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

CONTRO

EQUIPMENT

ENGINE

1. GENERAL INFORMATION

1-1

Location of Engine Serial Number

1

ENGINE SERIAL NUMBER

ENGINE SERIAL NUMBER ...................1- 1

LUBRICATION POINTS......................1-13

SPECIFICATIONS .................................1- 2

CABLE & HARNESS ROUTING.........1-15

SERVICE PRECAUTIONS.....................1- 3

WIRING DIAGRAM...............................1-20

TORQUE VALUES..................................1-11

TROUBLESHOOTING.........................1-21

TOOLS.....................................................1-12

1. GENERAL INFORMATION

1-2

SPECIFICATIONS

Name & Model No.

SD25AA

Motorcycle Name & Type

Overall length (mm)

1820

Overall width (mm)

685

Overall height (mm)

1095

Wheel base (mm)

1215

Engine type

O.H.C.

Displacement (cc)

124

Fuel Used

92# nonleaded gasoline

Front wheel

38.5

Net weight (kg)

Rear wheel

63.5

Total

102.0

Front wheel

67.5

Gross weight(kg)

Rear wheel

158.0

Total

225.5

Front wheel

100-90-10

Rear wheel

100-90-10

Ground clearance (mm)

123

Perform

-

Braking distance (m)

13 (Initial speed

20km/h 1 rider)

ance

Min. turning radius (m)

1.866

Starting system

Starting motor &

kick starter

Type

Gasoline, 4-stroke

Cylinder arrangement

Single cylinder

Combustion chamber type

Semi-sphere

Valve arrangement

O.H.C., chain drive

Bore x stroke (mm)

52.4 x 57.8

Compression ratio

9.2:1

Compression pressure

(kg/cm≤-rpm)

12.8-570

Max. output (ps/rpm)

9.34/7500

Max. torque (kg m/rpm)

1.01/5500

Intake

Open

0° BTDC

Port

(1mm)

Close

25° ABDC

timin

g

Exhaust

Open

33° BBDC

(1mm)

Close

0° TDC

Valve clearance ^Intake

0.12

(cold) (mm)

Exhaust

0.12

Idle speed (rpm)

1700rpm

Lubrication type

Forced pressure &

wet sump

Oil pump type

Inner/outer rotor

type

Oil filter type

Full-flow filtration

Oil capacity

0.9 liter

Cooling Type

Forced air cooling

Air cleaner type & No

Paper element, wet

Fuel capacity

7.8 liters

Type

VE45

Piston dia. (mm)

24

Venturi

dia.(mm)

22.1 equivalent

Throttle type

Butterfly type

Type

CDI

Ignition timing

13±3°BTDC/1700rp

Contact breaker

Non-contact point

type

Spark plug

NGK

C6HSA

C7HSA

C8HSA

ND

U20FS-U

U22FS-U

U24FS-U

Spark plug gap

0.6_

0.7mm

Battery Capacity

12V9AH

Clutch Type

Dry multi-disc clutch

Type

Non-stage transmission

Operation

Automatic

centrifugal

type

Type

Two-stage reduction

Reduction 1st

2.8

ratio

2nd

3.076

Front Caster angle

27°

Axle Trail length

80mm

Tire pressure

Front

1.75

(kg/cm≤)

Rear

2.00 (2.25)

Turning

Left

45°

angle

Right

45°

Brake system

Front

Disk brake

type

Rear

Drum brake

Suspension

Front

Telescope

type

Rear

Swing arm

Shock absorber

Front

Telescope

type

Rear

Swing arm

Frame type

Steel pipe

Tires

Engine

System

Fuel System

Carburetor

Electrical

Ignition System

Power Drive System

Transmis-

sion Gear

Reduction

Gear

Moving Device

Damping

Device

1. GENERAL INFORMATION

1-3

SERVICE PRECAUTIONS

n Make sure to install new gaskets, O-rings,

circlips, cotter pins, etc. when

reassembling.

n When tightening bolts or nuts, begin with

larger-diameter to smaller ones at several

times, and tighten to the specified torque

diagonally.

n Use genuine parts and lubricants.

n When servicing the motorcycle, be sure to

use special tools for removal and

installation.

n After disassembly, clean removed parts.

Lubricate sliding surfaces with engine oil

before reassembly.

1. GENERAL INFORMATION

1-4

n Apply or add designated greases and

lubricants to the specified lubrication

points.

n After reassembly, check all parts for

proper tightening and operation.

n When two persons work together, pay

attention to the mutual working safety.

n Disconnect the battery negative (-) terminal

before operation.

n When using a spanner or other tools, make

sure not to damage the motorcycle surface.

n After operation, check all connecting

points, fasteners, and lines for proper

connection and installation.

n When connecting the battery, the positive

(+) terminal must be connected first.

n After connection, apply grease to the

battery terminals.

n Terminal caps shall be installed securely.

1. GENERAL INFORMATION

1-5

n If the fuse is burned out, find the cause and

repair it. Replace it with a new one

according to the specified capacity.

n After operation, terminal caps shall be

installed securely.

n When taking out the connector, the lock on

the connector shall be released before

operation.

n Hold the connector body when connecting

or disconnecting it.

n Do not pull the connector wire.

n Check if any connector terminal is bending,

protruding or loose.

Confirm

Capacity

1. GENERAL INFORMATION

1-6

n The connector shall be inserted

completely.

n If the double connector has a lock, lock

it at the correct position.

n Check if there is any loose wire.

n Before connecting a terminal, check for

damaged terminal cover or loose negative

terminal.

n Check the double connector cover for

proper coverage and installation.

n Insert the terminal completely.

n Check the terminal cover for proper

coverage.

n Do not make the terminal cover opening

face up.

n 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.

Snapping!

1. GENERAL INFORMATION

1-7

n After clamping, check each wire to make

sure it is secure.

n Do not squeeze wires against the weld or

its clamp.

n After clamping, check each harness to make

sure that it is not interfering with any

moving or sliding parts.

n When fixing the wire harnesses, do not

make it contact the parts which will

generate high heat.

n Route wire harnesses to avoid sharp edges

or corners. Avoid the projected ends of

bolts and screws.

n Route wire harnesses passing through the

side of bolts and screws. Avoid the

projected ends of bolts and screws.

No Contact !

1. GENERAL INFORMATION

1-8

n Route harnesses so they are neither

pulled tight nor have excessive slack.

n Protect wires and harnesses with electrical

tape or tube if they contact a sharp edge or

corner.

n When rubber protecting cover is used to

protect the wire harnesses, it shall be

installed securely.

n Do not break the sheath of wire.

n If a wire or harness is with a broken sheath,

repair by wrapping it with protective tape

or replace it.

n When installing other parts, do not press or

squeeze the wires.

Do not

pull too

i h !

Do not press or

squeeze the wire.

1. GENERAL INFORMATION

1-9

n After routing, check that the wire harnesses

are not twisted or kinked.

n 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.

n When a testing device is used, make sure to

understand the operating methods

thoroughly and operate according to the

operating instructions.

n Be careful not to drop any parts.

n When rust is found on a terminal, remove

the rust with sand paper or equivalent

before connecting.

n Do not bend or twist control cables.

Damaged control cables will not operate

smoothly and may stick or bind.

Do you understand

the instrument? Is

the instrument set

correctly?

Remove Rust

!

1. GENERAL INFORMATION

1-10

n 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

lubrication.)

:Apply grease for lubrication.

:Transmission Gear Oil (90#)

:Use special tool.

:Caution

:Warning

(!12-3)

:Refer to page 12-3.

Engine Oil

Grease

Gear Oil

Special

＊

1. GENERAL INFORMATION

1-11

TORQUE VALUES

STANDARD TORQUE VALUES

Item

Torque (kg-m)

Item

Torque (kg-m)

5mm bolt, nut

6mm bolt, nut

8mm bolt, nut

10mm bolt, nut

12mm bolt, nut

0.5

1.0

2.2

3.5

5.5

5mm screw

6mm screw, SH bolt

6mm flange bolt, nut

8mm flange bolt, nut

10mm flange bolt, nut

0.4

0.9

1.2

2.7

4.0

Torque specifications listed below are for important fasteners.

ENGINE

Item

Q‘ty

Thread dia.(mm) Torque (kg-m)

Remarks

Cylinder head bolt A

Cylinder head bolt B

Oil filter screen cap

Exhaust muffler joint lock nut

Cylinder head nut

Valve adjusting lock nut

Cam chain tensioner slipper bolt

Oil bolt

Clutch outer nut

Clutch drive plate nut

Drive face seal cover bolt

Starter clutch cap bolt

Drive face nut

Spark plug

Starter clutch lock nut

Cam chain tensioner screw

2

4

1

2

4

2

1

1

1

1

3

3

1

1

1

1

8

8

30

6

8

5

6

8

12

12

4

6

12

10

22

6

0.9

0.9

1.5

1.2

2.0

0.9

1.0

1.3

5.5

5.5

0.3

1.2

5.5

1.2

9.5

0.4

Double end bolt

Double end bolt

Apply oil to

threads

Left hand threads

FRAME

Item

Q‘ty

Thread dia.(mm)

Torque (kg-m)

Remarks

Steering stem lock nut

Front axle nut

Rear axle nut

Rear shock absorber upper mount bolt

Rear shock absorber lower mount bolt

Speedometer cable set screw

Front shock absorber tube bolt

Front shock absorber upper mount bolt

Front shock absorber lower mount bolt

Front shock absorber hex bolt

Rear shock absorber lower joint lock nut

1

1

1

1

1

1

1

2

2

1

1

10

12

14

10

8

5

5

8

8

8

8

12.0

6.0

11.0

4.0

2.5

0.45

0.45

0.1

1.8

3.0

3.5

U-nut

U-nut

U-nut

Apply locking agent

1. GENERAL INFORMATION

1-12

SPECIAL TOOLS

Tool Name

Tool No.

Remarks

Ref. Page

Valve adjuster

Valve guide driver

Valve guide reamer

Valve spring compressor

Lock nut wrench, 39mm

Bearing driver

Bearing driver

Bearing remover, 12mm

Remover set, 12mm

Remover head, 12mm

Remover shaft

Remover weight

Bearing remover set, 15mm

Driver set, 15mm

Driver shaft, 15mm

Driver head, 15mm

Driver weight

Bearing driver

Driver handle

Driver weight

Clutch spring compressor

Outer extension

Crankshaft assembly tool

Crankshaft assembly collar

Crankshaft assembly shaft

Attachment

Lock nut wrench

Lock nut wrench

Ball race remover extension

Ball race remover

Spring compressor

Spring compressor attachment

Spring compressor attachment

Spring compressor attachment

Lock nut wrench

Driver outer extension

Float level gauge

Valve spring compressor

Valve seat cutter, 24.5mm

45° IN/EX

Valve seat cutter, 25mm

Plane cutter 32° IN

Valve seat cutter, 22mm

Plane cutter 32° EX

Valve seat cutter, 26mm

Plane cutter 60° IN/EX

Cutter clip, 5mm

Universal holder

Outer driver, 32x35mm

Outer driver, 37x40mm

Outer driver, 42x47mm

Pilot, 12mm

Pilot, 15mm

Pilot, 17mm

Pilot, 20mm

Driver handle A

Bearing remover shaft

Bearing remover head, 12mm

Flywheel puller

1. GENERAL INFORMATION

1-13

LUBRICATION POINTS

ENGINE

Lubrication Points

Lubricant

Valve guide/valve stem movable part

Cam lobes

Valve rocker arm friction surface

Cam chain

Cylinder lock bolt and nut

Piston surroundings and piston ring grooves

Piston pin surroundings

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

Starter reduction gear engaging part

Countershaft gear engaging part

Final gear engaging part

Bearing movable part

O-ring face

Oil seal lip

•Genuine KYMCO Engine Oil (SAE10W-30)

•API SE, SF or SG Engine Oil

Starter idle gear

Friction spring movable part/shaft movable part

Shaft movable grooved part

Starter spindle movable part

High-temperature resistant grease

Starter one-way clutch threads

Thread locking agent

A.C. generator connector

Transmission case breather tube

Adhesive

1. GENERAL INFORMATION

1-14

FRAME

The following is 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.

Seat Lock

Rear Wheel Bearings

Grease

Front Brake Cable/

Speedometer Cable/

Throttle Cable

Main Stand Pivot

Speedometer Gear/ Front Wheel

Bearings/ Brake Cam/ Anchor Pin

/Front Shock Absorber Lower

Mount Bushings/Pivot

Engine Oil

Grease

Grease

Grease

Grease

Front Brake Lever

Pivot

Engine Oil

Rear Brake Cab

Brake Cam/

Anchor Pin

Grease