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

1. GENERAL INFORMATION
1-9
X -Town 125 ABS/ CBS
SPECIAL TOOLS
Tool Name
Tool No.
Illustration
(Note: the special tools may differ
slightly from those shown in the
figure of this manual.)
Flywheel puller
(Refer to the “STARTER
CLUTCH” section in the chapter10.)
A120E00003
Oil seal and bearing
installer
A120E00014
Universal holder
(Refer to the “DRIVE PULLEY,
DRIVE BELTAND DRIVEN
PULLEY” section in the chapter8.)
A120E00017
Flywheel holder
(Refer to the “STARTER
CLUTCH” section in the chapter10.)
A120E00021
Clutch spring compressor
(Refer to the “DRIVE PULLEY,
DRIVE BELTAND DRIVEN
PULLEY” section in the chapter8.)
A120E00034
Valve adjuster
(Refer to the “VALVE
CLEARANCE” section in the
chapter 3.)
A120E00036

1. GENERAL INFORMATION
1-10
X -Town 125 ABS/ CBS
SPECIAL TOOLS
Tool Name
Tool No.
Illustration
(Note: the special tools may differ
slightly from those shown in the
figure of this manual.)
Bearing puller
A120E00037
Valve spring compressor
(Refer to the “CYLINDER
HEAD” section in the chapter 6.)
A120E00040
Lock nut wrench
(Refer to the “STEERING
STEM” section in the chapter 15.)
A120F00023
Lock nut wrench
(Refer to the “STEERING
STEM” section in the chapter 15.)
A120F00002
Bottom Ball Race
Remove special tool/ Top Ball
Cone Race Remove special tool
(Refer to the “STEERING
STEM” section in the chapter 15.)
A120F00009
Bottom Ball Race
Install special tool
Top Ball Cone Race
Install special tool
(Refer to the “STEERING
STEM” section in the chapter 15.)
A120F00019

1. GENERAL INFORMATION
1-11
X -Town 125 ABS/ CBS
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 R/L side oil seal
Starter reduction gear engaging part
Countershaft gear engaging part
Final gear engaging part
Bearing movable part
O-ring face
Oil seal lip
·GenuineKYMCOEngineOil(SAE5W-50)
·API , SJ Engine Oil
Starter idle gear
Friction spring movable part/shaft movable
part
Shaft movable grooved part
High-temperature resistant grease
A.C. generator connector
Transmission case breather tube
Adhesive

1. GENERAL INFORMATION
1-12
X -Town 125 ABS/ CBS
CABLE & HARNESS ROUTING
Fuel Pump Relay
Radiator
Wheel Speed Sensor
Winker Relay
ABS ECU(X-Town 125ABS)
Carbon Canister
Starter Relay
ECU Relay
Ignition Switch
Headlight Relay
Angle Detect Sensor
Coolant Cap

1. GENERAL INFORMATION
1-13
X -Town 125 ABS/ CBS
Regulator
Throttle Body
Met-in Box Light Wire
CBS Pump(X-Town 125 CBS)
Radiator Temperature
Sensor
Engine Temperature Sensor
Fuel Injector
Fuel Pump
ECU
O₂ Sensor
Ignition Coil
Fuel Tank
Radiator
Wheel Speed Sensor

1. GENERAL INFORMATION
1-14
X -Town 125 ABS/ CBS
Ignition Switch
Oil Filter Screen
Regulator/Rectifier
Horn
Fuel Filler Cap

1. GENERAL INFORMATION
1-15
X -Town 125 ABS/ CBS
Troubleshooting
Vehicle can not be started
Preliminary 6 Step Inspection
1. Is the battery fully charged (12 V or higher). See the Battery topic for
more information.
2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay
(It will turn off automatically in 5-10 seconds)
3. Key-On to check for any failure lamp light up on dashboard. See the
Self-Diagnosis topic for more information.
4. Is the Idle screw of Throttle Valve being changed or loose?
5. Has the vehicle under regular service? Is the gas station a good one?
6. Is the spark plug the correct model of specified by the vehicle builder?

1. GENERAL INFORMATION
1-16
X -Town 125 ABS/ CBS
General Troubleshooting
ENGINE WILL NOT START OR IS HARD TO START
Possible cause
1. Check for operation of the fuel pump Abnormal  Faulty fuel pump
Normal
2. Inspect the fuel flow Abnormal  Faulty pressure regulator
Normal
3. Inspect the fuel injector Abnormal  Faulty injector
Normal
4. Perform spark test Weak or no spark  Faulty spark plug
 Fouled spark plug
 Faulty ECU
Good spark  Broken or shorted spark plug wire
 Faulty ignition switch
 Faulty ignition pulse generator
 Loose or disconnected spark plug
wire
5. Test cylinder compression Low compression  Valve stuck open
 Worn cylinder and piston ring
 Damaged cylinder head gasket
Compression normal  Seized valve
 Improper valve timing
6. Starting following normal procedure Engine start  Intake pipe leaking
but stops  Improper ignition timing (Faulty
ignition coil or ignition pulse
generator)
Engine does not start  Fuel contaminated
7. Remove and inspect spark plug Wet plug  Throttle valve open
 Clogged air cleaner

1. GENERAL INFORMATION
1-17
X -Town 125 ABS/ CBS
ENGINE LACKS POWER
Possible cause
1. Raise wheel off the ground Wheels do not  Brake dragging
and spin by hand spin freely  Worn or damaged wheel bearing
Wheel spins freely
2. Check tire pressure Pressure low  Faulty tire valve
 Punctured tire
Pressure normal
3. Accelerate lightly Engine speed does  Air cleaner dirty
not increase  Restricted fuel flow
 Clogged muffler
Engine speed increase  Pinched fuel tank breather
4. Check ignition timing Incorrect  Faulty ECU
 Faulty ignition pulse generator
Correct
5. Test cylinder compression Incorrect  Valve stuck open
 Worn cylinder and piston rings
 Leaking head gasket
Normal  Improper valve timing
6. Inspect fuel flow Abnormal  Faulty pressure regulator
Normal
7. Inspect the fuel injector Abnormal  Faulty injector
Normal
8. Remove spark plug Fouled or discolored  Faulty spark plug
Not fouled or discolored

1. GENERAL INFORMATION
1-18
X -Town 125 ABS/ CBS
Possible cause
9. Check oil level and condition Incorrect  Oil level too high
 Oil level too low
 Contaminated oil
Correct
10. Remove cylinder head cover Valve train not  Clogged oil
and inspect lubrication lubricated properly  Clogged oil control orifice
Valve train lubricated properly
11. Check for engine overheating Overheating  Fan motor not working
 Excessive carbon build-up in
combustion chamber
 Use of poor quality fuel
Not overheating  Wrong type of fuel
 Drive and driven pulleys/clutch
slipping
12. Accelerate or run at high Engine knocks  Worn piston and cylinder
speed  Worn type of fuel
 Excessive carbon build-up in
combustion chamber
 Ignition timing to advanced (faulty
ECU)
Engine does not knock  Lean fuel mixture