Kymco Hipster 125 150 Motorcycle Complete Workshop Service Repair Manual

HIPSTER125/150 PREFACE This Service Manual describes the technical features and servicing procedures for the KYMCOHipster125. Section 1 contains the precautions for all operations stated in this manual. Read them carefully before starting any operation. Section 2 is the inspection/ adjustment procedures, safety rules and service information for each part, starting from periodic maintenance. Sections 3 and 4 state the servicing procedures and cautions for the removal and installation of lubrication and fuel systems. Sections 5 through 18 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 INSPECTION/ADJUSTMENT 2 LUBRICATION SYSTEM 3 FUEL SYSTEM 4 ENGINE REMOVAL/INSTALLATION 5 CYLINDER HEAD/VALVES 6 CYLINDER/PISTON 7 STARTER MOTOR/GENERATOR/ LEFT CRANKCASE COVER/STARTER CLUTCH/CAMSHAFT 8 CLUTCH/GEAR SHIFT MECHANISM 9 ENGINE CRANKCASE/CRANKSHAFT/TRANS- MISSION SYSTEM/STARTER SPINDLE 10 FRONT WHEEL/SUSPENSION/ STEERING 11 REAR WHEEL/BRAKE/SUSPENSION 12 HYDRAULIC BRAKE 13 CHASSIS REAR CARRIER/REAR FENDER/ EXHAUST MUFFLER 14 IGNITION SYSTEM 15 CHARGING SYSTEM 16 STARTING SYSTEM 17 ELECTRICAL EQUIPMENT LIGHTS/INSTRUMENTS/SWITCHES/ HORN 18 The information and contents included in this manual may be different from the motorcycle in case specifications are changed.

1. GENERAL INFORMATION 1-0 HIPSTER 125/150 1 __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ GENERAL INFORMATION __________________________________________________________________________________ ENGINE SERIAL NUMBER ---------------------------------------------- 1- 1 SPECIFICATIONS ---------------------------------------------------------- 1- 2 SERVICE PRECAUTIONS ------------------------------------------------ 1- 4 TORQUE VALUES --------------------------------------------------------- 1-12 SPECIAL TOOLS ----------------------------------------------------------- 1-13 LUBRICATION POINTS -------------------------------------------------- 1-14 CABLE & HARNESS ROUTING ---------------------------------------- 1-15 WIRING DIAGRAM-------------------------------------------------------- 1-17 TROUBLESHOOTING----------------------------------------------------- 1-18

1. GENERAL INFORMATION 1-1 HIPSTER 125/150 ENGINE SERIAL NUMBER Location of Engine Serial Number

1. GENERAL INFORMATION 1-2 HIPSTER 125/150 SPECIFICATIONS Motorcycle name & Model No. RJ25AA Motorcycle name HIPSTER125 Overall length (mm) 2250 Overall width (mm) 900 Overall height (mm) 1180 Wheel base (mm) 1475 Engine type 4 ∞ Displacement (cc) 124.1 Fuel type 92# nonleaded gasoline Front wheel 59 Rear wheel 80 Dry weight (kg) Total 139 Front wheel 67.5 Rear wheel 91 Gross weight(kg) Total 158.5 Front wheel 3.00-18-4PR Tires Rear wheel 130/90-15-4PR Ground clearance (mm) 150 Starting system Starting motor & kick starter Type OHC Cylinder arrangement Single cylinder Combustion chamber type Semi-sphere Valve train OHC-2V Bore x stroke (mm) 56.5 x 49.5 Compression ratio 9.4 Compression pressure (kg/cm²) 13 Max. output (ps/rpm) 11.5/9000 Max. torque (Kg.m/rpm) 1.0/6000 Open 5.5 Intake (mm) Close 27.5 Engine Open 4 Port timing Exhaust (mm) Close 36 Intake 0.06mm Valve clearance (cold) Exhaust 0.06mm Idle speed (rpm) 1600rpm Lubrication type Forced pressure & wet sump Oil pump type Inner/outer rotor Oil filter type Wire gauze filter Lubrication System Oil capacity 1.0L SAE#30 Cooling Type Air cooling Air cleaner type Paper element type Fuel capacity 12.0 liter Type CVK Piston dia. (mm) φ26.5 Venturi dia.(mm) φ26 Fuel System Carburetor Throttle type Piston type Type CDI Ignition timing 34.5° ±2/4000rpm Spark plug NGK-DR8EA Ignition System Spark plug gap 0.6 0.7mm Electrical Equipment Battery Capacity 12V6AH Clutch Type Wet multi-disc clutch Type Permanent gear meshing Operating method Foot operated Type International type 1st gear 2.846 2nd gear 2.063 3rd gear 1.4 4th gear 1.130 Transmission Gear Reduction ratio 5th gear 0.923 Tire pressure Front 1.75 (kg/cm²)(2 riders) Rear 2.25 Left 43° Turning angle Right 43° Power Drive System Front Disk brake Moving Device Brake system type Rear Drum brake Front Telescope Damping Device Shock absorber type Rear Double swing Frame type Double cradle SPECIFICATIONS

1. GENERAL INFORMATION 1-3 HIPSTER 125/150 Motorcycle name & Model No. RH30AA Motorcycle name HIPSTER150 Overall length (mm) 2275 Overall width (mm) 830 Overall height (mm) 1135 Wheel base (mm) 1475 Engine type 4 ∞ Displacement (cc) 149.4 Fuel type 92# nonleaded gasoline Front wheel 59 Rear wheel 80 Dry weight (kg) Total 139 Front wheel 67.5 Rear wheel 91 Gross weight(kg) Total 158.5 Front wheel 3.0-18-4PR Tires Rear wheel 130/90-15-4PR Ground clearance (mm) 140 Starting system Starting motor & kick starter Type OHC Cylinder arrangement Single cylinder Combustion chamber type Dome head Valve train SOHC-4V Bore x stroke (mm) 62 x 49.5 Compression ratio 10 Compression pressure (kg/cm²) 13 Max. output (Ps/rpm) 14/9000 Max. torque (Kg.m/rpm) 1.1/7500 Open 0 Intake (1mm) Close 30 Engine Open 0 Port timing Exhaust (1mm) Close 30 Intake 0.06mm Valve clearance (cold) Exhaust 0.06mm Idle speed (rpm) 1600rpm Lubrication type Forced pressure & wet sump Oil pump type Inner/outer rotor Oil filter type Wire gauze filter Lubrication System Oil capacity 1.0L SAE#30 Cooling Type Air cooling Air cleaner type Paper element type Fuel capacity 12.0L Type CVK Piston dia. (mm) φ26.5 Venturi dia.(mm) φ26 S y Carburetor Throttle type Piston type Type CDI Ignition timing 34.5° ±2/4000rpm Spark plug NGK-CR8EH9 Ignition System Spark plug gap 0.6 0.7mm Electrical Equipment Battery Capacity 12V6AH Clutch Type Wet multi-disc clutch Type Permanent gear meshing Operating method Foot operated Type International type 1st gear 2.846 2nd gear 2.063 3rd gear 1.4 4th gear 1.130 Transmission Gear Reductio n ratio 5th gear 0.923 Tire pressure Front 1.75 (kg/cm²)(2 riders) Rear 2.25 Left 45° Turning angle Right 45° Front Disk brake Moving Brake system type Rear Drum brake Front Telescope Damping Device Shock absorber type Rear Double swing Frame type Double cradle

1. GENERAL INFORMATION 1-4 HIPSTER 125/150 SERVICE PRECAUTIONS Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally. Use genuine parts and lubricants. When servicing the motorcycle, be sure to use special tools for removal and installation. After disassembly, clean removed parts. Lubricate sliding surfaces with engine oil before reassembly. Apply or add designated greases and

1. GENERAL INFORMATION 1-5 HIPSTER 125/150 lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety. Disconnect the battery negative (-) terminal before operation. When using a spanner or other tools, make sure not to damage the motorcycle surface. After operation, check all connecting points, fasteners, and lines for proper connection and installation. When connecting the battery, the positive (+) terminal must be connected first. After connection, apply grease to the battery terminals. Terminal caps shall be installed securely. If the fuse is burned out, find the cause

1. GENERAL INFORMATION 1-6 HIPSTER 125/150 and repair it. Replace it with a new one according to the specified capacity. After operation, terminal caps shall be installed securely. When taking out the connector, the lock on the connector shall be released before operation. Hold the connector body when connecting or disconnecting it. Do not pull the connector wire. Check if any connector terminal is bending, protruding or loose. Confirm Capacity

1. GENERAL INFORMATION 1-7 HIPSTER 125/150 The connector shall be inserted completely. If the double connector has a lock, lock it at the correct position. Check if there is any loose wire. Check the double connector cover for proper coverage and installation. Before connecting a terminal, check for damaged terminal cover or loose negative terminal. Insert the terminal completely. Check the terminal cover for proper coverage. Do not make the terminal cover opening face up. 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 1-8 HIPSTER 125/150 After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts. When fixing the wire harnesses, do not make it contact the parts which will generate high heat. Route wire harnesses to avoid sharp edges or corners. Avoid the projected ends of bolts and screws. Route wire harnesses passing through the side of bolts and screws. Avoid the projected ends of bolts and screws. No Contact !

Kymco Hipster 125 150 Motorcycle Complete Workshop Service Repair Manual

You're Reading a Preview

Recently Viewed