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KYMCO X -Town 125 ABS User Manual

KYMCO X -Town 125 ABS
272 pages
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X -Town 125 ABS/ CBS
PREFACE
This Service Manual describes the
technical features and servicing
procedures for the KYMCO X-Town
125 ABS/ CBS.
Section 1 contains the precautions for
all operations stated in this manual.
Read them carefully before any
operation is started.
Section 2 is the removal/installation
procedures for the frame covers
which are subject to
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 5 to 12 give instructions for
disassembly, assembly and
adjustment of engine parts. Section
13 is the AFI system. Section 14 to 15
is the removal/ installation of chassis.
Section 16 to 19 states the testing
and measuring methods 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
CYLINDER HEAD/VALVES
6
CYLINDER/PISTON
7
DRIVE AND DRIVEN PULLEYS
8
FINAL REDUCTION
9
A.C. GENERATOR/STARTER
CLUTCH
10
CRANKCASE/CRANKSHAFT
11
COOLING SYSTEM
12
Fi DIAGNOSTIC TOOL OPERATION
13
FUEL INJECTION SYSTEM
14
HANDLEBAR/FRONTWHEEL/
FRONT BRAKE/FRONT SHOCK
ABSORBER/ STEERING STEM
15
REAR BRAKE/REAR FORK/REAR
WHEEL/REAR SHOCK ABSORBER`
16
BATTERY/CHARGING SYSTEM
17
IGNITION SYSTEM
18
STARTING SYSTEM
19
LIGHTS/METERS/SWITCHES
20
ABS SYSTEM
21
The information and contents
included in this manual may be
different from the motorcycle in
case specifications are changed.
CHASSIS
ELECTRICAL
EQUIPMENT
ENGINE

Table of Contents

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KYMCO X -Town 125 ABS Specifications

General IconGeneral
Displacement124.6 cc
Fuel SystemElectronic Fuel Injection
Brakes FrontDisc
Brakes RearDisc
Front Tyre120/70-14
StarterElectric
TransmissionCVT

Summary

1. General Information

Engine Serial Number

Details on locating the engine serial number for identification.

Specifications

Key technical specifications and data for the X-Town 125 ABS/CBS model.

Service Precautions

Important safety and procedural guidelines for servicing the motorcycle.

Torque Values

Specific torque specifications for critical fasteners across engine and frame.

Special Tools

Listing of specialized tools required for various maintenance procedures.

Lubrication Points

Identifies specific points requiring lubrication and the recommended lubricants.

Troubleshooting

Guides for diagnosing and resolving common operational issues and faults.

2. Exhaust Muffler/Frame Covers

Service Information

General operational and safety advice specific to exhaust and frame covers.

Troubleshooting

Fault diagnosis for issues related to exhaust and frame covers, like noise or power loss.

Frame Covers Removal/Installation

Step-by-step guide for removing and reinstalling various body and frame covers.

Exhaust Muffler

Detailed instructions for the removal and installation of the exhaust muffler.

3. Inspection/Adjustment

Maintenance Schedule

Recommended service intervals and tasks based on mileage or time for upkeep.

Engine Oil

Procedures for checking, replacing, and managing engine oil, including capacity and type.

Spark Plug

Instructions for inspecting, cleaning, and replacing the spark plug and checking its gap.

Valve Clearance

Steps for measuring and adjusting valve clearance to ensure proper engine operation.

Brake Fluid

Guidelines for checking brake fluid level and condition, and fluid replacement procedures.

Suspension

Inspection of front and rear shock absorbers and adjustment of rear suspension preload.

4. Lubrication System

Troubleshooting

Diagnosing and resolving issues like low lubrication pressure or oil contamination.

Oil Pump

Procedures for the removal, installation, disassembly, and assembly of the oil pump.

5. Engine Removal/Installation

Engine Removal/Installation

Detailed step-by-step process for removing and reinstalling the engine.

Engine Hanger

Procedures for removing and installing the engine hanger and its associated components.

6. Cylinder Head/Valves

Troubleshooting

Diagnosing common problems related to the cylinder head and valves, like poor performance or noise.

Cylinder Head Cover

Instructions for removing and installing the cylinder head cover and its gasket.

Camshaft Holder

Procedures for removing, installing, and inspecting the camshaft holder.

Camshaft

Steps for removing, inspecting, and installing the camshaft and its associated parts.

Cylinder Head

Inspection and assembly procedures for the cylinder head, including valves and springs.

7. Cylinder/Piston

Troubleshooting

Common issues like low compression or excessive smoke and their potential causes.

Cylinder and Piston

Detailed procedures for removing and inspecting the cylinder and piston components.

Piston Ring

Inspection and installation of piston rings, including ring-groove and end gap measurements.

8. Drive and Driven Pulleys

Troubleshooting

Diagnosing problems like lack of power or engine stalls related to the pulley system.

Left Crankcase Cover

Procedures for removing and installing the left crankcase cover to access the pulleys.

Drive Pulley, Drive Belt and Driven Pulley

Comprehensive guide on removing, inspecting, and installing the drive pulley, belt, and driven pulley.

9. Final Reduction

Troubleshooting

Diagnosing issues like damaged transmission or abnormal noise in the final reduction gears.

Final Reduction

Step-by-step procedure for removing and disassembling the final reduction gears.

Bearing Replacement

Instructions for replacing bearings in the transmission case cover and transmission case.

10. A.C. Generator/Starter Clutch

Troubleshooting

Diagnosing problems like no start or starter motor issues related to the AC generator and starter clutch.

Alternator Stator

Procedures for removing, inspecting, and installing the alternator stator.

Starter Clutch

Steps for removing, inspecting, and installing the starter clutch assembly.

11. Crankcase/Crankshaft

Troubleshooting

Diagnosing excessive engine noise related to crankcase or crankshaft issues.

Crankcase Separation

Detailed process for separating the crankcase halves to access the crankshaft.

Crankcase Assembly

Steps for cleaning, installing seals, and assembling the crankcase.

12. Cooling System

Troubleshooting

Diagnosing engine overheating and coolant leak issues.

Coolant Replacement

Steps for replacing coolant, including draining, filling, and air bleeding the system.

Water Temperature Sensor

Steps for removing, inspecting, and installing the water temperature sensor.

Thermostat

Procedures for removing, inspecting, and installing the engine thermostat.

13. Fi Diagnostic Tool Operation

DTC Inspection Procedure

Guide on connecting the diagnostic tool and inspecting Diagnostic Trouble Codes (DTCs).

DTC Clear Procedure

Steps to clear Diagnostic Trouble Codes (DTCs) from the system memory.

Data Analysis

Instructions for analyzing engine data parameters using the diagnostic tool.

Diagnostic Standard Specifications

Table of standard specifications for various parameters checked via diagnostic tool.

14. Fuel System (Auto Control Fuel Injection System)

Troubleshooting

Common faults and potential causes for fuel system issues like starting problems or poor performance.

Check Engine Lamp (CELP)

Explanation of the Check Engine Lamp (CELP) operation and fault priority grades.

CELP Failure Code Chart

List of CELP blink codes, fault descriptions, priority, and fault management steps.

Fuel Pump

Procedures for removing, inspecting, and testing the fuel pump assembly.

15. Handlebar/Front Wheel/Front Brake/Front Shock Absorber/Steering Stem

Troubleshooting

Diagnosing issues like hard steering, wheel wobble, or poor brake performance.

Handlebar

Step-by-step instructions for removing and installing the handlebar assembly.

Front Wheel

Procedures for removing, installing, and servicing the front wheel and its bearings.

Front Brake Fluid

Guidelines for replacing brake fluid and bleeding the hydraulic system to remove air.

Front Brake Pad

Instructions for replacing the front brake pads and ensuring proper installation.

Steering Stem

Steps for removing, inspecting, and installing the steering stem and its bearing components.

16. Rear Assembly

Troubleshooting

Diagnosing issues like rear wheel wobble, soft suspension, or poor brake performance.

Rear Brake

Procedures for caliper removal, inspection, disassembly, assembly, and installation of the rear brake.

Rear Wheel

Steps for removing, inspecting, and installing the rear wheel.

Rear Shock Absorber

Procedures for removing, installing, and adjusting the rear shock absorbers.

17. Battery/Charging System

Troubleshooting

Diagnosing power loss or charging system failure issues.

Battery

Steps for removing and installing the motorcycle battery.

Charging Voltage Inspection

Method for measuring charging system voltage to ensure proper battery charging.

18. Ignition System

Troubleshooting

Diagnosing ignition system faults like low peak voltage, no peak voltage, or no spark.

Ignition Coil Inspection

Procedure for testing the primary peak voltage of the ignition coil.

Ignition Pulse Generator Inspection

Method for measuring the resistance of the ignition pulse generator.

19. Starting System

Troubleshooting

Diagnosing issues like starter motor not working or lack of power.

Starter Motor

Procedures for inspecting, removing, and installing the starter motor.

Starter Relay Inspection

Steps for testing the starter relay to ensure proper operation.

20. Lights/Meters/Switches

Bulb Replacement

Instructions for replacing bulbs in various lighting components like position lights, headlights, and turn signals.

Brake Light Switch

Inspection procedure for the brake light switch continuity.

Ignition Switch

Inspection of the ignition switch continuity based on color code wires.

Handlebar Switch

Inspection of right and left handlebar switch continuity.

Fuel Pump

Procedures for removing, inspecting, and testing the fuel pump assembly.

Side Stand Switch

Inspection and testing of the side stand switch continuity.

21. Anti-lock Brake System (ABS)

ABS Indicator Light

Information on the function and behavior of the ABS indicator light in the meter.

ABS Introduction

Overview of the ABS system's purpose, function, and characteristics.

Wheel Sensor

Procedures for removing, inspecting, and installing the front and rear wheel speed sensors.

ABS ECU & ABS Hydraulic Unit

Steps for disconnecting and removing the ABS ECU and hydraulic unit.

Diagnostic Tool Operation

Guide on using the diagnostic tool to inspect and analyze ABS system data and DTCs.

Bosch ABS8m DTC List

List of Bosch ABS8m Diagnostic Trouble Codes (DTCs) with descriptions and fault management.

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