KYMCO KYMCO Movie S 125i User manual

Movie S 125i
By KWANG YANG Motor Co., Ltd.
1st Edition, Nov 2008
All rights reserved. Any reproduction or
unauthorized use without the written permission of
KWANG YANG Motor Co., Ltd.
is expressly prohibited.
T100-SR25BA-A1

Movie S 125i
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the Movie S 125i.
Section 1 contains the precautions for all
operations stated in this manual. Read
them carefully before any operation is
started.
Section 2 is the removal/installation
procedures for the frame covers, which
are subject to 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 5 through 11 give instructions
for disassembly, assembly and adjustment
of engine parts. Section 12 through 13 is
the removal/ installation of chassis.
Section 15 through 17 states the testing
and measuring methods of electrical
equipment.
Most sections start with an assembly or
system illustration and troubleshooting
for the section. The subsequent pages give
detailed procedures for the section.
KWANG YANG MOTOR CO., LTD.
QUALITY TECHNOLOGY DEPT.
EDUCATION SECTION
TABLE OF CONTENTS
GENERAL INFORMATION 1
EXHAUST MUFFLER/FRAME COVERS 2
INSPECTION/ADJUSTMENT 3
LUBRICATION SYSTEM 4
FUEL INJECTION 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
STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
SHOCK ABSORBER/FRONT FORK 12
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER` 13
BATTERY/CHARGING SYSTEM 14
IGNITION SYSTEM 15
STARTING SYSTEM 16
SWITCHES/HORN/FUEL UNIT/ THERMO-
STATIC SWITCH/TEMPERATURE
GAUGE/INSTRUMENTS/ LIGHTS 17
EVAPORATIVE EMISSION CONTROL
SYSTEM 18
The information and contents
included in this manual may be
different from the motorcycle in case
specifications are changed.
CHASSIS
ELECTRICAL
E
Q
UIPMENT
ENGINE

1. GENERAL INFORMATION Movie S 125i
1-0
Location of Engine Serial Numbe
r
1
ENGINE/FRAME SERIAL NUMBER
1
ENGINE SERIAL NUMBER----- 1 - 0 TOOLS-------------------------------1-11
SPECIFICATION ------------------ 1 - 1 LUBRICATION POINTS---------1-12
SERVICE PRECAUTIONS------- 1 - 2 CABLE& HARNESSROUTING -1-14
TORQUE VALUES---------------- 1-10 WIRE DIAGRAM---------------------1-19
TROUBLESHOOTING -----------1-20
Location of Frame Serial Number

1. GENERAL INFORMATION Movie S 125i
1-1
SPECIFICATIONS
Name Movie S 125i
Model No. SR25BA
Overall length 1920 mm
Overall width 700 mm
Overall height 1135 mm
Wheel base 1284 mm
Engine type O.H.C.
Displacement 124.8cc
Fuel Used 92# nonleaded gasoline
Front wheel 41
Net weight (kg) Rear wheel 67
Total 108
Front wheel 45
Gross weight(kg) Rear wheel 73
Total 118
Front wheel 110/70-12
Rear wheel 130/70-12
Ground clearance 110 mm
Perform- Braking distance (m) 7.9m(40km/hr)
ance Min. turning radius 1860 mm
Starting system Starting motor &
kick starter
Type OHC air cooled 4-cycle
Cylinder arrangement Single cylinder 2V
Combustion chamber type Semi-sphere
Valve arrangement O.H.C.
Bore x stroke (mm) φ54×54.5
Compression ratio 11
Compression pressure
(kg/cm²-rpm) 15-570 rpm
Max. output (ps/rpm) 11.8/8500
Max. torque (kg m/rpm) 1.04/6500
Intake Open 8° BTDC
Port (1mm) Close 29° BTDC
timin
g
Exhaust Open 32° BTDC
(1mm) Close 4° BTDC
Valve Intake 0.12
clearance
(cold) Exhaust 0.12
Idle speed (rpm) 1800 rpm
Lubrication type Forced
p
ressure &
wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 0.9 liter
Exchanging capacity 0.8 liter
Cooling Type Forced air cooling
Air cleaner type & No Paper element, wet
Fuel capacity 7.3 liters
Throttle type Butterfly type
Type ECU
Spark plug NGK CR7HSA
Spark plug gap 0.6～0.7mm
Battery Capacity 12V8AH
Clutch Type Dry multi-disc clutch
Type Non-stage transmission
Operation Automatic centrifugal
type
Type Two-stage reduction
Reduction 1st 0.86~2.64
ratio 2nd 7.8
Front Caster angle 26.5°
Axle Trail length 80 mm
Tire
p
ressure Fron
t
1.75
(kg/cm²)Rear 2.25
Turning Left 45°
angle Right 45°
Brake s
y
ste
m
Front Disk brake
type Rear Drum brake
Front Telescope
Suspension
type Rear Single Swing
Frame type Under bone
Reduction Gear
Transmis- sion Gear
Tires
Fuel S
y
stem Power Drive System
En
g
ine
Lubrication S
y
stem
Throttle Bod
y
Electrical E
q
ui
p
.
I
g
nition S
y
stem
Moving Device Damping
Device

1. GENERAL INFORMATION Movie S 125i
1-2
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 Movie S 125i
1-3
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 Movie S 125i
1-4
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.
Confir
m
Capacity

1. GENERAL INFORMATION Movie S 125i
1-5
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 Movie S 125i
1-6
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 Movie S 125i
1-7
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 o
r
s
q
ueeze the wire.

1. GENERAL INFORMATION Movie S 125i
1-8
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 a sand papers 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 Movie S 125i
1-9
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.
: Transmission Gear Oil (90#)
: Use special tool.
: Caution
: Warning
Special
Engine Oil
Grease
Gear Oil
＊

1. GENERAL INFORMATION Movie S 125i
1-10
TORQUE VALUES
STANDARD TORQUE VALUES
Ite
m
Tor
q
ue
(
k
g
-m
)
Ite
m
Tor
q
ue
(
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
1.8～2.5
3.0～4.0
5.0～6.0
5mm screw
6mm screw, 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
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
Engine temperature sensor screw
Temperature manifold & pressure
sensor screw
2
4
1
2
4
2
1
1
1
1
3
3
1
1
1
1
1
1
8
8
30
6
8
5
6
8
12
12
4
6
12
10
22
6
8.8
4
0.9
0.9
1.5
0.9
2.0
0.9
1.0
1.3
5.5
5.5
0.3
1.2
5.5
1.2
9.5
0.4
0.75
0.25
Double end bolt
Double end bolt
Apply oil to
threads
Left hand threads
1/8-27 NPSF

1. GENERAL INFORMATION Movie S 125i
1-11
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 absorber upper mount bolt
Front shock absorber lower mount bolt
Front shock absorber hex bolt
Rear shock absorber lower joint lock nut
1
1
1
1
1
1
1
2
2
4
1
10
12
14
10
8
5
5
8
8
8
8
4.5
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
Applylockingglue
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
FLYWHEEL PULLER
TAPPET ADJUSTER
OIL SEAL & BEARING INSTALL
FLYWHEEL HOLDER
BEARING PULLER
LONG SOCKET WRENCH
CLUTCH SPRING COMPERESSOR
CRANKSHAF BEARING PULLER
LONG SOCKET WRENCH
RACE CONE INSTALL
E002
E036
E014
E021
E037
F007
E034
E030
F001
F005

1. GENERAL INFORMATION Movie S 125i
1-12
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part
Camshaft protruding surface
Valve rocker arm friction surface
Camshaft drive 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
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 KYMCO Engine Oil (SAE15W-40)
•API SE, SF or SG Egnine Oil
Starter idle gear
Friction spring movable part/shaft movable part
Shaft movable grooved part
Starter spindle movable part
High-temperature resistant grease
Starter one-way clutch threads Thread locking glue
A.C. generator connector
Transmission case breather tube Adhesive

1. GENERAL INFORMATION Movie S 125i
1-13
FRAME
The following is the lubrication points for the frame.
Use 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 scooter.
Seat Loc
k
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 Leve
r
Pivot

1. GENERAL INFORMATION Movie S 125i
1-14

1. GENERAL INFORMATION Movie S 125i
1-15
CABLE & HARNESS ROUTING
Brake Fluid Reservoi
r
Rear Brake Cable
Regulator/Rectifie
r
Tilt Switch
Seat Lock Cable
Fuel Filler Cap
Lock Cable
Separator Breathe
r
Hose
Horn
Wink Relay
Ignition Switch
Front Brake Hose

1. GENERAL INFORMATION Movie S 125i
1-16
Ignition Switch
Fuel Filler Cap
Wire Harness
Front Brake Hose
Fuel Overflow Hose
Fuel Tan
k
Fuel Pump
Separator Breather Hose
Fuel Filler Cap
Lock Cable
Seat Loc
k
Cable

1. GENERAL INFORMATION Movie S 125i
1-17
Fuel Tube Spark Plug Cap Vacuum Tube Fuel Injecto
r
Throttle Body
& TPS
Air Bypass Valve
Secondary Air Cleane
r
Starter Moto
r
Temperature-
Manifold Absolute
Pressure Sensor
Throttle Cable
Engine Temperature
Sensor