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DOWNTOWN 125i
By KWANG YANG Motor Co., Ltd.1st Edition, Dec 2009
All rights reserved. Any reproduction orunauthorized use without the written
permission of KWANG YANG Motor Co., Ltd.is expressly prohibited.
T300-SK25AA-A1
DOWNTOWN 125i
PREFACE
This Service Manual describes thetechnical features and servicingprocedures for the KYMCODowntown i.Section 1 contains the precautions forall operations stated in this manual.Read them carefully before anyoperation is started.
Section 2 is the removal/installationprocedures for the frame covers whichare subject to removal/installationfrequency during maintenance andservicing operations.
Section 3 describes the inspection/adjustment procedures, safety rulesand service information for each part,starting from periodic maintenance.
Sections 5 to 12 give instructions fordisassembly, assembly andadjustment of engine parts. Section 13is the AFI system. Section 14 to 15 isthe removal/ installation of chassis.Section 16 to 19 states the testing andmeasuring methods of electricalequipment.
Most sections start with an assemblyor system illustration andtroubleshooting for the section. Thesubsequent pages give detailedprocedures for the section.
KWANG YANG MOTOR CO., LTD.QUALITY TECHNOLOGY DEPT.
EDUCATION SECTION
TABLE OF CONTENTS
GENERAL INFORMATION 1
EXHAUST MUFFLER/FRAMECOVERS
2
INSPECTION/ADJUSTMENT 3
LUBRICATION SYSTEM 4
ENGINE REMOVAL/INSTALLATION 5
CYLINDER HEAD/VALVES 6
CYLINDER/PISTON 7
DRIVE AND DRIVEN PULLEYS/V-BELT
8
FINAL REDUCTION 9
A.C. GENERATOR/STARTERCLUTCH
10
CRANKCASE/CRANKSHAFT 11
COOLING SYSTEM 12
FUEL INJECTION SYSTEM 13STEERING HANDLEBAR/FRONTWHEEL/FRONT BRAKE/FRONTSHOCK ABSORBER/FRONT FORK
14
REAR BRAKE/REAR FORK/REARWHEEL/REAR SHOCK ABSORBER`
15
BATTERY/CHARGING SYSTEM 16
IGNITION SYSTEM 17
STARTING SYSTEM 18
LIGHTS SWITCHES / FUEL PUMP 19
The information and contentsincluded in this manual may bedifferent from the motorcycle in casespecifications are changed.
CH
AS
SIS
ELEC
TRIC
ALE
QU
IPM
EN
TE
NG
INE
1. GENERAL INFORMATION
1-0
DOWNTOWN 125i
1
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GENERAL INFORMATION________________________________________________________________________________
SERIAL NUMBER ------------------------------------------------------------------------------------ 1-1
SPECIFICATION ------------------------------------------------------------------------------------- 1-2
SERVICE PRECAUTIONS------------------------------------------------------------------------- 1-3
TORQUE VALUES ----------------------------------------------------------------------------------- 1-4
SPECIAL TOOLS------------------------------------------------------------------------------------- 1-6
LUBRICATION POINTS ---------------------------------------------------------------------------- 1-7
CABLE & HARNESS ROUTING--------------------------------------------------------------------- 1-8
1
1. GENERAL INFORMATION
1-1
DOWNTOWN 125i
SERIAL NUMBER
Location of Frame Serial Number(inside luggage box)
Location of Vehicle IdentificationNumber (VIN)
Location of Engine Serial Number
1. GENERAL INFORMATION
SPECIFICATIONS
- 2 -
Name DOWNTOWN125i
Model No. SK25AA
Overall length 2200mm
Overall width 800 mm
Overall height 1410 mm
Wheel base 1542 mm
Engine type O.H.C.
Displacement 124.8cc
Fuel Used 92# nonleaded gasoline
Front wheel 68
Net weight (kg) Rear wheel 96
Total 164
Front wheel 70
Gross weight(kg) Rear wheel 104
Total 178
Front wheel 120/80-14
Rear wheel 150/70-13
RR Ground clearance 140 mm
Perform- Braking distance (m) 7.9m/30km/hance Min. turning radius 2600mm
Starting systemStarting 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 x 54.5
Compression ratio 11.7:1Compression pressure(kg/cm) 15
Max .horsepower (ps/rpm) 15/8750~9000
Max. torque (kg m/rpm) 1.17/8500~8750
Intake Open 8 BTDC
Port (1mm) Close 31 BTDCtiming Exhaust Open 32 BTDC
(1mm) Close 6 BTDC
Valve Intake 0.10 mm
clearance Exhaust 0.10 mm
Idle speed (rpm) 1850rpm
Lubrication type Forced pressure &Wet sump
Oil pump type Inner/outer rotor type
Oil filter type Full-flow filtration
Oil capacity 1.2 L
Exchanging capacity 1.0 L
Cooling Type Liquid cooling
Tires
En
gin
e
Lu
bricatio
nS
ystem
Air cleaner type & No Paper element, wet
Fuel capacity 12.5 L
Throttle type Butterfly type
Type ECU
Spark plug NGK CR7E
Spark plug gap 0.60.7mm
Battery Capacity 12V10AH
Clutch Type Dry multi-disc clutch
Type Non-stage transmission
Operation Automatic centrifugaltype
Type Two-stage reduction
Reduction 1st 0.83~2.2
ratio 2nd 10.41
Front Caster angle 28
Axle Trail length 140mm
Tire pressure Front 2.0(kg/cm) 1person
Rear 2.25
Turning Left 40
angle Right 40
Brake system Front Disk braketype Rear Disk brake
Front Telescope
Suspensiontype Rear DOUBLE SWING
Frame type PIPE UNDER BONE
Red
uctio
nG
earT
ransm
is-sio
nG
ear
Fu
elS
ystem
Po
wer
Driv
eS
ystem
Electrical
Eq
uip
.
Ign
ition
Sy
stem
Mo
vin
gD
evice
Dam
pin
gD
evice
DOWNTOWN 125i
1. GENERAL INFORMATION
1-3
DOWNTOWN 125i
Symbols:The following symbols represent theservicing methods and cautions included inthis service manual.
: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Use special tool.
: Caution
: Warning
Special
Engine Oil
Grease
Gear Oil
1. GENERAL INFORMATION
1-4
DOWNTOWN 125i
TORQUE VALUES
1. GENERAL INFORMATION
1-5
DOWNTOWN 125i
TORQUE VALUESFRAME
1. GENERAL INFORMATION Downtown 125iSPECIAL TOOLS
Tool Name Tool No. Performance Photo
Flywheel Puller A120E00003 A.C. generator flywheel removal
Tappet Adjuster A120E00012 Tappet adjustment
Oil Seal & BearingInstaller
A120E00014 Oil seal & bearing installing
Flywheel Holder A120E00021 A.C. generator flywheel holding
#41 Nut & Fitting A120E00028 Clutch disassembly & assembly
Thread Protector A120E00029 Protecting the crankshaftsthread
Valve Cotter Installer A120E00051 Valve cotter installation
Clutch SpringCompressor
A120E00053 Clutch disassembly & assembly
Shaft Collar Puller A120E00088 Bearing crankcase removal
Shaft Collar Driver A120E00091 Bearing crankcase removal
Shaft Collar Installer A120E00092 Bearing crankcase installation
Bearing Puller A120E00093 Bearing removal
Lock Nut Socket Wrench A120F00002 Steering stem removal orinstallation
Electric Repair Kit A120F00032 Fuel injection system diagnosis
1-6
DOWNTOWN 125i
LUBRICATION POINTSFRAMEThe following is the lubrication 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 noiseand damage the durability of the motorcycle.
Grease
Grease
Front wheel axle &nut Rear wheel axle &nut
Grease
Side stand pivot& Main stand pivot
1. GENERAL INFORMATION
1-7
1. GENERAL INFORMATION
1-8
DOWNTOWN 125i
CABLE & HARNESS ROUTING
Tilt Switch Speedometer
Radiator Filler Cap
Ignition Switch
Horn
Winker RelayHi Beam Relay
Lo Beam Relay
DOWNTOWN 125i
Oil controller
Fuel Pump Relay
Ignition Coil
Output Voltage Connector
Coolant Reserve Tank
1. GENERAL INFORMATION
1-9
2. EXHAUST MUFFLER/FRAME COVERS
2-0
DOWNTOWN 125i
2 __________________________________________________________________________________
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EXHAUST MUFFLER/FRAME COVERS__________________________________________________________________________________
SCHEMATIC DRAWING ------------------------------------------------- 2- 1SERVICE INFORMATION------------------------------------------------ 2