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KYMCO MOVIE 125 User Manual

KYMCO MOVIE 125
213 pages
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PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO MOVIE
125.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before starting any
operation.
Section 2 is 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 19 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.
KWANG YANG MOTOR CO., LTD.
OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
TABLE OF CONTENTS
GENERAL INFORMATION
1
FRAME COVERS/EXHAUST MUFFLER
2
INSPECTION/ADJUSTMENT
3
LUBRICATION SYSTEM
4
FUEL SYSTEM
5
ENGINE REMOVAL/INSTALLATION
6
CYLINDER HEAD/VALVES
7
CYLINDER/PISTON
8
DRIVE AND DRIVEN PULLEYS/KICK
STARTER
9
FINAL REDUCTION
10
CRANKCASE/CRANKSHAFT
11
FRONT WHEEL/FRONT BRAKE/
FRONT SUSPENSION
12
REAR WHEEL /REAR BRAKE /REAR
SUSPENSION
13
BATTERY/CHARGING SYSTEM/A.C.
GENERATOR
14
IGNITION SYSTEM
15
STARTING SYSTEM
16
LIGHTS/ INSTRUMENTS/SWITCHES
17
EVAPORATIVE EMISSION CONTROL
SYSTEM
18
EXHAUST EMISSION CONTROL
SYSTEM
19
The information and contents
included in this manual may be
different from the motorcycle in case
specifications are changed.
CHASSIS
CONTROEQUIPMENT
ENGINE

Table of Contents

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KYMCO MOVIE 125 Specifications

General IconGeneral
Displacement124.6 cc
Fuel SystemCarburetor
Front SuspensionTelescopic Fork
Front BrakeDisc
Rear BrakeDrum
Cooling SystemAir-cooled
TransmissionCVT Automatic

Summary

1. General Information

Specifications

Technical specifications for the motorcycle model.

Service Precautions

Important safety and handling precautions for servicing.

Wiring Diagram

Electrical schematic diagram showing component connections.

Troubleshooting

Guides for diagnosing and resolving common engine starting and running issues.

3. Inspection/Adjustment

Maintenance Schedule

Periodic maintenance schedule based on mileage.

Carburetor Idle Speed

Adjusting idle speed and checking for erratic engine operation.

Ignition Timing

Checking ignition timing with a timing light.

Brake System

Procedures for inspecting and adjusting front and rear brakes.

4. Lubrication System

Engine Oil/Oil Filter

Procedures for checking and changing engine oil and filter.

5. Fuel System

Carburetor Removal

Steps for removing the carburetor assembly.

6. Engine Removal/Installation

Engine Removal

Step-by-step procedure for removing the engine.

Engine Installation

Step-by-step procedure for installing the engine.

7. Cylinder Head/Valves

Valve Clearance

Inspecting and adjusting valve clearance.

Valve Seat Inspection & Refacing

Inspecting and refacing valve seats.

8. Cylinder/Piston

9. Drive and Driven Pulleys/Kick Starter

11. Crankcase/Crankshaft

12. Front Wheel/Front Brake/Front Suspension

Hydraulic Brake (Front Brake)

Procedures for brake fluid replacement and air bleeding.

Brake Caliper (Front)

Removal, disassembly, and assembly of the front brake caliper.

13. Rear Wheel/Rear Brake/Rear Suspension

14. Battery/Charging System/A.C. Generator

15. Ignition System

16. Starting System

17. Lights/Instruments/Switches

18. Evaporative Emission Control System

Exhaust Emission Test and Adjustment

Performing exhaust emission tests and adjustments.

19. Exhaust Emission Control System

Troubleshooting

Troubleshooting common exhaust emission control issues.

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