Skytown 125 150

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 Skytown
INSPECTION/ADJUSTMENT 3
125 150
Section 1 contains the precautions for all LUBRICATION SYSTEM 4
operations stated in this manual. Read FUEL SYSTEM 5
them carefully before starting any ENGINE REMOVAL/INSTALLATION 6
operation.
CYLINDER HEAD/VALVES/PISTON 7
Section 2 is the removal/installation DRIVE AND DRIVEN PULLEYS/KICK 8
procedures for the frame covers, which STARTER
are subject to higher removal/installation FINAL REDUCTION
frequency during maintenance and 9
servicing operations. STEERING HANDLEBAR/FRONT
WHEEL/FRONT BRAKE/FRONT
10
SHOCK ABSORBER/FRONT FORK
Section 3 describes the inspection/
adjustment procedures, safety rules and REAR WHEEL /REAR BRAKE /REAR 11
service information for each part, starting SUSPENSION
from periodic maintenance. BATTERY /CHARGING SYSTEM 12
IGNITION SYSTEM 13
Sections 6 through 17 give instructions
for disassembly, assembly and inspection STARTING SYSTEM 14
of engine, chassis frame and electrical
LIGHTS/INSTRUMENTS/SWITCHES 15
equipment.
EVAPORATIVE EMISSION CONTROL 16
Most sections start with an assembly or SYSTEM
system illustration and troubleshooting ABS SYSTEM 17
for the section. The subsequent pages
give detailed procedures for the section.

Our company reserves the right to

make any alteration in the design.
The information and contents
included in this manual may be
different from the motorcycle in
case specifications are changed.

KWANG YANG MOTOR CO., LTD.

QUALITY TECHNOLOGY DEPARTMENT
EDUCATION SECTION
1. GENERAL INFORMATION Skytown 125 150

1ENGINE SERIAL NUMBER ................... 1- 1

SPECIFICATIONS .................................... 1- 2
LUBRICATION POINTS........................ 1-15
CABLE & HARNESS ROUTING ............. 1-17
1
SERVICE PRECAUTIONS ...................... 1- 3 TROUBLESHOOTUNG ........................... 1-20
TORQUE VALUES .................................. 1-11
SPECIAL TOOLS ..................................... 1-12

ENGINE SERIAL NUMBER

Location of Frame Serial Number

Location of Engine Serial Number

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1. GENERAL INFORMATION Skytown 125 150

SPECIFICATIONS
Name & Model Skytown 125(BLB3) Lubrication oil capacity (liter) 0.9L
Overall length (mm) 1940 Exchanging capacity 0.8L
Overall width (mm) 750 Air cleaner type & No. Wet, single
Overall height (mm) 1340 Gear Oil capacity 0.13L
Wheel base (mm) 1320 Exchanging capacity 0.11L
Engine type Air cooled 4-stroke Fuel capacity (liter) 7.0L
Fuel Used 92# nonleaded gasoline Type 
Displacement (cc) 125cc Carburetor Piston dia. (mm) 
Front wheel 54 Venturi dia. (mm) 
Net weight (kg) Rear wheel 72 ECU
Ignition system type
Total 126
Ignition timing F mark 
Front wheel 93
Max weight Spark
Rear wheel 183 NGK LR7D
Capacity (kg) plug
Total 276 Spark plug gap (mm) 0.6～0.7
Front wheel 110/70-14 Battery capacity 12V 7AH
Tires
Rear wheel 130/70-13 Power to transmission gear Power-transmission
gear-clutch
Ground clearance (mm) 135
Min. turning radius (mm)R/L 2000 Reduction ratio of power to 
transmission
Starting system Starting motor
Clutch type Dry multi-disc clutch
Fuel type Gasoline, 4-stroke Transmission gear operation type Automatic centrifugal
motor oil
type
Cylinder arrangement Single cylinder, flat
Transmission ratio 1 speed 
Combustion chamber type Semi-sphere
Reduction Type Two-stage reduction
Valve arrangement O.H.C.
gear 1st reduction ratio 0.87—2.70
Bore x stroke (mm) 2.4 X 57.8
2nd reduction ratio 10.25
Compression ratio 11 Transmission gear type Non-stage transmission
Compression pressure 15kg/cm² Tire pressure Front wheel 1.75 kg/cm²
(kg/cm² rpm)
(kg/cm²) Rear wheel 2.0/2.25 kg/cm²
Max. output 8.2kw/8500rpm
Turning angle Right43 & left 43
Max. torque (NM/rpm)
10.6 N.M/6500rpm Front wheel Disk
Brake system
type Rear wheel Disk
Port Open 2
Intake Front wheel Telescope
timing Close 28 Suspension
type Rear wheel Unit swing
Open 28
Exhaust Front wheel Telescope
Close -6 Shock absorber
type Rear wheel Unit swing
Intake 0.10mm
Valve clearance
Exhaust 0.10mm Frame type Pipe under bone
Idle speed (rpm) 1600
Lubrication type centrifugal type

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1. GENERAL INFORMATION Skytown 125 150

SPECIFICATIONS
Name & Model Skytown 150(BLB5) Lubrication oil capacity (liter) 0.9L
Overall length (mm) 1940 Exchanging capacity 0.8L
Overall width (mm) 750 Air cleaner type & No. Wet, single
Overall height (mm) 1340 Gear Oil capacity 0.13L
Wheel base (mm) 1320 Exchanging capacity 0.11L
Engine type Air cooled 4-stroke Fuel capacity (liter) 7.0L
Fuel Used 92# nonleaded gasoline Type 
Displacement (cc) 150cc Carburetor Piston dia. (mm) 
Front wheel 54 Venturi dia. (mm) 
Net weight (kg) Rear wheel 72 ECU
Ignition system type
Total 126
Ignition timing F mark 
Front wheel 93
Max weight Spark
Rear wheel 183 NGK LR7D
Capacity (kg) plug
Total 276 Spark plug gap (mm) 0.6～0.7
Front wheel 110/70-14 Battery capacity 12V 7AH
Tires
Rear wheel 130/70-13 Power to transmission gear Power-transmission
gear-clutch
Ground clearance (mm) 135
Min. turning radius (mm)R/L 2000 Reduction ratio of power to 
transmission
Starting system Starting motor
Clutch type Dry multi-disc clutch
Fuel type Gasoline, 4-stroke Transmission gear operation type Automatic centrifugal
motor oil
type
Cylinder arrangement Single cylinder, flat
Transmission ratio 1 speed 
Combustion chamber type Semi-sphere
Reduction Type Two-stage reduction
Valve arrangement O.H.C.
gear 1st reduction ratio 0.87—2.70
Bore x stroke (mm) 7.4 X 57.8
2nd reduction ratio 10.25
Compression ratio 11 Transmission gear type Non-stage transmission
Compression pressure 15kg/cm² Tire pressure Front wheel 1.75 kg/cm²
(kg/cm² rpm)
(kg/cm²) Rear wheel 2.0/2.25 kg/cm²
Max. output 8.45kw/7500rpm
Turning angle Right45 & left 45
Max. torque (N.m/rpm)
11.9 N.m/6500rpm Front wheel Disk
Brake system
type Rear wheel Disk
Port Open 2
Intake Front wheel Telescope
timing Close 28 Suspension
type Rear wheel Unit swing
Open 28
Exhaust Front wheel Telescope
Close -6 Shock absorber
type Rear wheel Unit swing
Intake 0.10mm
Valve clearance
Exhaust 0.10mm Frame type Pipe under bone
Idle speed (rpm) 1700
Lubrication type centrifugal type

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1. GENERAL INFORMATION Skytown 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.

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1. GENERAL INFORMATION Skytown 125 150

 Apply or add designated greases and

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.

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1. GENERAL INFORMATION Skytown 125 150

 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

 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.

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1. GENERAL INFORMATION Skytown 125 150

 The connector shall be inserted

completely.
Snapping!
 If the double connector has a lock, lock
it at the correct position.
 Check if there is any loose wire.

 Before connecting a terminal, check for

damaged terminal cover or loose
negative terminal.

 Check the double connector cover for

proper coverage and installation.

 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.

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1. GENERAL INFORMATION Skytown 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.

No Contact !
 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.

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1. GENERAL INFORMATION Skytown 125 150

 Route harnesses so they are neither

pulled tight nor have excessive slack.
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.

Do not press or
 When installing other parts, do not press or squeeze the wire.
squeeze the wires.

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1. GENERAL INFORMATION Skytown 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.

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

 Be careful not to drop any parts.

 When rust is found on a terminal, remove

the rust with sand paper or equivalent Remove Rust !
before connecting.

 Do not bend or twist control cables.

Damaged control cables will not operate
smoothly and may stick or bind.

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1. GENERAL INFORMATION Skytown 125 150

 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

Special : Use special tool.

＊ : Caution

: Warning

1-11
1. GENERAL INFORMATION Skytown 125 150

TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque (kg-m) Item Torque (kg-m)
5mm bolt, nut 0.45-0.6 5mm screw 0.35-0.5
6mm bolt, nut 0.6-1.2 6mm screw, SH bolt 0.7-1.1
8mm bolt, nut 1.8-2.5 6mm flange bolt, nut 1.0-1.4
10mm bolt, nut 3.0-4.0 8mm flange bolt, nut 2.4-3.0
12mm bolt, nut 5.0-6.0 10mm flange bolt, nut 3.5-4.5

Torque specifications listed below are for important fasteners.

ENGINE
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Cylinder head bolt A 2 6 0.7-1.1 Double end bolt
Cylinder head bolt B 4 6 0.7-1.1
Oil filter screen cap 1 30 1.0-2.0
Exhaust muffler lock bolt 2 6 0.7-1.1 Double end bolt
Cylinder head flange nut 4 7 1.2-1.6 Apply oil to
Valve adjusting lock nut 2 3 0.07-0.09 threads
Cam chain tensioner slipper bolt 1 8 0.4-0.7
Oil bolt 1 8 1.1-1.5
Clutch outer nut 1 10 3.5-4.5
Clutch drive plate nut 1 28 5.0-6.0
Starter motor mounting bolt 2 6 0.8-1.2
Oil pump bolt 3 4 0.1-0.3
Drive face nut 1 10 5.5-6.5
Spark plug 1 10 1.0-1.4
A.C. generator stator bolt 2 6 0.8-1.2
Cam chain tensioner bolt 1 6 0.8-1.2

FRAME
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Steering stem lock nut 1 BC1 6.0-8.0 U-nut
Steering handle post nut 1 10 4.0-5.0 U-nut
Front axle nut 1 12 5.0-7.0 U-nut
Rear axle nut 1 16 11.0-13.0 U-nut
Rear shock absorber upper bolt 1 10 3.5-4.5
Rear shock absorber lower bolt 1 8 2.4-3.0
Muffler Bracket/ Rear Fork 1 8 3.0-3.6
Rear Fork/Engine Case 1 8 2.4-3.0 Flange bolt
Engine Hanger---Frame side 2 10 4.5–5.5
Engine Hanger---Engine side 2 10 4.5–5.5 U-nut

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1. GENERAL INFORMATION Skytown 125 150

SPECIAL TOOLS

Description Tool No. Photo

Flywheel puller A120E00002

Oil seal and bearing installer A120E00014

Universal holder A120E00017

Flywheel holder A120E00021

Clutch spring compressor A120E00034

Valve adjuster A120E00036

Bearing puller A120E00037

Cylinder Compression Gauage A120E00039

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1. GENERAL INFORMATION Skytown 125 150

Description Tool No. Photo

Valve spring compressor A120E00040

Fuel Pressure Gauage A120E00048

INJECTOR CLEANER for

A120E00075
Synerjet

Wires Injector Connector A120E00090

Lock nut wrench A120F00002

Lower/Upper Race Remover &

A120F00008
Installer

Steering Stem Top Thread Wrench

A120F00024
(shoter type)

Steering Stem Top Thread Wrench A120F00029

Band Remover/Installer A120F00030

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1. GENERAL INFORMATION Skytown 125 150

Description Tool No. Photo

Pliers Fuel Pipe A120F00031

Electric Repair Kit A120F00032

1-15
1. GENERAL INFORMATION Skytown 125 150

LUBRICATION POINTS

ENGINE

Lubrication Points Lubricant

Valve guide/valve stem movable part Genuine KYMCO Engine Oil (SAE15W-40)
Cam lobes APISL 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 R/L side oil seal
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
Kick starter spindle movable part
A.C. generator connector Adhesive
Transmission case breather tube

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1. GENERAL INFORMATION Skytown 125 150

FRAME
The following is the lubrication points for the frame.
Use a 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
Brake Lever Pivot
Grease
Front Brake Cable/
Speedometer Cable/
Throttle Cable

Grease
Grease
Front Wheel Bearings Grease
axle &nut Rear Wheel axle
Main Stand Pivot Bearings & nut
&Side stand pivot

1-17
 1. GENERAL INFORMATION Skytown 125 150

CABLE & HARNESS ROUTING

Instrument

USB

Winker
Start Relay②
Battery

Diagnostic Tool Fuse

Connector

ECU Relay
Fuel Pump Relay
Start Relay①
Headlight Relay
Headlight Connector

Fuse Battery Winker Ignition Switch

USB

USB Connector

Start Relay② Diagnostic Tool ECU Relay Headlight Relay

Connector Start Relay① Fuel Pump Relay

1-18
 1. GENERAL INFORMATION Skytown 125 150

Start Relay②

Diagnostic Tool
Charcoal Canister/ Connector
Ignition Switch
Purge Control Valve
CBS Pump
O2 Sensor①
Ignition Coil
Connector
Front Wheel Speed
Sensor Connector

Fuel Tank

O2 Sensor② CPS Connector O2 Sensor①

Winker
Regulator/Rectifier
Battery
Charcoal Canister/
Purge Control Valve
Fuse
Ignition Coil

Ignition Switch
ECU Relay
Fuel Pump Relay
Start Relay①
Headlight Relay

Front Wheel
Speed Sensor Horn Side Standard Switch

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 1. GENERAL INFORMATION Skytown 125 150

Regulator/Rectifier

ECU
Throttle
Ignition Coil
Charcoal Canister/
Purge Control Valve

O2 Sensor①
Connector

O2 Sensor②
Connector

Crankcase Breather
Tube

Fuel Injector

Fuel Pump/Fuel Unit Fuel Tank Side Standard Switch

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1. GENERAL INFORMATION Skytown 125 150

Charcoal Canister/
ECU/Throttle
Purge Control Valve
ETS Fuel Injector Fuel Tank

Start Motor Ignition Coil O2 Sensor② Fuel Pump/Fuel Unit

Crankcase Breather
Connector
Tube

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1 GENERAL INFORMATION Skytown 125 150

Skytown 125 ABS/ 150

ABS ECU/Pump

Winker

Start Relay②

ABS Fuse

Diagnostic Tool Battery Fuse

Connector

Motor

Rear Wheel speed

Sensor Rotor

Transmission Gear
Rear Wheel Speed
Sensor
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1. GENERAL INFORMATION Skytown 125 150

Troubleshooting

Vehicle can not be started

Preliminary 6 Step Inspection

1. Is the battery fully charged (12 V or higher). See the Battery topic for
more information.

2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay
(It will turn off automatically in 5-10 seconds)

3. Key-On to check for any failure lamp light up on dashboard. See the
Self-Diagnosis topic for more information.

4. Is the Idle screw of Throttle Valve being changed or loose?

5. Has the vehicle under regular service? Is the gas station a good one?

6. Is the spark plug the correct model of specified by the vehicle builder?

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1 GENERAL INFORMATION Skytown 125 150

General Troubleshooting
ENGINE WILL NOT START OR IS HARD TO START

Possible cause

1. Check for operation of the fuel pump Abnormal  Faulty fuel pump

Normal

2. Inspect the fuel flow Abnormal  Faulty pressure regulator

Normal

3. Inspect the fuel injector Abnormal  Faulty injector

Normal

4. Perform spark test Weak or no spark  Faulty spark plug

 Fouled spark plug
 Faulty ECU
Good spark  Broken or shorted spark plug wire
 Faulty ignition switch
 Faulty ignition pulse generator
 Loose or disconnected spark plug
wire

5. Test cylinder compression Low compression  Valve stuck open

 Worn cylinder and piston ring
 Damaged cylinder head gasket
Compression normal  Seized valve
 Improper valve timing

6. Starting following normal procedure Engine start  Intake pipe leaking

but stops  Improper ignition timing (Faulty
ignition coil or ignition pulse
generator)
Engine does not start  Fuel contaminated

7. Remove and inspect spark plug Wet plug  Throttle valve open
 Clogged air cleaner

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1. GENERAL INFORMATION Skytown 125 150
ENGINE LACKS POWER

Possible cause

1. Raise wheel off the ground Wheels do not  Brake dragging

and spin by hand spin freely  Worn or damaged wheel bearing

Wheel spins freely

2. Check tire pressure Pressure low  Faulty tire valve

 Punctured tire

Pressure normal

3. Accelerate lightly Engine speed does  Air cleaner dirty

not increase  Restricted fuel flow
 Clogged muffler
Engine speed increase  Pinched fuel tank breather

4. Check ignition timing Incorrect  Faulty ECU

 Faulty ignition pulse generator

Correct

5. Test cylinder compression Incorrect  Valve stuck open

 Worn cylinder and piston rings
 Leaking head gasket
Normal  Improper valve timing

6. Inspect fuel flow Abnormal  Faulty pressure regulator

Normal

7. Inspect the fuel injector Abnormal  Faulty injector

Normal

8. Remove spark plug Fouled or discolored  Faulty spark plug

Not fouled or discolored

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1 GENERAL INFORMATION Skytown 125 150

Possible cause

9. Check oil level and condition Incorrect  Oil level too high
 Oil level too low
 Contaminated oil
Correct

10. Remove cylinder head cover Valve train not  Clogged oil
and inspect lubrication lubricated properly  Clogged oil control orifice

Valve train lubricated properly

11. Check for engine overheating Overheating  Fan motor not working
 Excessive carbon build-up in
combustion chamber
 Use of poor quality fuel
Not overheating  Wrong type of fuel
 Drive and driven pulleys/clutch
slipping

12. Accelerate or run at high Engine knocks  Worn piston and cylinder
speed  Worn type of fuel
 Excessive carbon build-up in
combustion chamber
 Ignition timing to advanced (faulty
ECU)
Engine does not knock  Lean fuel mixture

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1. GENERAL INFORMATION Skytown 125 150

POOR PERFORMANCE AT LOW AND IDLE SPEED

Possible cause

1. Check ignition timing Incorrect  Improper ignition timing

Correct

2. Inspect the fuel flow Abnormal  Faulty pressure regulator

Normal

3. Inspect the fuel injector Abnormal  Faulty injector

Normal

4. Check for leaks in the intake pipe Leaking  Loose insulator clamp
 Damage insulator

No leak

5. Perform spark test Weak or intermittent spark  Faulty the spark plug
 Faulty carbon or wet fouled spark
plug
 Faulty ECU
 Faulty ignition coil
 Faulty ignition pulse generator
 Faulty ignition switch
 Loose or disconnected spark plug
wires
Good spark

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 1 GENERAL INFORMATION Skytown 125 150

POOR PERFORMANCE AT HIGH SPEED

Possible cause

1. Check ignition timing Incorrect  Faulty ECU

Correct

2. Inspect the fuel flow Abnormal  Faulty pressure regulator

Normal

3. Inspect the fuel injector Abnormal  Faulty injector

Normal

4. Check valve timing Incorrect  Camshaft not installed properly

Correct

5. Check valve spring Weak  Faulty valve spring

Not weak

POOR HANDLING

Possible cause

1. If steering is heavy  Steering stem adjusting nut too tight

 Damaged steering head bearings

2. If either wheel is wobbling  Excessive wheel bearing play

 Bent rim
 Improper installed wheel hub
 Swing arm pivot bearing
excessively worn
 Bent frame

3. If the motorcycle pulled to one side  Faulty the shock absorber

 Front and rear wheel not aligned
 Bent fork
 Bent swing arm
 Bent axle

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