@© KYmco COBRA TOP BOY 50/100Dear KYMCO Motorcycle Users: Before the delivery of each new motorcycle, the fuel in carburetor is “drained off to ensure the excellent performance and safety of the motorcycle. Therefore, when first starting a new motorcycle, it is normal to take 20 ~ 30 seconds. The quality of each KYMCO motorcycle is guaranteed.Dear Users: We greatly appreciate your patronage of KYMCO TOP BOY 50/100. This User‘s Manual describes the correct operating methods, inspection and maintenance procedures for the KYMCO TOP BOY 50/100 in details in order to prolong the service life of motorcycle and provide you with a comfortable riding. The model meets the 2nd Phase Environmental Protection Motorcycle Emission Control Standards; therefore, it meets the environmental protection requirements of low pollution and low noise. Although this motorcycle is of high quality, periodic inspection and maintenance are also required to keep it in the best condition. To enable you to have a safe and comfortable riding, we recommend you to read this manual carefully and wish you a‘happy riding. Note: The contents of this manual may be different from the motorcycle in case specifications are changed. The information and specifications stated in this manual are for reference only and subject to change without notice.ere PI As . PRECAUTIONS FOR A SAFE RIDING . CORRECT RIDING .... '. HOW TO STOP RIDIN! . PRE-RIDE INSPECTION/PERIODIC INSPECTION TABLE OF CONTENTS ASSEMBLY PART! OPERATIONS...... IGNITION SWITCH/STEERING HANDLEBAR Li STARTER BUTTON/HEADLIGHT SWITCH... HEADLIGHT DIMMER SWITCH/HORN BUTTON, TURN SIGNAL SWITCH/INSTRUMENTS.... MOTOR OIL INDICATOR LIGHT/ SEAT LOCK/ HELMET BUCKLE/MET-IN BOX, START THE ENGINE FOR RIDING CORRECT RIDING METHOD..... PREVIOUS ABNORMAL PARTS‘INSPECTION/BRAKE PERFORMANCE CHECK.. TIRE INSPECTION... MOTOR OIL LEVEL INSPECTION/REFILLING. FUEL LEVEL INSPECTION/REFILLING ..TABLE OF CONTENTS STEERING HANDLEBAR INSPECTION... CHECK LIGHTS FOR DIRT AND DAMAG! BRAKE FLUID/BRAKE LEVER FREE PLA’ 9. EASY MAINTENANCE... LUBRICATION OF EACH PART/AIR CLEANER INSPECTION/ AIR CLEANER CLEANING & REPLACEMENT... TRANSMISSION GEAR OIL/FUEL SYSTEM/SPARK PLUG CHECK/ BATTERY INSPECTION FUSE CHANGE.. WIRE & CABLE RUBBER COVER CHECK/IN CASE OF BREAKDOWN 10, POLLUTION-FREE PERIODIC MAINTENANCE SCHEDULE 11. SPECIFICATIONS... 3 The information stated in this manual may be different from the motorcycle in case specifications are changed.1 PRECAUTIONS FOR A SAFE The rider must wear helmet, gloves and goggles. ‘¢ Do not wear any clothes which will affect riding safety. Loose cuff may hook the brake lever or clutch lever and pants with loose bottom may be drawn into the drive chain. It is very dangerous. ‘The operation of brake lever and clutch lever shall not be affected. © Peruse this Users Manual carefully.¢ Pre-ride inspection ‘© The exhaust contains poisonous carbon It is necessary to perform daily and periodic monoxide which is harmful to human body. inspection. Start the engine in a well-ventilated area.‘© After the engine is stopped, the temperature of engine body and exhaust muffler is very high. Donot touch them. ‘© When parking the motorcycle, keep it away from dry lawn or inflammables to avoid danger. ‘The temperature of exhaust muffler is very high after the engine is just stopped, Park the motorcycle with the e wall to avoid scalding, aust muffler facing, © When riding, use both hands to grasp the handlebar and put feet on the floor board. The back rider shall hold the first rider around the waist with two hands and put feet on the foot rests on each side. © When getting on or down the motoreycle, the back rider shall be more careful to avoid burns because the temperature of exhaust muffler is very high,© Do not make sharp turn of drive with one hand. _ The fee! of the handlebar will be different Make sure to observe traffic laws. when carrying goods on the motorcycle. Avoid riding with overload and the goods shall be securely fixed to have a safe riding.© When refi gasoline, do not smoke or allow flames or sparks near the working area. When refilling gasoline, be sure to stop the engine. ‘© The motorcycle structure is closely related to its function. To modify the motorcycle at will may affect the motorcycle servige life and riding safety. _ To modify the motorcycle at will is not allowed by law. Never make any modification. ‘Once a motorcycle is modified, its warranty will be no longer valid.FOR A SAFE RIDI To relax and wear comfortable clothes are the main points for a safe riding, To observe traffic laws, keep a cool mind, relax and be careful will provide you a safe riding. CAUTION: ‘#A motorcycle rider should not wear loose or 100 long clothes to avoid danger. ‘© During riding or 30 minutes after the motor- cycle is stopped, do not touch the exhaust muffler to avoid scalding. J* When parking the motorcycle, keep it away from dry lawn or inflammiables to avoid danger. CLOTHES Have the clothes © Wear helmet and well-arranged. fasten it tightly. Fasten the cuff and keep it from hooking the brake lever. ” Wear low-heeled ‘¢When riding, use both "shoes for a safe hands to grasp the riding. handlebar. It ts very dangerous to hold the handlebar with one hand. 6CARRYING GOODS Maximum loading capacity of the met- inbox is 10k. * Maximum loading capacity of the front tool box is 1.5kg.2. ASSEMBLY PARTS ‘Turn Signal Indicator Light High Beam Indicator Light Motor Oil Indicator Light Fuel gauge Mileage Counter Met-in Box (Helmet) Rear Brake Lever Left Front Turn Signal Light Motor Oil Filler Left Rear Turn. Front Too! Box Signal Light Helmet Buckle Kick Lever Main Stand Side StandHeadlight Dimmer Switch & Passing Signal Switch Tum Signal Switch Horn Button Fuel Filler Seat Lock Headlight Switch Starter Button Front Brake Lever Ignition Switch Tailligh/Stoplight Right Rear Turn Signal Light Exhaust Muffler:3. OPERATIONS () IGNITION SWITCH At this position, the steering handlebar is locked and the key can be taken out. wer is cut off and cen out. Lock At this position, OFF ] the key‘can be GN] At this position, power is connected and the key cannot be taken out. CAUTION: During ring, do not tum the ignition switch to “ON” or “LOCK” because it is the main cause of traffic accident. (2) STEERING HANDLEBAR LOCK When parking, the steering handlebar should be locked to prevent pilferage. Locking Method: Turn left the steering handlebar to the full and then press to turn the key to “LOCK™ position Take out the key. Unlocking Method: Turn the key from “LOCK” to “OFF” and the lock is released automatically. (CAUTION: ‘After the ignition switch is turned to LOCK", gently turn the handlebar to make sure it is locked. JeDon't park your motorcycle at a place to hinder the traffic. ~10-(3) STARTER BUTTON When starting the engine, first turn on the ignition switch and press the starter button [CAUTION : When using the starter button, be sure to apply the left rear brake lever’in order to lock the rear wheel and connect the power supply. (4) HEADLIGHT SWITCH At this position, the headlight, taillight Wand instrument lights go out. say. At this position, the instrument lights QDS and tai ight come on together. ey do not light if the engine is not started. At this position, the headlight, taillight and instrument lights come on together. They do not light if the engine is not started. -l-(5) HEADLIGHT DIMMER SWITCH & (6) HORN BUTTON PASSING SIGNAL SWITCH Headlight Dimmer Switch ED. Switch to this position for using high beam. Turn the ignition switch “ON” (It is no need to When riding in downtown area or there start the engine.) and press the horn button, the hor will sound. is a car coming from the opposite direction, switch to [LO] - [PASSING]]] When passing, continuously press and release the dimmer switch at the PASSING position and then the headlight. {will wink to warn the coming cars. -12-(7) TURN SIGNAL SWITCH > | For turning to the “right”. 4] For turning to the “left”. It only works when the ignition switch is turned “ON”. ‘* Press the turn signal switch button to release the function. CAUTION: }° The turn signal light will not release automatically. Be sure to reset it after use; otherwise it may affect the traffic safety. -13-(8) INSTRUMENTS FUEL GAUGE The fuel gauge is to show the volume of gasoline in the fuel tank. If the fuel gauge pointer is at the red area, there is only about | liter of gasoline left. Refill 92# or 95# non-leaded gasoline as. early as possible. TURN SIGNAL INDICATOR LIGHT When the tum signal switch is operated, this indicator light will wink and the buzzer will sounk HIGH BEAM INDICATOR LIGHT This indicator tight comes on when the long distance light is turned on. MILEAGE COUNTER The total riding mileage is indicated by kilometer. Turn Sign: Fuel Gauge Indicator Lights Mileage Counter High Beam Indicator Light -14-(9) MOTOR OIL INDICATOR LIGHT When the ignition switch is turned “ON”, it is normal if the motor oil indicator light comes on for Several seconds and then goes out , , a Me The motor oil tank capacity is about 1.5 lotor Oil Indicator Light liters and the remaining volume is 0.6 liter. If the motor oil indicator light comes on or winks, add SAE20W-20, JASO-FC or API- TC motor oil. -15-(10) SEAT LOCK When using the met-in box or adding motor oil , the seat should be opened and ied up. Seat Opening Method: 1. Insert the ignition switch key into the seat lock on the seat rear end and turn it right, 2. Lift up the seat, Seat Closing Method: 1. Put down the seat and press it down to make it lock automatically. 2. Slightly pull up the seat rear end to make - sure that it is locked. CAUTION: ‘Never put the key under the seat and then the seat. (11) HELMET BUCKLE Helmet Buckle (\ ass Usage: 1. Open the seat lock and lift up the seat. 2. Put the helmet retaining ring into the helmet buckle. 3. Put down the seat and it will lock automatically. Unfastening: ‘© Take out the helmet as per Usage 1. |CAUTION: ‘When riding, do not retain the helmet on the motorcycle to avoid damage of mechanical parts or coated appearance, -16-(12) MET-IN BOX The met-in box is under the seat. Refer to P16 for seat opening and closing. Make sure to place the helmet upright in the x. CAUTION: The load ofthe met-in box shall not exceed 2. ‘¢Make sure that the seat is locked. ‘©The temperature of engine is very hi never put food, low heat-resisting an flammable artictes in it, so Cautions for use: # Do not put precious or fragile articles in it. © Be careful that water may enter into the box when washing the motorcycle. ‘© Do not put oversize helmet in it ‘© The helmet hood should not contact the box to cause friction. ‘# Do not ride the motorcycte with the helmet in the met-in box. -17-4. START THE ENGINE FOR RIDING © Check the gasoline volume and motor oil level before starting the engine. ‘© Be sure to erect the main stand while starting the engine. (CAUTION: In order to prevent the motorcycle from rushing out with high speed, make sure to lock the rear wheel. ‘lf the rear brake lever free play is incorrect, the rear wheel cannot be braked and it will cause danger easily. (1) TURN THE IGNITION SWITCH “ON” “a CAUTION: ‘* When the ignition switch is turned “ON”, if the motor oil indicator light does not light, open te motor oil tank to check the ol level -18-(2) LOCK THE REAR WHEEL Apply the rear brake lever to connect the power for starting. (3) PUSH THE STARTER BUTTON WITHOUT ROTATING THE THROTTLE GRIP CAUTION: Ifthe rear brake lever free play is incorrect, the rear wheel cannot be braked and it will cause danger easily. -19- CAUTION: #Keep your finger away from the button immediately after the engine is started. ‘*Do not press the starter button after the engine {s started; otherwise the engine will be damaged.If the engine fails to start after the starter button is pressed for [3 ~ 4] seconds when it is warm, rotate the throttle grip for 1/8 ~ 1/4 turn to facilitate starting, © When the motorcycle is not used for a long time or the fuel tank is empty, if the engine is Still hard to start after the fuel tank is relilied with gasoline, slightly turn the throttle grip and press the starter button for several times to start the engine. In order to avoid battery overcharge, do not press the starter button more than 13 seconds. © If the engine does not start after the starter button is pressed for 15 seconds, wait for more than 15 seconds and then press the button again or start the engine by the kick lever. -20-(4) START BY THE KICK LEVER I. Place the motorcycle on its main stand on lever ground, CAUTION: 2. Depress the kick lever with force. ‘# After the engine is started, the kick lever must be returned to its original position. When the engine is cold and does not start after the kick lever is depressed for 3 ~ 4 times, rotate the throttle grip for 1/8 ~ 1/4 turn to facilitate starting.. ‘© Warm up the engine for a little while (about 2 ~ 3 minutes) afier cold start. © After the engine is started, do not accelerate Suddenly and keep riding at low speed to prolong the engine service life. -21-5. CORRECT RIDING METHOD (2) RIDING (1) REBOUND THE MAIN STAND. ‘@ Keep the rear brake lever at brakin, position and push the motorcycle forward, the main stand will rebound automatically. @ Ride astride on the motorcycle from the left side and sit upright. Touch the ground with left foot to avoid slipping CAUTION: |CAUTION: @ After starting the engine and before moving, ¢Keep the rear brake lever at braking position ‘do not turn the throttle grip to increase the before moving. engine speed. -22-(3) RELEASE THE BRAKE WHEEL Release the rear brake lever. (4) ROTATE THE THROTTLE GRIP Release the rear brake lever and slowly rotate the throttle grip, then the motoreycle will move smoothly. CAUTION: do not rotate the throttle grip suddenly to prevent the motorcycle from rushing out. |* After the rear wheel brake lever is released, -23- « Slowly rotate the throttle grip and the ql motorcycle will move smoothly. Do not rotate the throttle grip rapidly and suddenly; otherwise the motorcycle will rush out at high speed.6. CORRECT RIDING (1) SPEED CONTROL The speed is controlled by the throttle grip. # Before moving, turn on the turn signal igh ROTATE---~ The Pee haety become faster eis sae. and make sure whether the rear si slowly, When riding on an ascending road, rotate the throttle grip gradually to increase the horse power. RESTORE-— The speed will become slower. Restore the throttle grip quickly. -24-(2) PROPER RIDING WILL PROLONG (3) APPLY BOTH FRONT AND REAR THE SERVICE LIFE OF ENGINE BRAKES WHEN BRAKING ‘First restore the throttle grip to the closed position and then pull the brake levers tight. ‘© The best way to brake the motorcycle is to ‘© For a new motorcycle, keep the speed * ull the brake levers “slowly” at the very below 40km per hour within the first reginning, then pull them tight. month of riding. Avoid sudden acceleration and long-time riding at high speed. -25-(4) DO NOT MAKE SUDDEN STOP OR SHARP TURN ‘© Sudden stop and sharp turn are the main causes for slipping and could be very dangerous. In rainy days the road is slippery. Sudden stop will cause the motoreycle to slip. Be careful to avoid danger. -26- (5) BE MORE CAREFUL WHILE RIDING IN RAINY DAYS. © A longer braking distance is required in rainy days than in sunny days. - Be sure to slow down the speed and brake the motor- cycle slowly as early as possible ‘© When riding on a descending road, restore the throttle grip to closed position and slow down by making intermittent braking.7. HOW TO STOP RIDING (1) WHILE GO NEAR THE PARKING PLACE ‘© Tum on the turn signal light in advance. Watch out vehicles coming behind or aside and stop the motorcycle to the right side slowly. ‘© Restore the throttle grip to closed position and apply the front and rear brakes as carly as possible. ‘At this rhoment, the stoplight comes on to arn the vehicles coming behind (2) STOP THE ENGINE the turn signal switch to its original ion and turn the ignition switch CAUTION: ‘* During riding, never operate the ignition switch key. When the ignition switch is turned to “OFF” or “LOCK”, the electric system will not work which may result in traffic accident. Operate the switch after the motorcycle is fully stopped. -27-(3) PARKING (4) LOCK THE STEERING HANDLEBAR, © Place the motorcycle on its main stand on ‘After parking, be sure to lock the steering level ground and do not hinder the traffic, handlebar and take out the key to prevent (The motorcycle may easily fall down if it pilferage. (Refer to P10.) is parked on an uneven ground.) ‘ Stand on the left side and grip the handlebar straight with left hand and the side rod or rear carrier with right hand. Then, step down the main stand evenly with right foot and pull the motorcycle backward by force with right hand. t oe ° (CAUTION: «Don't park your motorcycle at a place to hinder the traffic, The temperature of engine and exhaust muffler ts very high. Be careful to avoid scalding. -28-8. PRE-RIDE INSPECTION & PERIODIC INSPECTION For the sake of safety and to prevent traffic accidents, be sure to perform the pre-ride inspection ‘* For inspection within the first manth or the first 1000km, go to a KYMCO service station, contracted service station or your motorcycle dealer, * Frequently perform exhaust emission test and adjustment to avoid air pollution and penalty. (1) PRE-RIDE INSPECTION -29- The pre-ride inspection is the inspection performed by the motorcycle user once a day before riding. Previous abnormal symptoms © Brake lever free play * Brake fluid (Disk brake) « Tire pressure, cracks and damages, abnormal wear or imbedded foreign objects of metal piece and gravel ‘© Depth of tire groove © Gear oil or motor oil ‘© Fuel level ights, bulbs and turn signal indicator Rearview mirror angle License plate for dirt or damage Reflector for dirt or damage(2) PREVIOUS ABNORMAL PARTS (3) BRAKE PERFORMANCE CHECK INSPECTION Make sure that the previous abnormal parts Ride the motorcycle at low speed on a dry are repaired. road and respectively apply the front and Check the brake levers for correct free play. rear brakes to check the brake performance. { Brake Lever Free Play ) Brake lever should have proper free play. Free play means the distance from the sition of loose brake to the position of fully applied brake. When the free play is proper, check the brake lever for smooth operation. Measure the free play a the brake lever end Pree Play and check if it is within the specified value | ~ 2em of | ~ 2em, ~30(4) TIRE INSPECTION ( Tire Pressure Check } Check if the tire pressure is normal when the tire i in contact with level groun If there is any abnormai condition, check the tire pressure with a tire pressure gauge. Measure the tire pressure under room temperature: TRider | 2 Riders Front Wheel | 1.75kg/em? | 1.75kg/em? Rear Wheel | 2.00kg/em? | 2.25k/em? xO x. OO 31- (5) ( CRACKS & DAMAGE ) Gheck the tire-contact area for crack or jamage- Damage Crack ( Abnormal Wear } ‘Check the tire-contact area for abnormal wear, Abnormal Wear aa(6) ( FOREIGN OBJECTS OF METAL PIECE & GRAVEL ) Check the tires and tire-contact area for imbedded objects of metal piece and gravel. Ms (CAUTION: Abnormal tire pressure, crack, damage and abnormal wear will cause unsteady handlebar and result in tire break. (7) { DEPTH OF TIRE GROOVE ) heck the tite groove wear by refering to the wear limit indication marh If the tire is worn to the wear limit indication mark, replace it with a new one. (Wear Limit Indication) Wear Indication Mark 32(8) MOTOR OIL LEVEL INSPECTION Ifthe motor oil is insufficient, the motor oil ieator light will display. When the itch is turned “ON”, if the indicator light remains on for snore than 3 ~ Fate eet arg oes NOt Be outs check the Motor Oil Indicator Light If the indicator light does not go out, it means that the motor oil is insufficient and should be added with SAE20W-20, JASO- FC or API-TC motor oil CAUTION: J#1f the indicator light comes on, add motor oil to specified level as early as possible. Insufficient motor oil is the main cause of burned engine and breakdown -33-(9) MOTOR OIL REFILLING 1. Place the motorcycle on its main stand on level ground, 2. Open the seat. (Refer to P16.) Open the motor oil tank cap by lifting it up. 4, When refilling the motor oil, the oil level shall not exceed the upper limit. 5. After refilling, press down the motor oil tank cap to close it. 6, Put down the seat and make sure that it is locked. Motor Oil Filler CAUTION: ‘© Use designated SAE20W-20, JASO-FC or {epper Limit API-TC motor oil. Use of unspecified motor oil may cause poor performance or engine damage. '# Be careful not to allow foreign matters or dust entering into the oif tank. : ‘© After refilling, tighten the oil tank cap securely. ‘* When refilling, the oil level shall not exceed the upper limit; otherwise the motor oil will flow out. 34-(10) FUEL LEVEL INSPECTION Check if the fuel is sufficient. ‘If the fuel gauge pointer is on “E” (red line), refill #92 or #95 nonleaded gasoline only as soon as possible, The fuel tank capacity is about 5 liters. Reference Plate Note: Be sure to stop the engine before opening the fuel tank cap. Do not smoke or allow sparks near the working area, -35-(11) FUEL REFILLING « Refilling Method ) 1. Open the seat with the ignition switch key. (Refer to P16.) 2. Turn the tank cap counterclockwise with hand to open the cap. 3. Use only #92 or #95 nonleaded gasoline. 4, Tum the fuel tank cap clockwise to tighten it.The “a” mark on the fuel tank cap shall be aligned with the “A” mark on the fuel tank. 5. Close the fuel tank cap in the reverse order of opening, CAUTION: /* When refilling, do not smoke or allow flames or sparks near the working area. J* Be sure to stop the engine before refilling, |} The gasoline level shall not exceed the reference plate; otherwise the fuel will penetrate out, ‘© When refilling, do not add other additives to avoid engine breakdown, Fuel Tank Cap -36-(22) STEERING HANDLEBAR INSPECTION (Damage ) Visually inspect the steering handlebar for damage. Apply the front brake and move the handlebar upward and downward to check for abnormal noise. ¢ Steering Handlebar Condition } Move the steering handlebar upward, down- ward, rightward and leftward to check for any loose parts.(13) CHECK LIGHTS AND TURN SIGNAL LIGHTS FOR DIRT AND DAMAGE { Headlight Taillight ) ‘Start the engine and turn on the headlight switch to check if the headlight and taillight are good and check the light shells for dirt and damage Headlight { Stoplight Inspection } ¢ Turn the ignition switch “ON”. © Apply the front and rear brake levers, respectively t check ifthe stoplight is ood And also check the stoplight shell for dirt and damage. Taillight/Stoplight{ Turn Signal Light Inspection ) Turn the ignition switch “ON”. ‘© Operate the turn signal switch to make sure whether the righi/Ieft front and rear tur signal lights can wink and buzz Also check the light shells for dirt and damage. (14) CHECK THE REARVIEW MIRROR ANGLE Sit on the motorcycle uprightly and make a viewing test of the rearview mirror angle. (15) CHECK LICENSE PLATE FOR. DIRT AND DAMAGE Check the license plate-for dirt and damage, then tighten it. (16) CHECK THE REFLECTOR FOR DIRT AND DAMAGE Check the reflector for dirt and damage. 39-(17) FRONT BRAKE FLUID INSPECTION ( Brake Fluid Level } eR Keep the handlebar straight and check the right brake fluid tank for fluid level which shal be kept between the upper and lower jimits. . Check the brake shoe for wear when the fluid level is close to the lower limit. . If the wear of brake shoe does not exceed the specified limit, it means there is fluid leakage. In this case, contact our service station or your motorcycle dealer for inspection and repair. Upper Liinit Lower Limit -40-{ Brake Fluid Refilling } 1, Remove the 2 screws from the brake fluid tank and take off the cover. 2. Add recommended brake fluid DOT-3 into the tank until the fluid level reaches the upper limit and then put on the cover and tighten the screws, Screws -41- Recommended Brake Fluid: DOT-3(18) BRAKE LEVER FREE PLAY INSPECTION & ADJUSTMENT Adjust the brake lever free play with the brake adjusting nuts. ‘© Turn the adjusting nuts for adjustment. After adjustment, fully apply the brake levers and check if the free play is within the specified value (1 ~ 2m). « Front ) (Drum Brake) Decrease play Increase play eV NN « Rear } a ela Decrease play Increase play Adjusting Pin “ aeo 84x CAUTION: }* After the brake is adjusted, align the groove of adjusting nut with the pin in order to avoid accident and danger during riding. (19) BRAKE SHOE INSPECTION Check brake shoe service limit, 4 Front > (Drum Brake) » Marks Co { Rear ) CAUTION: When the brake lever is fully applied, mark “2” on the brake indicator aligns with the reference mark “4.” on the brake panel, it means the brake shoe is worn out, Go to our designated distributors or service stations for brake shoe replacing. -42-9, EASY MAINTENANCE (1) AIR CLEANER INSPECTION ‘Take out the air cleaner and visually check if) (20) LUBRICATION OF EACH PART Visually check if each part of the motorcycle is sufficiently lubricated itis dirty or clogged. { Removal } Lever Joint . 1. Remove the 7 screws attaching the air cleaner cover and remove the air cleaner cover, 2. Remove the air cleaner element. -43-(2) AIR CLEANER CLEANING & REPLACEMENT ( Cleaning ) 1, Remove the air cleaner element. 2. Wash the air cleaner element in detergent oil, squeeze out and allow to dry. (Never use gasoline or vaporable oil for washing.) . Soak the element in clean engine oil and squeeze out the excess oil and then install the element and air cleaner. (Contains about 15g engine oil.) Specified Engine Oil: SAE30# « Replacement ) When replacing, refer to P52 Periodic Inspection & Maintenance Schedule. CAUTION: # When washing the element: donot allow flames or sparks near the working area. Never use gasoline to wash the element. ‘¢Be careful not to allow water to enter the air cleaner, otherwise, it may result in hard starting. { Installation > 1. Install in the reverse order of removal. [CAUTION ‘e1f the air cleaner is not installed properly, dust may be sucked into the cylinder directly to reduce engine horse poser and affect the service life of engine.(3) TRANSMISSION GEAR OIL ( Oil Leakage Inspection ) {Inspection & Refilling > Check the transmission gear oi tank For 1. Place the motorcycle on its main stand on level ground. Afier the engine stops for 2 ~ 3 minutes, remove the gear oil check boit to check the oil level. 2, If the oil level is lower than the check bolt hole lower edge, add gear oil to the lower edge. 3. After refilling, securely tighten the check n Gear Oil Filler {Oil Check Bolt Hole { Recommended Gear Oil } SAE90# Gear Oil Oi! Capacity : 120ce AtChange : 100ce Drain Bolt CAUTION: CAUTION: Add gear oil through the oil check bolt hole. ¢Change gear oil at first 300km and then After refilling, use a rag to wipe clean. change at every 5000km. Add specified Excess or insufficient gear oil will affect the gear oil whenever it is necessary engine performance. ‘Never use gear oil of different brand or inferior quality which may result in engine _45- | breakdown.(4) FUEL SYSTEM (5) MOTOR OIL SYSTEM { Fuel Leakage Inspection ) { Oil Leakage Inspection ) Check the fuel line between the fuel tank Check the motor oil tank and oil tube for oil and carburetor for fuel leakage. leakage. Oil Tank Oil Pump -46-(© SPARK PLUG INSPECTION Check the spark plug side electrodes for wear. Fouling deposits on spark plug electrodes and big gap may result in weak spark. ( Spark Plug Removal ) 1. Use a screwdriver to remove the center cover. Remove the spark plug with a spark plug remover The installation sequence is the reverse of removal. 2. 3. Spark Plug tee -47- ( Cleaning ) 1. It is better to remove spark plug deposits with a spark plug cleaner. 2. If'a spark plug cleaner is not available, clean with a wire brush. ( Adjustment ) © The side electrode gap is 0.6 ~ 0.7mm. ( Replacement ) Clean the spark plug at every 1000km and feplace it with anew one at every 5000km or when the center electrode is bumed out. Side electrode Center electrode £5 08~O7™ ( Specified Spark Plug 50ce : NGK-BR8HSA ‘Washer 100ce : NGK-BR6HSA. CAUTION '* The engine is very hot after stopping, be careful to avoid scalding. ‘First screw in the spark plug with fingers and then tighten with a spark plug wrench. Use unspecified spark plug may damage the engine.(7) BATTERY INSPECTION © This model adopts the battery which needs no refilling of distilled water. CAUTION: J*Never open this closed-type battery electrolyte cap. ¢ When the motorcycle is not used for a long time, the battery will discharge electricity by itself. Remove the battery and have it fully charged and put tin cool place to prevent electricity leakage. elf the motorcycle is not used for a long time, remove the negative (-) terminal. ® Battery Terminals Open the seat cushion and remove the 2 screws attaching the battery cover and then open the battery cover # When battery terminals are corroded, take out the battery for cleaning. @ After cleaning, apply a thin coat of grease ‘or Vaseline to battery terminals and then install the battery. -48- CAUTION: #Do not allow flames or sparks near the battery while removing and installing it Turn off the ignition switch before removal or installation. Negative (-) terminal shall be removed first and the positive (+) terminal shall be installed first. Tighten the loose terminal nuts securely.(8) FUSE CHANGE Turn off the ignition switch and check if the fase is bumed out. When the fuse is burned out, replace with a specified fuse. {Removal } 1, Open the seat. 2. Remove the screw attaching the battery cover, 3. Remove the fuse box. 4. Open the fuse box and take out the fuse to pall out the fase clip on each side ofthe use. 5. Check for the cause of breakdown before replacing, Fuse Specification: 7A,CAUTION: Removal Be careful not to excessively expand the fuse clip during removal. #nstallation After a new fuse is installed, check the fuse clip for looseness which is the main cause of trouble. ‘eNever use fuse of unspecified capacity, it ‘may cause wire overheating and burning out. © When replacing electric appliances (lights, instruments), be sure to use genuine KYMCO recommended parts. ‘# Fuses that do not meet the designated specification will burn out easily and cause imbalanced battery load. ‘lf the fuse is burned out frequently, find the cause before replacing; otherwise it will burn out again : elf the cause can not be found, contact our distributor of service station for inspection. ‘# When washing the motorcycle, avoid flushing it ( Removal ) (Installation ) Fest Wire Fuse Clip ora Insert Install Properly -50-(9) RUBBER COVER INSPECTION (10) IN CASE OF BREAKDOWN FOR WIRE AND CABLE For any trouble occurred during riding, go The cable cores are protected by the rubber is ice stati cover outside the connector. Check the toa KYMCO distributor or service station rubber cover frequently for proper Pe flush the rubber cover directly or brush it. during riding, check the following items: Use a wet rag to wipe off dirt and dust. Is the gasoline enough? Ie the fuel gauge pointer isa the red line, refill #92 oF #95 nonleaded gasoli Rubber Cover Is the way to start the engine correet? Check Points Rubber Cover Si-10. POLLUTION-FREE PERIODIC MAINTENANCE SCHEDULE In order to have a safe riding, maintain reduce pollution, make sure to perform Inspect and clean, lubricate, refill, repair or replace if necessary. 00d performance, prolong the periodic inspection and maintenance. Hust C: Clean R: Replace’ T: Tighten the motorcycle service life and iz Item 2 Regular Service Mileage (KM) Daily Pre-ride Stroke [300 [1000 | 3000 [ 5000 | 7000 | 9000 [11000] Inspection T. [Gear Oil OTR R R R 2. [Engine Oi! Pump ott I 1 1 3._|Cooling Water ° (Clean at every 10000Km or once a yea. I 4. [Spark Plug, ‘| Clean (C) at every 3000km or replace (R) ifnecessary. 3._[Carburetor © T 1 6. [Drive Belt ° T 7. [Drive Chain ° ATATATATATA 8. [Air Cleaner ° TPRttPeR{ tyr 9. [Battery Electrolyte o Te a I T 0, [Fuel Filter Screen oO R 11. [Motor Oil Strainer ° Cc 12, [Brake System oO a I 13, [Clutch Lever Free Play |~O | A ALALATATLTA 14. [Bolts & Nuts ott T T 15. [Tire Pressure ot charter yey T The above items are applicable to different models. Perform suitable items for each model. le When exceeding the listed mileages, perform maintenance according to the listed intervals, le The air cleaner requires more frequent cleaning or replacing when ridden in unusually dusty areas. 5214, SPECIFICATIONS Model SF20AB SFIOAF.G Engine Type Single cylinder, forcedly air-cooled 2stroke engine Single cylinder, forcedly air-cooled 2-stroke engine Displacement 97.4 ce 49.4 ce Bore x Stroke $51. 49.6 mm 639x414 mm Compression Ratio TAL 72:1 Compression Pressure 13 kg/em? 11.8 kg/em* Transmission Type Automatic non-stage transmission Automatic non-stage transmission Clutch Dry automatic centrifugal clutch Dry automatic centrifugal clutch Ignition CDI cDI Starting System Starting motor and kick starter Starting motor and kick starter Spark Plug NGK BR6HSA 53- NGK BR8HSABattery 12V4AH 12V3AH Overall Length 1824 mm. 1824 mm Overall Width 707 mm 707 mm Overall Height 1054 mm 1054 mm Wheel Base 1296 mm 1296 mm Dry Weight 87.5 kg 87.5 kg Max. Output 8.8/6700 ps/rmp $.2/7000 ps/tpm Max. Torque 0.977/5500 kg-mv/rpm 0.56/6500 kg-m/rpm Fuel Tank Capacity S liter 5 liter Oil Tank Capacity 15 liter 1.5 liter UL —54-CO KYMCO KWANG YANG MOTOR CO., LTD. NO. 35 Wan Hsing Street, San Min District Kaohsiung, Taiwan, Republic of China Telephone : 886-7-3822526 ae LLB eee LL!)