OWNER'S MANUAL KWANG YANG MOTOR CO.,LTD. DINK 125 Issued: JUN.30.
FOREWORD Thank you for purchasing this KYMCO scooter and welcome to the family of KYMCO scooter riders. Please read this owner's manual carefully before riding so that you will be thoroughly familiar with the proper operation of your scooter controls, its features, capabilities, and limitations. To ensure a long, trouble-free life for your scooter, give it the proper care and maintenance described in this manual. For replacement parts and accessories, we recommend genuine KYMCO products.
READ THIS MANUAL CAREFULLY Your Owner's Manual contains important information on safety, operation, and maintenance. Any one who operates this scooter should carefully read and understand the contents of this manual before riding the scooter. SPECIAL MESSAGES Please read this manual and follow its instructions carefully. To emphasize special information the words WARNING , CAUTION and Note carry special meanings and should be carefully reviewed.
CONTENTS Page Page BRAKES.........................................29 SCOOTER SAFETY........................1 FUEL FILL CAP................................30 SEAT..............................................32 CENTER COMPARTMENT/CENTER COMPARTMENT LIGHT...................33 HELMET HOLDERS.........................34 CENTER HOOK ...............................35 PASSENGER FOOTPEG ..................36 STAND...........................................37 SUSPENSION.................................
Page Page PARKING........................................49 BREAK-IN (RUNNING IN)................51 COOLANT.......................................71 FRONT AND REAR SUSPENSION INSPECTION..................................73 SIDE STAND...................................74 BRAKE FLUID................................75 BRAKE PAD WEAR........................76 BATTERY........................................77 FUSE REPLACEMENT....................80 TIRES............................................
SCOOTER SAFETY IMPORTANT SAFETY INFORMATION Your scooter can provide many years of service and pleasure, if you take responsibility for your own safety and understand the challenges that you can meet on the road. There is much that you can do to protect yourself when you ride. You will find many helpful recommendations throughout this manual. Following are a few that we consider most important. Wear a helmet Scooter safety equipment starts with a quality helmet.
Keep your scooter in safe condition For safe riding, it's important to inspect your scooter before every ride and perform all recommended maintenance. Never exceed load limits, and only use accessories that have been approved by KYMCO for this scooter. Inspection before riding Do not forget to perform an entire safety inspection to ensure the safety of the rider. Be extra safety conscious on bad weather days Riding on bad weather days, especially wet ones, requires extra caution.
PROTECTIVE APPAREL For your safety, we strongly recommend that you always wear an approved scooter helmet, eye protection, boots, gloves, long pants, and a long-sleeved shirt or jacket whenever you ride. Helmets and protection Your helmet is your most important piece of riding gear because it offers the best protection against head injuries. A helmet should fit your head comfortably and securely. Always wear a face shield or goggles to protect your eyes and help your vision.
(1) (2) (3) (4) (1)Wear gloves. (2)Clothes should be close-fitting. (3)Always wear an helmet. You should also wear a face shield or goggles. (4)Wear bright or reflective clothing. (5)Shoes should be close-fitting, have low heels and offer ankle protection. WARNING Not wearing a helmet increases the chance of serious injury or death in a crash. Be sure you and your passenger always wear an approved motorcycle helmet that fits properly.
LOAD LIMITS AND GUIDELINES These general guidelines may help you decide whether or how to equip your scooter and how to load it safely. Center compartment weight limit:10 kg (22 lbs) Load limits Following are the load limits for your scooter: Rear carrier weight limit:5 kg (11 lbs) Maximum weight capacity (Includes the weight of the rider, passenger, all cargo and All accessories.
Loading guidelines Improperly loading your scooter can affect its stability and handling. You should ride at reduced speeds whenever carrying cargo. Follow these guidelines whenever you carry a passenger or cargo: Check that both tires are properly inflated. To prevent loose items from creating a hazard, make sure that all cargo is securely tied down before you ride away Place cargo weight as close to the center of the scooter as possible. Balance cargo weight evenly on both sides.
Accessories and Modification There are great variety of accessories available to KYMCO owners. KYMCO cannot have direct control over the quality or suitability of accessories you may wish to purchase. The addition of unsuitable accessories can lead to unsafe operating conditions. It is not possible for KYMCO to test each accessory on the market or combinations of all the available accessories; however, your dealer can assist you in selecting quality accessories and installing them correctly.
PARTS LOCATION (02) (03) (04) (05) (01) (01) Right rearview mirror (02) Instruments/Indicators (03) Left rearview mirror (04) Passing light control switch/ Headlight dimmer switch/ Turn signal switch/ Horn button (05) Left rear suspension spring preload adjuster (06) Right rear suspension spring preload adjuster (07) Engine stop switch/Headlight switch/Start button (07) (06) 8
(14) (13) (08) Front brake lever (09) Throttle grip (10) Front brake fluid reservoir (11) Ignition switch (12) Fuel fill cap (13) Rear brake fluid reservoir (14) Rear brake lever (08) (12) (11) (10) (09) 9
(18) (17) (16) (15) (15) Battery/Fuse box/ Spare fuse (16) Center compartment (17) Helmet holder (18) Coolant fill cap (19) Coolant level (20) Side stand (21) Center stand (22) Left passenger footpeg (23) Air cleaner (19) (20) (21) (22) (23) 10
(25) (24) (24) Helmet hook (25) Seat (26) Right passenger footpeg (27) Oil filler cap/Dipstick (26) (27) 11
FRAME NUMBER The read frame number (1), please remove the cover on inner cover with a flat head screwdriver. Always check that the frame number stamped on your scooter is the same written in document and warranty scooter is the same written in document and warranty card. Please write down your frame number in place below.
ENGINE NUMBER The engine number is stamped on left engine case. Please write down your engine number in place below.
KEY NUMBER The key number (1) will be needed when you order replacement part. Record the number for your reference.
CONTROLS KEYS This scooter has two ignition switch keys and shutter keys. IGNITION SWITCH. Function “ ” Position: All electrical circuits are cut off. The engine will not start. " ” Position: The ignition circuit is completed and engine can now be started. The key cannot be removed from the ignition switch. “ ” Position: To lock the steering, turn the handlebar all the way to the left. Push down and turn the key to the " ” position and remove the key. All electrical circuits are cut off.
INSTRUMENT AND INDICATORS (1) (2) (3) (4) (5) 3 4 5 6 2 1 0 mph Km/h (10) TRIP ODO (9) (1) Multi-function display (4) Right turn signal indicator (7) Met-in indicator (10) Mode button 7 8 9 (6) 10 (7) (8) (2) Tachometer (5) High beam indicator (8) Overheating indicator 16 (3) Left turn signal indicator (6) Oil service indicator (9) Adjust button
(1) Multi-fuction display Initial display The display includes the following functions: When the ignition switch is turned ON, the multi-function display will temporarily show all the modes so that you can make sure the liquid crystal display functioning properly. (1) (4) Speedometer (3) mph Km/h Shows riding speed. Press and hold the Mode button for more than 2 seconds to select mph or Km/h.
Odometer/Tripmeter/Oil service meter To select Odometer/Tripmeter/Oil service meter: Press and hold Adjust button for more than 2 seconds to select Odometer/Tripmeter/Oil service meter. Press and hold the Mode button for more than 2 seconds to select mph or Km/h for speedometer and mile or km for odometer/tripmeter/oil service meter. mph Odometer ODO Tripmeter Km/h TRIP Odometer Shows accumulated mileage. Oil service meter Tripmeter Shows mileage per trip.
To reset the oil service meter: 1. Press and hold Adjust button for more than 2 seconds to select oil service meter. To reset the tripmeter: 1. Press and hold Adjust button for more than 2 seconds to select TRIP. TRIP 2. Press and hold both the Mode button and Adjust button in the same time until the oil service meter is reset. 2. Press and hold both the Mode button and Adjust button in the same time until the tripmeter is reset.
Fuel gauge Digital clock The fuel gauge shows the approximate fuel supply available in a graduated display. The normal operating fuel range is with the section between the segment F and segment E. When the segment E or the fuel indicator flashes, fuel will be low and you should refill the tank as soon as possible. Show the time (hours and minutes) while the ignition is ON. To adjust the time manually, proceed as follows: 1. Turn the ignition switch ON. 2.
4. To set the hour, press the Adjust button until the desired hour. 6. To set the minute, press the Adjust button until the desired minute. 5. Press the Mode button. The minute display will start flashing. 7. To end the adjustment, press both the Mode and Adjust buttons in the same time. The display will stop flashing automatically and the adjustment will be cancelled if the button is not pressed for about 10 seconds.
(2) Tachometer (5) High beam indicator “ Shows engine revolutions per minute (rpm). Lights when the headlight high beam is turned on. Initial display When the ignition switch is turned ON, the indicator of tachometer will run from zero to maxi limit then zero so that you can make sure the tachometer properly.
(8) Overheating indicator “ ” When the coolant is over specified temperature, the overheating indicator comes on. If this occurs, stop the engine and check the reserve tank coolant level. Read page 71 and to not ride the vehicle until the problem has been corrected. NOTE: 1. The overheating indicator comes on when the vehicle's ignition is turned on and must come off when the engine is running. 2. Restart after making sure that the indicator is out.
RIGHT HANDLEBAR SWITCH Headlight switch (1) IN E ENG P S TO “ ” position The headlight and taillight turn on. " ” position The position light and taillight turn on. " " position The headlight, position and taillight turn off.
INE ENG TOP S Electric starter button " ” (2) Push in the electric starter button to rotate the starter motor. NOTE: ! If the brake lever is not squeezed, the starter motor will not rotate. ! This scooter is equipped with interlock switches for the ignition circuit and the starter circuit. The engine can only be started if the side stand is fully up.
Engine stop switch (3) (3) “ ” position The ignition circuit is off. The engine cannot start or run. " ” position The ignition circuit is on and the engine can run.
LEFT HANDLEBAR SWITCH Turn signal switch (1) Use the turn signal switch while turning to another direction or shifting to another lane. The turn signal light will wink when the switch is operated, " ” For turning to the "left". " ”For turning to the "right". The instrument turn signal indicator light will also wink when the switch is operated. Push the switch and it will release. Horn button " (1) (2) ” (2) Press the button to sound the horn.
(3) Dimmer switch (3) " ” position The headlight low beam and taillight turn on. " " position The headlight high beam and taillight turn on. The high beam indicator light also turns on. Passing light control switch (4) (4) When this switch is pressed, the headlight flashes on to signal approaching cars or when passing.
BRAKES Rear brake lever (Left handlebar) The rear brake are applied by squeezing the rear brake lever gently towards the grip. The brake light will be lit when the lever is squeezed inward. Front brake lever (Right handlebar) The brake is applied by squeezing the front brake lever gently towards the grip. The brake light will be lit when the lever is squeezed inward.
FUEL FILL CAP To open the fuel fill cap: Insert the ignition key in the ignition switch and turn it to the “ ” position (the key can not remove). Rotate the key clockwise to the “ ” position and open the fuel fill cap (1). Do not overfill the tank. There should be no fuel in the filler neck (2). After refueling, be sure to lock the fuel fill cap firmly.
To lock the fuel fill cap: Push fuel fill cap down into place. WARNING Petrol is highly flammable and explosive. You can be burned or seriously injured when handling fuel. ! Stop the engine and keep heat, sparks, and flame away. ! Refuel only out doors. ! Wipe up spills immediately. Fuel recommendation Use unleaded petrol with a research octane number of 91 or higher. Unleaded gasoline can extend spark plug life and exhaust components life. Turn the ignition key from “ ” to " ” position to restarting.
(1) SEAT To unlock the seat “SEAT OPEN” (1) Ignition key at the " ” position (The engine is running.): Push the key and turn it counterclockwise from " ” to "SEAT OPEN" position. (2) Ignition key at the " “ position (The engine is stopped.): Turn it counterclockwise from " " to "SEAT OPEN” position. Pull the seat up to lift the seat. To lock seat: Lower and push down on the reverse side of the hooks of the seat until it locks. Make sure the seat is secure before riding.
CENTER COMPARTMENT/CENTER COMPARTMENT LIGHT The center compartment (1) is below the seat. Opening and closing:See "SEAT" (page 32) . MAXIMUM WEIGHT LIMIT: 10kg (22 lbs) The center compartment light (2) will be turned ON automatically when the seat is opened. Kept ON as long as the seat is opened regardless of the position of the ignitino switch. CAUTION Never exceed the maximum weight limit; handling and stability may be severely affected. (1) The center compartment may become heated by the engine.
HELMET HOLDERS To use the helmet holders, unlock the seat (see page 32) , hook your helmet fastener ring to the holder and lock the seat securely. WARNING Riding with a helmet attached to the holder can interfere with the rear wheel or suspension and could cause a crash in which you can be seriously hurt or killed. Use the helmet holder only while parked. Do not ride with a helmet secured by the holder.
CENTER HOOK 1. When using it, pull out the hook (1) from the inside. 2. Pushing the lock lever (2) left to unlock and hang your bag on the hook on the footboard. 3. To remove a bag unlock the lock lever. Lift the bag off the hook. (1) 4. When not using it, push the hook back into its original position to avoid hooking tour clothes during riding.
PASSENGER FOOTPEG 1. When using it, kick the button (1). (1) 2. When not using it, push the passenger footpeg into its original position.
STAND This scooter is equipped with a center stand and side stand. Center stand (1) To place the scooter on the center stand, place your foot on the stand extension and then rock the scooter to the rear and upward with the passenger hand rail with your right hand, while steadying the handlebars with your left hand. (1) Side stand (2) An interlock switch is provided to cut off the ignition circuit when the side stand is down.
WARNING Riding with the side stand incompletely retracted can result in an accident when you turn left. ! Check operation of the side stand/ignition interlock system before riding. ! Always retract the side stand completely before starting off. CAUTION Park the scooter on firm, level ground to help prevent it from falling over. If you must park on an incline, aim the front of the scooter uphill and place the scooter on the center stand, or the scooter on the side stand may roll off.
SUSPENSION Each shock absorber (1) has adjustment positions for different load or riding conditions. Use a pin spanner (2) to adjust the rear shocks. Be certain to adjust both shock absorbers to the same position.
PRE-RIDE INSPECTION 3. Coolant level: add coolant if required. Check for leaks (page 71). For your safety, it is very important to take a few moments before each ride to walk around your scooter and check its condition. If you detect any problem, be sure you take care of it, or have it corrected by your KYMCO dealer. 4. Front and rear brakes: check operation; make sure there is no brake fluid leakage (page 75). 5. Tires: check condition and pressure (page 82).
OPERATION STARTING THE ENGINE Always follow the proper starting procedure described below. This scooter is equipped with a side stand ignition cut-off system. The engine cannot be started if the side stand is down. A running engine will shut off if the side stand is lowered. To protect the catalytic converter in your scooter's exhaust system, avoid extending idling and the use of leaded petrol. Your scooter's exhaust contains poisonous carbon monoxide gas.
1. Place the scooter on its center stand and make sure to put the side stand up. 2. Make sure the engine stop switch is at " ” (RUN). 3. Turn the ignition switch to " “ (ON) 4. Squeeze the rear brake lever. The electric starter will only work when the rear brake lever is squeezed and the side stand is up.
5. With the throttle closed, push the starter button. Release the starter button as soon as the engine starts. INE ENG TOP S 6. Be sure to keep the throttle closed and the while warming up the engine. 7. Allow the engine to warm up before riding. Close Do not "BLIP" the throttle (open and close rapidly) as the scooter will move forward suddenly. Do not leave the scooter unattended while the engine is warming up.
If you cannot restart a warm engine: 1. Place the scooter on its center stand and squeeze the rear brake lever. 2. Open the throttle 1/8 - 1/4 turn while starting the engine.
RIDING Allow the engine oil to circulate before riding Allow sufficient idling time after warm or cold engine start up before applying load or revving the engine. This allows time for the lubricating oil to reach all critical engine components. Review scooter safety (page 1 - 7) before you ride. Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when riding, idling, or parking your scooter. 1.
3. Mount the scooter from the left side keeping at least one foot on the ground to steady the scooter. 4. Before starting off, indicate your direction with the turn signals, and check for safe traffic conditions. Grasp the handlebars firmly with both hands. Never attempt onehanded operation; loss of vehicle control could result. 5. To accelerate, open the throttle gradually; the scooter will move forward.
7. When slowing down the scooter, coordination of the throttle and front and rear brakes is most important. Both front and rear brakes should be applied together. Independent use of only the front or rear brake reduces stopping performance. Excessive brake application may cause either wheel to lock, reducing control of the scooter. 8. When approaching a corner or turn, close the throttle fully and slow the scooter down by applying both front and rear brakes at the same time. 9.
10. When descending a steep grade, close the throttle fully and apply both brakes to slow the scooter. Avoid continuous use of the brakes, which may result in overheating and reduction of braking efficiency. 11. When riding on wet or loose surfaces, be especially cautious. When riding in wet or rainy conditions or on loose surfaces, the ability to maneuver and stop will be reduced. For your safety: ! Exercise extreme caution when braking, accelerating or turning.
PARKING 1. After stopping the scooter turn the ignition switch counterclockwise to the " ” (OFF) position and remove the key. 2. Use the center stand to support the scooter while parked. Park the scooter on firm, level ground to prevent it from falling over. If you must park on a slight incline, aim the front of the scooter uphill to reduce the possibility of rolling off the center stand or overturning.
3. Lock the steering ( see page 15) to help prevent theft. The exhaust pipe and muffler become very hot during operation and remain sufficiently hot to inflict burns if touched even after shutting off the engine. Make sure flammable materials such as dry grass or leaves do not come in contact with the exhaust system when parking your scooter. To unlock WARNING A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine.
BREAK-IN (RUNNING-IN) The first 1600 km (1000 miles) are the most important in the life of your scooter. Proper break-in operation during this time will help ensure maximum life and performance from your new scooter. Proper break-in operation allows the machined surfaces to polish each other and mate smoothly. Scooter reliability and performance depend on special care and restraint exercised during the break-in period.
Breaking in the new tires New tires need proper break-in to assure maximum performance, just as the engine does. Wear in the tread surface by gradually increasing your cornering lean angles over the first 160 km (100 miles) before attempting maximum performance. Avoid hard acceleration, hard cornering, and hard braking for the first 160 km (100 miles). Observe your first and most critical service The 1000 km (600 miles) service is the most important service your scooter will receive.
INSPECTION AND MAINTENANCE WARNING THE IMPORTANCE OF MAINTENANCE A well-maintained scooter is essential for safe, economical and trouble-free riding. It will also help reduce air pollution. Improperly maintaining this scooter or failing to correct a problem before you ride can cause a crash in which you can be seriously hurt or killed. To help you properly care for your scooter, the following pages include a maintenance schedule for regularly scheduled maintenance.
MAINTENANCE SCHEDULE Perform the pre-ride inspection (see page 40) at each scheduled maintenance period. This interval should be judged by odometer reading or months, whichever comes first. I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN R: REPLACE A: ADJUST L: LUBRICATE The following maintenance schedule specifies all maintenance required to keep your scooter in peak operating condition.
FREQUENCY ITEM ＊ AIR CLEANER SPARK PLUGS ＊ THROTTLE OPERATION ＊ VALVE CLEARANCE ＊ FUEL LINE CRANKCASE BREATHER ENGINE OIL ＊ ENGINE OIL FILTER ＊ ENGINE OIL STRAINER SCREEN ＊ ENGINE IDLE SPEED RADIATOR COOLANT ＊ COOLING SYSTEM ＊ SECONDARY AIR SUPPLY SYSTEM WHICHEVER ODOMETER READING [NOTE (1)] COMES FIRST X 1000 km 0.3 1 3 5 7 9 11 REFER X 1000 mi 0.2 0.6 1.8 3 4.2 5.4 6.
FREQUENCY ITEM ＊ TRANSMISSION OIL ＊ DRIVE BELT ＊＊ CLUTCH SHOE WEAR BRAKE FLUID BRAKE PAD WEAR BRAKE SYSTEM ＊ BRAKE LIGHT SWITCH SIDE STAND ＊ SUSPENSION ＊ HEADLIGHT AIM ＊ NUTS, BOLTS, FASTENERS ＊＊ WHEELS/TIRES ＊＊ STEERING BEARINGS WHICHEVER ODOMETER READING [NOTE (1)] COMES FIRST X 1000 km 0.3 1 3 5 7 9 11 REFER X 1000 mi 0.2 0.6 1.8 3 4.2 5.4 6.
TOOL KIT (1) To assist you in the performance of periodic maintenance, a tool kit (1) is supplied and in the center compartment (see page 32). CRANKCASE BREATHER 1. Remove the crankcase breather tube plug (1) from the tube and drain deposits into a suitable container. 2. Reinstall the crankcase breather tube plug. Service more frequently when riding in rain, at full throttle, or after the scooter is washed or overturned.
ENGINE OIL Engine oil recommendation Use a premium quality 4-stroke motor oil to ensure longer service life of your scooter. Use only oils which are rated, SG under the API service classification. The recommended viscosity is SAE 10W-30. If a SAE 10W-30 motor oil is not available, select an alternative according to the right chart.
Engine oil level check Check the engine oil level each day before riding the scooter. The level must be maintained between the upper (1) and lower level (2) marks on the oil filler cap/dipstick. 1. Start the engine and let it idle for a few minutes. 2. Stop the engine and put the scooter on its center stand on level ground. 3. After a few minutes, remove the oil filler cap/dipstick, wipe it clean, and reinsert the oil filler cap/dipstick without screwing it in. Remove the oil filler cap/dipstick.
Engine oil replacement Engine oil quality is the chief factor affecting engine service life. Change the engine oil as specified in the maintenance schedule (see page 55). When running in very dusty conditions, oil changes should be performed more frequently than specified in the maintenance schedule. Please dispose of used engine oil in a manner that is compatible with the environment. We suggest you take it in a sealed container to your local recycling center or service station for reclamation.
3. Remove the oil drain plug (2) to drain the oil. 4. Reinstall the drain plug and tighten the drain plug to specification. Oil drain plug torque: 25 N-m (2.5 kgf-m, 18lbf-ft) 5. Fill the crankcase with the recommended grade oil (see page 58) and install the oil fill cap. Oil capacity (after draining): 0.9 liter (0.95 US qt, 0.8 lmp qt) 6. Start the engine and let it idle for 2－3 minutes. 7.
Oil strainer screen clean (1) Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. NOTE: Let the engine and exhaust system cool before working in those areas. 1. Remove the oil filler cap/dipstick (1) from the right crankcase cover.
2. Place a drain pan under the crankcase and remove the oil strainer screen cap (2). The spring (3) and oil strainer screen (4) will come out when the drain plug is removed. Let the engine oil drain out. 3. Clean the oil strainer screen. 4. Check that the oil strainer screen, sealing rubber and drain plug O-ring are in good condition. 5. Install the oil strainer screen, spring and oil strainer screen cap. Oil strainer screen cap torque: 15N-m (1.5 kgf-m, 11lbf-ft) (2) 5.
Oil filter replacement (1) Change the engine oil with the engine at normal operating temperature and the scooter on its center stand to assure complete and rapid draining. NOTE: Let the engine and exhaust system cool before working in those areas. 1. Remove the oil filler cap/dipstick (1) from the right crankcase cover.
2. Place a drain pan under the crankcase. Remove three bolt and then remove the oil filter cap (2) and O-ring (3). The spring (4) will come out when the filter cap is removed. Let the engine oil drain out. 3. Remove and discard the oil filter (5). 4. Check that the O-ring are in good condition. 5. Install the new oil filter, spring, O-ring and cap. Cap bolt torque: 12 N-m (1.2 kgf-m, 8.6 lbf-ft) (2) 6. Fill the crankcase with the recommended grade oil (see page 58) and install the oil filler cap.
TRANSMISSION OIL Oil change 1. Place the scooter in its center stand. 2. Place a drain pan under the drain bolt (1). 3. Remove the transmission oil drain bolt. 4. Remove the transmission oil filler bolt (2), slowly turn the rear wheel and drain the oil. After draining the oil completely, install the oil drain bolt with a new sealing washer and tighten it. Torque: 13 N-m (1.3 kgf-m, 9.5 lbf-ft) 5. Fill the transmission case with recommended oil.
AIR CLEANER The air cleaner should be serviced at regular intervals. Service more frequently when riding in unusually wet or dusty areas. (1) Air cleaner element replacement 1. Remove the band (1). 2. Remove a bolt from the crankcase and six screws from the air cleaner cover (2), then remove air cleaner cover. (2) 3. Remove six screws from the air cleaner element (3), then remove and discard this air cleaner element. 4. The new air cleaner element installation is in the reverse order of removal.
THROTTLE OPERATION 1. Check for smooth rotation of the throttle grip from the fully open to the fully closed position at both full steering positions. 2 ~ 6 mm (0.08 ~ 0.24 in) 2. Measure the throttle grip free play at the throttle grip flange. The standard free play should approximately: 2 ~ 6 mm (0.08 ~ 0.24 in) To adjust the free play: 1. Slide the rubber sleeve (1) back to expose the throttle cable adjuster (2). 2. Loosen the lock nut (3), then turn the adjuster to obtain the correct free play. 3.
IDLE SPEED (1) The engine must be at normal operating temperature for accurate idle speed adjustment. Ten minutes of stop-andgo riding is sufficient. 1. Warm up the engine place the scooter on its center stand. 2. Open the seat (see page 32). Push 3. Open the carburetor cover (1). 4. Adjust idle speed with the throttle stop screw (2).
SPARK PLUG Remove the carbon deposits from the spark plug with a small wire brush or a spark plug cleaning machine. Readjust the spark plug gap to specified limit by using a spark plug gap thickness gauge. The spark plug should be replaced periodically. Whenever removing the carbon deposits, be sure to observe the operational color of the spark plug's porcelain tip. This color tells you whether or not the standard spark plug is suitable for your type of usage.
COOLANT Inspection The reserve tank is under footboard left. Check the coolant level through the inspection window (1) at the front fender while the engine is at the normal operating temperature with the scooter in an upright position. If the coolant level is below the LOWER level mark (3), remove screw (4) and reserve tank lid (5) and reserve tank cap (6) and add coolant mixture until it reaches the upper level mark (2). Always add coolant to the reserve tank.
Coolant replacement Coolant recommendation Coolant should be replaced by a KYMCO dealer, unless the owner has proper tools and service data and is mechanically qualified. The owner must properly maintain the coolant to prevent freezing, overheating, and corrosion, use only high quality ethylene glycol antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines.(See antifreeze container label.
FRONT AND REAR SUSPENSION INSPECTION A higher concentration of antifreeze decreases the cooling system performance and is recommended only when additional protection against freezing is needed. A concentration of less than 40:60 (40% antifreeze) will not provide proper corrosion protection. During freezing temperatures, check the cooling system frequently and add higher concentrations of antifreeze (up to a maximum of 60% antifreeze) if required. 1.
SIDE STAND Perform the following maintenance in accordance with the maintenance schedule. Functional check: ! Check the spring for damage or loss of tension and the side stand assembly for freedom of movement. ! Check the side stand ignition cut-off system: Side stand up 1. Place the scooter on its center stand. 2. Put the side stand up and start the engine. 3. Lower the side stand. The engine should stop as you put the side stand down.
BRAKE FLUID L Brake fluid level: With the scooter in an upright position, check the front and rear fluid level. It should be above the lower level mark. If the level is at or below the lower level mark "L", check the brake pads for wear (see page 76). Worn pads should be replaced. If the pads are not worn, have your brake system inspected for leaks. The recommended brake fluid is DOT 4 brake fluid from a sealed container, or an equivalent. Other checks: Make sure there are no fluid leaks.
BRAKE PAD WEAR Brake pad wear depends upon the severity of usage, the type of riding, and road conditions. (Generally, the pads will wear faster on wet and dirty roads.) Inspect the pads at each regular maintenance interval. Front brake Check the cutout in each pad. If either pad is worn to the cutout, replace both pads as a set. See your KYMCO dealer for this service. Rear brake Check the cutout in each pad. If either pad is worn to the cutout, replace both pads as a set.
BATTERY It is not necessary to check the battery electrolyte level or add distilled water as the battery is a maintenance-free (sealed) type. If your battery seems weak and/or is leaking electrolyte (causing hard starting or other electrical troubles), contact your KYMCO dealer. NOTE: Your battery is a maintenance-free type and can be permanently damaged if the cap strip is removed. WARNING The battery gives off explosive hydrogen gas during normal operation.
Battery removal (Always keep ignition switch is OFF) The battery is in the battery box below seat. 1. Open the seat (see page 32). 2. Remove the two screws and battery cover (1). (1) 3. Remove the four screws and then remove the battery retainer (2).
4. Pull battery out to expose the terminal leads 5. Disconnect the negative (-) terminal lead (3) from the battery first, then disconnect the positive (+) terminal lead (4). 6. Remove the battery from the battery box. Battery installation: Install in the reverse order of the removal. (4) NOTE: When install the battery, first connect the positive (+) cable and then negative (-) cable to avoid short circuit.
FUSE REPLACEMENT Blown fuse When frequent fuse failure occurs, it usually indicates a short circuit or an overload in the electrical system. See your KYMCO dealer for repair. NOTE: Never use a fuse with a different rating from that specified. Serious damage to the electrical system or a fire may result, causing a dangerous loss of lights or engine power. Fuse list ! 20A (Yellow) CHARGE fuse protects battery charging system. ! 15A (Blue) MAIN fuse protects all electrical circuits.
Fuse box : (3) The fuse box is located under the battery in the battery box . The specified fuses (2) are: 10A (red), 15A (blue), 20A (yellow) (1) 1. Open the seat (see page 32). 2. Open the battery cover.(see page 78). 3. Open the fuse box cover (1). 4. Pull out the old fuse and install a new fuse. The spare fuse (3) are located in the battery retainer. 5. Close the fuse box covers and seat.
TIRES WARNING WARNING Failure to follow these warnings may result in an accident due to tire failure. The tires on your scooter form the crucial link between your scooter and the road. Failure to perform break-in of the tires could cause tire slip and loss of control. Use extra care when riding on new tires.
Tire pressure Tire tread condition Proper tire condition and proper tire type affect vehicle performance. Cuts or cracks in the tires can lead to tire failure and loss of vehicle control. Worn tires are susceptible to puncture failures and subsequent loss of vehicle control. Tire wear also affects the tire profile, changing vehicle handling characteristics. Insufficient air pressure in the tires not only hastens tire wear but also seriously affects the stability of the scooter.
When you replace a tire, be sure to replace it with a tire of the size listed below. If you use a different size of tire, scooter handling may be adversely affected, possibly resulting loss of scooter control. Front WARNING An improperly repaired, installed, or balanced tire can cause loss of control or shorten tire life.
WARNING Failure to follow these instructions about tubeless tires may result in an accident due to tire failure. Tubeless tires require different service procedures than tube tires. ! Tubeless tires require an air-tight seal between the tire bead and wheel rim. Special tire irons and rim protectors or a specialized tire mounting machine must be used for removing and installing tires to prevent tire or rim damage which could result in an air leak.
CLEANING Clean your scooter regularly to protect the surface finishes and inspect for damage, wear, and oil, coolant or brake fluid leakage. Avoid cleaning products that are not specifically designed for scooter or automobile surfaces. They may contain harsh detergents or chemical solvents that could damage the metal, paint, and plastic on your scooter. If your scooter is still warm form recent operation, give the engine and exhaust system time to cool off.
3. Clean the plastic parts using a cloth or sponge dampened with a solution of mild detergent and water. Rub the soiled area gently rinsing it frequently with fresh water. Take care to keep brake fluid or chemical solvents off the scooter. They will damage the plastic and painted surfaces. The inside of the headlight lens may be clouded immediately after washing the scooter. Moisture condensation inside the headlight lens will disappear gradually by lighting the headlight in high beam.
6. Test the brakes before riding the scooter. Several applications may be necessary to restore normal braking performance. Braking efficiency may be temporarily impaired immediately after washing the scooter. Anticipate longer stopping distance to avoid a possible accident. Finishing touches After washing your scooter, consider using a commercially-available spray cleaner/polish or quality liquid or paste wax to finish the job.
Removing road salt The salt contained in the road surface freezing prevention medicine which a road was sprayed with in winter, and the seawater becomes the cause which rust occurs in. Wash your scooter by the following point after it runs through such a place. 1. Clean the scooter using cool water (see page 86). Do not use warm water. This worsens the effect of the salt. 2. Dry the scooter and the surface of the metal is protected with the wax.
Clean the windshield Using plenty of water, clean the windshield with a soft cloth or sponge. (Avoid using detergents or any kind of chemical cleaner on the windshield.) Dry with a soft, clean cloth. To avoid possible scratching or other damage, use only water and a soft cloth or sponge to clean the windshield. For a dirtier windshield, use a diluted neutral detergent with a sponge and plenty of water. Make sure to wash off all the detergent. (Detergent residue may cause windshield cracks.
STORAGE GUIDE Extended storage, such as for winter, requires that you take certain steps to reduce the effects of deterioration from non-use of the scooter. In addition, necessary repairs should be made before storing the scooter; otherwise, these repairs may be forgotten by the time the scooter is removed from storage. Storage 1. Change the engine oil and filter. 2. Make sure the cooling system is filled with a 50/50% antifreeze solution. 3.
4. To prevent rusting in the cylinders, perform the following: ．Remove the spark plug caps from the spark plugs, using tape or string, secure the caps to any convenient plastic body part so that they are positioned away from the spark plugs. ．Remove the spark plugs from the engine and store them in a safe place. Do not connect the spark plugs to the spark plug caps. ．Pour a tablespoon (15－20 cc) of clean engine oil into each cylinder and cover the spark plug holes with a piece of cloth.
Removal from storage 1. Uncover and clean the scooter. 2. Change the engine oil if more than 1 months have passed since the start of storage. 3. Charge the battery as required. Install the battery. 4. Drain any excess aerosol rust-inhibiting oil from the fuel tank. Fill the fuel tank with fresh petrol. 5. Perform all Pre-ride inspection checks (see page 40). Test ride the scooter at low speeds in a safe riding area away from traffic.
SPECIFICATIONS DIMENSIONS Overall length Overall width Overall height Wheel base 2030 mm (81.2 in) 760 mm (30.4 in) 1255 mm (50.2 in) 1390 mm (55.6 in) WEIGHT Dry weight 138 kg (303.6 lbs) CAPACITIES Engine oil After draining After disassembly Transmission oil After draining After disassembly Fuel tank Maximum weight capacity 0.9 L (0.95 US qt, 0.8 lmp qt) 1.1 L (1.2 US qt, 1 lmp qt) 0.18 L (0.2 US qt, 0.16 lmp qt) 0.2 L (0.21 US qt, 0.18 lmp qt) 11 L (2.86 US gal, 2.
ENGINE Bore and stroke Compression ratio Displacement Spark plug 52.4 X 57.8 mm (2.1 X 2.31 in) 10:1 3 124.6 cm (7.
KWANG YANG MOTOR CO.,LTD. NO.35 Wan Hsing Street, San Min District Kaohsiung, Taiwan, Republic of China Telephone : 886-7-3822526 FAX : 886-7-3950021 By KWANG YANG Motor Co., Ltd. Second Edition, Jun 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of KWANG YANG Motor Co., Ltd. is expressly prohibited.
KWANG YANG MOTOR CO.,LTD. NO.
