KYMCO 125 MOVIE S INJECTION User manual

PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO MOVIE
125.
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 19 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.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
FRAME COVERS/EXHAUST MUFFLER
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
FUEL SYSTEM
5
ENGINE REMOVAL/INSTALLATION
6
CYLINDER HEAD/VALVES
7
CYLINDER/PISTON
8
DRIVE AND DRIVEN PULLEYS/KICK
STARTER
9
FINAL REDUCTION
10
CRANKCASE/CRANKSHAFT
11
FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12
REAR WHEEL /REAR BRAKE /REAR
SUSPENSION
13
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
14
IGNITION SYSTEM
15
STARTING SYSTEM
16
LIGHTS/ INSTRUMENTS/SWITCHES
17
EVAPORATIVE EMISSION CONTROL
SYSTEM
18
EXHAUST EMISSION CONTROL
SYSTEM
19
The information and contents
included in this manual may be
different from the motorcycle in case
specifications are changed.
CHASSIS CONTROEQUIPMENT
ENGINE

1. GENERAL INFORMATION
1-1
Location of Engine Serial Number
1
ENGINE SERIAL NUMBER
1
ENGINE SERIAL NUMBER
...................
1- 1 LUBRICATION POINTS
......................
1-13
SPECIFICATIONS
.................................
1- 2 CABLE & HARNESS ROUTING
.........
1-15
SERVICE PRECAUTIONS
.....................
1- 3 WIRING DIAGRAM
...............................
1-20
TORQUE VALUES
..................................
1-11 TROUBLESHOOTING
.........................
1-21
TOOLS
.....................................................
1-12

1. GENERAL INFORMATION
1-2
SPECIFICATIONS
Name & Model No.
SD25AA
Motorcycle Name & Type
Overall length (mm)
1820
Overall width (mm)
685
Overall height (mm)
1095
Wheel base (mm)
1215
Engine type
O.H.C.
Displacement (cc)
124
Fuel Used
92# nonleaded gasoline
Front wheel
38.5
Net weight (kg)
Rear wheel
63.5
Total
102.0
Front wheel
67.5
Gross weight(kg)
Rear wheel
158.0
Total
225.5
Front wheel
100-90-10
Rear wheel
100-90-10
Ground clearance (mm)
123
Perform
-
Braking distance (m)
13 (Initial speed
20km/h 1 rider)
ance
Min. turning radius (m)
1.866
Starting system
Starting motor &
kick starter
Type
Gasoline, 4-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C., chain drive
Bore x stroke (mm)
52.4 x 57.8
Compression ratio
9.2:1
Compression pressure
(kg/cm≤-rpm)
12.8-570
Max. output (ps/rpm)
9.34/7500
Max. torque (kg m/rpm)
1.01/5500
Intake
Open
0°BTDC
Port
(1mm)
Close
25°ABDC
timin
g
Exhaust
Open
33°BBDC
(1mm)
Close
0°TDC
Valve clearance
Intake
0.12
(cold) (mm)
Exhaust
0.12
Idle speed (rpm)
1700rpm
Lubrication type
Forced pressure &
wet sump
Oil pump type
Inner/outer rotor
type
Oil filter type
Full-flow filtration
Oil capacity
0.9 liter
Cooling Type
Forced air cooling
Air cleaner type & No
Paper element, wet
Fuel capacity
7.8 liters
Type
VE45
Piston dia. (mm)
24
Venturi
dia.(mm)
22.1 equivalent
Throttle type
Butterfly type
Type
CDI
Ignition timing
13±3°BTDC/1700rp
m
Contact breaker
Non-contact point
type
Spark plug
NGK
C6HSA
C7HSA
C8HSA
ND
U20FS-U
U22FS-U
U24FS-U
Spark plug gap
0.6_0.7mm
Battery
Capacity
12V9AH
Clutch
Type
Dry multi-disc clutch
Type
Non-stage transmission
Operation
Automatic
centrifugal
type
Type
Two-stage reduction
Reduction
1st
2.8
ratio
2nd
3.076
Front
Caster angle
27°
Axle
Trail length
80mm
Tire pressure
Front
1.75
(kg/cm≤)
Rear
2.00 (2.25)
Turning
Left
45°
angle
Right
45°
Brake system
Front
Disk brake
type
Rear
Drum brake
Suspension
Front
Telescope
type
Rear
Swing arm
Shock absorber
Front
Telescope
type
Rear
Swing arm
Frame type
Steel pipe
Tires
Engine
System
Fuel System
Carburetor
Electrical
Ignition System
Power Drive System
Transmis- sion Gear Reduction
Gear
Moving Device Damping
Device

1. GENERAL INFORMATION
1-3
SERVICE PRECAUTIONS
nMake sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
nWhen tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
nUse genuine parts and lubricants.
nWhen servicing the motorcycle, be sure to
use special tools for removal and
installation.
nAfter disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.

1. GENERAL INFORMATION
1-4
nApply or add designated greases and
lubricants to the specified lubrication
points.
nAfter reassembly, check all parts for
proper tightening and operation.
nWhen two persons work together, pay
attention to the mutual working safety.
nDisconnect the battery negative (-) terminal
before operation.
nWhen using a spanner or other tools, make
sure not to damage the motorcycle surface.
nAfter operation, check all connecting
points, fasteners, and lines for proper
connection and installation.
nWhen connecting the battery, the positive
(+) terminal must be connected first.
nAfter connection, apply grease to the
battery terminals.
nTerminal caps shall be installed securely.

1. GENERAL INFORMATION
1-5
nIf the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
nAfter operation, terminal caps shall be
installed securely.
nWhen taking out the connector, the lock on
the connector shall be released before
operation.
nHold the connector body when connecting
or disconnecting it.
nDo not pull the connector wire.
nCheck if any connector terminal is bending,
protruding or loose.
Confirm
Capacity

1. GENERAL INFORMATION
1-6
nThe connector shall be inserted
completely.
nIf the double connector has a lock, lock
it at the correct position.
nCheck if there is any loose wire.
nBefore connecting a terminal, check for
damaged terminal cover or loose negative
terminal.
nCheck the double connector cover for
proper coverage and installation.
nInsert the terminal completely.
nCheck the terminal cover for proper
coverage.
nDo not make the terminal cover opening
face up.
nSecure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the
insulated surfaces contact the wire
harnesses.
Snapping!

1. GENERAL INFORMATION
1-7
nAfter clamping, check each wire to make
sure it is secure.
nDo not squeeze wires against the weld or
its clamp.
nAfter clamping, check each harness to make
sure that it is not interfering with any
moving or sliding parts.
nWhen fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
nRoute wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
nRoute wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
No Contact !

1. GENERAL INFORMATION
1-8
nRoute harnesses so they are neither
pulled tight nor have excessive slack.
nProtect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
nWhen rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
nDo not break the sheath of wire.
nIf a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
nWhen installing other parts, do not press or
squeeze the wires.
Do not
pull too
tight!
Do not press or
squeeze the wire.

1. GENERAL INFORMATION
1-9
nAfter routing, check that the wire harnesses
are not twisted or kinked.
nWire harnesses routed along with handlebar
should not be pulled tight, have excessive
slack or interfere with adjacent or
surrounding parts in all steering positions.
nWhen a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
nBe careful not to drop any parts.
nWhen rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
nDo not bend or twist control cables.
Damaged control cables will not operate
smoothly and may stick or bind.
Do you understand
the instrument? Is
the instrument set
correctly?
Remove Rust
!

1. GENERAL INFORMATION
1-10
nSymbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
:Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
:Apply grease for lubrication.
:Transmission Gear Oil (90#)
:Use special tool.
: Caution
:Warning
(!12-3) : Refer to page 12-3.
Engine Oil
Grease
Gear Oil
Special
＊

1. GENERAL INFORMATION
1-11
TORQUE VALUES
STANDARD TORQUE VALUES
Item
Torque (kg-m)
Item
Torque (kg-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.5
1.0
2.2
3.5
5.5
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.4
0.9
1.2
2.7
4.0
Torque specifications listed below are for important fasteners.
ENGINE
Item
Q‘ty
Thread dia.(mm)
Torque (kg-m)
Remarks
Cylinder head bolt A
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
2
4
1
2
4
2
1
1
1
1
3
3
1
1
1
1
8
8
30
6
8
5
6
8
12
12
4
6
12
10
22
6
0.9
0.9
1.5
1.2
2.0
0.9
1.0
1.3
5.5
5.5
0.3
1.2
5.5
1.2
9.5
0.4
Double end bolt
Double end bolt
Apply oil to
threads
Left hand threads
FRAME
Item
Q‘ty
Thread dia.(mm)
Torque (kg-m)
Remarks
Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper mount bolt
Rear shock absorber lower mount bolt
Speedometer cable set screw
Front shock absorber tube bolt
Front shock absorberupper mount bolt
Front shock absorberlower mount bolt
Front shock absorber hex bolt
Rear shockabsorber lower joint locknut
1
1
1
1
1
1
1
2
2
1
1
10
12
14
10
8
5
5
8
8
8
8
12.0
6.0
11.0
4.0
2.5
0.45
0.45
0.1
1.8
3.0
3.5
U-nut
U-nut
U-nut
Apply lockingagent

1. GENERAL INFORMATION
1-12
SPECIAL TOOLS
Tool Name
Tool No.
Remarks
Ref. Page
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
Driver set, 15mm
Driver shaft, 15mm
Driver head, 15mm
Driver weight
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°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
Universal holder
Outer driver, 32x35mm
Outer driver, 37x40mm
Outer driver, 42x47mm
Pilot, 12mm
Pilot, 15mm
Pilot, 17mm
Pilot, 20mm
Driver handle A
Bearing remover shaft
Bearing remover head, 12mm
Flywheel puller

1. GENERAL INFORMATION
1-13
LUBRICATION POINTS
ENGINE
Lubrication Points
Lubricant
Valve guide/valve stem movable part
Cam lobes
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
•Genuine KYM CO Engine Oil (SAE10W-30)
•API SE, SF or SG Engine Oil
Starter idle gear
Friction springmovable part/shaft movable part
Shaft movable grooved part
Starter spindle movable part
High-temperature resistant grease
Starter one-way clutch threads
Thread locking agent
A.C. generator connector
Transmission case breather tube
Adhesive

1. GENERAL INFORMATION
1-14
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.
Seat Lock
Rear Wheel Bearings
Grease
Front Brake Cable/
Speedometer Cable/
Throttle Cable
Main Stand Pivot
Speedometer Gear/ Front Wheel
Bearings/ Brake Cam/ Anchor Pin
/Front Shock Absorber Lower
Mount Bushings/Pivot
Engine Oil
Grease
Grease
Grease
Grease
Front Brake Lever
Pivot
Engine Oil
Rear Brake Cable
Brake Cam/
Anchor Pin
Grease

1. GENERAL INFORMATION
1-15
CABLE & HARNESS ROUTING
Front Stop Switch Wire
Rear Stop Switch Wire
Throttle Cable
Regulator/Rectifier
Resistor
Buzzer
Front Brake Fluid
Tube
Rear Brake Cable
Speedometer Cable
Horn
Instrument Cable
Ignition Switch
Secondary
Air Cleaner
Charging Indicator
Front Brake Fluid Tube
Front Brake Reservoir

1. GENERAL INFORMATION
1-16
Throttle Cable
Regulator/Rectifier
Speedometer Cable
Wire Harness
Secondary Air Inlet Tube
Charging Indicator
Secondary Air Inlet Tube
Resistor
Front Brake Fluid Tube
Rear Brake Cable
Front Brake Fluid Tube

1. GENERAL INFORMATION
1-17
Wire Harness
Ground
Reserve Fuse
Fuse
Battery (+) Cable
Battery (-) Cable
CDI Unit
Battery (+) Cable
Battery (-) Cable
CDI Unit

1. GENERAL INFORMATION
1-18
Fuel Valve Vacuum Tube
Throttle Cable
Fuel Vapor
Recovery Tube
Vacuum Tee
Fuel Tube
Ignition Coil
Auto Bystarter Wire
Crankcase Breather Tube
Ground
A.C. Generator Wire

1. GENERAL INFORMATION
1-19
Throttle Cable
Starter Relay
Fuel Tube
Carburetor
Vacuum Tube
Auto Bystarter Wire
Starter Motor Wire
Auto Bystarter
Fuel Vapor Tube
Fuel Unit
Fuel Unit
Wire Harness
Crankcase Breather
Tube
Vacuum Tee
Charcoal Canister/
Purge Control Valve
Reed Valve
Starter Relay