engine serial number - scooter- · pdf filelocation of engine serial number 1 ... wet sump oil...
TRANSCRIPT
1. GENERAL INFORMATION
1-1
Location of Engine Serial Number
1
ENGINE SERIAL NUMBER
1
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. SD25AAMotorcycle Name & TypeOverall length (mm) 1820Overall width (mm) 685Overall height (mm) 1095Wheel base (mm) 1215Engine type O.H.C.Displacement (cc) 124Fuel Used 92# nonleaded gasoline
Front wheel 38.5Net weight (kg) Rear wheel 63.5
Total 102.0Front wheel 67.5
Gross weight(kg) Rear wheel 158.0Total 225.5
Front wheel 100-90-10Rear wheel 100-90-10
Ground clearance (mm) 123
Perform
-
Braking distance (m) 13 (Initial speed20km/h 1 rider)
ance Min. turning radius (m) 1.866
Starting systemStarting motor &
kick starterType Gasoline, 4-strokeCylinder arrangement Single cylinderCombustion chamber type Semi-sphereValve arrangement O.H.C., chain driveBore x stroke (mm) 52.4 x 57.8Compression ratio 9.2:1Compression pressure(kg/cm≤-rpm) 12.8-570
Max. output (ps/rpm) 9.34/7500Max. torque (kg m/rpm) 1.01/5500
Intake Open 0° BTDCPort (1mm) Close 25° ABDCtiming
Exhaust Open 33° BBDC
(1mm) Close 0° TDC
Valve clearance Intake 0.12(cold) (mm) Exhaust 0.12Idle speed (rpm) 1700rpm
Lubrication type Forced pressure &wet sump
Oil pump type Inner/outer rotortype
Oil filter type Full-flow filtrationOil capacity 0.9 liter
Cooling Type Forced air cooling
Air cleaner type & No Paper element, wetFuel capacity 7.8 liters
Type VE45Piston dia. (mm) 24Venturidia.(mm)
22.1 equivalent
Throttle type Butterfly typeType CDIIgnition timing 13±3°BTDC/1700rp
mContact breaker Non-contact pointtype
Spark plug
NGKC6HSAC7HSAC8HSA
NDU20FS-UU22FS-UU24FS-U
Spark plug gap 0.6_ 0.7mmBattery Capacity 12V9AHClutch Type Dry multi-disc clutch
Type Non-stage transmission
Operation Automaticcentrifugal
type
Type Two-stage reduction
Reduction 1st 2.8ratio 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 braketype Rear Drum brake
Suspension Front Telescopetype Rear Swing arm
Shock absorber Front Telescopetype Rear Swing arm
Frame type Steel pipe
Tires
Engine
System
Fuel System
Carburetor
Electrical
Ignition System
Power D
rive System
Transm
is-sion G
earR
eductionG
ear
Moving D
eviceD
amping
Device
1. GENERAL INFORMATION
1-3
SERVICE PRECAUTIONS
nMake sure to install new gaskets, O-rings,circlips, cotter pins, etc. whenreassembling.
nWhen tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torquediagonally.
n Use genuine parts and lubricants.
nWhen servicing the motorcycle, be sure touse special tools for removal andinstallation.
n After disassembly, clean removed parts.Lubricate sliding surfaces with engine oilbefore reassembly.
1. GENERAL INFORMATION
1-4
n Apply or add designated greases andlubricants to the specified lubricationpoints.
n After reassembly, check all parts forproper tightening and operation.
nWhen two persons work together, payattention to the mutual working safety.
n Disconnect the battery negative (-) terminalbefore operation.nWhen using a spanner or other tools, make
sure not to damage the motorcycle surface.
n After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.nWhen 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 andrepair it. Replace it with a new oneaccording to the specified capacity.
n After operation, terminal caps shall beinstalled securely.
nWhen taking out the connector, the lock onthe connector shall be released beforeoperation.
n Hold the connector body when connectingor disconnecting it.n Do not pull the connector wire.
n Check if any connector terminal is bending,protruding or loose.
ConfirmCapacity
1. GENERAL INFORMATION
1-6
n The connector shall be insertedcompletely.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 fordamaged terminal cover or loose negativeterminal.
n Check the double connector cover forproper 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 withtheir respective wire bands at thedesignated locations.Tighten the bands so that only theinsulated surfaces contact the wireharnesses.
Snapping!
1. GENERAL INFORMATION
1-7
n After clamping, check each wire to makesure it is secure.
n Do not squeeze wires against the weld orits clamp.
n After clamping, check each harness to makesure that it is not interfering with anymoving or sliding parts.
nWhen fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.
n Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends ofbolts and screws.n Route wire harnesses passing through the
side of bolts and screws. Avoid theprojected ends of bolts and screws.
No Contact !
1. GENERAL INFORMATION
1-8
n Route harnesses so they are neitherpulled tight nor have excessive slack.
n Protect wires and harnesses with electricaltape or tube if they contact a sharp edge orcorner.
nWhen rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled 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 tapeor replace it.
nWhen installing other parts, do not press orsqueeze the wires.
Do notpull tootight!
Do not press orsqueeze the wire.
1. GENERAL INFORMATION
1-9
n After routing, check that the wire harnessesare not twisted or kinked.
nWire harnesses routed along with handlebarshould not be pulled tight, have excessiveslack or interfere with adjacent orsurrounding parts in all steering positions.
nWhen a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.
n Be careful not to drop any parts.
nWhen rust is found on a terminal, removethe rust with sand paper or equivalentbefore connecting.
n Do not bend or twist control cables.Damaged control cables will not operatesmoothly and may stick or bind.
Do you understandthe instrument? Isthe instrument setcorrectly?
Remove Rust!
1. GENERAL INFORMATION
1-10
n Symbols:The following symbols represent theservicing methods and cautions included inthis service manual.
: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)
: 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
0.51.02.23.55.5
5mm screw6mm screw, SH bolt6mm flange bolt, nut8mm flange bolt, nut10mm flange bolt, nut
0.40.91.22.74.0
Torque specifications listed below are for important fasteners.
ENGINE
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Cylinder head bolt ACylinder head bolt BOil filter screen capExhaust muffler joint lock nutCylinder head nutValve adjusting lock nutCam chain tensioner slipper boltOil boltClutch outer nutClutch drive plate nutDrive face seal cover boltStarter clutch cap boltDrive face nutSpark plugStarter clutch lock nutCam chain tensioner screw
2412421111331111
8830685681212461210226
0.90.91.51.22.00.91.01.35.55.50.31.25.51.29.50.4
Double end bolt
Double end boltApply oil tothreads
Left hand threads
FRAME
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Steering stem lock nutFront axle nutRear axle nutRear shock absorber upper mount boltRear shock absorber lower mount boltSpeedometer cable set screwFront shock absorber tube boltFront shock absorber upper mount boltFront shock absorber lower mount boltFront shock absorber hex boltRear shock absorber lower joint lock nut
11111112211
101214108558888
12.06.011.04.02.50.450.450.11.83.03.5
U-nutU-nutU-nut
Apply locking agent
1. GENERAL INFORMATION
1-12
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. PageValve adjusterValve guide driverValve guide reamerValve spring compressorLock nut wrench, 39mmBearing driverBearing driverBearing remover, 12mmRemover set, 12mmRemover head, 12mmRemover shaftRemover weightBearing remover set, 15mmDriver set, 15mmDriver shaft, 15mmDriver head, 15mmDriver weightBearing driverDriver handleDriver weightClutch spring compressorOuter extensionCrankshaft assembly toolCrankshaft assembly collarCrankshaft assembly shaftAttachmentLock nut wrenchLock nut wrenchBall race remover extensionBall race removerSpring compressorSpring compressor attachmentSpring compressor attachmentSpring compressor attachmentLock nut wrenchDriver outer extensionFloat level gaugeValve spring compressorValve seat cutter, 24.5mm 45° IN/EXValve seat cutter, 25mm Plane cutter 32° INValve seat cutter, 22mm Plane cutter 32° EXValve seat cutter, 26mm Plane cutter 60° IN/EXCutter clip, 5mmUniversal holderOuter driver, 32x35mmOuter driver, 37x40mmOuter driver, 42x47mmPilot, 12mmPilot, 15mmPilot, 17mmPilot, 20mmDriver handle ABearing remover shaftBearing remover head, 12mmFlywheel 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
FRAMEThe 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 avoidabnormal 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 WheelBearings/ Brake Cam/ Anchor Pin/Front Shock Absorber LowerMount Bushings/Pivot
Engine Oil
Grease
Grease Grease
Grease
Front Brake LeverPivot
Engine Oil
Rear Brake Cable
Brake Cam/Anchor Pin
Grease
1. GENERAL INFORMATION
1-15
CABLE & HARNESS ROUTING
Front Stop Switch WireRear Stop Switch Wire
Throttle Cable
Regulator/Rectifier Resistor
Buzzer
Front Brake FluidTube
Rear Brake Cable
Speedometer Cable
Horn
Instrument Cable
Ignition Switch
SecondaryAir Cleaner
Charging Indicator
Front Brake Fluid Tube
Front Brake Reservoir
1. GENERAL INFORMATION
1-16
Throttle Cable
Regulator/Rectifier
Speedometer Cable
Wire Harness
Secondary Air Inlet Tube
Charging Indicator
Secondary Air Inlet Tube
Resistor
Front Brake Fluid Tube
Rear Brake Cable
Front Brake Fluid Tube
1. GENERAL INFORMATION
1-17
Wire HarnessGround
Reserve Fuse
Fuse
Battery (+) Cable
Battery (-) Cable
CDI Unit
Battery (+) Cable
Battery (-) CableCDI Unit
1. GENERAL INFORMATION
1-18
Fuel Valve Vacuum TubeThrottle Cable
Fuel VaporRecovery Tube
Vacuum Tee
Fuel Tube
Ignition Coil
Auto Bystarter Wire
Crankcase Breather Tube
Ground
A.C. Generator Wire
1. GENERAL INFORMATION
1-19
Throttle Cable
Starter Relay
Fuel Tube
CarburetorVacuum Tube
Auto Bystarter Wire
Starter Motor Wire
Auto Bystarter
Fuel Vapor Tube Fuel Unit
Fuel Unit
Wire Harness
Crankcase BreatherTube
Vacuum Tee
Charcoal Canister/Purge Control Valve
Reed Valve
Starter Relay
1. GENERAL INFORMATION
1-20
WIRING DIAGRAM
R Red O OrangeB Black P PinkW White Br BrownG Green LG Light greenV Violet SB Light blueL Blue GR GrayY Yellow
1. GENERAL INFORMATION
1-21
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Empty fuel tankClogged fuel line between fueltank and carburetorClogged float oil passageClogged fuel tank cap breatherholeClogged fuel filterClogged fuel strainerFaulty auto fuel valve
Faulty charging systemFaulty spark plugFouled spark plugFaulty CDI unitFaulty pulser coilBroken or shorted ignition coilBroken or shorted exciter coilFaulty ignition switchWeak or dead battery
Faulty starter clutchValve clearance too smallImproper valve and seat contactWorn cylinder, piston and pistonringsLeaking cylinder head gasketSeized valveImproper valve timing
Faulty auto bystarterAir leaking through intake
pipeIncorrect ignition timingIncorrectly adjusted pilot screw
Flooded carburetorFaulty auto bystarterThrottle valve excessively
open
Check if fuel reachescarburetor byloosening drain screw
Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground
Inspection/Adjustment Probable Cause
Spark jumps
Normal compression
Engine does not fire
Weak or no spark
Low or no compression
Engine fires but does not start
Test cylindercompression
Start engine by follow-ing normal startingprocedure
Remove spark plug andinspect again
Symptom
Fuel reaches carburetor
Fuel does not reach carburetor
Wet spark plugDry spark plug
1. GENERAL INFORMATION
1-22
ENGINE LACKS POWER
Clogged air cleanerRestricted fuel flowClogged fuel tank cap breather holeClogged exhaust mufflerFaulty auto bystarterSplit carburetor vacuum pistondiaphragmFaulty auto fuel valve
Faulty CDI unit
Faulty pulser coil
Improper valve clearanceadjustmentWorn valve seat (valve stem tooprotruding
Improper valve and seat contactWorn cylinder and piston ringsLeaking cylinder head gasketImproper valve timing
Clogged carburetor jets
Fouled spark plugIncorrect heat range plug
Oil level too highOil level too lowOil not changed
Clogged oil pipe
Faulty oil pump
Worn cylinder and piston ringsMixture too leanPoor quality fuelExcessive carbon buildup incombustion chamberIgnition timing too early
Excessive carbon build-up incombustion chamberPoor quality fuelClutch slippingMixture too leanIgnition timing too early
Start engine and acceleratelightly for observation
Inspection/Adjustment Symptom Probable Cause
Engine speed increases
Correct timing
Engine speed does notincrease sufficiently
Incorrect timing
Check ignition timing(using a timing light)
Test cylinder compression
Check carburetor forclogging
Rapidly accelerate or runat high speed
Remove spark plug andinspect
Check if engine overheats
Check valve clearance
Correct Incorrect
Normal compression
Abnormal compression
Remove oil dipstick andcheck oil level and condition
Remove cylinder head oilpipe bolt and inspect
Engine overheats Engine does not overheats
Plug not fouled or discolored
Plug fouled or discolored
Correct and not contaminated
Incorrect or contaminated
Valve train lubricatedproperly
Valve train notlubricated properly
Engine does not knock Engine knocks
Not clogged Clogged
1. GENERAL INFORMATION
1-23
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Faulty CDI unitFaulty pulser coil
Mixture too rich (turn screwout)Mixture too lean (turn screw
in)
Deteriorated O-ringCarburetor not securelytightenedDamaged insulator rubberBroken vacuum tube
Faulty or fouled spark plugFaulty CDI unitFaulty A.C. generatorFaulty ignition coilBroken or shorted spark plugwireFaulty ignition switch
Faulty air cut-off valveDamaged vacuum tubeClogged or damaged air venthole
Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check air cut-off
valve
Check carburetorgasket for air leaks
Check carburetor pilotscrew adjustment
Correct timing Incorrect timing
Correctly adjusted
No air leak Air leaks
Good spark Weak or inter- mittent spark
Good Faulty
Incorrectlyadjusted
1. GENERAL INFORMATION
1-24
POOR PERFORMANCE (AT HIGH SPEED)
Faulty CDI unitFaulty pulser coil
Improperly adjusted valveclearanceWorn valve seat
Empty fuel tankClogged fuel tube or filterClogged Fuel tank cap breatherholeFaulty auto fuel valve
Clean and unclog
Cam timing gear aligningmarks not aligned
Faulty spring
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check carburetor jetsfor clogging
Check fuel pump forfuel supply
Correct timing Incorrect timing
Check valve springtension
Check valve clearance
Fuel flows freely Fuel flow restricted
Correct Incorrect
Not clogged Clogged
Correctly adjusted Incorrectly adjusted
Not weakened Weak spring
Check valve timing
1. GENERAL INFORMATION
1-25
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Dead batteryFaulty battery
Faulty A.C. generator coilBroken yellow wireLoose connector
Broken red wire
Faulty regulator/rectifierPoorly connected coupler
Faulty A.C. generator
Overcharging
Broken green wire
Poorly connected coupler
Faulty regulator/rectifier
Start engine and testlimit voltage ofbattery terminals
Connect battery (+)wire toregulator/rectifiercoupler red wire andbattery (-) wire to engineground and test voltage
Inspection/Adjustment
Inspection/Adjustment
Symptom
Symptom
Probable Cause
Probable Cause
Normal voltage
Battery hasvoltage withignition switch“ON”
Normal
Voltage does notincrease
Battery has novoltage withignition switch“ON”
Resistance toohigh
Normal voltage No voltage
Measure resistancebetween AC generatorcoil terminals
Normal Abnormal
Checkregulator/rectifiercoupler for looseconnection
Normal Abnormal
Connect battery (+)wire toregulator/rectifiercoupler green wire andbattery (-) wire to engineground and test voltage
Checkregulator/rectifiercoupler for looseconnection
1. GENERAL INFORMATION
1-26
NO SPARK AT SPARK PLUG
Faulty spark plug
Loose spark plug cap
Poorly connected coupler
Faulty ignition switchWeak batteryFaulty pulser coilFaulty ignition coilFaulty charging system
Broken wire harnessPoorly connected coupler
ÅFaulty CDI unit
ÅFaulty ignition coil
Replace with a newspark plug and inspectagain
Check CDI unitcoupler for looseness
Inspection/Adjustment Symptom Probable Cause
Normal
Abnormal
Normal
Abnormal
Normal Abnormal
Abnormal
Measure resistancebetween terminals ofCDI unit coupler
Check related parts
Check ignition coilwith a CDI unit tester
Weak or no spark
Not loose
Good spark
Loose
Good Good
Check spark plug capand high-tension wirefor looseness
Check CDI unit with aCDI unit tester