PREFACE

TABLE OF CONTENTS
This Service Manual describes the GENERAL INFORMATION 1
technical features and servicing
FRAME COVERS/EXHAUST MUFFLER 2
procedures for the KYMCO MOVIE
125. INSPECTION/ADJUSTMENT 3
LUBRICATION SYSTEM 4
Section 1 contains the precautions for FUEL SYSTEM 5
all operations stated in this manual.

ENGINE
Read them carefully before starting any ENGINE REMOVAL/INSTALLATION 6
operation. CYLINDER HEAD/VALVES 7
CYLINDER/PISTON 8
Section 2 is the removal/installation
DRIVE AND DRIVEN PULLEYS/KICK
procedures for the frame covers which STARTER
9
are subject to higher removal/installation
frequency during maintenance and FINAL REDUCTION 10
servicing operations. CRANKCASE/CRANKSHAFT 11
FRONT WHEEL/FRONT BRAKE/
CHASSIS

Section 3 describes the inspection/ FRONT SUSPENSION 12

adjustment procedures, safety rules and REAR WHEEL /REAR BRAKE /REAR
service information for each part, SUSPENSION 13
starting from periodic maintenance. BATTERY/CHARGING SYSTEM/A.C. 14
EQUIPMENT

GENERATOR
Sections 4 through 19 give instructions IGNITION SYSTEM 15
for disassembly, assembly and
inspection of engine, chassis frame and STARTING SYSTEM 16
electrical equipment. LIGHTS/ INSTRUMENTS/SWITCHES 17
EVAPORATIVE EMISSION CONTROL
CONTRO

Most sections start with an assembly or SYSTEM 18

system illustration and troubleshooting EXHAUST EMISSION CONTROL
for the section. The subsequent pages SYSTEM 19
give detailed procedures for the section.

The information and contents

included in this manual may be
different from the motorcycle in case
specifications are changed.

KWANG YANG MOTOR CO., LTD.

OVERSEAS SALES DEPARTMENT
OVERSEAS SERVICE SECTION
1. GENERAL INFORMATION

1ENGINE 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

ENGINE SERIAL NUMBER

Location of Engine Serial Number

1-1
1. GENERAL INFORMATION
SPECIFICATIONS
Cooling Type Forced air cooling
Name & Model No. SD25AA
Motorcycle Name & Type
Overall length (mm) 1820
Overall width (mm) 685
Air cleaner type & No Paper element, wet
Overall height (mm) 1095

Fuel System
Fuel capacity 7.8 liters
Wheel base (mm) 1215
Type VE45

Carburetor
Engine type O.H.C.
Piston dia. (mm) 24
Displacement (cc) 124
Venturi 22.1 equivalent
Fuel Used 92# nonleaded gasoline
dia.(mm)
Front wheel 38.5
Throttle type Butterfly type
Net weight (kg) Rear wheel 63.5
Type CDI
Total 102.0

Electrical
Ignition timing 13±3°BTDC/1700rp

Ignition System
Front wheel 67.5
Gross weight(kg) Rear wheel 158.0 m point
Contact breaker Non-contact
Total 225.5 type
Front wheel 100-90-10 NGK ND
Tires C6HSA U20FS-U
Rear wheel 100-90-10 Spark plug
C7HSA U22FS-U
Ground clearance (mm) 123
C8HSA U24FS-U
13 (Initial speed
Perform Braking distance (m) 20km/h 1 rider) Spark plug gap 0.6_ 0.7mm
Battery Capacity 12V9AH
-
Clutch Type Dry multi-disc clutch
ance
Power Drive System

Min. turning radius (m)1.866

sion Gear
Transmis-

Starting motor & Type Non-stage transmission

Starting system kick starter
Operation Automatic
Type Gasoline, 4-stroke centrifugal
Cylinder arrangement Single cylinder type
Combustion chamber type Semi-sphere Type Two-stage reduction
Gear
Reduction

Valve arrangement O.H.C., chain drive Reduction 1st 2.8

Bore x stroke (mm) 52.4 x 57.8 ratio 2nd 3.076
Compression ratio 9.2:1 Front Caster angle 27°
Compression pressure
Moving Device

(kg/cm≤-rpm) 12.8-570 Axle Trail length 80mm

Max. output (ps/rpm) 9.34/7500 Front
Tire pressure 1.75
Engine

Max. torque (kg m/rpm) 1.01/5500 (kg/cm≤)

Rear 2.00 (2.25)
Intake Open 0° BTDC Turning Left 45°
Port (1mm) Close 25° ABDC angle Right 45°
timin Exhaust Open 33° BBDC
g Brake system Front Disk brake
type Rear Drum brake
(1mm) Close 0° TDC
Suspension Front Telescope
Valve clearance Intake 0.12
Device
Damping

(cold) (mm) type Rear Swing arm

Exhaust 0.12
Idle speed (rpm) 1700rpm Shock absorber Front Telescope
type
Lubrication type Forced pressure & Rear Swing arm
System

wet sump
Frame type Steel pipe
Oil pump type Inner/outer rotor
type
Oil filter type Full-flow filtration
Oil capacity 0.9 liter

1-2
1. GENERAL INFORMATION

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.

1-3
1. GENERAL INFORMATION

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.

1-4
1. GENERAL INFORMATION

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

repair it. Replace it with a new one Confirm
according to the specified capacity. 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.

1-5
1. GENERAL INFORMATION

n The connector shall be inserted

completely.
n If the double connector has a lock, lock
it at the correct position.
Snapping!
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.

1-6
1. GENERAL INFORMATION

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 No Contact !

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.

1-7
1. GENERAL INFORMATION

n Route harnesses so they are neither

pulled tight nor have excessive slack. Do not
pull too
tight!

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 press or
squeeze the wire.

1-8
1. GENERAL INFORMATION

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.

Do you understand
the instrument? Is
the instrument set
n When a testing device is used, make sure to correctly?
understand the operating methods
thoroughly and operate according to the
operating instructions.

n Be careful not to drop any parts.

Remove Rust
!
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.

1-9
1. GENERAL INFORMATION

n Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.

: Apply engine oil to the

specified points. (Use
Engine Oil designated engine oil for
lubrication.)

Grease : Apply grease for lubrication.

: Transmission Gear Oil (90#)

Gear Oil

: Use special tool.

Special

＊ : Caution

: Warning

(!12-3) : Refer to page 12-3.

1-10
1. GENERAL INFORMATION

TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque (kg-m) Item Torque (kg-m)
5mm bolt, nut 0.5 5mm screw 0.4
6mm bolt, nut 1.0 6mm screw, SH bolt 0.9
8mm bolt, nut 2.2 6mm flange bolt, nut 1.2
10mm bolt, nut 3.5 8mm flange bolt, nut 2.7
12mm bolt, nut 5.5 10mm flange bolt, nut 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 2 8 0.9 Double end bolt
Cylinder head bolt B 4 8 0.9
Oil filter screen cap 1 30 1.5
Exhaust muffler joint lock nut 2 6 1.2 Double end bolt
Cylinder head nut 4 8 2.0 Apply oil to
Valve adjusting lock nut 2 5 0.9 threads
Cam chain tensioner slipper bolt 1 6 1.0
Oil bolt 1 8 1.3
Clutch outer nut 1 12 5.5
Clutch drive plate nut 1 12 5.5
Drive face seal cover bolt 3 4 0.3
Starter clutch cap bolt 3 6 1.2
Drive face nut 1 12 5.5
Spark plug 1 10 1.2
Starter clutch lock nut 1 22 9.5 Left hand threads
Cam chain tensioner screw 1 6 0.4

FRAME
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Steering stem lock nut 1 10 12.0 U-nut
Front axle nut 1 12 6.0 U-nut
Rear axle nut 1 14 11.0 U-nut
Rear shock absorber upper mount bolt 1 10 4.0
Rear shock absorber lower mount bolt 1 8 2.5
Speedometer cable set screw 1 5 0.45
Front shock absorber tube bolt 1 5 0.45
Front shock absorber upper mount bolt 2 8 0.1
Front shock absorber lower mount bolt 2 8 1.8
Front shock absorber hex bolt 1 8 3.0
Rear shock absorber lower joint lock nut 1 8 3.5 Apply lockingagent

1-11
1. GENERAL INFORMATION

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

1-12
1. GENERAL INFORMATION

LUBRICATION POINTS

ENGINE

Lubrication Points Lubricant

Valve guide/valve stem movable part •Genuine KYM CO Engine Oil (SAE10W-30)
Cam lobes •API SE, SF or SG Engine Oil
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
Starter idle gear
Friction spring movable part/shaft movable part High-temperature resistant grease
Shaft movable grooved part
Starter spindle movable part
Starter one-way clutch threads Thread locking agent
A.C. generator connector Adhesive
Transmission case breather tube

1-13
 1. GENERAL INFORMATION

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.

Grease
Front Brake Lever
Engine Oil Pivot
Front Brake Cable/
Speedometer Cable/
Throttle Cable

Grease
Seat Lock

Engine Oil

Rear Brake Cable

Grease
Grease
Brake Cam/
Speedometer Gear/ Front Wheel Anchor Pin
Bearings/ Brake Cam/ Anchor Pin Grease Grease
/Front Shock Absorber Lower
Mount Bushings/Pivot Main Stand Pivot Rear Wheel Bearings

1-14
1. GENERAL INFORMATION

CABLE & HARNESS ROUTING

Front Stop Switch Wire

Front Brake Reservoir Rear Stop Switch Wire

Front Brake Fluid Tube

Throttle Cable
Rear Brake Cable

Ignition Switch Speedometer Cable

Instrument Cable

Charging Indicator Buzzer

Secondary
Air Cleaner

Regulator/Rectifier Resistor

Horn
Front Brake Fluid
Tube

1-15
1. GENERAL INFORMATION

Regulator/Rectifier

Charging Indicator

Secondary Air Inlet Tube

Wire Harness

Speedometer Cable

Throttle Cable

Resistor

Front Brake Fluid Tube

Rear Brake Cable

Secondary Air Inlet Tube

1-16
1. GENERAL INFORMATION

Battery (+) Cable

CDI Unit

Battery (-) Cable Wire Harness

Ground

Fuse Battery (-) Cable

CDI Unit

Reserve Fuse
Battery (+) Cable

1-17
 1. GENERAL INFORMATION

Crankcase Breather Tube

Vacuum Tee

Ignition Coil

Throttle Cable
Fuel Valve Vacuum Tube

Auto Bystarter Wire

Fuel Tube

A.C. Generator Wire

Fuel Vapor
Recovery Tube

Ground

1-18
 1. GENERAL INFORMATION

Fuel Vapor Tube Fuel Unit

Fuel Tube

Carburetor
Vacuum Tube

Charcoal Canister/
Purge Control Valve
Auto Bystarter Wire

Starter Relay

Throttle Cable

Starter Relay Starter Motor Wire

Wire Harness

Crankcase Breather Fuel Unit

Tube

Reed Valve

Vacuum Tee

Auto Bystarter
1-19
1. GENERAL INFORMATION
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START

Inspection/Adjustment Symptom Probable Cause

Check if fuel reaches

carburetor by
loosening drain screw Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Fuel does not Clogged float oil passage
Fuel reaches Clogged fuel tank cap breather
carburetor reach carburetor hole
Clogged fuel filter
Clogged fuel strainer
Faulty auto fuel valve
Remove spark plug
and install it into
spark plug cap to test Faulty charging system
spark by connecting it Faulty spark plug
to engine ground Fouled spark plug
Faulty CDI unit
Spark jumps Weak or no spark Faulty pulser coil
Broken or shorted ignition coil
Broken or shorted exciter coil
Faulty ignition switch
Weak or dead battery
Test cylinder
compression
Faulty starter clutch
Valve clearance too small
Improper valve and seat contact
Normal Low or no Worn cylinder, piston and piston
compression compression rings
Leaking cylinder head gasket
Seized valve
Improper valve timing
Start engine by follow-
ing normal starting
procedure
Faulty auto bystarter
Engine does not Engine fires but Air leaking through intake
fire does not start pipe
Incorrect ignition timing
Incorrectly adjusted pilot screw

Remove spark plug and

inspect again

Flooded carburetor
Dry spark plug Wet spark plug Faulty auto bystarter
Throttle valve excessively
open

1-21
1. GENERAL INFORMATION

ENGINE LACKS POWER

Inspection/Adjustment Symptom Probable Cause

Start engine and accelerate
lightly for observation Clogged air cleaner
Restricted fuel flow
Clogged fuel tank cap breather hole
Engine speed Engine speed does not Clogged exhaust muffler
increases increase sufficiently Faulty auto bystarter
Split carburetor vacuum piston
Check ignition timing diaphragm
(using a timing light) Faulty auto fuel valve
Faulty CDI unit
Correct timing Incorrect timing
Faulty pulser coil
Check valve clearance
Improper valve clearance
Correct Incorrect adjustment
Worn valve seat (valve stem too
protruding
Test cylinder compression
Improper valve and seat contact
Normal Abnormal Worn cylinder and piston rings
compression compression Leaking cylinder head gasket
Improper valve timing
Check carburetor for
clogging

Not clogged Clogged Clogged carburetor jets

Remove spark plug and

inspect

Plug not fouled or Plug fouled or Fouled spark plug

discolored discolored Incorrect heat range plug
Remove oil dipstick and
check oil level and condition
Oil level too high
Correct and not Incorrect or
contaminated Oil level too low
contaminated Oil not changed
Remove cylinder head oil
pipe bolt and inspect
Clogged oil pipe
Valve train lubricated Valve train not
properly lubricated properly Faulty oil pump

Check if engine overheats

Worn cylinder and piston rings
Mixture too lean
Engine does not Engine overheats Poor quality fuel
overheats Excessive carbon buildup in
combustion chamber
Ignition timing too early
Rapidly accelerate or run
at high speed
Excessive carbon build-up in
combustion chamber
Engine does not knock Engine knocks Poor quality fuel
Clutch slipping
Mixture too lean
Ignition timing too early

1-22
1. GENERAL INFORMATION

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

Faulty CDI unit

Correct timing Incorrect timing
Faulty pulser coil

Check carburetor pilot

screw adjustment

Mixture too rich (turn screw

Correctly adjusted Incorrectly out)
adjusted Mixture too lean (turn screw
in)

Check carburetor
gasket for air leaks
Deteriorated O-ring
Carburetor not securely
No air leak Air leaks tightened
Damaged insulator rubber
Broken vacuum tube
Remove spark plug
and install it into
spark plug cap to test
spark by connecting it
to engine ground
Faulty or fouled spark plug
Faulty CDI unit
Weak or inter- Faulty A.C. generator
Good spark mittent spark Faulty ignition coil
Broken or shorted spark plug
wire
Faulty ignition switch
Check air cut-off
valve

Faulty air cut-off valve

Good Faulty Damaged vacuum tube
Clogged or damaged air vent
hole

1-23
1. GENERAL INFORMATION

POOR PERFORMANCE (AT HIGH SPEED)

Inspection/Adjustment Symptom Probable Cause

Check ignition timing

Faulty CDI unit

Correct timing Incorrect timing
Faulty pulser coil

Check valve clearance

Improperly adjusted valve

Correctly adjusted Incorrectly adjusted clearance
Worn valve seat
Check fuel pump for
fuel supply
Empty fuel tank
Clogged fuel tube or filter
Fuel flows freely Fuel flow restricted Clogged Fuel tank cap breather
hole
Faulty auto fuel valve
Check carburetor jets
for clogging

Not clogged Clogged Clean and unclog

Check valve timing

Correct Incorrect Cam timing gear aligning

marks not aligned

Check valve spring

tension

Not weakened Weak spring Faulty spring

1-24
1. GENERAL INFORMATION

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)

Undercharging

Inspection/Adjustment Symptom Probable Cause

Start engine and test

limit voltage of
battery terminals
Voltage does not Dead battery
Normal voltage
increase Faulty battery

Measure resistance
between AC generator
coil terminals
Faulty A.C. generator coil
Normal Resistance too Broken yellow wire
high Loose connector
Connect battery (+)
wire to
regulator/rectifier
coupler red wire and
battery (-) wire to engine
ground and test voltage Normal voltage No voltage Broken red wire

Check
regulator/rectifier
coupler for loose
connection
Faulty regulator/rectifier
Normal Abnormal
Poorly connected coupler

Faulty A.C. generator

Overcharging

Inspection/Adjustment Symptom Probable Cause

Connect battery (+)

wire to
regulator/rectifier
coupler green wire and
battery (-) wire to engine
ground and test voltage Battery has Battery has no
voltage with voltage with Broken green wire
ignition switch ignition switch
“ON” “ON”
Check
regulator/rectifier
coupler for loose
connection

Normal Abnormal Poorly connected coupler

Faulty regulator/rectifier

1-25
1. GENERAL INFORMATION

NO SPARK AT SPARK PLUG

Inspection/Adjustment Symptom Probable Cause

Replace with a new

spark plug and inspect
again

Weak or no spark Good spark Faulty spark plug

Check spark plug cap

and high-tension wire
for looseness

Not loose Loose Loose spark plug cap

Check CDI unit

coupler for looseness

Good Good Poorly connected coupler

Measure resistance
between terminals of
CDI unit coupler

Normal Abnormal

Check related parts

Faulty ignition switch

Weak battery
Normal Abnormal Faulty pulser coil
Faulty ignition coil
Faulty charging system
Broken wire harness
Poorly connected coupler

Check CDI unit with a

CDI unit tester

Normal Abnormal ÅFaulty CDI unit

Check ignition coil

with a CDI unit tester

Abnormal ÅFaulty ignition coil

1-26
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