HIPSTER125/150
PREFACE TABLE OF CONTENTS This Service Manual describes the technical features and servicing procedures for the KYMCOHipster125.
ENGINE
Section 1 contains the precautions for all operations stated in this manual. Read them carefully before starting any operation.
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
2
LUBRICATION SYSTEM
3
FUEL SYSTEM
4
ENGINE REMOVAL/INSTALLATION
5
CYLINDER HEAD/VALVES
6
CYLINDER/PISTON
7
9
CRANKCASE/CRANKSHAFT/TRANS10 MISSION SYSTEM/STARTER SPINDLE
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.
INSPECTION/ADJUSTMENT
CLUTCH/GEAR SHIFT MECHANISM
CHASSIS
Sections 5 through 18 give instructions for disassembly, assembly and inspection of engine, chassis frame and electrical equipment.
1
STARTER MOTOR/GENERATOR/ LEFT CRANKCASE COVER/STARTER 8 CLUTCH/CAMSHAFT
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.
GENERAL INFORMATION
FRONT WHEEL/SUSPENSION/ STEERING
11
REAR WHEEL/BRAKE/SUSPENSION
12
HYDRAULIC BRAKE
13
REAR CARRIER/REAR FENDER/ EXHAUST MUFFLER
14
IGNITION SYSTEM
15
CHARGING SYSTEM
16
STARTING SYSTEM
17
LIGHTS/INSTRUMENTS/SWITCHES/ HORN
18
1. GENERAL INFORMATION
HIPSTER 125/150
1
1
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GENERAL INFORMATION __________________________________________________________________________________
ENGINE SERIAL NUMBER ---------------------------------------------SPECIFICATIONS ---------------------------------------------------------SERVICE PRECAUTIONS -----------------------------------------------TORQUE VALUES --------------------------------------------------------SPECIAL TOOLS ----------------------------------------------------------LUBRICATION POINTS -------------------------------------------------CABLE & HARNESS ROUTING ---------------------------------------WIRING DIAGRAM-------------------------------------------------------TROUBLESHOOTING-----------------------------------------------------
1- 1 1- 2 1- 4 1-12 1-13 1-14 1-15 1-17 1-18
1-0
1. GENERAL INFORMATION ENGINE SERIAL NUMBER
Location of Engine Serial Number
1-1
HIPSTER 125/150
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1. GENERAL INFORMATION
HIPSTER 125/150
SPECIFICATIONS
Ignition System
Electrical Equipment
Transmission Gear
Power Drive
System
Moving Device
Air cleaner type Paper element type Fuel capacity 12.0 liter Type CVK Piston dia. (mm) φ26.5 Venturi dia.(mm) φ26 Throttle type Piston type Type CDI Ignition timing 34.5° ±2/4000rpm Spark plug NGK-DR8EA Spark plug gap 0.6 0.7mm 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 Reduction 3rd gear 1.4 ratio 4th gear 1.130 5th gear 0.923 Front 1.75 Tire pressure (kg/cm²)(2 riders) Rear 2.25 Left 43° Turning angle Right 43° Front Disk brake Brake system type Rear Drum brake Carburetor
Fuel System Damping Device
Engine
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 Dry weight (kg) Rear wheel 80 Total 139 Front wheel 67.5 Gross weight(kg) Rear wheel 91 Total 158.5 Front wheel 3.00-18-4PR Tires Rear wheel 130/90-15-4PR Ground clearance (mm) 150 Starting motor & Starting system 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 13 (kg/cm²) Max. output (ps/rpm) 11.5/9000 Max. torque (Kg.m/rpm) 1.0/6000 Intake Open 5.5 (mm) Close 27.5 Port timing Exhaust Open 4 (mm) Close 36 0.06mm Valve clearance Intake (cold) Exhaust 0.06mm Idle speed (rpm) 1600rpm Forced pressure & Lubrication type wet sump Oil pump type Inner/outer rotor Oil filter type Wire gauze filter Oil capacity 1.0L SAE#30 Cooling Type Air cooling
Shock absorber type
Front
Telescope
Rear
Double swing
Frame type
Double cradle
Lubrication System
SPECIFICATIONS
1-2
1. GENERAL INFORMATION
Air cleaner type Fuel capacity Type Piston dia. (mm) Venturi dia.(mm) Throttle type Type Ignition timing Spark plug Spark plug gap Battery Capacity Clutch Type Type Operating method Type Carburetor
Ignition System
Electrical Equipment
Transmission Gear
Moving
y
1st gear Reductio 2nd gear 3rd gear n ratio 4th gear 5th gear
Front (kg/cm²)(2 riders) Rear Left Turning angle Right Front Brake system type Rear Tire pressure
Damping Device
Lubrication System
1-3
S y
Engine
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 Dry weight (kg) Rear wheel 80 Total 139 Front wheel 67.5 Gross weight(kg) Rear wheel 91 Total 158.5 Front wheel 3.0-18-4PR Tires Rear wheel 130/90-15-4PR Ground clearance (mm) 140 Starting motor & Starting system 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 13 (kg/cm²) Max. output (Ps/rpm) 14/9000 Max. torque (Kg.m/rpm) 1.1/7500 Intake Open 0 (1mm) Close 30 Port timing Exhaust Open 0 (1mm) Close 30 Intake 0.06mm Valve clearance (cold) Exhaust 0.06mm Idle speed (rpm) 1600rpm Forced pressure & Lubrication type wet sump Oil pump type Inner/outer rotor Oil filter type Wire gauze filter Oil capacity 1.0L SAE#30 Cooling Type Air cooling
HIPSTER 125/150
Shock absorber type
Frame type
Paper element type 12.0L CVK φ26.5 φ26 Piston type CDI 34.5° ±2/4000rpm NGK-CR8EH9 0.6 0.7mm 12V6AH Wet multi-disc clutch Permanent gear meshing
Foot operated International type 2.846 2.063 1.4 1.130 0.923 1.75 2.25 45° 45° Disk brake Drum brake
Front
Telescope
Rear
Double swing Double cradle
1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
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
1-5
1. GENERAL INFORMATION and repair it. Replace it with a new one according to the specified capacity.
HIPSTER 125/150 Confirm 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.
1-6
1. GENERAL INFORMATION 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.
1-7
HIPSTER 125/150
Snapping!
1. GENERAL INFORMATION
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.
No Contact !
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.
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1. GENERAL INFORMATION Route harnesses so they are neither pulled tight nor have excessive slack.
HIPSTER 125/150
Do not pull too tight!
Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.
When rubber protecting cover is used to protect the wire harnesses, it shall be installed securely.
Do not break the sheath of wire. If a wire or harness is with a broken sheath, repair by wrapping it with protective tape or replace it.
When installing other parts, do not press or squeeze the wires.
1-9
Do not press or squeeze the wire.
1. GENERAL INFORMATION
HIPSTER 125/150
After routing, check that the wire harnesses are not twisted or kinked.
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.
When a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions.
Do you understand the instrument? Is the instrument set correctly?
Be careful not to drop any parts.
When rust is found on a terminal, remove the rust with sand paper or equivalent before connecting.
Remove Rust !
Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind.
1-10
1. GENERAL INFORMATION „ Symbols: The following symbols represent the servicing methods and cautions included in this service manual.
Engine Oil
: Apply engine oil to the specified points. (Use designated engine oil for lubrication.)
: Apply grease for lubrication. Grease
Special
: Use special tool.
: Caution
: Warning
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HIPSTER 125/150
1. GENERAL INFORMATION
HIPSTER 125/150
TORQUE VALUES STANDARD TORQUE VALUES Item 5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut
Torque (kg-m) 0.45 0.6 0.8 1.2 1.8 2.0 3.0 4.0 5.0 6.0
Item 5mm screw 6mm nut, SH bolt 6mm flange bolt, nut 8mm flange bolt, nut 10mm flange bolt, nut
Torque (kg-m) 0.35 0.5 0.7 1.1 1.0 1.4 2.0 3.0 3.5 4.5
Torque specifications listed below are for important fasteners. ENGINE Item Cylinder head bolt A Cylinder head bolt B Oil filter screen cap Exhaust muffler joint lock nut Valve adjusting lock nut Oil bolt Cylinder bolt A.C. generator bolt Cylinder head cover bolt Oil pump bolt Oil filter lock nut Rocker arm lock bolt Cylinder head lock bolt Cylinder bolt Crankcase assembly bolt Crankshaft damper bolt Right crankcase cover bolt Left crankcase cover bolt A.C. generator coil lock bolt Starter gear set plate bolt Carburetor lock bolt
Q‘ty Thread dia.(mm) Torque (kg-m) 2 2 1 2 2 1 2 1 4 2 1 3 1 2 10 1 8 4 4 1 2
8 8 30 6 5 12 6 14 6 6 16 8 8x79 6x22 6 6x25 6 6 5 6 6
2.8 2.8 1.5 0.8 1.4 2.0 0.8 4.0 0.8 0.7 1.5 1.5 1.5 0.8 0.8 0.8 0.8 0.8 0.4 1.0 0.8
3.2 3.2 3.0 1.2 1.8 3.0 1.2 5.2 1.2 1.1 3.0 2.0 2.0 1.2 1.5 1.2 1.2 1.2 1.7 1.6 1.2
Remarks Double end bolt Double end bolt Double end bolt
FRAME Item Steering stem lock nut Front axle nut Rear axle nut Rear shock absorber upper mount bolt Rear shock absorber lower mount bolt
Rear fork pivot nut Handlebar lock bolt Rear driven gear bolt Rear brake panel bolt
Q‘ty Thread dia.(mm) Torque (kg-m) 1 1 1 2 2 1 4 4 1
22 14 16 10 10 12 6 8 8
6.0 5.5 6.0 3.0 3.0 5.5 6.0 1.8 1.8
Remarks
9.0 7.0 8.0 4.0 4.0 7.0 9.0 2.0 2.5
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1. GENERAL INFORMATION
HIPSTER 125/150
SPECIAL TOOLS Tool Name
Tool No.
Flywheel puller Bearing puller 18mm Lock nut socket wrench
E005 E008 E010
Tappet adjuster Oil seat & bearing install Bearing puller 15mm Bearing puller 12mm Flywheel holder
E012 E014 E018 E020 E021
Crankshaf bearing puller
E030
Bearing puller 10mm
E031
Race cone install
F005
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Remarks
Ref. Page
1. GENERAL INFORMATION
HIPSTER 125/150
LUBRICATION POINTS
Grease
Throttle Cable
Engine Oil
Clutch Cable
Grease
Speedometer Cable
Front Brake Fluid Tube
1-14
1. GENERAL INFORMATION
HIPSTER 125/150
CABLE & HARNESS ROUTING
Handlebar Switch Connectors
CDI Unit
A.C. Generator Wire Connector
Wire Harness Fuel Filter
Ignition Coil
Fuel Tube Ignition Switch
Taillight Wire Connector
1-15
1. GENERAL INFORMATION Starter Relay
HIPSTER 125/150 Battery Positive Cable
Negative Cable
Fuse Box
Starter Motor Wire
Winker
Throttle Cable Purge Control Valve
CDI Unit
Vacuum Tube
A.I.C.V.
Ignition Coil Wire
A.C.V. Vacuum Tube A.C.V. Accelerating Pump Cable
Air Cleaner
Clutch Cable
1-16
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• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
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