KYMCO SERVICE MANUAL
Contents
1. SERVICE MANUAL MXU 150 MX er 150 125 Issued 08 06 2005 KWANG YANG Motor Co Ltd First Edition Jun 2005 All rights reserved Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co Ltd is expressly prohibited 4122 LCA4 LLB1 S00 PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCO ATV 150 125 Section 1 contains the precautions for all operations stated 1n this manual Read them carefully before starting any operation Section 2 1s the removal installation procedures for the frame covers which are subject to higher 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 4 through 18 give instructions for disassembly assembly and inspection of engine chassis frame and 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 The information and contents included in this manual may be different from the ATV in case specifications are changed KYMCO reserves the right to make changes at any time without notice and without incurring any obligation KWANG YANG MOTOR CO LTD OVERSEAS SALES DEPARTMENT2. 1 te Ure s L S i zl an fe ne EN ERI Location of Frame Serial Number Location of Engine Serial Number 1 GENERAL INFORMATION SPECIFICATIONS MX er 150 Model No ATV Name Overall length LA30 MX er 150 1600 mm 64 11 e z z CH ei CH 3 pm e lt 3 CH Q 5 C 5 Exhaust Idle speed Lubrication type apacity 980 mm 39 2 in 990 mm 39 6 in 1120 mm 44 8 in OHC 149 4 ce 9 1 cu in 92 nonleaded gasoline 74 kg 162 8 Ibs 78 kg 171 6 Ibs 152 kg 334 4 Ibs 80 kg 176 Ibs 82 kg 180 4 Ibs 162 kg 356 4 Ibs 22 10 8 130 mm 5 2 in 20 6 below in 3 Starting system Starting motor Gasoline 4 stroke Single cylinder Semi sphere H C chain drive 2 48 x1 98 in 9 7 1 Compression pressure 1600 kPa 16 kg cm 5 5 BTDC 27 5 ABDC 36 BBDC 4 ATDC 0 06 mm 0 0024 in 0 06 mm 0 0024 in 1700 rpm Forced pressure amp wet sump Oil pump type _ 1 Oil filter type Full flow filtration 1 liter 0 88 Imp qt 1 06 US qt Oil exchanging 1 0 9 liter 0 79 Imp qt C Cooling Type ir cooling ee rh E 5 elz 9 5 O10 4 UOHEOLIQN J S go e lt K Un a T dO KYMCO ATV 150 125 Air cleaner type amp No 8 1 liters 1 7 Imp gal 2 11 Usgal 14 8 mm 0 592 in 025 mm 61 in PISTON Fuel capa
3. GENERAL INFORMATION 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 Engine Oil lubrication Apply grease for lubrication Transmission Gear Oil 907 Gear Oil Note Warning dO KYMCO ATV 150 125 1 12 dO KYMCO 1 GENERAL INFORMATION ATV 150 125 TORQUE VALUES STANDARD TORQUE VALUES jm lorque iem Torque kgf m N m lbf ft kgf m N m Ibf ft 5mm bolt and nut 0 5 5 3 6 4mm screw 0 3 3 2 2 6mm bolt and nut 1 10 7 2 5mm screw 0 4 4 2 9 8mm bolt and nut 2 2 22 16 6mm screw SH bolt 0 9 9 6 5 10mm bolt and nut 3 5 35 25 6mm flange bolt and nut 1 2 12 9 12mm bolt and nut 5 5 55 40 8mm flange bolt and nut 2 1 27 20 14mm bolt and nut 7 70 50 10mm flange bolt and nut 4 40 29 Torque specifications listed below are for important fasteners ENGINE Thread dia Torque R k 8 Stud bolt 0 9 9 6 5 Oil filter screen cap 1 5 15 11 Seat ball stopper bolt 4 8 48 35 L cover 1 2 12 8 6 Cam holder 2 20 14 Tappet ADJ nut 0 9 9 6 5 Pivot tensioner 1 10 7 Lifter tensioner 1 2 12 8 6 Lifter tensioner 0 4 4 2 9 Right crankcase bolt 1 10 7 Driver face 6 60 43 Apply oil Clutch outer 5 5 55 40 Balancer shaft nut 4 5 45 32 Left threaded Start clutch nut 9 5 95 68 Apply oil
4. Left threaded ACG flywheel 5 5 55 40 Spark plug 1 5 15 11 Drain bolt mission 1 10 7 Drain plug 2 5 25 18 Motor srart 1 10 7 Oil pump 1 10 7 Oil pump sprocket 1 10 7 Head CYL bolt 1 10 7 Drive plate nut 5 5 55 40 Stator 1 10 7 N N RRR RR Wi AN D BOR 1 13 1 GENERAL INFORMATION ENGINE Cont d Thread dia eT Guide star change handle Sprocket drive plate Carburetor Transmission oil check bolt FRAME dO KYMCO ATV 150 125 lorque R k 1 10 7 1 10 7 1 10 7 1 10 7 1 10 7 1 10 7 1 2 12 9 dia Torque R k Steering stem nut Swing arm nut Rear wheel nut Front wheel nut Rear shock absorber upper mount bolt Front shock absorber upper mount bolt Front shock absorber lower mount bolt Rear fork axle Rear hub nut Rear wheel shaft nut Rear engine bracket up bolt Rear engine bracket bolt Engine hanger bracket bolt Exhaust muffler lock bolt D ka ra N BR N NY ra FA NV E 7 70 50 4 5 45 32 7 70 50 7 70 50 4 40 29 4 40 29 4 40 29 7 70 50 7 70 50 12 120 86 4 40 29 4 40 29 4 40 29 3 5 35 25 1 14 dO KYMCO 1 GENERAL INFORMATION ATV 150 125 SPECIAL TOOLS Flywheel puller Flywheel removal Lock nut wrench Start clutch nut removal installation Lock nut wrench Balancer gear nut removal installation Valve adjuster Valve
5. D o o D D o 5 5 REG PULSER SPARK PLUG STOP SW HORN SW WINKER SW f STARTER SW DIMMER SW L YA HORN RHFRWINKER ENGINE HAZARD SW DIMMER SW START SW WINKER SW COMB SW ONT OO OO rus OHO e Jen JR j eeren GR GRAY se S Y cue BLUE LG LIGHT GREEN v le dO KYMCO 1 GENERAL INFORMATION ATV 150 125 MX er 150 125 OFF ROAD sso AAE LAE 107 an Astor LH ANE AE I LO Td TM i MS E NLEHENX 1 HILLS HOLS sHION MS SOAS AMI VS 1109 NE ACI LEE Sy 1 29 1 30 150 125 av d or o 1 EU E EHI imn _ HORN SW START SW GROUNG MARKING CS BLACK e Y YELLOW 0 RIGHT HEAD LIGHT 12V35W 35W BATTERY 12V8AH 3 ACG L BLUE ih S TOI STARTER MOTOR 03 REGULATORIRECTIFIER 0 ORANGE Ca FUEL UNIT 13 RIGHT REAR TURN SIGNAL HORN SWITCH G GREEN lt RIGHT FRONT TURN SIGNAL LIGHT 12V10W WINKER SWITCH LIGHT 12V10W STARTER SWITCH R RED TAILLIGHT 12V5W DIMMER SWITCH e x 4 FRONT STOP SWITCH STOP LIGHT 12V21W HAZARD SWITCH HAZARD UNIT LEFT REAR TURN SIGNAL P PINK 5 49 26 REAR STOP SWITCH pi
6. OVERSEAS SERVICE SECTION TABLE OF CONTENTS Ej Z t Z Tj gt Q 2 rj ENGINE REMOVAL INSTALLATION DRIVE AND DRIVEN PULLEYS INS lt lt decia d coe 222 C sl e 5 1 B Mar ei r mioiz u m L Z gt J gt Oj Z 2 gt gt lt lt SS Ce 2 FINAL REDUCTION TRANSMISSION HNIDONH Un lt Un ei ve gt gt Z S T Nn as gt wi WHEEL FRONT BRAKE FRONT SUSPENSION STEERING SYSTEM SISSVHO lt gt v JE EE L un 26 Ge UJ gt we s a gt T 2 Z e lt 72 gt rri lt gt IVOTISELLOH IA GENERATOR GNITION SYSTEM TARTING SYSTEM IGHTS SWITCHES LNHINdICYOH Un 6 n CRANKCASE CRANKSHAFT 3 5 I 2 T dO KYMCO 1 GENERAL INFORMATION ATV 150 125 GENERAL INFORMATION 1 1 SPECIEICATIONS 1 2 SERVICE PRECAUTIONS 1 5 TORODE VALUBS 1 13 SPECIAL TOOL meee 1 15 EUBBIC ON PO AA 1 16 CABLE amp HARNESS ROUTING MX er 150 125 1 19 CABLE amp HARNESS ROUTING MXU 150 23 WIKI DA 1 28 AA 1 32 1 0 KYMCO 1 GENERAL INFORMATION ATV 150 125 SERIAL NUMBER al 8 E M pr
7. clearance adjustment Valve spring compressor Cylinder head disassembly assembly Oil seal and bearing install Universal holder Clutch outer nut removal installation Flywheel holder Flywheel nut removal installation Clutch spring compressor Driven pulley clutch removal installation Bearing puller Nut wrench Rear axle nut removal installation 1 15 KYMCO 1 GENERAL INFORMATION ATV 150 125 LUBRICATION POINTS ENGINE Valve guide valve stem movable part eGenuine KYMCO Engine Oil 5 15 40 Cam lobes eAPI SG Engine Oil Valve rocker arm friction surface x Cam chain Cylinder lock bolt and nut Piston surroundings and piston ring grooves Piston pin surroundings See A Cylinder inside wall Connecting rod piston pin hole Connecting rod big end Crankshaft right side oil seal Crankshaft one way clutch movable part Oil pump drive chain Balance gear A C generator Starter one way clutch Bearing movable part O ring face Oil seal lip Transmission gear and movable parts Gear oil SAE90 1 16 GC KYMCO 1 GENERAL INFORMATION 150 125 FRAME The following 15 the lubrication points for the frame Use general purpose grease for parts not listed Apply clean engine oil or grease to cables and movable parts not specified This will avoid abnormal noise and rise the durability of the motorcycle Front Brake Cable Throttle Cable Rear Brake Cable c NY Front Arm Bush St
8. 2 Combustion chamber type FR RR tire rolling 1596 1756 mm eee circumference 63 84 70 24 in 56 5 x 49 5 mm Bore x stroke 2 26 x1 98 in Front DUT a E si 92 1 Tire pressure Comprgssion pressure 1400 kPa 14 kg cm Rear 25 kPa 0 25 kg cm kg cm 198 8 psi 3 55 psi 2757 ABDC 36 BBDC Rear Disk brake Brake system type 4 0 06 mm 0 0024 m Suspension Swing 0 06 mm 0 0024 in 1700 rpm 5 Swing Ile Rear Swingarm wet sump Rear wing arm Inner outer rotor type Steel tube type Full flow filtration 1 liter 0 88 Imp qt 1 06 US qt 0 9 liter 0 79 Imp qt 0 95 US qt Air cooling SUIAOW dO KYMCO 1 GENERAL INFORMATION ATV 150 125 MXU 150 LA30 Air cleaner type amp No 1775 mm 71 in 2 11 Usgal 950 mm 38 in Type PD 1040 mm 41 6 in 1115 mm 44 6 in 175 kg 385 Ibs Spark plug NGK DR 8EA 92 kg 202 4 Ibs Spark plug gap EM 93 kg 204 6 Ibs 0 024 0 028 in e 185 kg 407 Ibs I2V8AH 21 7 I0 Clutch type O O CVT 155 mm 6 2 in system Secondary reduction system 20 6 below tus 35209 Gasoline 4 stroke pecondaty reduction 7 226 Single cylinder ratio Semi sphere 26 902 H C chain drive FR RR tire rolling 1675 1756 mm 62 x 49 5 circumference 67 70 24 in 2 48 x1 98 in a 0 28 kg cm S Tire pressure 3 976 psi 1600 kPa 16 kg Ss Rear 28 0 28 kg cm 227 2 psi 3 976 psi Turni
9. ORMATION ATV 150 125 1 26 KYMCO 1 GENERAL INFORMATION ATV 150 125 starter Relay Negative Battery Cable Starter Motor Cable Change Gear Control Unit eS Positive Battery Cable Fuse Box Battery 1 27 150 125 1 GENERAL INFORMATION WIRING DIAGRAM MX er 150 125 ON ROAD co METER LED 34 TURN R PILO 124 124 TURN L PILOT 1212 REVERSE GEAR PILOT 127 12W HIGH BEAM PILOT 12V 1 2 NEUTRAL PILOT 12V 1 2 L HEAD LIGHT 12V 35W 35W du FR POSITION 12V3W LCD METER HORN SW reel OO cour ve REAR RH FR WINKER GEAR CHANGE SW STOP SW 12V 10W COMB SW n eL He Pm m ON CONTROL S 92 9 Be R 9 2e Lu 58 SB i 4 90 L amp L G 757 H 9 SH2 i Y G o e e UR Lo G 582 582 a E L L L pt Peep 1111 EB 1 GASS GP GIP Clg DIRE 1 BR p Ae po n START MAG 12V 8AH BATTERY STARTER MOTOR SR 5 RH WINKER 12V 10W TAIL STOP LIGHT 12V 5 21W E 5 II LK SR LELLI deg H LH RR WINKER R d d 12V 10W V G L H LGER GRO RL RW E v NA BRGYP p v d IGN COIL 2 Ya WHELL RPM SENSOR NYA o
10. ar Control ee Fuse 1 22 KYMCO 1 GENERAL INFORMATION ATV 150 125 CABLE amp HARNESS ROUTING MXU 150 Hazard Unit Connector Rear Brake Hose Hazard Unit Fp Harness Wire Fuel Valve RPM Sensor Wire Rear Right Turn Signal Headlight Light Connectors Fuel Unit Wire Control Unit ON ROAD Frame Ground Wire d e Front Right Turn signal Light Wire ON ROAD Taillight Wire N omo Rear Brake Light Generator Wire Ignition Coil Change Gear Control Change Gear Switch Wire Unit Connectors starter Motor Cable Engine Ground Cable Rectifier Regulator 1 23 1 GENERAL INFORMATION ATV 150 125 Front Brake Light Switch Wire Front Brake Cables Fuel Tank Breather Hose Throttle Cable A C Generator Connector Rear Brake Cables Handlebar Switch Wire Fuel Hose Rear Brake Light Switch Wire 1 24 1 GENERAL INFORMATION ATV 150 125 Throttle Cable Front Brake Light Switch EN Meter Connector Cr DOG Headlight Turn Signal Light Connectors ON Handlebar Switch Wire ROAD Harness Wire Handlebar Switch Connector Rear Brake Hose Headlight Right Turn Signal Light Wire ON ROAD Front Right Brake Cable N ROAD Ignition Switch Wire Front Left Brake Cable Rear Brake Light Switch Wire 1 25 KYMCO 1l GENERAL INF
11. cem 6 come SWITCH RIGHT FRONT TURN SIGNAL 7 GEAR CHANGE SWITCH WHEEL RPM SENSOR LIGHT 12v10w BR BROWN gt 8 FUSE 20 M 8 CHANGE GEAR CONTROL UNIT 8 HORN LG LIGHT GREEN 7 gt WINKER RELAY IGNITIONGOIL 9 LIGHTING CONTROL UNIT GR GRAY gt lt 6 REAR STOP SWITCH LEFT HEAD LIGHT 12V35W 35WY SB SKY BLUE START RELAY Gi FRONT POSITION LIGHT 12V5W 2 PUSLER 3 METER LED Lem 150 125 dO KYMCO 1 GENERAL INFORMATION MXU 150 OFF ROAD F 1 31 dO KYMCO 1 GENERAL INFORMATION ATV 150 125 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection Adjustment carburetor by E gooo Check if fuel reaches drain screw Fuel reaches carburetor Probable Cause Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float oil passage logged fuel tank cap breather hole Clogged fuel filter logged fuel valve passage Fuel does not reach carburetor Remove spark plug and install it into spark plug cap to test spark by gt connecting 1t to engine Spark jumps Weak or no spark Faulty spark plug Fouled spark plug Faulty CDI unit Faulty change gear control unit Faulty pulser coil Broken or shorted ignition coil Broken or shorted exciter coil Faulty ignition
12. city I 5 BTDC 1700rpm Non contact point type DE 8EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Clutch type 12V8AH Primary reduction system Secondary reduction system 2 8 0 95 7 226 Secondary reduction ratio 26 902 FR RR tire rolling 1596 1756 mm circumference 63 84 70 24 in 2 Front 20 KPa 02 kg cm 2 84 psi Tire pressure Rear 25 kPa 0 25 kg cm 3 55 psi Turning 449 angle 445 Brake system type Disk brake Front Drum brake 0193848 on JO 3 InQ I yuouldinbyY 29113991 W9JS S uous Helical gear spur gear Chain drive 9 6 6 I2M0d SUIAOW Front Swing Rear Swing arm Front Swing Steel tube type dO KYMCO 1 GENERAL INFORMATION ATV 150 125 MX er 125 ELI 425 mm 61 in Wheel base 1120 mm 44 8 in Throttle type PISTON 0938 ony JO 2 InQ I upime Sipo T CDI 124 cc 7 55 cu in Fuel Used 92 nonleaded gasoline 74 kg 162 8 Ibs Dry weight 78 kg 171 6 lbs L5 BTDC 1700rpm Non contact point type ype 16 97 mm Gross weight Sa 20 7 8 22 10 8 Helical gear spur gear system 130 mm 5 2 in Secondary reduction T Chain drive system Breaking distance Perform m ANGI 20 6 below Primary reduction ratio 2 8 0 95 Juswdmba 89119914 9 54 uous 9 6 6 2 5 Secondary reduction 7226 Gasoline 4 stroke ratio Starting motor Cylinder arrangement single cylinder 26 90
13. connected coupler Check CDI unit with a CDI unit tester Faulty CDI unit Faulty change gear control unit Check ignition coil with CDI unit tester Faulty ignition coil
14. eering Column Upper a Front Brake camshaft Oil Seal O ring E Front Brake camshaft Oil Seal O ring we ya e 1 LJ D D 147 ms E S 2 al a LI Front Wheel Oil Seal Steering Column Lower Eroni Wheel Seal Steering knuckle Thrust Steering knuckle Thrust Cover Bush Collar Cover Bush Collar 1 17 KYMCO 1 GENERAL INFORMATION ATV 150 125 Swing arm Thrust Cover Rear Brake Cam Axle Hub Collar Oil Seal Bearing a Sprocket hub Rear Axle Hub Collar Oil Seal Bearing Driven Sprocket 1 18 GQ KYMCO 1 GENERAL INFORMATION ATV 150 125 CABLE amp HARNESS ROUTING MX er 150 125 Rear Brake Cable Throttle Cable D D P AA Handlebar Switch Lead Front Brake Cable Right Front Brake Cable Left Front Brake Cable 1 19 GQ KYMCO 1 GENERAL INFORMATION ATV 150 125 Breather Hose CYL Main Switch Head Cover Inlet Hose weg Ae Sta s a ke V _ EL i p Breather Hose 1 20 GQ KYMCO 1 GENERAL INFORMATION ATV 150 125 Breather Hose Wire Harness Rectifier Regulator Outlet Hose Ignition Coil 1 21 dC KYMCO 1 GENERAL INFORMATION ATV 150 125 A C G Wire Connector MM or X Breather Hose CYL ue Head Cover P Battery Negative Cable Positive Cable Battery starter Relay Change Ge
15. fore 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 KYMCO ATV 150 125 dO KYMCO 1 GENERAL INFORMATION ATV 150 125 B The connector shall be inserted completely TEN X W If the double connector has a lock Lc Snapping lock it at the correct position Check if there 1s any loose wire Before connecting a terminal check X for damaged terminal cover or loose negative terminal Check the double connector cover for proper coverage and installation X B 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 1 8 1 GENERAL INFORMATION After clamping check each wire to make sure it 1 secure Do not squeeze wires against the weld or its clamp B After clamping check each harness to make sure that it 1s not interfering with any moving or sliding parts B When fixing the wire harnesses do not make it contact the parts which will generate high heat Route wire harnesses to avoid sharp edges or corners Avoid the projected ends of bolts and screws Route wire ha
16. fouled or Plug fouled or Fouled spark plug discolored discolored Incorrect heat range plug Remove oil dipstick and yT check oil level and condition Correct and not Incorrect or Wa ep contaminated contaminated l level too low Oil not changed Remove cylinder head oil bolt and inspect Valve train lubricated Valve train not Clogged oil line properly lubricated properly puteo ou ete ie MN m Mixture too lean Engine does not Engine overheats Poor quality fuel overheats Excessive carbon build up in combustion chamber Ignition timing too early Rapidly accelerate or run at high speed Excessive carbon build up in combustion chamber Poor quality fuel lutch slipping Engine does not knock Engine knocks Mixture too lean Ignition timing too early 1 33 dO KYMCO 1 GENERAL INFORMATION ATV 150 125 POOR PERFORMANCE ESPECIALLY AT IDLE AND LOW SPEEDS Inspection Adjustment Probable Cause E S Faulty pulser coil Check carburetor air Screw adjustment ixture too rich turn screw Incorrectly adjusted out ixture too lean turn screw in Correctly adjusted Check carburetor gasket for air leaks R AN SNS X Deteriorated O ring Carburetor not securely tightened Damaged insulator rubber Remove spark plug and install it into spark plug cap to test spark by connecting it to engine ground Good
17. generator coil Resistance too high Broken yellow wire Shorted pink and yellow Connect battery wire wres to regulator rectifier coupler red wire and ba ttery Wire to engine gt ground and test voltage Normal voltage Broken red wire Check regulator rectifier coupler for loose m E wA connection Faulty regulator rectifier Poorly connected couple generator Overcharging Inspection Adjustment Probable Cause Connect battery wire to regulator rectifier 2 ea gt coupler green wire and 5 battery wire to engine ground and test voltage Battery has voltage Battery has no with ignition with ignition Broken green wire switch ON switc Check regulator rectifier coupler for loose connection Faulty regulator rectifier 1 36 dO KYMCO 1 GENERAL INFORMATION ATV 150 125 NO SPARK AT SPARK PLUG Inspection Adjustment Probable Cause Q Replace with a new spark plug and inspect again Check spark plug and high tension wire for looseness Check CDI unit coupler for looseness H gt Good Good Poorly connected coupler Measure resistance between terminals of gt CDI unit coupler Faulty ignition switch Weak battery Faulty pulser coil Faulty 1gnition coil Faulty charging system Broken wire harness Poorly
18. lts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally Use genuine parts and lubricants B When servicing the motorcycle be sure to use special tools for removal and installation B After disassembly clean removed parts Lubricate sliding surfaces with engine oil before reassembly 1 5 KYMCO ATV 150 125 dO KYMCO 1 GENERAL INFORMATION ATV 150 125 Apply or add designated greases and lubricants to the specified lubrication points B After reassembly check all parts for proper tightening and operation B When two persons work together pay attention to the mutual working safety Disconnect the battery negative terminal before operation B When using a spanner or other tools make sure not to damage the motorcycle surface B After operation check all connecting points fasteners and lines for proper connection and installation B When connecting the battery the positive terminal must be connected first B After connection apply grease to the battery terminals B Terminal caps shall be installed securely 1 6 1 GENERAL INFORMATION B If the fuse is burned out find the cause repair it Replace it with new according to the specified capacity After operation terminal caps shall be installed securely B When taking out the connector the lock on the connector shall be released be
19. ng 27 55 ABDC angle 40 36 0193845 on I0joJnqe SS ngine type 149 cc 9 1 cu in 92 nonleaded gasoline Front whee 87 kg 191 4 Ibs 88 kg 193 6 Ibs 511215151512 m 5 5 8 geg FE E gt lala 5 lel lo SEE et 25 Fuel Used Juswdmba 89119914 9 54 uous 2 z lt 2 CH ga a my C cu e Co C gt e Breaking distance m ANSI Min turning radius m Starting system Cylinder arrangement Combustion chamber type Valve arrangement Bore x stroke Compression ratio SUIAOW Compression pressure lt 5 4 ATDC 06 mm 0 in Valve clearance Exhaust 0 06 mm 0 0024 in Idle speed 1700 rpm S Sw NYA Forced pressure amp Z Wing Poet sump Oil filter type Gett C anne j 202900 3 Samen 2 F Perform opze 3 C 2 Gees suoke bric Inner outer rotor type Steel tube pipe Full flow filtration liter 0 88 Imp qt Oil capacity 1 06 US qt Oil exchanging 0 9 liter 0 79 Imp qt capacit 0 95 US qt Cooling Type Air cooling uon oLiqnT 1 GENERAL INFORMATION SERVICE PRECAUTIONS Make sure to install new gaskets O rings circlips cotter pins etc when reassembling B When tightening bo
20. rnesses passing through the side of bolts and screws Avoid the projected ends of bolts and screws 1 9 KYMCO 150 125 e o Contact dO KYMCO 1 GENERAL INFORMATION ATV 150 125 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 B When rubber protecting cover 15 used to protect the wire harnesses it shall be installed securely B Do not break the sheath of wire B wire or harness is with a broken sheath repair by wrapping it with protective tape or replace it B When installing other parts do not press or squeeze the wires Do not pres Or Squeeze the wire 1 10 KYMCO 1 GENERAL INFORMATION ATV 150 125 B After routing check that the wire harnesses are not twisted or kinked B 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 1s used make sure to understand the operating methods thoroughly and operate according to the operating instructions Do you understand the instrument Is the instrument set correctly Be careful not to drop any parts B When rust 1s found on a terminal remove the rust with sand paper or equivalent before connecting 1 11 1
21. spark p M M gt Faulty or fouled spark plug Faulty CDI unit Weak or inter A C mittent spark Faulty ignition coil Broken or shorted spark plug wire Faulty ignition switch 1 34 dO KYMCO 1 GENERAL INFORMATION ATV 150 125 POOR PERFORMANCE AT HIGH SPEED Inspection Adjustment Probable Cause DEEE AAA Check ignition timing M aulty CDI unit Faulty pulser coil Improperly adjusted valve clearance Worn valve seat KAA AAA AAA AAA AAA AAA AAA AAA Check fuel pump for fuel supply 0 d Empty fuel tank Clogged fuel tube or filter Fuel flows freely Fuel flow restricted Clogged Fuel tank cap breather Check carburetor jets hole for clogging X H Not clogged Clogged Clean and unclog Check valve timing sss not aligne Check valve spring tension Weak spring Faulty spring 1 35 dO KYMCO 1 GENERAL INFORMATION ATV 150 125 POOR CHARGING BATTERY OVER DISCHARGING OR OVERCHARGING Undercharging Inspection Adjustment Probable Cause D Start engine and test limit VO tage loose terminals Normal voltage Voltage does not Dead battery increase Faulty battery Measure resistance between AC generator gt coil terminals Faulty A C
22. switch Weak or dead battery ground fes einda Q compression e Faulty starter clutch Valve clearance too small Valve stuck open compression compression rings Leaking cylinder head gasket ing normal starting A gt procedure Air leaking through intake pipe Engine does not Engine fires but Leaking intake manifold fire does not start Incorrect ignition timing Incorrectly adjusted air screw Remove spark plug and inspect again Dry spark plug Flooded carburetor Clogged air cleaner Throttle valve excessively open Wet spark plug 1 32 dO KYMCO 1 GENERAL INFORMATION ATV 150 125 ENGINE LACKS POWER Probable Cause Clogged air cleaner Engine speed does not Restricted fuel flow increase sufficiently Clogged fuel tank cap breather hole Clogged exhaust muffler Carburetor fuel level too low Start engine and accelerate lightly for observation Engine speed increases using a timing light Faulty CDI unit Faulty pulser coil o Improper valve clearance Excessively worn valve seat protruded valve stem Improper valve and seat contact Normal Abnormal Worn cylinder and piston rings compression compression Leaking cylinder head gasket Improper valve timing Check carburetor for clogging Not clogged Clean and unclog Remove spark plug and Inspect Plug not
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