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FK Motors FK 200, Manual

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FK Motors FK 200 Manual Download Page 4

6. Repair & maintenance                                                   18 

Throttle inspection & adjustment     ………………………… 18 

Valve clearance inspection & adjustment   ………………. 18 

Clutch adjustment      ……………………………………………….. 19 

Drive chain      ………………………………………………………….. 19  

Drive chain inspection   ……………………………………………. 19  

Drive chain adjustment    …………………………………………. 20 

Drive chain cleaning and lubrication   ………………………. 20 

Front & rear brakes adjustment   …………………………….. 20 

Brake fluid inspection     ………………………………………….. 20 

Free stroke of front brake     ……………………………………. 21 

Brake oil   ………………………………………………………………… 21 

Brake pad wear limit indicator      ……………………………. 21 

Lighting signal system inspection    …………………………. 21 

Battery     ………………………………………………………………... 22  

Battery recharging     ………………………………………………. 22 

Battery mounting & dismounting    ………………………... 22 

Fuse   …………………………………………………………………….… 23 

Fuse inspection & replacement   ………………………….…. 23 

Fuse box     ………………………………………………………….….. 23 

LED bulbs replacement    …………………………………….….. 23 

Fuel pump assembly     …………………………………………… 23 

Overall maintenance of motorcycle    …………………….. 24 

Lubricating oil replacement      ………………………………… 25 

Air filter cleaning, maintenance and assembly  ……….. 25 

Ignition plug inspection and replacement     ……………… 25 

Daily maintenance of engine EFI system    ………………… 26 

Precautions for engine EFI system troubleshooting   … 26 

Vehicle storage guidelines    ……………………………………… 27 

When unused motorcycle is used again ………………….… 28 

Cleaning of motorcycle       ……………………………………..… 28 

Wheel maintenance        …………………………………………… 28 

7. Main technical parameters                                          29 

8. Common Troubleshooting & FAQ                               30 

Transmission box troubleshooting & FAQ  …………….… 30 

Driving controls troubleshooting & FAQ  ……………….… 30 

Engine troubleshooting & FAQ  …………………………..…… 31 

Engine EFI system malfunction indicators   …………….… 32 

on instrument panel 

Engine EFI system malfunction code list     …………….… 32 

Electrical fuel injection (EFI) troubleshooting & FAQ… 33 

9. Electrical Diagram                                                             34 

10. National EV Emission Control                                       35 

 Schematic Diagram                             

11. Servicing records                                                             36 

Page 03 

 

 

Summary of Contents for FK 200

Page 1: ...mfortable and convenient This manual provides an overview of the correct care and maintenance methods for our motorcycles Proper use of the motorcycle as instructed by the manual will keep it durable and malfunction free If you have any questions regarding the operation and maintenance of your motorcycle please contact an authorised FKM dealer We have professionally trained technicians who are rea...

Page 2: ...hazards Obey all safety messages that follow this symbol to avoid possible injury or death A caution indicates special precautions that must be taken to avoid damage to the vehicle or other properties This symbol indicates important information Page 01 A warning indicates a hazardous situation which if not avoided could result in serious injury or death ...

Page 3: ... the keys 09 USB charging Bluetooth functions 09 EFI fault signal light 09 Ignition Lock 10 Handlebar switch 10 4 Instruments control function 09 Fuel tank and tank cap 11 Seat cover removal 11 Guidelines for fuel engine oil 12 Engine lubricating oil 13 Tyre 13 Tyre wear tear inspection 13 Tyre damage inspection 13 Abnormal wear and tear inspection 14 Tyre tread inspection 14 Tyre replacement 14 T...

Page 4: ...torcycle 24 Lubricating oil replacement 25 Air filter cleaning maintenance and assembly 25 Ignition plug inspection and replacement 25 Daily maintenance of engine EFI system 26 Precautions for engine EFI system troubleshooting 26 Vehicle storage guidelines 27 When unused motorcycle is used again 28 Cleaning of motorcycle 28 Wheel maintenance 28 7 Main technical parameters 29 8 Common Troubleshooti...

Page 5: ...itch on light indicators before changing lanes or making a turn always check blind spots Pay more aHenGon at road juncGons intersecGons road filters highways Always ride with both hands on the handlebars both feet on the foot pedals brake levers and foot clutch at all times Pillion riders should grab onto available grab handles or the rider with both feet on the foot pedals Protective clothing 1 We...

Page 6: ... Never attach any large or heavy items to the handlebar or front fork It might create unstable handling or slow steering response situations 5 Never exceed the load limit of 150kg for this motorcycle Accessories FKM accessories have been specially designed and test on your motorcycle If the rider selects and installs non FKM accessories he she will be solely be responsible for their decisions When...

Page 7: ...iew 1 Instrument panel 2 Front brake handlebar 3 Rear view mirror 4 Right handlebar switch 6 Rear brake pedal 7 Clutch handlebar 8 Accelerator knob 9 Fuel tank lock 10 Front pedal 11 Rear pedal 12 Silencer 13 Electric door lock Page 06 ...

Page 8: ...eat 4 Rear seat 5 Rear hand grab 6 Front seat ring pull 7 Rear seat ring pull 8 Drive Chain 9 License plate lamp 10 Headlight 11 Front steering light 12 Tail light 13 Rear steering light 14 Shift lever 15 Main fuse 16 Rear seat 17 Side stand 18 Engine oil drainage lock Page 07 ...

Page 9: ...quired by the maintenance station if you want to purchase new parts Please refer back for future reference Vehicle Identification Number VIN Engine number Vehicle Identification Number VIN engraved on the head pipe Vehicle nameplate is riveted to the front of the head pipe Engine number is engraved on the lower left of the engine Engine number Vehicle Identification Number VIN Page 08 Vehicle name...

Page 10: ...signal light Under normal circumstances the light goes out after the engine starts If it is always on or flickering it indicates that the EFI system is out of order Please contact our FKM dealers as soon as possible Never put the tachometer pointer into the red band even if after the running in of engine has been conducted When the rider turns the throttle forcefully or accelerate in the first and...

Page 11: ...ght position lamp are cut off The vehicle is locked and the key can be removed Handlebar switch 1 Move up down to turn on the high or dipped beam 2 Turn left right to turn on the steering light 3 Horn button 1 Stop switch 2 Lighting switch 3 Electrical starting button Page 10 Options Description This option enables to turn on the high beam of headlight This option enables to turn on the dipped bea...

Page 12: ...ling Do not exceed the neck of fuel tank After refuelling the fuel tank cap must be tightly secured as gasoline is highly flammable or even cause an explosion Process of refuelling should be carried out in a well ventilated place and away from any naked flames such as lighted cigarettes or any fire sources Seat cover removal 1 Detach the left side cover of the fuel tank by pulling it out from rubb...

Page 13: ... change of engine oil and oil filters should be carried out at authorised FKM dealers or workshops Capacity quantity for each oil change is about 1 litre 3 Inspection of engine oil level Please check the engine oil occasionally and ensure that the oil level must be between the lower and upper limits of the oil scale Inspection 1 If the engine is cold switch it on and let it idle for 3 5 minutes 2 ...

Page 14: ...gauge Whenever there are signs of insufficient tyre pressure take measurements using a pressure gauge to ensure that the tyre has sufficient air pressure Correct tyre pressure optimizes the stability of the motorcycle ride enhances riding comfortability An underinflated tyre will cause the tyre tread to wear off excessively cause overheating issues shorten tyre lifespan and compromise safety Over ...

Page 15: ...nctures Repair for punctures or disassembly of wheels needs special tools and skill sets We recommend that such repairs are to be done by a skilled FKM technician If emergency repairs had to be done please send the motorcycle back to authorised FKM workshops for inspection of repair works done or replacement of tyres if required Emergency repair with tyre repair kit In the event of slight puncture...

Page 16: ...nd lubricate if necessary Check the condiGon of the accelerator and the rotating movement of the accelerator handlebar Check the condiGon and funcGonality of the lights and horn and make sure they are operaGng well If the temperature of the engine is high do not adopt this inspecGon system Running in of engine The service life of the motorcycle depends on the operation during its first 1000km Comm...

Page 17: ...r to increase the rotaGon speed of the engine while slowly releasing the clutch handlebar at the same time to sync the two movements together to achieve a stable start off the stationary position of the motorcycle APer the motorcycle starts moving off release the accelerator handle bar slowly to lower the rotational speed of the engine and then release the clutch again stepping on the gear change l...

Page 18: ...ition otherwise it might lose balance and topple over The temperature of the exhaust silencer is high after the motorcycle stops ignition Therefore it should be parked at safe areas which are away from pedestrians or children Page 17 Gearshift diagram Gearshift options of the motorcycle are as shown in the figure below Forward step Forward lift Brake and stop 1 Brake The normal method of braking i...

Page 19: ...hole Gently shake the rocker arm with hand If the rocker arm is loose With clearance it means that the piston is at the peak position of the compression stroke On the contrary if it is too tight rotate the flywheel 360 counter clockwise to align the T line with the indication mark of the case cover hole Page 18 Throttle inspection adjustment Adjusting nut Hold down nut A Check whether the rotation...

Page 20: ...otate clockwise to reduce the free clearance of clutch handlebar 2 There is an upper adjuster of the left hand clutch handlebar 3 Adjust it as described above Drive chain The service life of the drive chain depends on good lubrication and proper adjustments Poor maintenance causes early wear and damage to the chain and chain wheel Drive chain inspection Check the wear and tension of the drive chai...

Page 21: ...in slipping If the drive chain show signs of wear and tear it must be replaced immediately Apply a large amount of oil or chain lubricant to lubricate the chain During re installation reverse the steps mentioned above When the chain master link is installed back the opened end of the chain link should be in the opposite direction of of the chain movement while moving forward Brake fluid inspection...

Page 22: ...l in the cylinder will be automatically injected into the tube and the fluid level will decrease along with it Brake pad wear limit indicator The key to inspection the condition of the brake pad for the front wheel is to check whether the brake pad wear limit indicators can be seen If the wear exceeds the indicators replace the brake pad accordingly Lighting signal system inspection Turn the key o...

Page 23: ... spark or flame might cause the battery to explode causing serious injury or even death Battery recharging Recharge the battery with a proper battery charger Remove the battery from the motorcycle before charging Do not use passenger car chargers as it will cause overheating and permanent damage to the battery If the battery cannot be recharged to full capacity or restored to original condition pl...

Page 24: ... inspect the fuse If it is blown replace it with a similar specified new fuse Do not use other fuses other than the specified ones as it may damage the electrical system It may even cause a fire blow the electrical lamps or damage the engine Replacement of the fuse with a higher rated value can increase the chance of damaging the electrical system Fuse box The fuse box is located near the battery ...

Page 25: ...sues the symbol means repair or maintenance works can only be performed by a skilled FKM technician at authorized workshops Cycle No of month or distance travelled Whichever comes first for every x100km or interval of months Item No of month 1 4 8 12 Fuel tube 1 1 1 Fuel ilter mesh 1 C C C Accelerator operation 1 1 1 1 Air filter C C C Ignition plug 1 1 R 1 Valve clearance 1 1 1 1 Engine lubricati...

Page 26: ...ried out regularly When operating vehicle in dusty areas the air filter should be replaced frequently 1 Remove the air filter 2 Remove the bolt on the cover of the air filter followed by the cover plate and take out the air filter cartridge 3 Gently flick away any dust particles and check whether the air filter cartridge is damaged If yes replace with a new air filter cartridge 4 When reinstalling...

Page 27: ...letter H Once completed tighten the reserve tank cap securely 3 Changing Replacement of engine coolant Place motorcycle level ground deploy the side stand let the engine cool down to room temperature Place servicing tray below the outlet pipe under the engine unscrew the cap and allow the coolant to drain completely out of the engine Next secure the cap back tightly begin adding in new engine cool...

Page 28: ...oids freezing direct sunlight Carry out a slow charging process every once a month 5 Clean and dry the motorcycle apply wax to all painted surfaces and apply a thin layer of anti rust oil to the chromed surface 6 Apply a layer of lubricating oil to the drive chain 7 Inflate the tyre to its recommended pressure After the motorcycle is parked lift the wheel with a wooden block to elevate it from the...

Page 29: ...fuel tanks handlebar switches of the motorcycle 1 After your motorcycle is cleaned make sure to rinse it thoroughly with plenty of water 2 After your motorcycle is dried start the engine keep it running for a few minutes 3 Always test the brakes are in working condition before operating the motorcycle again It requires repeated tries on the brakes before it resumes its normal functions 4 Lubricate...

Page 30: ...e Specification of battery 12V 6AH Model of ignition plug FK 125A Main fuse 12V 15A Auxiliary fuse 12V 10A 12V 10A 7 Main technical parameters Page 29 Main parameters of the finished motorcycle L W H mm 1960 790 1080 Wheel Base 1360mm Unloaded weight 138kg Max loading weight 150kg Min ground clearance 180mm Max speed 114km h Gradient 23 Braking distance 7m 30km h Brake type front rear Disc Disc Ri...

Page 31: ...nuous vibration of the motorcycle 1 Damaged oil leakages at the springs of the front and rear shock abosrbers 2 Warped bent shock absorbers 1 Replace damaged parts Unstable driving direction 1 Insufficient tyre pressure 2 Overtighten drive chain 3 Worn out or stucked jammed wheel bearing related parts 1 Adjust accordingly 2 Inflate to recommended air pressure 3 Adjust accordingly Brake failure 1 E...

Page 32: ...ine unable to start or engine cut off while travelling 1 When the compression pressure discharge from high tension coil or spark plugs are abnormal 1 Check spark plug for carbon deposit or traces of dirt 2 Incorrect gap between side and centre electrodes 3 Damaged insulation parts or short circuits between the side and centre electrodes 1 Re weld the adapter or replace entire coil unit 2 Replace e...

Page 33: ...ut piston pinhole 3 Worn out crankshaft ball bearing 4 Worn out connecting rod needle bearing 5 Huge gap clearance between intake exhaust valve 6 Worn out camshaft cam axle sleeve rocker arm rocker arm axle sleeve 7 Oil leakage in engine operation components 1 Replace piston piston ring boring block 2 Replace piston pin and piston 3 Replace crankshaft ball bearing 4 Replace connecting rod needle b...

Page 34: ...e lamp will be off when there is no failure and it will flicker regularly when there is a failure Wait for 5 seconds or more after turning off the axis lock key the ECU automatically exits the Failure lamp flickering mode and shifts to Normal mode Sensor Device Name Tested to be low level Tested to be high level Open Circuit Logical Assessment Sensor Device Name Tested to be low level Tested to be...

Page 35: ...eck oxygen sensor for any damages or not properly connected tightened 6 Inconsistent idling speed RPM too low or too high Check overall vehicle with diagnostic apparatus Rotation speed of cold engine as compared to already warmed up engine is 200rpm faster Normal status Check for air leakage Example Absense of paper gasket between intake manifold engine block loose bolts clamps or tighteners damag...

Page 36: ...9 Electrical Diagram Page 34 ...

Page 37: ...10 National EV Emission Control Schematic Diagram Page 35 ...

Page 38: ...be in its peak condition Original factory formulated engine oil The original factory formulated engine oil is specifically designed to suit the unique design of the engine unit The engine unit maximises its peak performance while using the special lubricative properties of the original factory formulated engine oil Recommended engine oil Original factory formulated engine oil Recommended gearbox o...

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