KYMCO 125 ZING II QE - User manual

PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO Zing
125/150.
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before starting any
operation.
Section is the inspection/ adjustment
procedures, safety rules and service
information for each part, starting from
periodic maintenance.
Sections 3 and 4 state the servicing
procedures and cautions for the removal
and installation of lubrication and fuel
systems.
Sections 5 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
INSPECTION/ADJUSTMENT
LUBRICATION SYSTEM 3
FUEL SYSTEM 4
ENGINE REMOVAL/INSTALLATION 5
CYLINDER HEAD/VALVES 6
CYLINDER/PISTON 7
STARTER MOTOR/GENERATOR/
LEFT CRANKCASE COVER/STARTER
CLUTCH/CAMSHAFT
8
CLUTCH/GEAR SHIFT MECHANISM 9
ENGINE
CRANKCASE/CRANKSHAFT/TRANS-
MISSION SYSTEM/STARTER SPINDLE
10
FRONT WHEEL/SUSPENSION/
STEERING 11
REAR WHEEL/BRAKE/SUSPENSION 1
HYDRAULIC BRAKE 13
CHASSIS
REAR CARRIER/REAR FENDER/
EXHAUST MUFFLER 14
IGNITION SYSTEM 15
CHARGING SYSTEM 16
STARTING SYSTEM 17
ELECTRICAL
EQUIPMENT
LIGHTS/INSTRUMENTS/SWITCHES/
HORN 18
EVAPORATIVE EMISSION CONTROL
SYSTEM
EM
ISSION
CONTROL
EXHAUST EMISSION CONTROL
SYSTEM
19
The information and contents included
in this manual may be different from
the motorcycle in case specifications
are changed.

1. GENERAL INFORMATION
1-0
1
ENGINE SERIAL NUMBER
1
Location of Engine Serial Numbe
r
ENGINE SERIAL NUMBER................1- 0 LUBRICATION POINTS.......................1-13
SPECIFICATIONS................................1- 2 CABLE & HARNESS ROUTING............1-14
SERVICE PRECAUTIONS ..................1- 3 WIRING DIAGRAM..............................1-16
TORQUE VALUES...............................1-11 TROUBLESHOOTING..........................1-17
SPECIAL TOOLS .................................1-12
ZING 150

1. GENERAL INFORMATION
1-1
SPECIFICATIONS
Motorcycle name & Model No. RT30AU
Motorcycle name Zing 150
Overall length (mm) 2183
Overall width (mm) 810
Overall height (mm) 1162
Wheel base (mm) 1460
Engine type 4∞
Displacement (cc) 149.4
Fuel type 92# nonleaded gasoline
Front wheel 55.5
Rear wheel 74
Dry weight (kg) Total 129.5
Front wheel 62.5
Rear wheel 79.5
Gross weight(kg) Total 142
Front wheel 3.00-18
Tires Rear wheel 130/90-15
Ground clearance (mm) 140
Braking distance (m) 7.9
Perform-
ance Min. turning radius (m) 2.35
Starting system Starting motor &
kick starter
Type OHV
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement Single cam, OHV
Bore x stroke (mm) 62 x 49.5
Compression ratio 9.7
Compression pressure
(kg/cm²) 16
Max. output (Kw/rpm) 8.8/8000
Max. torque (Nm/rpm) 1.1/6000
Open 0°
Intake
(1mm) Close 30°
Engine
Open 0°
Port
timing Exhaust
(1mm) Close 30°
Intake 0.05mm
Valve clearance
(cold) Exhaust 0.05mm
Idle speed (rpm) 1600rpm
Lubrication type Forced pressure &
wet sump
Oil pump type Gear type
Oil filter type Wire gauze filter
Lubrication System
Oil capacity 1.1 liter
Cooling Type Air & oil cooling
Air cleaner type Sponge type
Fuel capacity 14.0 liter
Type CVK
Piston dia. (mm)
Venturi dia.(mm) φ25 equivalent
Fuel System
Carburetor
Throttle type Piston type
Type CDI
Ignition timing 15°/1600rpm
Spark plug DR8EA
Ignition System
Spark plug gap 0.6～0.7mm
Electrical Equipment
Battery Capacity 12V7AH
Clutch Type Wet multi-disc clutch
Type Permanent gear meshing
Operating method Foot operated
Type International type
1st gear 2.846
2nd gear 2.063
3rd gear 1.27
4th gear 1.130
Power Drive System
Transmission Gear
Reduction
ratio
5th gear 0.923
Front Caster angle 36°
Axle Wheel base 1460
Tire
p
ressure Front 1.75
(kg/cm²)(2 riders) Rear 2.25
Left 45°
Turning angle Right 45°
Front Disk brake
Brake system
type Rear Drum brake
Front Oil damper spring
Damping Device
Shock absorber
type Rear Oil damper spring
Frame type Double cradle
Moving Device

1. GENERAL INFORMATION
1-2
SPECIFICATIONS
Motorcycle name & Model No. RF25AA
Motorcycle name Zing 125
Overall length (mm) 2183
Overall width (mm) 810
Overall height (mm) 1162
Wheel base (mm) 1460
Engine type 4∞
Displacement (cc) 124.0
Fuel type 92# nonleaded gasoline
Front wheel 55.5
Rear wheel 74
Dry weight (kg) Total 129.5
Front wheel 62.5
Rear wheel 79.5
Gross weight(kg) Total 142
Front wheel 3.00-18
Tires Rear wheel 130/90-15
Ground clearance (mm) 140
Braking distance (m) 7.9
Perform-
ance Min. turning radius (m) 2.35
Starting system Starting motor &
kick starter
Type OHV
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement Single cam, OHV
Bore x stroke (mm) 56.5 x 49.5
Compression ratio 9.0
Compression pressure
(kg/cm²) 12
Max. output (Kw/rpm) 7.8/9000
Max. torque (Nm/rpm) 9.3/6500
Open 0°
Intake
(1mm) Close 30°
Engine
Open 0°
Port
timing Exhaust
(1mm) Close 30°
Intake 0.05mm
Valve clearance
(cold) Exhaust 0.05mm
Idle speed (rpm) 1600rpm
Lubrication type Forced pressure &
wet sump
Oil pump type Gear type
Oil filter type Wire gauze filter
Lubrication System
Oil capacity 1.1 liter
Cooling Type Air & oil cooling
Air cleaner type Sponge type
Fuel capacity 14.0 liter
Type CVK
Piston dia. (mm)
Venturi dia.(mm) φ25 equivalent
Fuel System
Carburetor
Throttle type Piston type
Type CDI
Ignition timing 15°/1600rpm
Spark plug DR8EA
Ignition System
Spark plug gap 0.6～0.7mm
Electrical Equipment
Battery Capacity 12V7AH
Clutch Type Wet multi-disc clutch
Type Permanent gear meshing
Operating method Foot operated
Type International type
1st gear 2.846
2nd gear 2.063
3rd gear 1.27
4th gear 1.130
Power Drive System
Transmission Gear
Reduction
ratio
5th gear 0.923
Front Caster angle 36°
Axle Wheel base 1460
Tire
p
ressure Front 1.75
(kg/cm²)(2 riders) Rear 2.25
Left 45°
Turning angle Right 45°
Front Disk brake
Brake system
type Rear Drum brake
Front Oil damper spring
Damping Device
Shock absorber
type Rear Oil damper spring
Frame type Double cradle
Moving Device

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

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

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

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

1. GENERAL INFORMATION
1-7
After clamping, check each wire to make
sure it is secure.
Do not squeeze wires against the weld or
its clamp.
After clamping, check each harness to
make sure that it is not interfering with
any moving or sliding parts.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp
edges or corners. Avoid the projected
ends of bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
N
o Contact !

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

1. GENERAL INFORMATION
1-9
After routing, check that the wire
harnesses are not twisted or kinked.
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.
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.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do 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
Symbols:
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.
: Use special tool.
: Caution
: Warning
Grease
＊
Engine Oil
Special

1. GENERAL INFORMATION
1-11
TORQUE VALUES
STANDARD TORQUE VALUES
Ite
m
Torque (k
g
-m) Ite
m
Torque (k
g
-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.45～0.6
0.8～1.2
1.8～2.0
3.0～4.0
5.0～6.0
5mm screw
6mm nut, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.35～0.5
0.7～1.1
1.0～1.4
2.0～3.0
3.5～4.5
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
Valve adjusting lock nut
Oil bolt
Cylinder bolt
A.C. generator bolt
Cylinder head cover bolt
Oil pump bolt
Oil filter lock nut
Rocker arm lock bolt
Cylinder head lock bolt
Cylinder bolt
Crankcase assembly bolt
Crankshaft damper bolt
Right crankcase cover bolt
Left crankcase cover bolt
A.C. generator coil lock bolt
Starter gear set plate bolt
Carburetor lock bolt
2
2
1
2
2
1
2
1
4
2
1
3
1
2
10
1
8
4
4
1
2
8
8
30
6
5
12
6
14
6
6
16
8
8x79
6x22
6
6x25
6
6
5
6
6
2.8～3.2
2.8～3.2
1.5～3.0
0.8～1.2
1.4～1.8
2.0～3.0
0.8～1.2
4.0～5.2
0.8～1.2
0.7～1.1
1.5～3.0
1.5～2.0
1.5～2.0
0.8～1.2
0.8～1.5
0.8～1.2
0.8～1.2
0.8～1.2
0.4～1.7
1.0～1.6
0.8～1.2
Double end bolt
Double end bolt
Double end bolt
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
Rear fork pivot nut
Handlebar lock bolt
Rear driven gear bolt
Rear brake panel bolt
1
1
1
2
2
1
4
4
1
22
14
16
10
10
12
6
8
8
6.0～9.0
5.5～7.0
6.0～8.0
3.0～4.0
3.0～4.0
5.5～7.0
6.0～9.0
1.8～2.0
1.8～2.5

1. GENERAL INFORMATION
1-12
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
Valve adjuster 780614
Valve guide driver
Valve guide reamer
Valve spring compressor attachment
IN valve seat cuter
EX valve seat cutter
IN valve seat cutter
EX valve seat cutter
Valve seat cutter clip, 5.5mm
Clutch holder
Generator stator puller
Valve remover
Valve guide remover
T socket wrench, 16mm
Flywheel puller
Universal holder 5008405
Rear shock absorber compressor 5008411
Steering stem wrench 5008422
Ball race remover
Steering stem bottom ball race driver 5008001-01～07
Bearing remover head, 12mm 5008416-03
Bearing remover, 15mm 5008416-05

1. GENERAL INFORMATION
1-13
LUBRICATION POINTS
Grease
Throttle Cable
Speedometer Cable
Engine Oil
Front Brake Fluid Tube
Clutch Cable
Grease

1. GENERAL INFORMATION
1-14
CABLE & HARNESS ROUTING
A.C. Generator
Wire Connector
Fuel Tube Taillight Wire
Connector
Ignition Switch
Wire Harness
CDI Uni
t
Fuel Filte
r
Ignition Coil
Handlebar Switch
Connectors
Secondary Air
Reed Valve

1. GENERAL INFORMATION
1-15
Starter Relay
A.I.C.V.
Throttle Cable Accelerating Pump
Cable
Vacuum Tube
Oil Coole
r
Purge Control
Valve
Fuse Box
Starter Motor Wire
Battery Positive
Cable
A.C.V.
N
egative Cable
Winke
r
CDI Uni
t
A.C.V. Vacuum
Tube
Charcoal Caniste
r
Ignition Coil
Wire
Secondary Air
Cleaner Clutch Cable

1. GENERAL INFORMATION
1-16
WIRING DIAGRAM

1. GENERAL INFORMATION
1-17
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Clogged float oil passage
Clogged fuel filter
Clogged charcoal canister
Clogged auto fuel valve strainer
Faulty auto fuel valve passage
Clogged carburetor air balance
tube
Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty pulser coil
Faulty exciter coil
Faulty ignition switch
Broken or shorted ignition coil
wire
Faulty or slipping clutch
Valve clearance too small
Valve stuck open
Worn cylinder and piston rings
Leaking cylinder head gasket
Faulty choke control system
Leaking intake manifold
Incorrect ignition timing
Incorrectly adjusted pilot screw
Flooded carburetor
Throttle valve excessively open
Clogged air cleaner
Check if fuel reaches
carburetor by loosening
drain screw
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground
Inspection/Adjustment Probable Cause
Spark jumps
Normal
compression
Engine does not
fire
Weak or no spark
Low or no
compression
Engine fires but
does not start
Test cylinder
compression
Start engine by
follow-ing normal
starting procedure
Remove spark plug and
inspect again
Symptom
Fuel reaches
carburetor Fuel does not
reach carburetor
Wet spark plug
Dry spark plug

1. GENERAL INFORMATION
1-18
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Faulty CDI unit
Faulty pulser coil
Mixture too lean (turn screw in)
Mixture too rich (turn screw
out)
Faulty intake manifold gasket
Carburetor not securely
tightened
Damaged insulator rubber
Broken vacuum tube
Faulty or fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Faulty ignition switch
Faulty A.C. generator
Damaged vacuum tube
Clogged air vent hole
Remove spark plug and
install it into spark plug
cap to test spark by
connecting it to engine
ground
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check A.C. generator
Check carburetor gasket
for air leaks
Check carburetor pilo
t
screw adjustment
Correct Incorrec
t
Correctly adjusted
No air leak Air leaks
Good spark Weak or inte
r
-
mittent spark
Good Faulty
Incorrectly adjusted