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KYMCO K-XCT 125i, Service Manual

The KYMCO K-XCT 125i is a stylish and reliable scooter designed to provide a smooth ride. For all your maintenance needs, the downloadable Service Manual is available for free at manualshive.com, ensuring you have easy access to essential instructions and guidelines to keep your scooter running at its best.

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9

. FINAL REDUCTION   

 

 

 

9-0

K-XCT 125i 

9 

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FINAL REDUCTION

 

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SCHEMATIC DRAWING -------------------------------------------------   9-1 

SERVICE INFORMATION ------------------------------------------------    9-2 

TROUBLESHOOTING -----------------------------------------------------    9-2 

FINAL REDUCTION -------------------------------------------------------    9-3 

BEARING REPLACEMENT ----------------------------------------------    9-7 

 

 

 

   

 

 

 

 

 

 

9

 

 

Summary of Contents for K-XCT 125i

Page 1: ...T 125i By KWANG YANG Motor Co Ltd 1st Edition Aug 2012 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited T100 LKG5 A1 ...

Page 2: ...ods 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 CY...

Page 3: ...______________________________________ ________________________________________________________________________________ ________________________________________________________________________________ GENERAL INFORMATION ________________________________________________________________________________ SERIAL NUMBER 1 1 SPECIFICATION 1 2 SERVICE PRECAUTIONS 1 3 TORQUE VALUES 1 8 SPECIAL TOOLS 1 10 L...

Page 4: ...1 GENERAL INFORMATION 1 1 K XCT 125i Identification Numbers Record ...

Page 5: ... 10 Exhaust 0 10 Idle speed rpm 1800 100 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 2 liter Exchanging capacity 1 0 liter Fi injection system Air cleaner type No Paper element wet Fuel capacity 10 liters Brand Synerject Throttle Body Butterfly type Venturi diameter mm 27 Fuel pump pre...

Page 6: ...embly 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 instal...

Page 7: ...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 th...

Page 8: ...rews 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...

Page 9: ... 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 ...

Page 10: ...ent 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 ...

Page 11: ...g 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 TORQUE VALUES ...

Page 12: ...1 GENERAL INFORMATION 1 9 K XCT 125i TORQUE VALUES FRAME ...

Page 13: ...1 GENERAL INFORMATION 1 10 K XCT 125i SPECIAL TOOLS ...

Page 14: ...1 GENERAL INFORMATION 1 11 K XCT 125i ...

Page 15: ...ion points for the frame Use grease for parts not listed Apply engine oil or grease to cables and movable parts not specified It will avoid abnormal noise and damage the durability of the motorcycle Grease Grease Front wheel axle nut Rear wheel axle nut Grease Side stand pivot Main stand pivot ...

Page 16: ...1 GENERAL INFORMATION 1 13 K XCT 125i ENGINE ...

Page 17: ...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 Imp...

Page 18: ...leaner 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 Insp...

Page 19: ...rol 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 I...

Page 20: ...gulator Normal 3 Inspect the fuel injector Abnormal Faulty injector Normal 4 Check for leaks in the intake pipe Leaking Loose insulator clamp Damage insulator No leak 5 Perform spark test Weak or intermittent spark Faulty the spark plug Faulty carbon or wet fouled spark plug Faulty ECU Faulty ignition coil Faulty ignition pulse generator Faulty ignition switch Loose or disconnected spark plug wire...

Page 21: ...amshaft not installed properly Correct 5 Check valve spring Weak Faulty valve spring Not weak POOR HANDLING Possible cause 1 If steering is heavy Steering stem adjusting nut too tight Damaged steering head bearings 2 If either wheel is wobbling Excessive wheel bearing play Bent rim Improper installed wheel hub Swing arm pivot bearing excessively worn Bent frame 3 If the motorcycle pulled to one si...

Page 22: ..._________________________________________________________________________ EXHAUST MUFFLER FRAME COVERS __________________________________________________________________________________ Exhaust System 1 2 1 13 Luggage Box 1 14 1 16 Seat 1 17 1 19 Rear Carrier 1 20 1 22 Body Cover 1 23 1 32 Windshield 1 33 1 36 Front Cover Meter 1 37 1 38 Side Molding A 1 39 1 48 Side Cover 1 49 1 59 Front Fender 1...

Page 23: ...aged Make sure to route cables and harnesses according to the Cable Harness Routing TORQUE VALUES Exhaust muffler pipe nuts 1 8 2 2 kgf m Exhaust muffler brake RR Frok 3 2 3 8 kgf m RR Engine case 3 0 4 0 kgf m TROUBLESHOOTING Noisy exhaust muffler Damaged exhaust muffler Exhaust muffler joint air leaks Lack of power Caved exhaust muffler Clogged exhaust muffler Exhaust muffler air leaks ...

Page 24: ...2 EXHAUST MUFFLER FRAME COVERS 2 2 K XCT 125i ...

Page 25: ...2 EXHAUST MUFFLER FRAME COVERS 2 3 K XCT 125i ...

Page 26: ...2 EXHAUST MUFFLER FRAME COVERS 2 4 K XCT 125i ...

Page 27: ...2 EXHAUST MUFFLER FRAME COVERS 2 5 K XCT 125i ...

Page 28: ...2 EXHAUST MUFFLER FRAME COVERS 2 6 K XCT 125i ...

Page 29: ...2 EXHAUST MUFFLER FRAME COVERS 2 7 K XCT 125i Remove the muffler heat shield bolts ...

Page 30: ...2 EXHAUST MUFFLER FRAME COVERS 2 8 K XCT 125i ...

Page 31: ...2 EXHAUST MUFFLER FRAME COVERS 2 9 K XCT 125i ...

Page 32: ...2 EXHAUST MUFFLER FRAME COVERS 2 10 K XCT 125i ...

Page 33: ...2 EXHAUST MUFFLER FRAME COVERS 2 11 K XCT 125i ...

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Page 122: ...__________________________________________ INSPECTION ADJUSTMENT __________________________________________________________________________________ SERVICE INFORMATION 3 1 MAINTENANCE SCHEDULE 3 2 FUEL LINE 3 4 THROTTLE OPERATION 3 4 ENGINE OIL 3 5 TRANSMISSION OIL 3 11 AIR CLEANER 3 12 SPARK PLUG 3 13 VALVE CLEARANCE 3 14 IDLE SPEED 3 15 CYLINDER COMPRESSION 3 16 DRIVE BELT 3 16 CLUTCH SHOE WEAR ...

Page 123: ...l ventilated and do not smoke or allow flames or sparks near the working area or fuel storage area SPECIFICATIONS Throttle grip free play 2 6 mm Spark plug NGK CR7E Spark plug gap 0 6 0 7 mm Valve clearance IN 0 1 mm EX 0 1 mm Idle speed 1800 rpm Cylinder compression 15 kg cm Engine oil capacity At disassembly 1 2L At change 1 0L Gear oil capacity At disassembly 0 13L At change 0 12L Coolant capac...

Page 124: ...equired to keep your scooter in peak operating condition Maintenance work should be performed in accordance with standards and specifications of KYMCO by properly trained and equipped technicians Your KYMCO dealer meets all of these requirements Should be serviced by your KYMCO dealer unless the owner has the proper tools and service data and is mechanically qualified In the interest of safety we ...

Page 125: ...ETER READING NOTE 1 BRAKE PAD WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH NUTS BOLTS FASTENERS WHEELS TIRES STEERING BEARINGS I I I I I I HEADLIGHT AIM CLUTCH SHOE WEAR BRAKE FLUID REFER TO PAGE I I I I I I I I I I I I I I I I 30 24 18 5 12 6 1 10 15 20 25 30 36 0 6 3 6 9 12 15 18 1 R I I R R I I I I I I I I I I I I I I I I I I I I I I I I ...

Page 126: ...eterioration damage or leakage THROTTLE OPERATION Check the throttle grip for smooth movement Measure the throttle grip free play Free Play 2 6 mm Major adjustment of the throttle grip free play is made with the adjusting nut at the throttle body side Adjust by loosening the lock nut and turning the adjusting nut ...

Page 127: ...ore riding the scooter The level must be maintained between the upper and lower level marks on the oil filler cap dipstick 1 Start the engine and let it idle for a few minutes 2 Stop the engine and put the scooter on its center stand on level ground 3 After a few minutes remove the oil filler cap dipstick wipe it clean and reinsert the oil filler cap dipstick without screwing it in Remove the oil ...

Page 128: ... suggest you take it in a sealed container to your local recycling center or service station for reclamation Do not throw it in the trash or pour it on the ground or down a drain Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods Although this is unlikely unless you handle used oil on a daily basis it is still advisable to thoroughly wash your h...

Page 129: ...ain plug torque 25 N m 2 5 kgf m 5 Fill the crankcase with the recommended grade oil and install the oil filler cap Oil capacity after draining 1 0 L 0 95 US qt 0 8 lmp qt 6 Start the engine and let it idle for 2 3 minutes 7 Stop the engine and check that the oil level is at the upper level mark on the oil filler cap dipstick with the scooter upright on firm level ground Make sure there are no oil...

Page 130: ...3 Clean the oil strainer screen 4 Check that the oil strainer screen sealing rubber and drain plug O ring are in good condition 5 Install the oil strainer screen spring and oil strainer screen cap Oil strainer screen cap torque 15N m 1 5 kgf m 6 Fill the crankcase with the recommended grade oil and install the oil strainer screen cap Oil capacity after draining 1 0 L 7 Start the engine and let it ...

Page 131: ...the right crankcase cover 2 Place a drain pan under the crankcase Remove three bolts and then remove the oil filter cap 2 and O ring 3 The spring 4 will come out when the filter cap is removed Let the engine oil drain out 3 Remove and discard the oil filter 5 4 Check that the O ring is in good condition Let the engine and exhaust system cool before working in those areas Do not remain the rubber s...

Page 132: ... and install the oil filler cap Oil capacity after draining 1 0 L 8 Start the engine and let it idle for 2 3 minutes 9 Stop the engine and check that the oil level is at the upper level mark on the oil filler cap dipstick with the scooter upright on firm level ground Make sure there are no oil leaks Make sure the rubber seal on the oil filter facing the left crankcase Rubber Seal ...

Page 133: ... oil filler bolt 2 slowly turn the rear wheel and drain the oil After draining the oil completely install the oil drain bolt with a new sealing washer and tighten it Torque 13 N m 1 3 kgf m 5 Fill the transmission case with recommended oil Recommended transmission oil SAE 90 Oil capacity at draining 0 12 L 6 Install the transmission oil filler bolt with a new sealing washer and tighten it Torque 1...

Page 134: ...eaner cover 2 Remove screws from the air cleaner element then remove and discard this air cleaner element 4 The new air cleaner element installation is in the reverse order of removal Use the KYMCO genuine air cleaner element or an equivalent air cleaner element specified for your model Using the wrong KYMCO air cleaner element or a non KYMCO air cleaner element which is not of equivalent quality ...

Page 135: ...sits Clean any fouling deposits with a spark plug cleaner or a wire brush Specified Spark Plug NGK CR7E Measure the spark plug gap Spark Plug Gap 0 6 0 7 mm Torque 0 9 kgf m 9 N m Gap Wear Fouling Deposits Cracks Damage Deformation 0 6 0 7mm When installing first screw in the spark plug by hand and then tighten it with a spark plug wrench ...

Page 136: ...dead center TDC on the compression stroke so that the T mark on the flywheel aligns with the index mark on the left crankcase cover The punch mark on the camshaft should face upward as shown If the punch mark on the camshaft are facing downward turn the crankshaft one full turn 180 and the punch mark are facing upward Inspect and adjust valve clearance while the engine is cold below 35 Timing hole...

Page 137: ...0E00036 After tightening the lock nut recheck the valve clearance Install the removed parts in the reverse order of removal IDLE SPEED Warm up the engine before this operation Start the engine and connect a tachometer Turn the throttle stop screw 1 to obtain the specified idle speed Idle Speed DINK 125 1700 rpm 1800 rpm When the engine misses or run erratic adjust the pilot screw 2 It is not neces...

Page 138: ...ession 15 kg cm If the compression is low check for the following Leaky valves Valve clearance too small Leaking cylinder head gasket Worn pistons Worn piston cylinder If the compression is high it indicates that carbon deposits have accumulated on the combustion chamber and the piston head DRIVE BELT Remove the left crankcase cover Inspect the drive belt for cracks or excessive wear Replace the d...

Page 139: ... engine and check the clutch operation by increasing the engine speed gradually If the scooter tends to creep or the engine stalls check the clutch shoes for wear and replace if necessary refer to the DRIVE PULLEY DRIVE BELT AND DRIVEN PULLEY section in the chapter 8 ...

Page 140: ...3 INSPECTION ADJUSTMENT 3 18 K XCT 125i ...

Page 141: ...3 INSPECTION ADJUSTMENT 3 19 K XCT 125i ...

Page 142: ...ear but also seriously affects the stability of the scooter Under inflated tires make smooth cornering difficult and overinflated tires decrease the amount of tire in contact with the ground which can lead to skids and loss of control Be sure that the tire pressure is within the specified limits at all times Tire pressure should only be adjusted when the tires are cold Cold inflation tire pressure...

Page 143: ...ssing them several times Check the entire shock absorber assembly for oil leaks looseness or damage Jack the rear wheel off the ground and move the rear wheel sideways with force to see if the engine hanger bushings are worn Replace the engine hanger bushings if there is any looseness Rear suspension adjustment ...

Page 144: ...3 INSPECTION ADJUSTMENT 3 22 K XCT 125i ...

Page 145: ..._________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ LUBRICATION SYSTEM __________________________________________________________________________________ LUBRICATION SYSTEM DIAGRAM 4 1 SERVICE INFORMATION 4 2 TROUBLESHOO...

Page 146: ...4 LUBRICATION SYSTEM 4 1 K XCT 125i LUBRICATION SYSTEM DIAGRAM Oil Pump Oil Strainer Screen Crankshaft Rocker Arm Shaft Oil Filter Screen ...

Page 147: ...limit After the oil pump is installed check each part for oil leaks SPECIFICATIONS Unit mm Standard Inner rotor to outer rotor clearance 0 15 Outer rotor to pump body clearance 0 15 0 2 Rotor end to pump body clearance 0 04 0 09 ENGINE OIL Engine Oil Capacity At disassembly 1 2 liter At change 1 0 liter Recommended Oil SAE15W40 API SJ TROUBLESHOOTING Oil level too low Poor lubrication pressure Nat...

Page 148: ...RTER CLUTCH section in the chapter 10 Remove the bolt and then oil separator cover Pry the snap ring off and remove the oil pump driven gear then remove the oil pump drive chain Remove the two oil separator bolts to remove the oil pump Oil Separator Cover Oil Pump When removing and installing the oil pump be careful not to allow dust or dirt to enter the engine ...

Page 149: ...rrow mark must be keep upward Install the pump drive chain and driven gear then set the snap ring securely on the pump shaft Install the oil separator cover properly Oil Separator Pump Drive Chain Snap Ring Arrow Mark Make sure the pump shaft rotates freely and arrow on the oil pump is upside Fit the tab of the separator cover into the slit in the separator Snap Ring ...

Page 150: ...p Shaft DISASSEMBLY Remove the screw and disassemble the oil pump as shown ASSEMBLY Install the outer rotor inner rotor and pump shaft into the pump body There is one punch mark on the surface of the inner rotor and outer rotor The mark is upside Insert the pump shaft by aligning the flat on the shaft with the flat in the inner rotor Install the dowel pin ...

Page 151: ...________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ ENGINE REMOVAL INSTALLATION __________________________________________________________________________________ SERVICE INFORMATION 5 1 ENGINE REMOVAL INSTALLATIO...

Page 152: ...l Drain the coolant before removing the engine After the engine is installed fill the cooling system with coolant and be sure to bleed air from the water jacket Start the engine to check for coolant leaks Before removing the engine the rear brake caliper must be removed first Be careful not to bend or twist the brake fluid tube SPECIFICATIONS Engine oil capacity at disassembly 1 2 L 1 27 US qt at ...

Page 153: ...nnector Disconnect the throttle cable B Remove a bolt from fuel hose guide C Disconnect the fuel hose D from fuel injector Disconnect the WTS connector E from WTS Disconnect the coolant temperature sensor connector F from coolant temperature sensor Disconnect the fuel injector connector G Disconnect the output water hose H Disconnect the air bleed hose I A B G I H C D E F ...

Page 154: ...main stand Remove bolts attaching to rear brake hose clamps Remove two bolts then remove the rear brake caliper Disconnect the alternator connector Disconnect the ignition pulse generator connector Release the rubber cap and remove the terminal screw to disconnect the start motor cable from the start motor ...

Page 155: ...LATION 5 4 K XCT 125i Remove the bolts and engine ground cable Remove the two nuts 7 then remove the intake manifold from cylinder head Remove the bolt 8 then remove the thermostat from cylinder head Remove the spark plug cap ...

Page 156: ...5 ENGINE REMOVAL INSTALLATION 5 5 K XCT 125i Disconnect the lower radiator hose from lower radiator pipe Remove the right and left rear shock absorber lower mount bolts ...

Page 157: ...ALLATION 5 6 K XCT 125i Remove the engine mount nut Pull out the engine mount bolt Remove the engine from the frame At removing the engine be careful not to catch your hand or finger between the engine hanger and crankcase ...

Page 158: ... the right and left rear shock absorber lower mount bolts to the specified torque Torque 4 0kgf m 40N m Install the rear brake caliper and tighten the mount bolts to the specified torque Torque 3 2 kgf m 32 N m 23 lbf ft After installation inspect and adjust the following Throttle grip free play Fill the cooling system with coolant and start the engine to bleed air from the system API ABV Reset ...

Page 159: ...move the right engine hanger mount bolt and collar Remove the engine from frame INSTALLATION Installation is in the reverse order of removal Tighten the engine hanger mount bolts to the specified torque engine side Torque 5 kgf m 50 N m Tighten the engine mount bolt nut to the specified torque frame side Torque 5 kgf m 50 N m 36 lbf ft Be careful to put the engine down ...

Page 160: ...______________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER HEAD VALVES __________________________________________________________________________________ SCHEMATIC DRAWING 6 1 SERVICE INFORMATION 6 2 TROUBLESHOOTING 6 3 CYLINDER HEAD COVER 6 4 C...

Page 161: ...6 CYLINDER HEAD VALVES 6 1 K XCT 125i SCHEMATIC DRAWING ...

Page 162: ... compressed air before inspection After removal mark and arrange the removed parts in order When assembling install them in the reverse order of removal SPECIFICATIONS Unit mm Item Standard IN 0 1 EX 0 1 Cylinder head compression pressure 15kg cm Cylinder head warpage Camshaft cam height IN 25 965 EX 25 810 Valve rocker arm I D IN 10 0 10 015 EX 10 0 10 015 Valve rocker arm shaft IN 9 972 9 987 O ...

Page 163: ...ide Damaged valve stem oil seal Compression too low Incorrect valve clearance adjustment Abnormal noise Burned or bend valves Incorrect valve clearance adjustment Incorrect valve timing Sticking valve or broken valve spring Broken valve spring Damaged or worn camshaft Poor valve and seat contact Worn cam chain tensioner Leaking cylinder head gasket Worn camshaft and rocker arm Warped or cracked cy...

Page 164: ...emove the cylinder head cover INSTALLATION Install a new cylinder head cover O ring and install the cylinder head cover Install and tighten the cylinder head cover bolts to the specified torque in a crisscross pattern Torque 0 8 0 9kgf m Be sure to install the O ring into the groove properly ...

Page 165: ...ove four nuts of camshaft holder and remove the sprocket fixed nut then remove the sprocket Remove the camshaft gear bolt INSTALLATION Install the camshaft gear bolt and holder washers and nuts Tighten four cylinder head nuts to the specified torque Torque 0 7 1 1 kgf m Holder nuts 1 0 1 4 kgf m Cam shaft set plate 1 8 2 2 kgf m Cylinder head M8X1 25 Install the camshaft holder with the EX mark fa...

Page 166: ...age Inspect the rocker arm bore cam lobe contact surface and adjuster surface for wear pitting scratches blue discoloration If any defects are found replace the rocker arm shaft with a new one then inspect lubrication system Rocker Arm Shafts Camshaft Holder Rocker Arm Shafts Rocker Arm Bore Contact Surface Adjuster Surface If the valve rocker arm contact surface is worn check each cam lobe for we...

Page 167: ...he rocker arms and rocker arm shafts Install the rocker arms and shafts into the camshaft holder Rocker Arm Shafts Install the exhaust valve rocker arm shaft on the EX side of the camshaft holder Clean the intake valve rocker arm shaft off any grease before installation ...

Page 168: ...Hold the round hole on the camshaft gear facing up and the location is the top dead center on the compression stroke Remove the tensioner sealing bolt and spring Remove the two bolts from cam chain tensioner and then remove the tensioner and gasket Remove the camshaft gear and bolt Remove the camshaft from the cylinder head Tensioner Sealing Bolt Round Hole Camshaft ...

Page 169: ...itting scratches blue discoloration If any defects are found replace the camshaft with a new one then inspect lubrication system Check each camshaft bearing for play or damage Replace the camshaft assembly with a new one if the bearings are noisy or have excessive play Camshaft Bearings ...

Page 170: ...crankcase Keep the round hole on the camshaft gear facing up and align the punch marks on the camshaft gear with the cylinder head surface Position the intake and exhaust cam lobes down and install the cam chain onto the camshaft gear Install the rocker arms shafts fixed bolt Install the camshaft gear Bolt Punch Marks Cam shaft Round Hole Camshaft Gear ...

Page 171: ...tainers springs spring seats oil seals and valves using a valve spring compressor Special tool Valve Spring Compressor A120E00040 Valve Spring Compressor Be sure to compress the valve springs with a valve spring compressor Mark all disassembled parts to ensure correct reassembly Valves ...

Page 172: ...ches or abnormal stem wear If any defects are found replace the valve with a new one Service limits IN 0 08 mm EX 0 1 mm Valve spring Measure the free length of the inner and outer valve springs Exhaust Port Combustion Chamber Be careful not to damage the cylinder head mating surface If the stem to guide clearance exceeds the service limits replace the cylinder head is necessary ...

Page 173: ...and insert the valves into the valve guides Install the valve springs and retainers Compress the valve springs using the valve spring compressor then install the valve cotters Special tool Valve Spring Compressor A120E00040 Tap the valve stems gently with a plastic hammer for 2 3 times to firmly seat the cotters Valve Spring Compressor Plastic Hammer Cylinder Head Be sure to install the new oil se...

Page 174: ...________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CYLINDER PISTON __________________________________________________________________________________ SCHEMATIC DRAWING 7 1 SERVICE INFORMATION 7 2 TROUBLESHOOTING 7 3 CYLI...

Page 175: ...7 CYLINDER PISTON 7 1 K XCT 125i SCHEMATIC DRAWING ...

Page 176: ... Unit mm Item Standard Cylinder I D 52 4 52 41 Warpage Cylindricity True roundness Piston piston ring Ring to groove Top 0 015 0 055 clearance Second 0 015 0 055 Top 0 10 0 25 Ring end gap Second 0 10 0 25 Oil side rail 0 2 0 7 Piston O D 52 37 52 39 Piston O D measuring position 9 mm from bottom of skirt Piston to cylinder clearance 0 01 0 04 Piston pin hole I D 15 002 15 008 Piston pin O D 14 99...

Page 177: ...n Compression too low or uneven compression Excessive smoke from exhaust muffler Worn or damaged cylinder and piston rings Worn or damaged piston rings Worn stuck or broken piston rings Worn or damaged cylinder and piston Compression too high Abnormal noisy piston Excessive carbon build up in combustion Worn cylinder piston and piston rings chamber or on piston head Worn piston pin hole and piston...

Page 178: ... the cylinder Remove the two cylinder bolts washers 2 Remove the cylinder Remove the cylinder gasket 4 and dowel pins 3 Clean any gasket material onto the cylinder surface Remove the piston pin clip Press the piston pin out of the piston and remove the piston Place a clean shop towel in the crankcase to keep the piston pin clip from falling into the crankcase 3 4 ...

Page 179: ...ating the rings The rings should be able to move in their grooves without catching Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring to groove clearance Insert each piston ring into the bottom of the cylinder squarely Measure the piston ring end gap Use the piston head to push each piston ring into the cylinder Do not damage the piston ri...

Page 180: ...YLINDER PISTON 7 6 K XCT 125i Piston Piston pin Measure the piston O D at the point A from the bottom and 90 to the piston pin hole Service Limit 15 04 mm 0 6016 in Service Limit 0 02 mm 0 0008 in 10 mm A ...

Page 181: ...r I D at three levels in an X and Y axis Take the maximum reading to determine the cylinder wear Measure the piston to cylinder clearance Take a maximum reading to determine the clearance Measure the taper and out of round at three levels in an X and Y axis Take the maximum reading to determine them Measure the connecting rod small end I D vi Measure the connecting rod to piston pin clearance TOP ...

Page 182: ...ings into the piston ring grooves with the markings facing up Do not confuse the top and second rings To install the oil ring install the oil ring then install the side rails Stagger the piston ring end gaps 120 degrees apart from each other Stagger the side rail end gaps as shown Be careful not to damage the piston and rings Intake Side Guide Exhaust Side Guide ...

Page 183: ...e connecting rod small end and piston pin hole Install the piston with the IN mark face intake side and piston pin Place a clean shop towel over the crankcase prevent the clip from falling into the crankcase Install the new pin clip Install the dowel pins and gasket Make sure that the piston pin clips are seated securely Do not align the piston pin clip end gap with the piston cut out Gasket Dowel...

Page 184: ...ng outer surfaces Pass the cam chain through the cylinder and install the cylinder over the piston Install the cylinder head and camshaft holder has installed refer to the CYLINDER HEAD section in the chapter 6 Connect the water hose Be careful not to damage the piston rings and cylinder walls ...

Page 185: ...________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ DRIVE AND DRIVEN PULLEYS __________________________________________________________________________________ SCHEMATIC DRAWING 8 1 SERVICE INFORMATION 8 2 TROUBLESHOOTING 8 3 LEFT CRANKCASE COVE...

Page 186: ...8 DRIVE AND DRIVEN PULLEYS 8 1 K XCT 125i SCHEMATIC DRAWING ...

Page 187: ...ing of drive belt and drive pulley SPECIFICATIONS Unit mm Item Standard Movable drive face bushing I D 24 011 24 052 Drive face collar O D 23 960 23 974 Clutch outer I D 130 130 2 Driven face O D 33 965 33 985 Movable driven face I D 34 34 025 Weight roller O D 17 920 18 080 TORQUE VALUES Drive face nut 5 5 6 5 kgf m Clutch outer nut 5 0 6 0 kgf m Clutch plate comp 5 0 6 0 kgf m SPECIAL TOOLS Bear...

Page 188: ... but motorcycle fail to move Lack of power Worn drive belt Worn drive belt Broken ramp plate Weak driven face spring Worn or damaged clutch lining Worn weight roller Broken driven face spring Faulty driven face Engine stalls or motorcycle creeps Broken clutch weight spring ...

Page 189: ...OVAL Remove ten left crankcase cover bolts and then remove the left crankcase cover Remove the gasket and dowel pins INSTALLATION Install the dowel pins and gasket Install the left crankcase cover Install and tighten ten bolts diagonally to specified torque Dowel Pins ...

Page 190: ...ratchet Special tool Universal holder A120E00017 Remove the drive pulley face and washer Hold the clutch outer with the universal holder and remove the clutch outer nut Special tool Universal Holder A120E00017 Remove the clutch outer driven pulley assembly and drive belt together Drive Pulley Face Universal Holder Clutch Outer Driven Pulley Assembly Drive Belt Nut Ratchet Nut Universal Holder ...

Page 191: ...heck the drive belt for cracks separation or abnormal or excessive wear Replace a new belt at every 20000KM Clutch out inspection Inspect the clutch outer for wear or damage Measure the clutch outer I D Service Limit 130 5 mm 5 22 in Movable Drive Face Assembly Use specified genuine parts for replacement ...

Page 192: ...sembly clutch outer and drive belt together Use the special tool to hold clutch outer then tighten the nut to the specified torque Torque 5 0 6 0kgf m 50 60N m Special tool Universal holder A120E00017 A120E00056 Movable Drive Face Assembly Boss Clutch Outer Driven Pulley Assembly Drive Belt Nut Universal Holder The drive belt should be installed so that the arrows on the drive belt periphery point...

Page 193: ...e pulley face then tighten the nut to the specified torque Torque DINK 200i 5 8 kgf m 58 N m 42 lbf ft 5 5 6 5 kgf m 55 65 N m Special tool Universal holder A120E00017 Noted There is a washer between the drive pulley face and nut don t forget to mount it when installation Drive Pulley Face Universal Holder Nut Ratchet ...

Page 194: ...8 DRIVE AND DRIVEN PULLEYS 8 9 K XCT 125i DRIVE PULLEY DISASSEMBLY Remove the drive face boss Remove the ramp plate Take out six weight rollers Ramp Plate Weight Roller Boss ...

Page 195: ... wear or damage Measure outside diameter Service limit 19 8 mm 0 792 in Movable drive face Slide pieces Drive pulley face Check the movable drive face splines for wear cracks or damage Check the ramp plate for cracks or damage Check the movable drive face and drive pulley face cracks or damage Ramp Plate ...

Page 196: ...ve face drive pulley face weight rollers slide pieces ramp plate and drive face boss Install the weight rollers Install the slide pieces and ramp plate Remove any excess grease Weight Roller Ramp Plate The direction of all weight rollers is the same The thin side is towards to clockwise ...

Page 197: ...8 DRIVE AND DRIVEN PULLEYS 8 12 K XCT 125i Install the drive face boss Boss ...

Page 198: ...n pulley assembly with the clutch spring compressor Special tool Clutch Spring Compressor A120E00034 Set the tool in a vise and remove the clutch drive plate nut Remove the clutch weight Be sure to use a clutch spring compressor to avoid spring damage Clutch spring compressor Lock Nut Wrench ...

Page 199: ...ce Remove the three guide pins rollers then remove the movable driven face Remove the needle bearing from driven face Remove the snap ring then remove the bearing from driven face Movable Driven Face Guide Pins Rollers Needle Bearing Bearing Snap Ring Driven Face Dust Seal Dust Seal O ring Spring Collar Spring ...

Page 200: ... or damage is found then replace as a set Check guide pins and rollers for wear or damage If any scratches or d amage is found then replace as a set Check the spring for damage Measure the spring free length Ser Check the clutch shoe for heat damage Measure the clutch shoe thickness Service limit A 2 mm 0 08 in Guide Pins Grooves ...

Page 201: ... and install them into the movable driven face grooves Install the movable driven face onto the driven face Install the guide rollers and guide roller pins Filling 5 g of grease to each guide groove Install the guide pins rollers Install spring collar Use the special tool to install spring and clutch then install and tighten the nut to the specified torque Torque 5 5 6 5m 55 65N m Special tool Clu...

Page 202: ...______________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ FINAL REDUCTION __________________________________________________________________________________ SCHEMATIC DRAWING 9 1 SERVICE INFORMATION 9 2 TROUBLESHOOTING 9 2 FINAL REDUCTIO...

Page 203: ...9 FINAL REDUCTION 9 1 K XCT 125i SCHEMATIC DRAWING ...

Page 204: ...ation SPECIFICATIONS Specified Oil SAE 90 Oil Capacity At disassembly 0 13L At change 0 12L TORQUE VALUES Transmission case cover bolt 1 0 1 4kgf m SPECIAL TOOLS Oil seal and bearing installer A120E00014 Bearing puller A120E00037 TROUBLESHOOTING Engine starts but motorcycle fail to move Damaged transmission Seized or burnt transmission Abnormal noise Worn seized or chipped gears Worn bearing Oil l...

Page 205: ...chapter 3 Remove the driven pulley refer to the DRIVE PULLEY DRIVE BELT AND DRIVEN PULLEY section in the chapter 8 Remove nine bolts attached the transmission case cover then remove the transmission case cover Remove the dowel pins and gasket Remove the final gear and shaft then remove the countershaft Gasket Drive shaft Dowel Pins Countershaft Final gear ...

Page 206: ... the countershaft and gear for wear or damage Inspect the final gear and final gear shaft for wear damage or seizure Check the driveshaft for wear or damage Check the left crankcase bearings for excessive play and inspect the oil seal for wear or damage ...

Page 207: ...ft bearing oil seal for wear or damage INSTALLATION Install the final gear and final gear shaft Install the Countershaft Install the driveshaft Drive Shaft Bearing Final Shaft Bearing Countershaft Bearing Drive Shaft Bearing Final Gear Shaft Bearing Countershaft Bearing Driveshaft Final Gear Shaft Final Gear Countershaft ...

Page 208: ...ns Install the transmission case cover Install and tighten the nine bolts to the specified torque in a crisscross pattern in 2 or 3 steps Torque 1 0 1 4kgf m Fill the transmission case with the specified oil refer to the TRANSMISSION OIL section in the chapter 3 Dowel pins ...

Page 209: ... the special tool Special tool Bearing puller A120E00037 Install the new bearings or new oil seal into the transmission case cover by using the special tool Special tool Oil seal and bearing installer A120E00014 TRANSMISSION CASE Remove the all transmission gears Remove the transmission case bearings by using the special tool Special tool Bearing puller A120E00037 ...

Page 210: ... Special tool Oil seal and bearing installer A120E00014 After installation fill the transmission case with the specified oil Specified gear oil SAE90 Oil capacity At disassembly 0 12 L At change 0 11L Install and tighten the oil check bolt Torque 0 8 1 2kgf m Start the engine and check for oil leaks Drain Bolt Oil Filler Bolt ...

Page 211: ...______________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ A C GENERATOR STARTER CLUTCH __________________________________________________________________________________ SCHEMATIC DRAWING 10 1 SERVICE INFORMATION 10 2 TROUBLESHOOTING 10 ...

Page 212: ...10 A C GENERATOR STARTER CLUTCH 10 1 K XCT 125i SCHEMATIC DRAWING ...

Page 213: ...ainer Drain the engine oil into a clean container before removing the right crankcase cover When the right crankcase cover is installed fill with the recommended engine oil and coolant Then bleed air from the water jacket SPECIFICATIONS Engine oil SAE 15W 40 API SJ Oil capacity at change 1 0 L Coolant distilled water coolant concentrate Coolant capacity 0 87L SPECIAL TOOLS Flywheel puller A120E000...

Page 214: ...in the chapter 3 Disconnect the generator connectors Remove ten bolts attached the right crankcase cover and then remove the cover Remove two dowel pins and gasket Remove two pulse coil mount screws Remove three stator mount bolts grommet and the stator attached the right crankcase cover Pulser Coil Dowel Pins Gasket Stator ...

Page 215: ...he stator and tighten the stator mount bolts to the specified torque Torque 1 kgf m Apply sealant to the grommet seating surface and install it to the cover groove properly Install the pulse coil and tighten mount screws securely Clean the mating surfaces of the right crankcase and cover Pulser Coil Stator Dowel Pins Gasket ...

Page 216: ...10 A C GENERATOR STARTER CLUTCH 10 5 K XCT 125i Install the dowel pins and gasket Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 or 3 steps ...

Page 217: ...old the flywheel with a special tool and remove the flywheel nut Special tool Flywheel holder A120E00021 Remove the flywheel by using the special tool Special tool Flywheel puller A120E00003 Remove the reduction gear shaft and reduction gear Reduction Gear Shaft Flywheel Nut Flywheel Holder Flywheel Puller ...

Page 218: ...ould be able to turn the driven gear clockwise smoothly but the gear should not turn counterclockwise Remove the starter driven gear by turning the driven gear Check the starter driven gear teeth for wear or damage Service limit 41 mm 1 64 in Service limit 20 15 mm 0 806 in Check the starter reduction gear teeth and shaft for wear or damage Starter Driven Gear Starter Driven Gear Starter Idle Gear...

Page 219: ...tion gear shaft Install the starter reduction gear and shaft to the right crankcase Install the flywheel onto the crankshaft by aligning the key on the crankshaft with the groove in the flywheel Groove Flywheel Key Starter Driven Gear Reduction Gear Shaft Before installation check and make sure that the inside the flywheel is not contaminated ...

Page 220: ...ith the special tool and tighten the flywheel nut Torque 5 0 6 0 kgf m Special tool Flywheel holder A120E00021 Install the dowel pins and gasket Install the right crankcase cover and tighten the bolts in a crisscross pattern in 2 or 3 steps Flywheel Nut Flywheel Holder ...

Page 221: ...__________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ CRANKCASE CRANKSHAFT __________________________________________________________________________________ SCHEMATIC DRAWING 11 1 SERVICE INFORMATION 11 2 TROUBLESHOOTING 11 2 CRANKCASE ...

Page 222: ...11 CRANKCASE CRANKSHAFT 11 1 K XCT 125i SCHEMATIC DRAWING ...

Page 223: ...ing parts must be removed before separating the crankcase Cylinder head Cylinder piston chapter 7 Drive and driven pulley chapter 8 A C generator starter clutch chapter 10 Rear wheel rear shock absorber chapter 16 Starter motor chapter 19 Oil pump chapter 4 SPECIFICATIONS Unit mm Item Standard Crankshaft Connecting rod big end side clearance 0 15 0 35 Connecting rod big end radial clearance 0 0 00...

Page 224: ... bolts Place the crankcase with the left crankcase down and remove the right crankcase from the left crankcase Remove the gasket and dowel pins Remove the crankshaft from the left crankcase Bolt Never use a driver to pry the crankcase mating surfaces apart Left Crankcase Crankshaft Bolts Right Crankcase Left Crankcase Left Crankcase ...

Page 225: ...l seal from the left crankcase CRANKCASE ASSEMBLY Clean off all gasket material from the crankcase mating surfaces Install a new oil seal into the left crankcase Oil Seal Left Crankcase Oil Seal Left Crankcase Avoid damaging the crankcase mating surfaces ...

Page 226: ...e Change a new gasket Place into the crankshaft and onto the left crankcase Install and tighten the right and left crankcase attaching bolts Torque 1 kgf m Bolts Install the right crankcase squarely and do not tap it with an iron or plastic hammer Avoid damaging the oil seal Apply grease to the lip of the oil seal Bolts ...

Page 227: ...CRANKCASE CRANKSHAFT 11 6 K XCT 125i Install the cam chain Install the cam chain tensioner slipper Install and tighten the cam chain tensioner slipper bolt Torque 1 0kgf m Cam Chain Tensioner Slipper Bolt ...

Page 228: ...__ __________________________________________________________________________________ __________________________________________________________________________________ COOLING SYSTEM __________________________________________________________________________________ SERVICE INFORMATION 12 1 TROUBLESHOOTING 12 1 COOLING SYSTEM TESTING 12 3 COOLANT REPLACEMENT 12 4 RADIATOR 12 7 FAN MOTOR 12 9 FAN M...

Page 229: ...ater as soon as possible After servicing the system check for leaks with a cooling system tester SPECIAL TOOL Mechanical seal driver TORQUE VALUES Water pump impeller 1 2 kgf m 12 N m 9 lbf ft Left hand threads Water pump cover bolt 1 0 kgf m 10 N m 7 lbf ft TROUBLESHOOTING Engine temperature too high Coolant leaks Faulty temperature gauge or thermosensor Faulty pump mechanical water seal Faulty r...

Page 230: ...49 1 046 1 043 1 040 40 1 072 1 070 1 068 1 066 1 064 1 062 1 059 1 056 1 053 1 050 1 047 45 1 080 1 078 1 076 1 074 1 072 1 069 1 056 1 063 1 062 1 057 1 054 50 1 086 1 084 1 082 1 080 1 077 1 074 1 071 1 068 1 065 1 062 1 059 55 1 095 1 093 1 091 1 088 1 085 1 082 1 079 1 076 1 073 1 070 1 067 60 1 100 1 098 1 095 1 092 1 089 1 086 1 083 1 080 1 077 1 074 1 071 COOLANT MIXTURE WITH ANTI RUST AND...

Page 231: ...8 psi Pressurize the radiator engine and hoses and check for leaks Repair or replace components if the system will not hold the specified pressure for at least six seconds Radiator Cap Cap Tester Pressure CapTester Removing the radiator cap while the engine is hot can cause the coolant to spray out seriously scalding you Always let the engine and radiator cool down before removing the radiator cap...

Page 232: ...nance schedule Mix only distilled low mineral water with the antifreeze Recommended mixture 1 1 Distilled water and antifreeze REPLACEMENT AIR BLEEDING Remove the front cover refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Remove the radiator cap 1 Remove the drain bolt 2 and drain the coolant from the system When filling the system or reserve tank with coolant checking the...

Page 233: ...12 COOLING SYSTEM 12 5 K XCT 125i ...

Page 234: ... air from the system as follow 1 Start the engine and let it idle for 2 3 minutes 2 Snap the throttle three to four times to bleed air from the system 3 Stop the engine and add coolant to the proper level if necessary Reinstall the radiator cap 4 Check the level of coolant in the reserve tank and fill to the upper level if it is low 1 ...

Page 235: ...coolant Disconnect the siphon hose 1 and air bleed hose 2 Loosen the hose bands then disconnect the input radiator hose and output radiator hose from the radiator Disconnect the thermal switch connectors Disconnect the fan motor connector 1 2 Fan motor connector ...

Page 236: ...12 COOLING SYSTEM 12 8 K XCT 125i Remove bolts and then remove the radiator from frame INSTALLATION Installation is in the reverse order of removal Refill the coolant ...

Page 237: ...REMOVAL Remove the radiator Remove the three mounting bolts 1 and then remove the fan motor 2 INSPECTION Check the fan motor to operate using an available battery INSTALLATION Installation is in the reveres order of removal Fan Motor Battery 2 1 ...

Page 238: ...rature at which the starts to operate If the thermal switch operating temperature is not within the specified range replace the thermal switch with a new one OFF ON Over 88 92 C ON OFF Lower 88 92 C INSTALLATION Change a new O ring Tighten the cooling fan motor switch to specified torque Torque 1 8 kgf m 18 N m 13 lbf ft Handle the cooling fan motor switch carefully as it is vulnerable to impact 1...

Page 239: ...tale hole for signs of mechanical seal coolant leakage If the mechanical seal is leaking remove the right crankcase cover and replace the mechanical seal WATER PUMP IMPELLER REMOVAL Drain the coolant Remove the coolant inlet hose and outlet hose Right Crankcase Cover Water Pump Outlet Hose Inlet Hose ...

Page 240: ...l pins Remove the water pump impeller Inspect the mechanical water seal and seal washer for wear or damage Impeller Left Hand Threads Mechanical Seal Seal Washer Porcelain Water Pump Cover Bolts The impeller has left hand threads The mechanical seal and seal washer must be replace as a set Impeller ...

Page 241: ... SHAFT REMOVAL Disconnect the water hose from the right crankcase cover Remove five bolts attaching the water pump assembly Remove the water pump assembly gasket and dowel pins Remove the water pump shaft clip and water pump shaft Water Pump Shaft ...

Page 242: ...en five bolts to secure the water pump assembly WATER PUMP IMPELLER INSTALLATION When the mechanical seal is replaced a new seal washer must be installed to the impeller Water Pump Assembly Mechanical Seal Seal Washer Porcelain Impeller When installing the water pump assembly aligning the groove on the water pump shaft with the tab on the oil pump shaft ...

Page 243: ...pump shaft Torque 1 2 kgf m 12 N m 9 lbf ft Install two dowel pins and a new gasket Install the water pump cover and tighten the 4 bolts Torque 1 kgf m 10 N m 7 lbf ft Impeller Left Hand Threads Dowel Pins Water Pump Cover Bolt The impeller is with left hand threads Gasket ...

Page 244: ...in a pan which is placed on an electric heater Gradually raise oil temperature while reading the thermometer in the pan and the ohmmeter connected If the resistance measured is out of specification replace the temperature gauge with a new one Temperature Standard resistance 50ºC 133 9 178 9 100ºC 26 29 3 Sensor Thermometer Handle the water temperature sensor carefully as it is vulnerable to impact...

Page 245: ...2 17 K XCT 125i INSTALLATION Tighten the water temperature sensor Torque 0 8 kgf m 8 N m 5 8 lbf ft Connect the sensor connectors After the water temperature sensor has been installed fill coolant and perform air bleeding ...

Page 246: ...uggage box Disconnect the water hose 1 from the thermostat housing Remove the mounting bolt 2 and the thermostat housing attaching the cylinder head INSTALLATION The installation sequence is the reverse of removal After the water thermostat has been installed fill coolant and perform air bleeding 1 Bolts ...

Page 247: ...12 COOLING SYSTEM 12 19 K XCT 125i DISASSEMBLY Remove two screws and separate the thermostat housing halves Remove the thermostat from the thermostat housing Thermostat Screws Thermostat ...

Page 248: ...71 1 5 C Full open 80 C Valve lift 3 5 mm 0 14 in minimum ASSEMBLY Thermostat assembly is in the reverse order of disassembly Thermostat Housing Thermostat Thermometer Do not let the thermostat touch the pan as it will give a false reading Replace the thermostat if the valve stays open at room temperature Test the thermostat after it is opened for about 5 minutes and holds the temperature at 70 ...

Page 249: ...iagnostic Tool Operation Instructions Part No 3620A LEB2 E00 KEY FUNCTION ModelNo DownButton DTCindicator Failurecodes EnterorExit Powerindicator UPButton Adjust TPIandABVresetfunction 3 4 5 6 7 8 9 10 DATAAnalyze DTCInspect ECUVersion 6 7 8 9 10 1 2 3 4 5 ...

Page 250: ...3 0 Adjust 13 8 DTC Inspection Precedure DTC Inspection Precedure 13 2 13 5 13 6 DTC Clear Procedure DTC Clear Procedure Data Analysis 13 1 13 Fi DIAGNOSTIC TOOL OPERATION Diagnostic Standard Specifications Diagnostic Standard Specifications 13 9 K XCT 125i ...

Page 251: ...connector of harnesswirelocatedbesidetheBattery 13 2 Diagnostic Tool Connector Pressthe Enter button Checkthesoftwareversion Press the Enter button and then turn to the first page Pressthe Down buttontoentertheDTCInspect 13 Fi DIAGNOSTIC TOOL OPERATION K XCT 125i ...

Page 252: ...tontochecktheDTCnumber Pressthe Enter button Pressthe Enter button Displaywhat sDTCnumberonthisDTC List RefertoDTCsummarylist Press the Enter button and then turn to the previouspage 13 Fi DIAGNOSTIC TOOL OPERATION K XCT 125i ...

Page 253: ...13 4 Pressthe UP button Press the Enter button and then turn to the previouspage Pressthe UP button Press the Enter button and then turn to the first page 13 Fi DIAGNOSTIC TOOL OPERATION K XCT 125i ...

Page 254: ...CLEAR PROCEDURE Choose Load DTC 13 5 Pressthe Down button Pressthe Enter button TheDTCindicatorislightingatthattime ClearingDTCcompleteduntiltheDTC indicatorisoff 13 Fi DIAGNOSTIC TOOL OPERATION K XCT 125i ...

Page 255: ...Down buttontoenterpage02 ThefigureincludesTPSposition TPIidle adaptedvoltageandTPIWOTadapted Throttlegripfullyopened Refertostandardspecifications Pressthe Down buttontoenterpage03 Thefigureincludesengineworking temperature atmospherepressureand Manifoldpressure Refertostandardspecificationsonpage18 9 Pressthe Down buttontoenterpage04 13 Fi DIAGNOSTIC TOOL OPERATION K XCT 125i ...

Page 256: ...igureincludes O2sensorvoltage O2 heaterworkingconditionand O2 correction Refertostandardspecifications Pressthe Down buttontoenterpage06 Thefigureincludesrollovervoltage Refertostandardspecifications Pressthe Down buttontoenterpage07 Thefigureincludes ECU counterhours Pressthe UP buttontothefirstpage 13 Fi DIAGNOSTIC TOOL OPERATION K XCT 125i ...

Page 257: ...I ABVReset Pleasekeyswitchoffthenkeyswitchon Completed theTPI ABVresetoperate Pressthe Enter button Need to make TPI ABV reset to operate after changing new ECU and clean THROTTLE BODY and changing the engine department product let ECU set up and set up initially 13 8 K XCT 125i ...

Page 258: ...13 Fi DIAGNOSTIC TOOL OPERATION 13 9 K XCT 125i ...

Page 259: ...m SYSTEM DIAGRAM 14 1 SYSTEM LOCATION 14 2 SERVICE INFORMATION 14 3 TROUBLESHOOTING 14 4 CHECK ENGINE LAMP CELP 14 5 HOW TO SHOW THE FAILURE CODE 14 6 CELP FAILURE CODES CHART 14 7 MAINTAINING BY CHECKING COMPONENT 14 11 MAINTAINING SPECIAL NOTICE 14 16 MAINTAINING RESET 14 17 DIAGNOSTIC RECORD SHEET 14 18 14 ...

Page 260: ...LSYSTEM AutoControlFuelInjectionSystem 14 1 SYSTEM DIAGRAM 進氣壓力及 大氣壓力感 知器 曲軸感知器 感知器 含氧 O2 感知器 CPS T MAP TPS WTS O2 Voltage 進氣壓力及大氣壓力 感知器 感知器 INJECTOR ABV KEY OFF INDUCTIVE IGNITION COIL ECU FUEL PUMP KEY ON 曲軸感知器 ROLL ...

Page 261: ...jectionSystem 14 2 01 Inductive ignition coil 02 Fuel pump 03 ECU 04 Fuel injector 05 WTS sensor 06 T MAP sensor 07 ABV 08 TPS 09 Roll sensor Angle detect sensor 10 CPS 11 O2 O2 HT sensor 09 10 11 04 05 06 07 08 03 01 02 SYSTEM LOCATION 09 02 ...

Page 262: ...15 9Ω Water temperature sensor resistance 2 075 10 KΩ 20 30 C Throttle position sensor voltage Idle 0 0 23 0 05V Throttle fully 90 3 27V over Fuel pump resistance 20 C 68 F F about 1100Ω E about 100Ω O2 sensor O2 sensor heater resistance 6 7 9 5Ω Voltage Air Fuel 14 7 Rich 0 7V Air Fuel 14 7 Lean 0 18V Item Standard Crank position sensor Pulser resistance 20 C 68 F 95 144Ω Inductive ignition coil ...

Page 263: ... fuel hose Poor performance drive ability and poor Faulty fuel pump operating system fuel economy Clogged fuel filter fuel pump Pinched or clogged fuel hose Clogged fuel injector Faulty fuel injector Faulty spark plug or wrong type Cut by ECU due to angle detect sensor or incorrect function Engine stall hard to start rough idling Intake air leak Fuel contaminated deteriorated Pinched or clogged fu...

Page 264: ...ch part get trouble There are 3 kinds of priority grade let user to know what kind of trouble was happened Priority grade 1 CELP blinks continuously This is the most emergent situation like engine over heat User better slow down the riding and go to dealer for checking Priority grade 2 CELP lights all the time It means components get trouble or circuit something wrong Do the further check to find ...

Page 265: ... number failure code and then show the other higher number one after four seconds All the failure codes would be shown repeatedly How To Reset Failure Code After repairing the trouble you should clear the failure code or it will still exist in the ECU memory When you maintain this vehicle next time it will show again and you get confuse Turn switch on The CELP will be lighted for two seconds then ...

Page 266: ...ensor or circuit malfunction 2 1 Check if the connector of crankshaft position sensor is loosen 2 Check if the Rotor is align with Crankshaft position sensor during the crankshaft running 3 P1120 Throttle position sensor setting value problem 2 1 Make sure if the connector of Throttle position sensor is connected correctly 2 Check if the Throttle position sensor is adjusted 4 P1121 Throttle positi...

Page 267: ... Inlet air temperature sensor or electric circuit malfunction 2 1 Check if the connector of Inlet air temperature sensor loosen 2 Check if the resistance of sensor is normal 8 P0410 Idle air valve or electric circuit malfunction 2 1 Check if the connector of Idle air valve loosen 2 Check if the resistance of valve is normal 9 P0505 Idle speed volume control range bl 2 1 Check if the opening angle ...

Page 268: ...ine speed is over than top speed 2 Check if the belt of CVT is broken 14 P1560 Sensor don t receive power source from ECU 2 1 Check if ECU output DC5V to sensor 2 Check if the power source of all sensor is DC5V 3 Replace a new ECU if the CELP still blinks even the output power source of ECU is normal 15 P0700 Engine starting speed exceed CVT speed limited 2 1 Check if the throttle wire locked 2 Ch...

Page 269: ...it in specification 22 P1110 Roll sensor or electric circuit malfunction 2 1 Check if the sensor installation direction is correct 2 Check if voltage of sensor is fit in specification 3 Check if ECU pin is broken 23 P0136 O2 sensor malfunction 1 1 Check if the connector of sensor is loosen 2 Check if ECU pin is broken 24 P0141 O2 sensor heater malfunction 1 1 Check if the connector of sensor is lo...

Page 270: ...ctionSystem 14 11 Maintaining By Checking Component ECU Engine Control Unit Outlook checking Voltage inspection Connect the meter probe to the F4 R W wire and the meter probe to the H4 G B wire to measure the voltage MAP content edition issue no ...

Page 271: ...2 FUEL PUMP Connect the meter probe to the red black wire and the meter probe to the green wire to measure the voltage from the ECU input to fuel pump unit Standard 8 16 V Battery volt Measure the resistance of the fuel pump to see if it is short circuit or not ...

Page 272: ...rrect It is possible T map sensor is not normal Standard 101 3 3 kpa see level The ambient pressure drop about 12Kpa at the altitude every raised TPS Throttle Position Sensor Connect the PDA or KYMCO Fi diagnostic tool Into the Data Analyze item Check if the TPS position data is malfunction Key switch ON but engine is not start If data was incorrect Idle and throttle fully It is possible TPS is no...

Page 273: ...perature Sensor Connect the meter probe to the V G wire and the meter probe to the G L wire to measure the voltage Standard 5 0 25 V Measure the resistance of the WTS Standard 20 C 68 F 2 075 10 kΩ INJECTOR Measure the resistance of the Injector Standard 20 C 68 F 10 6 15 9Ω ...

Page 274: ...ance of the O2 sensor heater 2 white wire pin Standard 20 C 68 F 6 7 9 5Ω Connect the PDA or KYMCO Fi diagnostic tool Into the Data Analyze item Check Page 05 Key switch ON then start engine until O2 heater activation is ON If data was incorrect It is possible O2 sensor is not normal 0 1 ON ...

Page 275: ...ty When you place the vehicle back to normal situation you have to key off and key on the switch then it can be restarted Standard Normal 0 4 1 4V OVER 65 3 7 4 4 V Maintaining Special Notice Never adjust those two TP screws those were adjusted to be the best condition by KYMCO if change this condition it may cause instable riding TP screws ...

Page 276: ...ic tool Into the Data Analyze item Check if the ignition advance data is malfunction Key switch is ON then start engine until 80 C If data was over 20 you can adjustment the air bypass adjustment screw 1 1 5 circle counterclockwise Don t adjust the air bypass adjustment screw over 1 5 circle 23 25º ...

Page 277: ...14 K XCT125i FUELSYSTEM AutoControlFuelInjectionSystem 14 18 ...

Page 278: ...____________________________________________ __________________________________________________________________________________ HANDLEBAR FRONTWHEEL FRONTBRAKE FRONTSHOCKABSORBER STEERINGSTEM __________________________________________________________________________________ SERVICE INFORMATION 15 2 TROUBLESHOOTING 15 3 Steering Stem Removal 15 4 Steering Stem Installation 15 11 Handlebar 15 17 Fro...

Page 279: ...er cylinder I D 12 7 12 74 0 508 0 5096 Brake master cylinder piston O D 12 65 12 68 0 506 0 5072 Brake caliper piston O D 26 93 26 96 1 077 1 0784 Brake caliper cylinder I D 27 27 05 1 08 1 082 TORQUE VALUES Handlebar lock nut 45 N m 4 5 kgf m Steering stem lock nut 63 N m 6 3 kgf m Steering stem pinch bolt 27 N m 2 7 kgf m Front axle 20 N m 2 0 kgf m Master cylinder reservoir cover screw 1 6N m ...

Page 280: ... or does not track straight Improperly tightened axle nut Uneven front shock absorbers Soft front shock absorber Bent front fork Weak shock springs Bent front axle or uneven tire Insufficient damper oil Poor brake performance Front shock absorber noise Worn brake pads Slider bending Contaminated brake pad surface Loose fork fasteners Deformed brake disk Lack of lubrication Air in brake system Dete...

Page 281: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 4 K XCT 125i ...

Page 282: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 5 K XCT 125i ...

Page 283: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 6 K XCT 125i ...

Page 284: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 7 K XCT 125i ...

Page 285: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 8 K XCT 125i ...

Page 286: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 9 K XCT 125i ...

Page 287: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 10 K XCT 125i ...

Page 288: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 11 K XCT 125i ...

Page 289: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 12 K XCT 125i ...

Page 290: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 13 K XCT 125i ...

Page 291: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 14 K XCT 125i ...

Page 292: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 15 K XCT 125i ...

Page 293: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 16 K XCT 125i ...

Page 294: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 17 K XCT 125i ...

Page 295: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 18 K XCT 125i ...

Page 296: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 19 K XCT 125i ...

Page 297: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 20 K XCT 125i ...

Page 298: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 21 K XCT 125i ...

Page 299: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 22 K XCT 125i ...

Page 300: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 23 K XCT 125i ...

Page 301: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 24 K XCT 125i ...

Page 302: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 25 K XCT 125i ...

Page 303: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 26 K XCT 125i ...

Page 304: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 27 K XCT 125i ...

Page 305: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 28 K XCT 125i ...

Page 306: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 29 K XCT 125i ...

Page 307: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 30 K XCT 125i ...

Page 308: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 31 K XCT 125i ...

Page 309: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 32 K XCT 125i ...

Page 310: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 33 K XCT 125i ...

Page 311: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 34 K XCT 125i ...

Page 312: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 35 K XCT 125i ...

Page 313: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 36 K XCT 125i ...

Page 314: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 37 K XCT 125i ...

Page 315: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 38 K XCT 125i ...

Page 316: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 39 K XCT 125i ...

Page 317: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 40 K XCT 125i ...

Page 318: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 41 K XCT 125i ...

Page 319: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 42 K XCT 125i ...

Page 320: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 43 K XCT 125i ...

Page 321: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 44 K XCT 125i ...

Page 322: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 45 K XCT 125i ...

Page 323: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 46 K XCT 125i ...

Page 324: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 47 K XCT 125i ...

Page 325: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 48 K XCT 125i ...

Page 326: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 49 K XCT 125i ...

Page 327: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 50 K XCT 125i ...

Page 328: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 51 K XCT 125i ...

Page 329: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 52 K XCT 125i ...

Page 330: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 53 K XCT 125i ...

Page 331: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 54 K XCT 125i ...

Page 332: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 55 K XCT 125i ...

Page 333: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 56 K XCT 125i ...

Page 334: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 57 K XCT 125i ...

Page 335: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 58 K XCT 125i ...

Page 336: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 59 K XCT 125i ...

Page 337: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 60 K XCT 125i ...

Page 338: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 61 K XCT 125i ...

Page 339: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 62 K XCT 125i ...

Page 340: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 63 K XCT 125i ...

Page 341: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 64 K XCT 125i ...

Page 342: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 65 K XCT 125i ...

Page 343: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 66 K XCT 125i ...

Page 344: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 67 K XCT 125i ...

Page 345: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 68 K XCT 125i ...

Page 346: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 69 K XCT 125i ...

Page 347: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 70 K XCT 125i ...

Page 348: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 71 K XCT 125i ...

Page 349: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 72 K XCT 125i ...

Page 350: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 73 K XCT 125i ...

Page 351: ...15 HANDLEBAR FRONT WHEEL FRONT BRAKE FRONT SHOCK ABSORBER STEERING STEM 74 K XCT 125i ...

Page 352: ..._____________________ ________________________________________________________________________________ ________________________________________________________________________________ REARBRAKE REARFORK REARWHEEL REARSHOCKABSORBER _________________________________________________________________________________________ SERVICE INFORMATION 16 1 TROUBLESHOOTING 16 1 Shock Absorbers 16 2 Rear Fork 16...

Page 353: ...O D 12 65 12 68 TORQUE VALUES Exhaust muffler lock bolt 35 N m 3 5 kgf m Exhaust muffler pipe nut 20 N m 2 kgf m Rear axle nut 120 N m 12 kgf m Rear shock absorber lower mount bolt 40N m 4 kgf m Rear shock absorber upper mount bolt 40N m 4 kgf m Rear brake caliper holder bolt 27 N m 2 7 kgf m TROUBLESHOOTING Rear wheel wobbling Poor brake performance Bent rim Air in brake system Faulty tire Deteri...

Page 354: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 2 K XCT 125i ...

Page 355: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 3 K XCT 125i ...

Page 356: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 4 K XCT 125i ...

Page 357: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 5 K XCT 125i ...

Page 358: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 6 K XCT 125i ...

Page 359: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 7 K XCT 125i ...

Page 360: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 8 K XCT 125i ...

Page 361: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 9 K XCT 125i ...

Page 362: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 10 K XCT 125i ...

Page 363: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 11 K XCT 125i ...

Page 364: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 12 K XCT 125i ...

Page 365: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 13 K XCT 125i ...

Page 366: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 14 K XCT 125i ...

Page 367: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 15 K XCT 125i ...

Page 368: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 16 K XCT 125i ...

Page 369: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 17 K XCT 125i ...

Page 370: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 18 K XCT 125i ...

Page 371: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 19 K XCT 125i ...

Page 372: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 20 K XCT 125i ...

Page 373: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 21 K XCT 125i ...

Page 374: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 22 K XCT 125i ...

Page 375: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 23 K XCT 125i ...

Page 376: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 24 K XCT 125i ...

Page 377: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 25 K XCT 125i ...

Page 378: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 26 K XCT 125i ...

Page 379: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 27 K XCT 125i ...

Page 380: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 28 K XCT 125i ...

Page 381: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 29 K XCT 125i ...

Page 382: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 30 K XCT 125i ...

Page 383: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 31 K XCT 125i ...

Page 384: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 32 K XCT 125i ...

Page 385: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 33 K XCT 125i ...

Page 386: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 34 K XCT 125i ...

Page 387: ...16 REAR BRAKE REAR FORK REAR WHEEL REAR SHOCK ABSORBER 16 35 K XCT 125i ...

Page 388: ...__________________________ __________________________________________________________________________________ __________________________________________________________________________________ BATTERY CHARGING SYSTEM __________________________________________________________________________________ CHARGING SYSTEM LAYOUT 17 1 CHARGING CIRCUIT 17 1 SERVICE INFORMATION 17 2 TROUBLESHOOTING 17 3 BATT...

Page 389: ...17 BATTERY CHARGING SYSTEM 17 1 K XCT 125i CHARGING SYSTEM LAYOUT CHARGING CIRCUIT ACG BATTERY REGULATOR RECTIFIER ...

Page 390: ...it should be recharged when the capacity is insufficient Recharging a new battery will prolong its service life Inspect the charging system according to the sequence specified in the Troubleshooting It is not necessary to check the MF battery electrolyte or fill with distilled water Check the load of the whole charging system Do not quick charge the battery Quick charging should only be done in an...

Page 391: ...tery cable Loose charging system connection Fuse burned out Loose connection or short circuit in Faulty ignition switch ignition system Low power Charging system failure Weak battery Loose broken or shorted wire or connector Loose battery connection Faulty regulator rectifier Charging system failure Faulty A C generator Faulty regulator rectifier ...

Page 392: ...battery cover Pull battery out to expose the terminal leads Disconnect the negative terminal lead from the battery first then disconnect the positive terminal lead Remove the battery from the battery box Battery installation Install in the reverse order of the removal When install the battery first connect the positive cable and then negative cable to avoid short circuit ...

Page 393: ...rger positive cable to the battery positive terminal Connect the charger negative cable to the battery negative terminal Charging current time Standard 1 2A 5 10h Quick 5A 1h Quick charging should only be done in an emergency slow charging is preferred For battery charging do not exceed the charging current and time specified on the battery Using excessive current or extending the charging time ma...

Page 394: ...ly certain which are the positive and negative terminals or cable With the headlight on and turned to the high beam position restart the engine Measure the voltage on the multimeter when the engine runs at 5000 min rpm Standard Measure charging voltage 14 5 0 5 V Do not disconnect the battery or any cable in the charging system without first switching off the ignition switch Failure to follow this...

Page 395: ...RAME COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the regulator rectifier connectors Check the connector for loose contacts of corroded terminals Measure the voltage between the Red White wire terminal and ground There should be same with battery voltage at all times Regulator Rectifier Regulator Rectifier ...

Page 396: ...re terminal and ground There should be continuity at all times Measure the resistance between each Yellow wire terminals Disconnect the regulator rectifier connector Check for continuity between each Yellow wire terminal regulator rectifier side and ground There should be no continuity ...

Page 397: ...__________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ IGNITION SYSTEM __________________________________________________________________________________ IGNITION SYSTEM LAYOUT 18 1 SERVICE INFORMATION 18 2 TROUBLESHOOTING 18 3 IG...

Page 398: ...18 IGNITION SYSTEM 18 1 K XCT 125i IGNITION SYSTEM LAYOUT Roll sensor ECU Ignition coil ACG ...

Page 399: ...s flowing the excessive voltage may damage the ignition control module or ECU Always turn off the ignition switch before servicing A faulty ignition system is often related to poor connections Check those connections before proceeding Make sure the battery is adequately charged Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark pl...

Page 400: ...VOLTAGE Short circuit in engine stop switch or ignition switch wire Faulty engine stop switch or ignition switch Loose or poorly connected ignition control module connectors Open circuit or poor connection in ground wire of the ignition control module Faulty ignition pulse generator Faulty ignition control module PEAK VOLTAGE IS NORMAL BUT NO SPARK JUMPS AT THE PLUG Faulty spark plug or leaking ig...

Page 401: ...hat the spark plug 1 is installed correctly in the cylinder Disconnect the spark plug cap 2 from the spark plug Turn the ignition switch to ON and engine stop switch ON and side stand is up Connect the multimeter probe to the black wire and the multimeter to the body ground Check for initial voltage at this time The battery voltage should be measured If the initial voltage cannot be measured check...

Page 402: ...ECTION Remove the luggage box refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the ignition pulse generator connector Measure the pulse generator resistance between the Green White wire and Blue Yellow wire Standard 96 144 20ºC 68ºF ...

Page 403: ...the luggage box refer to the FRAME COVERS REMOVAL INSTALLATION section in the chapter 2 Disconnect the spark plug cap attaching the spark plug 1 Disconnect the ignition coil connector Remove two bolts attaching the ignition coil Installation is in the reverse order of removal 1 ...

Page 404: ...________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ STARTING SYSTEM __________________________________________________________________________________ STARTING SYSTEM LAYOUT 19 1 SERVICE INFORMATION 19 2 TROUBLESHOOTING 19 2 STARTER MOTO...

Page 405: ...19 STARTING SYSTEM 19 1 K XCT 125i STARTING SYSTEM LAYOUT Battery Start relay Start motor ...

Page 406: ...Starter motor mounting bolt 1 kgf m 10 N m TROUBLESHOOTING Starter motor can not working Lack of power Fuse burned out Weak battery Weak battery Loose wire or connection Faulty ignition switch Foreign matter stuck in starter motor Faulty starter clutch or gear Faulty front or rear stop switch Faulty starter relay Starter motor rotates but engine does Poorly connected broken or shorted wire not sta...

Page 407: ...cable directly to the battery positive terminal If the starter motor fail to work the starter motor is faulty REMOVAL Turn the ignition switch turned to OFF position Release the rubber cap 1 and remove the terminal screw 2 to disconnect the start motor cable from the start motor Remove two mounting bolts 3 then remove the start motor 1 2 3 ...

Page 408: ...ne oil and install it into the start motor groove Install the starter motor into the crankcase Install the two mounting bolts and engine ground cable then tighten the bolts securely Connect the start motor cable to motor terminal with the terminal screw and tighten it securely 1 ...

Page 409: ...witch clicks Release the rubber caps and remove the nuts then disconnect the start motor cable battery positive cable and harness wire Disconnect the start relay connector and then remove start relay Connect a fully charged 12 V battery positive wire to the relay switch Yellow Red wire terminal and negative wire to the Green Yellow wire terminal There should be continuity between the cable termina...

Page 410: ..._____________________________________________________________________ __________________________________________________________________________________ LIGHTS METERS SWITCHES __________________________________________________________________________________ SERVICE INFORMATION 20 1 HEADLIGHT 20 2 AIM 20 4 FRONT TURN SIGNALS 20 4 TAILLIGHTS 20 6 REAR TURN SIGNALS 20 7 LICENSE TAG LIGHT 20 8 IGNITI...

Page 411: ...with a cloth moistened with alcohol to prevent its early failure Be sure to install the dust cover after replacing the bulb Check the battery condition before performing any inspection that requires proper battery voltage A continuity test can be made with the light switches installed on the scooter Route the wires and cables properly after servicing each component A halogen head light bulb become...

Page 412: ...20 LIGHTS METERS SWITCHES 20 2 K XCT 125i ...

Page 413: ...20 LIGHTS METERS SWITCHES 20 3 K XCT 125i ...

Page 414: ...20 LIGHTS METERS SWITCHES 20 4 K XCT 125i ...

Page 415: ...20 LIGHTS METERS SWITCHES 20 5 K XCT 125i ...

Page 416: ...20 LIGHTS METERS SWITCHES 20 6 K XCT 125i ...

Page 417: ...20 LIGHTS METERS SWITCHES 20 7 K XCT 125i ...

Page 418: ...20 LIGHTS METERS SWITCHES 20 8 K XCT 125i ...

Page 419: ...20 LIGHTS METERS SWITCHES 20 9 K XCT 125i ...

Page 420: ...20 LIGHTS METERS SWITCHES 20 10 K XCT 125i ...

Page 421: ...20 LIGHTS METERS SWITCHES 20 11 K XCT 125i ...

Page 422: ...20 LIGHTS METERS SWITCHES 20 12 K XCT 125i ...

Page 423: ...20 LIGHTS METERS SWITCHES 20 13 K XCT 125i ...

Page 424: ...20 LIGHTS METERS SWITCHES 20 14 K XCT 125i ...

Page 425: ...20 LIGHTS METERS SWITCHES 20 15 K XCT 125i ...

Page 426: ...20 LIGHTS METERS SWITCHES 20 16 K XCT 125i ...

Page 427: ...20 LIGHTS METERS SWITCHES 20 17 K XCT 125i ...

Page 428: ...20 LIGHTS METERS SWITCHES 20 18 K XCT 125i ...

Page 429: ...20 LIGHTS METERS SWITCHES 20 19 K XCT 125i ...

Page 430: ...20 LIGHTS METERS SWITCHES 20 20 K XCT 125i ...

Page 431: ...20 LIGHTS METERS SWITCHES 20 21 K XCT 125i ...

Page 432: ...20 LIGHTS METERS SWITCHES 20 22 K XCT 125i ...

Page 433: ...20 LIGHTS METERS SWITCHES 20 23 K XCT 125i ...

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