIE SYSTEM Clutch Cover Starter Idle Gear Anchor Pin Hole Idle Gear Shaft Clutch Cover Clutch Body Universal Holder Lock Nut KYMCO 17 LIGHTS INSTRUMENTS SWITCHES MOVIE SYSTEM LIGHTS INSTRUMENTS SWITCHES SERVICE INFORMATION 1259 TROUBLESHOOTING Set 1759 PADI R Easton 1752 FRONT TURN SIGNAL neni 198 POSITION REAR TURN SIGNAL LIGHT 17 3 17 4 HANDLEBAR SWITCHES gt ihanap 1724 STORRS Sa ae 17 6 HORN en E NR 17 6 FURL GAUGE 17 6 17 6 ADIOBYSTARTER 1727 INSERUMENETS 17 8 17 0 KYMCO 17 LIGHTS INSTRUMENTS SWITCHES MOVIE SYSTEM ELECTRICAL EQUIPMENT LAYOUT Headlight Switch Starter Button Headlight Dimmer Switch Turn Signal Switch Fuel Unit Ignition Switch Horn Button Auto Bystarter Stop Switche
95. tch driven pulley onto the drive shaft Keep grease off the drive shaft Clutch Driven Pulley Guide Roller Guide Roller Pin Install the clutch outer 9 12 9 DRIVE AND DRIVEN PULLEYS KYMCO KICK STARTER MOVIE SYSTEM old the clutch outer with the universa holder Install and tighten the clutch outer nut Torque 5 5kg m Special Universal Holder Install the drive belt Install the left crankcase cover P d Universal Holder KICK STARTER REMOVAL Remove the left crankcase cover Remove the seal rubber and dowel pins Left Crankcase Cover Kick Starter Spindle Remove the kick lever Remove the circlip and washer from the kick starter spindle Gently turn the kick starter spindle to remove the starter driven gear together with the friction spring Friction Spring Starter Driven Gear Clutch Outer Remove the kick starter spindle and return 9 DRIVE AND DRIVEN PULLEYS dC KYMCO KICK STARTER MOVIE SYSTEM spring trom the left crankcase cover Remove the kick starter spindle bushing Return Spring INSPECTION Spindle Return Spring Inspect the kick starter spindle and gear for wear damage Inspect return spring for weakness damage Inspect the kick starter spindle bushings for wear or damage Plastic Bushing Spindle Bushing Inspect the starter driven gear for wear or Fiction Spring damage Inspect the friction spring for
96. ter installing the axle turn the wheel to make sure that the speedometer drive Cutouts shaft rotates freely Apply a thin coat of grease to the axle shaft Install the front wheel by aligning the brake panel groove with the front fork tab Insert the axle shaft Connect the speedometer cable and secure it with the screw Install and tighten the axle nut Torque 6 0kg m Install the front brake cable and adjust the front brake lever free play Axle Nut Side Collar FRONT BRAKE 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION MOVIE SYSTEM Remove the front wheel Remove the front brake panel INSPECTION Measure the brake drum Service Limit 111mm replace if over Remove the brake shoes and springs and replace the brake shoes Keep oil or grease off the brake linings Inspect the brake panel dust seal for damage and replace if necessary BRAKE PANEL DISASSEMBLY Remove the brake shoes Remove the brake arm and return spring Remove the wear indicator plate and felt seal Remove the brake cam Remove the speedometer gear and brake panel collar Brake Cam E ASSEMBLY Wear Indicator Plate Return Spring Apply grease to anchor and brake Brake Cam cam Install the brake cam Install the return spring by aligning the 12 6 12 FRONT WHEEL FRONT BRAKE KYMCO FRONT SUSPENSION MOVIE SYSTEM spring hook end with the hole in brake pane
97. the battery cover screws on the floor board Open the battery cover and remove the battery by removing the bolt and band First disconnect the battery negative cable and then the positive cable When disconnecting the battery positive cable do not touch the frame with tool otherwise it will cause short circuit and sparks to fire the fuel The installation sequence is the reverse of removal First connect the positive cable and then negative cable to avoid short circuit BATTERY VOLTAGE OPEN CIRCUIT VOLTAGE INSPECTION Remove the floor board Open the battery cover and disconnect the battery cables Measure the voltage between the battery terminals Fully charged 13 1V Undercharged 12 3V max Battery charging inspection must be performed with a voltmeter CHARGING Connect the charger positive cable to the battery positive 4 terminal Connect the charger negative cable to the battery negative terminal V e Keep flames and sparks away from a charging battery e Turn power ON OFF at the charger not at the battery terminals to prevent sparks near the battery to avoid explosion Charge the battery according to the umm QN Www 27222777 e Quick charging should only be done an emergency e Measure the voltage 30 minutes after the battery is charged Charging current Standard 0 9A Quick 3 0A Charging time St
98. ticking Second Side Oil Ring Side Rail KYMCO 8 CYLINDER PISTON MOVIE SYSTEM PISTON INSTALLATION Remove any gasket material from the crankcase surface Be careful not to drop foreign matters into the crankcase Install the piston piston pin and a new piston pin clip e Position the piston IN mark on the intake valve side e Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase Piston Pin Clip Piston Pin Piston CYLINDER INSTALLATION Install the dowel pins and a new cylinder gasket on the crankcase Coat the cylinder bore piston and piston rings with clean engine oil Carefully lower the cylinder over the piston by compressing the piston rings Be careful not to damage or break the piston rings e Stagger the ring end gaps at 120 to piston pin 8 7 KYMCO 8 CYLINDER PISTON MOVIE SYSTEM Loosely install the cylinder base bolts Install the cam chain guide Insert the tab on the cam chain guide into the cylinder groove Install the cylinder head Tighten the cylinder base bolts Cylinder Base Bolt 8 8 9 DRIVE AND DRIVEN PULLEYS QO KICK STARTER MOVIE SYSTEM DRIVE AND DRIVEN PULLEYS KICK STARTER SERVICE INFORMATION AL 9 1 TROUBDESHOOTINGS 9 1 9 2 DRIVE PULUBY
99. tion Oil capacity Cooling Type Forced air cooling KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM SPECIFICATIONS 7 5 liters VE 928 nonleaded gasoline Front wheel 44 NGK Spark plu CR7HSA 5 Total 48 park plug gap 119 12V8AH 130 70 12 Non stage transmission Ground clearance mm Operation Automatic centrifugal type 7 9m Initial speed Perform Braking distance m 1 ride Two stage reduction Min turning radius m Starting motor amp Reduction kick starter rati 2nd 8 89 Type Gasoline 4 stroke x Front Cylinder arrangement Single cylinder 8 Trail length Combustion chamber type Tire pressure O H C chain drive Many gt Bore x stroke mm 57 4 x 51 8 2 00 2 25 Turning Left 45 urojs g IO aTndIe eornoo q 16 4 lt uonrus 15 90 uo STUISUPL ur SAS JaMog 1890 N gt gt eu IMAI SUIAOIA type Max torque kg 11 6800 em Port imm m cold mm Lubrication type Forced pressure amp wet sump ura SA uoneorqn T Oil pump type Inner outer rotor type Oil filter type Full flow filtration Oil capacity Cooling Type Forced air cooling KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM SERVICE PRECAUTIONS B Make sure to install new gaskets O rings circlips cotte
100. to the left crankcase 10 4 KYMCO 10 FINAL REDUCTION MOVIE SYSTEM Install the countershaft Install the dowel pins and a new gasket d Countershaft Install the transmission case cover Install and tighten the transmission case cover bolts Install the clutch driven pulley Install the rear wheel Install the rear brake cable After installation fill the transmission case with the specified oil Place the motorcycle on its main stand on level ground Check the oil sealing washer for wear or damage Specified Gear Oil KYMCO SIGMA GEAR OIL 90s Oil Capacity At disassembly 0 2 liter At change 0 18 liter Install and tighten the oil check bolt Torque 1 0 1 5kg m Start the engine and check for oil leaks Check the oil level from the oil check bolt hole and add the specified oil to the proper 9 7 level if the oil level is low Drain Bolt Oil Check Bolt Hole Oil Filler 11 CRANKCASE CRANKSHAET KYMCO MOVIE SYSTEM CRANKCASE CRANKSHAFT SEBVICEINPORMATIONS 11 1 TROUBLESHOOTING 2 S n al Bh 11 1 CRANKCASE SEPARATION 11 2 GRANKSHAFT INSPEC TION Eom 1 3 CRANKCASE ASSEMBLY 11 4 11 0 KYMCO 11 CRANKCASE CRANKSHAFT MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS e This section covers crankcase separation to service the crankshaft The engine must b
101. tor Apply grease to the dust seal in the front cover Install the brushes onto the brush holders Apply a thin coat of grease to the two ends of the armature shaft Insert the commutator into the front cover Be careful not to damage the brush and armature shaft mating surfaces e When installing the commutator the armature shaft should not damage the dust seal lip Front Cover Tab Groove O ring Install a new O ring to the front cover Install the starter motor case aligning the tab on the motor case with the groove on the front cover Tighten the starter motor case screws When assembling the front cover and motor case slightly press down the armature shaft to assemble them Motor Case Starter Relay STARTER RELAY INSPECTION Remove the frame body cover Turn the ignition switch ON and the starter relay is normal if you hear a click when the starter button is depressed If there 15 no click sound Inspect the starter relay voltage e Inspect the starter relay ground circuit Inspect the starter relay operation STARTER RELAY VOLTAGE INSPECTION Place the motorcycle on its main stand Measure the voltage between the starter relay connector green yellow wire and engine ground Turn the ignition switch ON and the battery voltage should be normal when the brake lever is fully applied If the battery has no voltage inspect the stop switch continuity and cable 16 5 16 STARTIN
102. ts seat to prevent damage Warm up the engine and adjust the throttle stop screw to obtain the specified idle speed Idle Speed 1700 100rpm Turn the pilot screw in or out slowly to obtain the highest engine speed Slightly accelerate several times to make sure that the idle speed is within the specified range If the engine misses or runs erratic repeat the above steps FUEL TANK REMOVAL Remove the frame body cover Disconnect the fuel unit wire connector Disconnect the fuel tube and vacuum tube at the auto fuel valve Remove the five fuel tank mounting bolts and fuel tank INSTALLATION Install the fuel tank in the reverse order of removal KYMCO 5 FUEL SYSTEM MOVIE SYSTEM Fuel Tank AUTO FUEL VALVE No Smoking First clean the fuel tube Disconnect the fuel tube and vacuum tube from the carburetor Connect a vacuum pump to the vacuum tube and apply vacuum Check if fuel flows out Auto Fuel Valve The valve 15 operating normally if fuel flows out of the fuel tube when the vacuum 15 applied e The fuel shall stop flowing out when the vacuum pump 15 disconnected If the fuel valve does not operate normally Check the vacuum diaphragm for poor installation or damage and inspect the fuel tube for clogging FUEL UNIT Fuel Unit Refer to Section 17 for the fuel unit inspection REMOVAL Disconnect the fuel unit wire connector Turn the fuel unit retainer counter
103. ttery 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 voltmeter SPECIFICATIONS Voltage Battery 20 U mv Single phase half wave Regulator Rectifier Lighting 12 0 14 0V 5000rpm Electric tester tachometer Limit voltage 10 13 0V 5000rpm 13 5 15 5V 5000rpm Resist Resistance 20 20W5 90 5 0 7 00 Resistance 20 20W5 92 140 600 14 2 14 BATTERY CHARGING SYSTEM dC KYMCO A C GENERATOR TORQUE VALUES Pulser coil bolt Coil lock bolt Flywheel nut Cooling fan bolt SPECIAL TOOLS Universal holder Flywheel puller TESTING INSTRUMENTS Kowa electric tester Sanwa electric tester TROUBLESHOOTING No power Dead battery e Disconnected battery cable e Fuse burned out e Faulty ignition switch Low power e Weak battery Loose battery connection e Charging system failure e Faulty regulator rectifier 14 3 0 5kg m 0 9kg m 5 5kg m 0 9kg m MOVIE SYSTEM Intermittent power Loose battery cable connection e Loose charging system connection e Loose connection or short circuit in lighting system Charging system failure Loose broken or shorted wire or connector e Faulty regulator rectifier e Faulty A C generator 14 BATTERY CHARGING SYSTEM O KYMCO A C GENERATOR MOVIE SYSTEM BATTERY REMOVAL A Remove
104. uence 15 reverse of removal CRANKSHAFT INSPECTION Measure the connecting rod big end side clearance Service Limit 0 55mm replace if over Measure the connecting rod big end radial clearance at two points at right angels to the shaft Service Limit 0 05mm replace if over Measure the crankshaft runout Service Limit 0 10mm replace if over KYMCO MOVIE SYSTEM es Connecting Rod Big End Turn the crankshaft bearings and check for excessive play If they do not turn smoothly quietly or if they fit loosely in the crankshaft replace the 11 CRANKCASE CRANKSHAFT crankshaft as a set CRANKCASE ASSEMBLY Install the cam chain into the left crankcase Install the crankshaft into the left crankcase Install the dowel pins and a new gasket onto the left crankcase Place the right crankcase over the crankshaft and onto the left crankcase KYMCO MOVIE SYSTEM Dowel Pins Tighten the two crankcase attaching bolts Torque 0 9kg m 11 4 KYMCO 11 CRANKCASE CRANKSHAFT MOVIE SYSTEM 12 FRONT WHEEL FRONT BRAKE QC KYMCO FRONT SUSPENSION MOVIE SYSTEM FRONT WHEEL FRONT BRAKE FRONT SUSPENSION SERVICE INFORMATION 12 1 TROUBLESHOOTING 12 2 FRONT WHEEL 12 3 FRONT BRAKE
105. uffler joint lock nuts and exhaust muffler lock bolt Torque Exhaust muffler joint lock nut 1 2kg m Exhaust muffler lock bolt 3 5kg m REAR BRAKE Remove the rear wheel Inspect the rear brake drum Measure the rear brake drum Service Limits 131mm replace if over Rear Axle Nut BRAKE LINING INSPECTION gt 4 13 2 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION MOVIE SYSTEM Measure the brake lining thickness Service Limit 2 0mm replace if below Keep oil or grease off the brake linings REAR DISASSEMBLY Brake Arm Brake Shoe Remove the rear brake adjusting nut and 4 disconnect brake cable Remove the rear brake shoes Adjusting Nut Brake Arm Da E Remove the brake arm bolt to remove the brake arm wear indicator plate and felt seal Remove the brake cam au SEL Wear Indicator Plate Bolt REAR BRAKE ASSEMBLY Brake Arm Apply grease to the anchor pin Apply grease to the brake cam and install it Install the brake shoes Apply engine oil to the felt seal and install it 13 REAR WHEEL REAR BRAKE KYMCO REAR SUSPENSION MOVIE SYSTEM to the brake cam Install the wear indicator plate and brake arm Align wide groove on wear indicator plate with the wide tooth of the brake cam Install and tighten the brake arm bolt Align the scribed line on the brake arm with the punch mark on the brake cam Torque
106. upler for loose f connection Poorly connected coupler Faulty regulator rectifier 1 27 KYMCO 1 GENERAL INFORMATION MOVIE SYSTEM NO SPARK AT SPARK PLUG Inspection Adjustment Probable Cause O Replace with a new spark plug and inspect i again Check spark plug cap and high tension wire Tor looseness Check CDI unit coupler for looseness M Measure resistance i between terminals of i CDI unit coupler Check related parts Faulty ignition switch Weak battery Faulty 1gnition coil Faulty charging system Broken wire harness Poorly connected coupler Check CDI unit witha CDI unit tester Check ignition coil wit CDI unit tester Faulty ignition coil 1 28 KYMCO 2 FRAME COVERS EXHAUST MUFFLER MOVIE SYSTEM FRAME COVERS EXHAUST MUFFLER SERVICE INFORMATION 2 1 TROUBLESHOOTING 254 ERAME COVERS EXHAUST MUFFLER 2 5 2 0 KYMCO 2 FRAME COVERS EXHAUST MUFFLER MOVIE SYSTEM SERVICE INFORMATION GENERAL INSTRUCTIONS e When removing frame covers use special 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 lock bolt 3 5
107. wear damage or seizure Check the left crankcase bearings for excessive play and inspect the oil seal for 10 2 KYMCO 10 FINAL REDUCTION MOVIE SYSTEM wear or damage Countershaft Bearing Drive Shaft Bearing Final Shaft Inspect the drive shaft and gear for wear or damage Check the transmission case cover bearings for excessive play and inspect the final shaft bearing oil seal for wear or damage Do not remove the transmission case cover except for necessary part replace ment When replacing the drive shaft also replace the bearing and Drive Shaft Bearing Countershaft Bearing Oil Seal Drive Shaft Bearing Final Shaft Bearing BEARING REPLACEMENT TRANSMISSION CASE COVER Remove transmission case cover bearings using a bearing remover Remove the final shaft oil seal Drive new bearings into the transmission case cover Outer Driver 32x35mm inal Shafi i BEARING REPLACEMENT LEFT NN CRANKCASE KYMCO 10 FINAL REDUCTION MOVIE SYSTEM Remove the drive shaft Remove the drive shaft oil seal Remove the left crankcase bearings using a bearing remover Bearing Remover 12mm Drive new bearings into the left crankcase Install a new drive shaft oil seal Pilot FINAL REDUCTION ASSEMBLY Install the drive shaft into the left crankcase Install the final gear and final shaft into the left crankcase Install the countershaft and gear in
108. wear or damage O Starter Driven Gear Kick Starter Spindle Forcing Part Inspect the kick starter spindle and starter driven gear forcing parts for wear or damage x 4 Starter Driven Gear Shaft Forcing Part INSTALLATION 9 14 9 DRIVE AND DRIVEN PULLEYS QC KYMCO KICK STARTER MOVIE SYSTEM nstall the kick starter spindle bushings an return spring onto the left crankcase cover When installing the return spring use a screw driver to press the inward and outward return spring hooks into their original positions respectively Kick Starter Spindle Install the starter driven gear and friction spring as the figure shown Friction Spring Starting Ratchet Left Crankcase Cover Install the kick lever Install left crankcase cover and tighten the cover bolts diagonally Connect the drive belt air tube and tighten the band screw For drum brake be sure to install the rear brake cable clamp to the specified location and install the brake cable into the brake cable holder KYMCO 10 FINAL REDUCTION MOVIE SYSTEM FINAL REDUCTION SERVICE 10 1 TROUB ESHOOTINGEs SE ene 10 1 FINAL REDUCTION DISASSEMBLY 10 2 FINAL REDUCTION 10 2 BEARING REPLACEMENT 10 3 FINAL REDUCTION ASSEMBLY

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