KYMCO X -Town 125 ABS Bedienungsanleitung

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

EXHAUST MUFFLER/FRAME

COVERS

INSPECTION/ADJUSTMENT

LUBRICATION SYSTEM

ENGINE REMOVAL/INSTALLATION

CYLINDER HEAD/VALVES

CYLINDER/PISTON

DRIVE AND DRIVEN PULLEYS

FINAL REDUCTION

A.C. GENERATOR/STARTER

CLUTCH

CRANKCASE/CRANKSHAFT

COOLING SYSTEM

Fi DIAGNOSTIC TOOL OPERATION

FUEL INJECTION SYSTEM

HANDLEBAR/FRONTWHEEL/

FRONT BRAKE/FRONT SHOCK

ABSORBER/ STEERING STEM

REAR BRAKE/REAR FORK/REAR

WHEEL/REAR SHOCK ABSORBER`

BATTERY/CHARGING SYSTEM

IGNITION SYSTEM

STARTING SYSTEM

LIGHTS/METERS/SWITCHES

ABS SYSTEM

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

________________________________________________________________________________

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. 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

Rear wheel

100

Total

170

Front wheel

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)

Max.horsepower(kw/rpm)

10.7/8750

Max. torque (N.m/rpm)

12.2/6750

Intake(1mm)

Open

8° BTDC

31° BTDC

Exhaust(1mm)

Open

32° BTDC

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

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

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

6.0~6.5

1.5~2.5

11~13

3.5~4.5

1.8~2.0

U - nut

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