KYMCO X -Town 125 ABS User manual

X -Town 125 ABS/ CBS
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO X-Town
125 ABS/ CBS.
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
removal/installation frequency during
maintenance and servicing
operations.
Section 3 describes the inspection/
adjustment procedures, safety rules
and service information for each part,
starting from periodic maintenance.
Sections 5 to 12 give instructions for
disassembly, assembly and
adjustment of engine parts. Section
13 is the AFI system. Section 14 to 15
is the removal/ installation of chassis.
Section 16 to 19 states the testing
and measuring methods of electrical
equipment.
Most sections start with an assembly
or system illustration and
troubleshooting for the section. The
subsequent pages give detailed
procedures for the section.
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
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/VALVES
6
CYLINDER/PISTON
7
DRIVE AND DRIVEN PULLEYS
8
FINAL REDUCTION
9
A.C. GENERATOR/STARTER
CLUTCH
10
CRANKCASE/CRANKSHAFT
11
COOLING SYSTEM
12
Fi DIAGNOSTIC TOOL OPERATION
13
FUEL INJECTION SYSTEM
14
HANDLEBAR/FRONTWHEEL/
FRONT BRAKE/FRONT SHOCK
ABSORBER/ STEERING STEM
15
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
16
BATTERY/CHARGING SYSTEM
17
IGNITION SYSTEM
18
STARTING SYSTEM
19
LIGHTS/METERS/SWITCHES
20
ABS SYSTEM
21
The information and contents
included in this manual may be
different from the motorcycle in
case specifications are changed.
CHASSIS
ELECTRICAL EQUIPMENT
ENGINE

1. GENERAL INFORMATION
1-0
X -Town 125 ABS/ CBS
1
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
GENERAL INFORMATION
________________________________________________________________________________
ENGINE SERIAL NUMBER ------------------------------------------------------------- 1-1
SPECIFICATIONS --------------------------------------------------------------------------- 1-2
SERVICE PRECAUTIONS -------------------------------------------------------------- 1-3
TORQUE VALUES --------------------------------------------------------------------------- 1-8
SPECIAL TOOLS ----------------------------------------------------------------------------- 1-9
LUBRICATION POINTS ---------------------------------------------------------------- 1-11
1

1. GENERAL INFORMATION
1-1
X -Town 125 ABS/ CBS
ENGINE SERIAL NUMBER
Location of Engine Serial Number

1. GENERAL INFORMATION
1-2
X -Town 125 ABS/ CBS
SPECIFICATIONS
Name
X-Town 125
Model No.
KS25AD
Overall length
2250 mm
Overall width
800 mm
Overall height
1385 mm
Wheel base
1545 mm
Engine type
O.H.C.
Displacement
125 cc
Fuel Used
92# nonleaded
gasoline
Front wheel
70
Rear wheel
100
Total
170
Front wheel
77
Rear wheel
107
Total
184
RRGround clearance (mm)
135
Braking distance (m)
7.9m / 30 km/hr
Min. turning radius (mm)
2600
Engine part
Starting system
Starting motor
Type
Liquid cooled 4
stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
O.H.C. 4V
Bore x stroke (mm)
54*54.5
Compression ratio
11.7:1
Compression pressure
(kg/cm²-rpm)
15
Max.horsepower(kw/rpm)
10.7/8750
Max. torque (N.m/rpm)
12.2/6750
Intake(1mm)
Open
8° BTDC
Close
31° BTDC
Exhaust(1mm)
Open
32° BTDC
Close
6° BTDC
Intake
0.1mm
Exhaust
0.1mm
Idle speed (rpm)
Cooling Type
Liquid cooling
Lubrication type
Forced pressure &
wet sump
Oil pump type
Inner/outer rotor
Oil filter type
Full-flow filtration
Oil capacity
1.2L
Exchanging capacity
1.0L
Fuel system
Air cleaner type & No
Paper element, wet
Fuel capacity
13 L
Throttle type
Butterfly type
Electrical system
Ignition type
ECU
Spark plug
NGK CR7E
/CPR7EA-9
Spark plug gap
0.8~0.9mm
Battery Capacity
12V 12AH
Transmission system
Clutch type
Dry multi-disc
Transmission Gear type
Non-stage
Transmission
Transmission Gear operation
Automatic centrifugal
Reduction Gear type
Two-stage reduction
Reduction ratio
1st
0.83~2.2
2nd
10.41
Moving device
Front
Axle
Caster angle
28
Trail length
140mm
Turning angle
Left
40
Right
40
Tire pressure
(kg/cm²)
Front
2.0
Rear
2.25
Brake system
type
Front
Disk brake
Rear
Disk brake
Damping Device
Suspension
type
Front
Telescope
Rear
Double Swing
Frame type
Pipe under bone
weight (kg)
Gross weight
(kg)
Valve
clearance

1. GENERAL INFORMATION
1-3
X -Town 125 ABS/ CBS
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.
 Apply or add designated greases and
lubricants to the specified lubrication
points.
 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.
 If the fuse is burned out, find the cause
and repair it. Replace it with a new one
according to the specified capacity.

1. GENERAL INFORMATION
1-4
X -Town 125 ABS/ CBS
 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.
 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.
 After clamping, check each wire to make
sure it is secure.
Confirm
Capacity

1. GENERAL INFORMATION
1-5
X -Town 125 ABS/ CBS
 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 that 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.
 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 protector 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.
 After routing, check that the wire
harnesses are not twisted or kinked.
Do not pull
too tight！
No Contact
Do not press or
squeeze the wire

1. GENERAL INFORMATION
1-6
X -Town 125 ABS/ CBS
 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 you understand
the instrument？
Remove Rust！

1. GENERAL INFORMATION
1-7
X -Town 125 ABS/ CBS
 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
1-8
X -Town 125 ABS/ CBS
TORQUE VALUES
STANDAR TORQUE VALUES
Item
Torque (kgf-m)
Item
Torque (kgf-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
0.45~0.6
0.7~1.1
1.0~1.4
2.4~3.0
3.0~4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item
Qty
Thread dia.(mm)
Torque (kgf-m)
Remarks
Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
O2 sensor
Cylinder head cover
Tappet adjusting hole cap
Cam chain set plate
Engine oil drain bolt
Clutch outer nut
Clutch drive plate nut
Starter motor mounting bolt
Oil pump bolt
Drive face nut
Spark plug
A.C. Generator flywheel
Cam chain tensioner pivot
6
6
30
12
6
30
6
12
12
28
6
6
12
10
12
6
0.7~1.1
0.7~1.1
2.0~3.0
0.7~1.1
0.8~0.9
1.0~2.0
1.0~1.4
2.0~3.0
5.0~6.0
5.0~6.0
0.8~1.2
0.7~1.1
5.5~6.5
1.0~1.4
5.0~6.0
0.8~1.2
FRAME
Item
Qty
Thread dia.(mm)
Torque (kgf-m)
Remarks
Steering stem lock nut
Front axle
Rear axle nut
Rear shock absorber upper bolt
Rear shock absorber lower bolt
Muffler exh. Pipe
Bc1
14
16
10
10
8
6.0~6.5
1.5~2.5
11~13
3.5~4.5
3.5~4.5
1.8~2.0
U - nut
U - nut