KYMCO SR25BA - Cable & Harness Routing

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1. GENERAL INFORMATION Movie S 125i

1-15

CABLE & HARNESS ROUTING

Brake Fluid Reservoi

Rear Brake Cable

Regulator/Rectifie

Tilt Switch

Seat Lock Cable

Fuel Filler Cap

Lock Cable

Separator Breathe

Hose

Horn

Wink Relay

Ignition Switch

Front Brake Hose

Main Page

Table of Contents2
Location of Frame Serial Number3
General Information3
Location of Engine Serial Number3
Engine/Frame Serial Number3
Specifications4
Service Precautions5
Symbols12
Torque Values13
Standard Torque Values13
Engine13
Frame14
Special Tools14
Lubrication Points15
Cable & Harness Routing18
Wiring Diagram23
Troubleshooting24
Engine will Not Start or Is Hard to Start24
Engine Lacks Power25
Poor Performance at Low and Idle Speed27
Poor Performance at High Speed28
Poor Handling28
Exhaust Muffler/Frame Cover29
Service Information29
Noisy Exhaust Muffler29
Lack of Power29
Frame Cover30
Right/Left Side Skirt Removal30
Rear Career Removal30
Luggage Box Removal30
Front Cover Removal31
Front Bottom Cover Removal31
Front Center Cover Remoavl31
Rear Fender & Taillight Len Removal31
Rear Handlebar Cover Removal32
Front Handlebar Cover Removal32
Floorboard Removal32
Inner Leg Shield Removal33
Under Cover Removal33
Exhaust Muffler33
Front Fender33
Inspection/Adjustment34
Engine Oil Capacity34
Gear Oil Capacity34
Special Tool35
Tire Size35
Tire Pressure35
Maintenance Schedule36
Throttle Operation37
Air Cleaner38
Air Filter Replacement38
Maintain Interval38
Spark Plug38
Valve Clearance39
Cylinder Compression39
Final Reduction Gear Oil40
Gear Oil Change40
Drive Belt40
Brake Fluid41
Brake Disk/Brake Pad41
Brake Lever41
Brake System41
Headlight Aim42
Clutch Shoe Wear42
Suspension42
Front42
Nuts/Bolts/Fasteners43
Wheels/Tires43
Steering Handlebar43
Lubrication System44
Oil Level too Low45
Poor Lubrication Pressure45
Oil Change46
Oil Capacity46
Oil Level46
Engine Oil/Oil Filter46
Oil Pump47
Table of Contents52
Injection System52
System Diagram53
Fi INJECTION SYSTEM53
Parts Drawing54
General Instructions55
Service Information55
- Engine Won’t Start56
- Engine Stall, Hard to Start, Rough Idling56
- Backfiring or Misfiring During Acceleration56
- Poor Performance (Drive Ability) and Poor Fuel Economy56
Troubleshooting56
Check Engine Lamp (Celp)57
How to Show the Failure Code58
- DTC Code List59
- Function and Structure63
- Disassembly of ECU Module63
Synerject M3A Ecu Module63
- ECU Module Replacement64
- Ecu Moudle65
- Ecu Module Coupler66
To Initial Tps and Abv67
- Ecu Adapt the New Thottle Position Voltage68
- Inspection or Re-Adjustment of the Output Voltage of Throttle68
- Fuel Pump69
- T-MAP Sensor69
- TPS (Throttle Position Sensor)70
- Engine Temperature Sensor70
- Inspection70
- Injector71
- FI Fuel Injector Cleaning Method72
O2 Sensor73
Roll Sensor74
The Ignition Switch Is Turned on75
TPI and ABV Initialization75
- Fi Diagnostic Tool Operation Instructions77
- Dtc Inspection Procedure78
- Dtc Clear Procedure81
- Data Analysis82
- Engine Removal/Installation86
- Engine Hanger Bracket Installation89
- Engine Installation89
- Cylinder Head/Valves90
- Abnormal Noise92
- Compression too High92
- Compression too Low92
- Poor Performance at Idle Speed92
- Camshaft Removal93
- Camshaft Holder Disassembly95
- Camshaft Inspection95
- Cylinder Head Removal96
- Cylinder Head Disassembly97
- Cylinder Head Inspection98
- Valve Spring98
- Valve/Valve Guide98
- Cylinder Head Assembly99
- Cylinder Head Installation99
- Camshaft Holder100
- Camshaft Installation100
- Cylinder/Piston101
- Abnormal Noisy Piston102
- Compression too Low or Uneven Compression102
- Cylinder Removal103
- Piston Removal103
- Cylinder Inspection105
- Piston Ring Installation106
- Cylinder Installation107
- Piston Installation107
- Final Reduction109
- Engine Starts but Motorcycle Won't Move110
- Final Reduction Disassembly111
- Final Reduction Inspection111
- Bearing Replacement112
- Transmission Case Cover112
- Final Reduction Assembly113
- Left Crankcase113
- Crnakcase/Crankshaft116
- Excessive Engine Noise117
- Crankcase Separation118
- Crankshaft Inspection119
- Crankcase Assembly120
- Front Wheel/Brake/Suspension122
- Front Wheel/Brake/Suspension124
- Service Information124
  - Front Wheel Wobbling125
  - Hard Steering (Heavy)125
  - Poor Brake Performance125
  - Steers to One Side or Does Not Track Straight125
- Troubleshooting125
- Front Wheel126
- Bearing Inspection127
- Bearing Replacement127
  - Brake Fluid Bleeding130
  - Brake Fluid Refilling130
  - Brake Pad/Disk Replacement130
- Hydraulic Brake130
- Brake Disk131
- Front Suspension132
- Steering Handlebar135
  - Ball Race Replacement136
  - Bottom Cone Race Replacement136
- Steering Stem136
  - Bottom Cone Race Installation137
  - Handlebar Installation138
  - Rear Wheel/Rear Brake/Rear Suspension139
  - Rear Wheel Wobbling140
  - Soft Rear Shock Absorber140
  - Rear Brkae141
  - Rear Wheel141
  - Brake Lining Inspection142
  - Rear Brake Assembly142
  - Rear Brake Disassembly142
  - Rear Shock Absorber Removal143
  - Battery145
  - Charging System Diagram145
  - Charging System Failure147
  - Intermittent Power147
  - Low Power147
  - No Power147
  - Battery Charging148
  - Battery Removal148
  - Battery Voltage Inspection148
  - Charging Performance149
  - Charging System149
  - Resistance149
  - Performance Test150
  - Regulator/Rectifier150
  - A.C. Generator151
  - Ignition System155
- Ignition System Layout156
- Ignition Circuit157
  - Low Peak Voltage158
  - No Peak Voltage158
  - Peak Voltage Is Normal, but no Spark Jumps at the Plug158
- Service Information158
- Troubleshooting158
- Ac Generator159
- Ignition Coil159
  - Modes of Trouble160
  - Tilt Switch160
  - Tilt Switch Removal161
  - Voltage Measure161
  - Starting System162
  - Starter Motor Won't Turn163
  - Performance Inspection164
  - Starter Motor Removal164
  - Starter Relay164
  - Volt Inspection164
  - Starter Clutch Removal165
  - Starter Relay Ground Circuit Inspection165
  - Clutch Body Disassembly166
  - Starter Clutch Disassembly166
  - Light/Instrument/Switch169
  - Fuel Gauge Pointer Does Not Register Correctly170
  - Fuel Gauge Pointer Fluctuates or Swing170
  - Light Dims170
  - Bulb Replacement171
  - Headlamp171
  - Taillamp/Brake Lamp/Rear Winker Lamp171
  - Engine Stop Switch172
  - Headlight Switch172
  - Ignition Switch172
  - Dimmer/Passing Switch173
  - Horn Switch173
  - Starter Switch173
  - Turn Signal Switch173
  - Fuel Gauge174
  - Fuel Unit174
  - Horn174
  - Stop Switch174
  - Speedometer175
  - Speedometer Replacement175
  - Evaporative / Emission Control System178
- Schematic Drawing178
  - Engine Idles or Accelerates Roughly179
  - Engine Loses Power or Runs Erratic at Idle Speed179
  - Evaporative Emission Control System Function179
- Evaporative Control System180
- Service Information180
  - Purge Control Valve181
  - P.C.V. (Crankcase Blow By)182
  - Purge Control Valve Flow Inspection182
- Charcoal Canister183
- Emission Control System184
  - Backfiring at Sudden Deceleration185
  - Exhaust Muffler Noise185
  - High CO at Idle Speed185
- Troubleshooting185
- Secondary Air Cleaner / A.I.C.V186
- Reed Valve187
- Fi Diagnostic Tool188
- DTC Inspection190
- DTC Clear193

KYMCO SR25BA - Cable & Harness Routing

Table of Contents

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