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KINROAD 150 SERVICE MANUAL VERSION 1, DEC., 2005

Install the right crankcase cover.

Install the left crankcase cover.

Take the reduction mechanism and the engaging mechanism as a whole unit, then this unit is called the

starter.

CONTROLING MECHANISM

STARTER RELAY INSPECTION

Turn the main switch to the “ON” position, and press down the starting motor button, and listen if there is a

“click” sound. If there is, it is normal; if there isn’t, follow the below procedures.

Inspect if the brake switch is conductive. At this time, turn the main switch on and hold the brake lever.

Measure the voltage between the inlet line (the green/yellow line) starting relay and the ground wire of the

body. The voltmeter reading should be close to the magnitude of voltage between the two ends of the

battery. If not, the brake switch, its wire or the wire connector is not good.

Inspect if the start button is conductive. At this time, remove the starting relay inlet line (the green/yellow

line.)

Connect the yellow/red line with the ground wire, and press the start button. It should be conductive

between the yellow/red line and the ground wire; otherwise the start button, its wire, or the wire connector is

not good.

Inspect if the working condition of the starting relay. At this time, remove the starting relay.

Connect the C end and the D end of the starting relay with the battery, and the A and B end with the

multimeter.

At this time the multimeter should indicate conductive condition; otherwise the starting relay is not good.

The battery voltage should be at 12 volts.

Summary of Contents for 150

Page 1: ...KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 1 KINROAD ...

Page 2: ...re performing any repair or service All information illustrations photographs and specifications contained in the manual are based on the latest product information available at the time of publication Due to improvement or other changes there may be some discrepancies in this manual Therefore if newest information is requested in the future please contact the local distributor Distributor reverse...

Page 3: ...KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 3 CONTENTS 1 GENERAL INFORMATION 4 2 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 7 3 ENGINE 13 4 ELECTRIC SYSTEM 64 5 CHASIS 74 6 WIRING DIAGRAM 81 ...

Page 4: ...1 GENERAL INFORMATION MODEL IDENTIFICATION FRAME NUMBER The frame number or VIN is stamped under the seat on the frame cross member and stuck behind the seat ENGINE NUMBER The engine number is located on the lower front left side of the engine cases ...

Page 5: ...for long periods of time SPECIFICATIONS DIMENSIONS DOUBLE SEAT SINGLE SEAT Overall Length 2159mm 2075mm Overall Width 1400mm 1235mm Overall Height 1470mm 1400mm Wheelbase 1499mm 1450mm Ground Clearance 170mm 130mm ENGINE Type Forced air cooled single cylinder 4 Stroke Engine Capacity 150cc Displacement 149 5cc Bore x Stroke 57 4mm x 57 8mm Compression Ratio 9 2 1 Max Power 7 4kw 7500rpm Max Torque...

Page 6: ...il Light 12V 21W 5W Fuse 10A Brake Track 7 m 20mph Top Speed 30mph CHASSIS Front rear Brake Hydraulic disc left foot control Front Tire 21x7 10 Rear Tire 22 x 11 10 Front Suspension Independent Dual A Arm Rear Suspension Swing Arm Double Damped Shock TIRE PRESSURE Front 175kpa Rear 200kpa WEIGHT Net Weight 170kg 105kg The specifications are subject to change without notice ...

Page 7: ...tery I I Engine oil R Valve clearance of engine A A adjust C clean I inspect clean or replace if necessary L lubricate R replace MAINTENANCE AND TUNE UP PROCEDURE This section describes the servicing procedures for each item in the Periodic Maintenance Intervals SPARK PLUG Clear up the carbon around the spark plug to prevent it from dripping into the cylinder when removing the spark plug Remove th...

Page 8: ...every time the vehicle is ridden The tire pressure is very important for the stability of the ride BRAKE PERFORMANCE 1 Always check that there is plenty of brake fluid in the brake fluid reservoir 2 Check that the front rear brake pads are in good condition 3 Check the brake rotor for abnormal wear AIR CLEANER Clean the air cleaner quarterly or more often in dusty conditions If the air cleaner is ...

Page 9: ... 0 3 0 6 2 0 4 5 6 4 7 0 4 0 7 3 0 5 0 8 12 0 8 1 2 6 0 8 5 8 10 16 1 0 1 6 7 0 11 5 18 28 1 8 2 8 13 0 20 0 10 22 35 2 2 3 5 16 0 25 5 40 60 4 0 6 0 29 0 43 5 12 35 55 3 5 5 5 25 5 40 0 70 100 7 0 10 0 50 5 72 5 14 50 80 5 0 8 0 36 5 58 0 110 160 11 0 16 0 79 5 115 5 16 80 130 8 0 13 0 58 0 94 0 170 250 17 0 25 0 123 0 181 0 18 130 190 13 0 19 0 94 0 137 5 200 280 20 0 28 0 144 5 202 5 FUEL SWITC...

Page 10: ...FF position When the vehicle is not in use always make sure the petcock is in the OFF position FINAL GEAR OIL Inspect monthly and change quarterly 1 To check the oil level remove the level screw on the left rear engine case 2 To drain oil remove the drain plug at the rear bottom of the engine case It is recommended to warm the engine for 10 minutes or more before draining final gear oil NOTE Mobil...

Page 11: ...leaning solvent and refit making sure the O ring is still in good conditions 4 Refill the engine with SAE10W 30SF engine oil and run for 5 minutes 5 Check oil level on the filler cap stick to assure proper level 6 The cap needs to be screwed in to check CHASSIS 1 Grease chassis bushings and bearings with grease quarterly to assure smooth operation and extended life of the bushings and the componen...

Page 12: ...asure the difference of diameter between two points mutually perpendicular which is the circularity of the cylinder In the situation without a dial gauge a feeler gauge can be used to make relativity measurement Put a new piston into the cylinder and use the feeler gauge to measure the gap between the piston skirt and the cylinder wall and then figure out the abrasion loss of the cylinder If the c...

Page 13: ...ton pin If the result is less than service limit it should be replaced After replacement the clearance between piston pin and the pinhole of piston must comply with the requirement Measure the inner diameter of piston pin If the result is more than service limit it should be replaced After replacement the clearance between the pinhole of piston and piston pin must be sure to comply with the requir...

Page 14: ...ston rings AT the same time cover them on the piston and move forwards gradually until piston rings fall into the ring groove PISTON RING INSTALLATION Remove the gasket attached to the crankcase Mount piston onto the small end of the connecting rod Mounting piston pin and piston pin clip First ring 0 09 mm Second ring 0 09 mm z The top of the piston with IN mark should be mounted towards the direc...

Page 15: ...ank connecting rod component CRANKCASE AND CRANKSHAFT REMOVAL Take the following procedures when removing the crankcase and crankshaft Remove the engine Remove the cylinder cover Remove the cylinder Remove the piston Remove the drive plate and the driven plate Remove the AC generator Remove the starting motor Remove the oil pump Then remove the cam chain tensioner bolt Remove the cam chain tension...

Page 16: ...ning bolts Separate the right crankcase and the left crankcase Remove the gasket and the dowel pins Remove the crankshaft from the crankcase Take out the cam chain Clean up the gasket on the crankcase joint face Pay attention not to damage the joint face Remove the oil seal from the left crankcase The joint face cannot be damaged ...

Page 17: ...p is too much it will cause the engine to shake abnormally and shorten the life of the engine So it must be examined carefully when inspecting 0 10mm A 90 Service limit 0 10mm B 105 Examine if there is any looseness or unusual sound when the crank journal bearing turns If there is the whole set should be replaced Inspect if the joint face of the crankcase is smooth and clean and notice if it will ...

Page 18: ...ket on the left crankcase Join the right crankcase and the left crankcase together Tighten the crankcase positioning bolts Mount the starting driven gear Mount the cam chain tensioner Mount the new O ring on the cam chain tensioner bolt Apply some oil on the O ring Tighten the cam chain tensioner bolt Tightening torque 1 98 lbs m z Pay attention to avoid the cam chain damaging the oil seal z The o...

Page 19: ...pression stroke Expansion stroke Exhaust stroke VALVE CLEARANCE ADJUSTMENT Valve clearance is an important technical parameter Make sure that the valve can close tightly under any conditions especially when the engine is overheated there must be certain clearance kept when the valve is in the cold condition This clearance is called valve clearance When the engine is running the valve clearance sho...

Page 20: ...ge tighten the lock nuts and then inspect the valve clearance again Valve clearance 0 06 0 07 mm CAMSHAFT The camshaft is a main driving unit of the valve train There are the air inlet cam the exhaust cam and the cam journal on the shaft It controls the intake and exhaust valve to open and close at the correct time The camshaft wear will affect engine performance and cause excessive noise CAMSHAFT...

Page 21: ...spect cam surface for damage Measure the height of the cam Inlet cam 25 96 mm Exhaust cam 25 815 mm CAMSHAFT INSTALLATION Rotate the flywheel to align the T mark on the flywheel with the camshaft mark The round hole on the cam chain wheel should be up The left and right sit parallel with the cylinder head the lobes of the camshaft are down Install the camshaft on the cylinder head Mount the cam ch...

Page 22: ...Inspect if there is any abrasion or damage on the rocker arm and rockshaft or if the oil hole clogged Measure the inner diameter of the rocker arm Service limit 10 10 mm Measure the outer diameter of the rockshaft Service limit 9 91 mm ROCKER ARM AND ROCKSHAFT INSTALLATION Read the EX mark on the camshaft holder then mount the exhaust port rocker arm and the rockshaft After that mount the inlet po...

Page 23: ... Cam chain 2 Cam chain tensioner 3 Cam chain tensioner lifter 4 Gasket 5 Cam chain tensioner pivot 6 Cam chain guide 7 Bolt 8 Screw pan 9 O ring 10 O ring The operational principle of the tensioner is as shown in the picture As for the adjustment of the cam chain tensioner turning clockwise is tightening and turning counterclockwise is loosening ...

Page 24: ...alve spring Valve Inlet valve Exhaust valve Inner spring 31 2mm 31 2mm Outer spring 34 1 mm 34 1 mm VALVE AND VALVE SPRING INSPECTION Mount the spring retainer valve guide oil seal After applying oil on the valve stem mount it into the valve guide Mount the inner and outer valve springs Mount the valve locker with a spring compressor Tap at the valve gently two or three times with a rubber hammer ...

Page 25: ...meter of the guide subtracts the outer diameter of the valve stem Valve Inlet valve Exhaust valve Service limit 0 08mm 0 10mm VALVE GUIDE REPLACEMENT Heat the cylinder head to 100 150 ｏC Tap the valve guide out with a valve guide remover or similar tool z Turn right when using the reamer and do not push in or out directly with the reamer z When the abrasion of the valve guide exceeds the use limit...

Page 26: ...the valve seat width uneven too wide or too narrow it will result in bad contact between the valve and the valve seat and cannot seal tight At this time it must be reamed with a customized valve seat grinding cutter The valve seat grinding cutter is the customized trimming tool for the valve seat and it has three cutting angles 32ｏ 45ｏ and 60ｏ While trimming press the valve seat grinding cutter to...

Page 27: ...fluid on the valve seat and put the valve on the seat rotate joint then take out the valve and observe the contact surface on the valve face If the contact position is too high then cut out some of the upper part of the valve seat with a 32ｏ grinding cutter to reduce the working face of the valve seat If the contact position is too low then cut out some of the lower part of the valve seat with a 6...

Page 28: ...e and valve seat the air impermeability of their joint surface should be inspected Method one same as the method of valve seat contact position inspection Method two evenly draw several lines on the working surface of the valve with a pencil Put the valve into the valve seat if the lines are all broken after turning 1 8 1 4 ring then it shows the air impermeability is good Method three mount the v...

Page 29: ... of it goes into the big end of the connecting rod and splashes on the cylinder wall and the small end of the connecting rod the other goes through some oil passages such as the shaft neck of the camshaft and splashes on the cam rockshaft and cam chain The lubrication oil that falls back into the oil groove can be re circulated OIL SYSTEM INSPECTION AND REPLACEMENT OIL REPLACEMENT Tighten the dips...

Page 30: ...dle position to make sure there is no oil leakage Stop the engine and inspect if the oil level is proper ROTARY OIL PUMP The oil pump is the critical component of the lubrication system so it should be maintained periodically and should be replaced as a unit when damaged seriously OIL PUMP REMOVAL Remove the flywheel of the magneto Remove the stator coil trigger winding Remove the right crankcase ...

Page 31: ...ews and disassemble the oil pump OIL PUMP INSPECTION Inspect the clearance between the oil pump body and the outer rotator Service limit 0 12 mm Inspect the clearance between the inner rotor and the outer rotor Service limit 0 12 mm Inspect the clearance between the rotor plane and the oil pump Service limit 0 20 mm z If the inspection result exceeds the above stated service limit the whole set sh...

Page 32: ...e oil pump shaft and make sure the oil pump can turn smoothly OIL PUMP INSTALLATION Install the oil pump on the crankcase Tighten the oil pump positioning bolts Align the oil pump driving gear with the oil pump shaft unfilled corner then assemble the driving gear chain z When assembling align the unfilled corner of the oil pump shaft with the corner of the inner rotor and then assemble z Before in...

Page 33: ...USTING SCREW ADJUSTMENT Step one Turn on the air adjusting screw in then turn out by the prescribed number of turns Turn out numbers of turns 3 1 8 3 4 Step two Adjust the throttle adjusting screw to the prescribed idle rpm Step three Adjust the air adjusting screw slightly to find the highest position of the rpm Add throttle quickly and gently the rpm is from low to high and return throttle immed...

Page 34: ...oning nut remove the throttle cable Loosen the carburetor air inlet vent clip and the inlet manifold clip remove the carburetor Remove the vacuum cover bolt and remove the vacuum cover Notice Move slowly to prevent the spring from ejecting Take out the spring the vacuum membrane and the plunger Press down the holding clamp of the needle valve top and turn left to take out the clamp Take out the sp...

Page 35: ...e two lead wires The choke value should be below 10Ω If it exceeds the specific value it should be replaced When the engine is cold link a hose on the reserve supply fuel line and blow very gently The auto side starter is faulty if it is abstracted It should be replaced Remove the auto side starter cover Remove its positioning bolts and pieces Remove the auto side starter Inspect the auto side sta...

Page 36: ... while removing Assemble the float valve the float and the float pin Tighten the float pin positioning screw FUEL CHAMBER INSTALLATION Measure the fuel level Fuel level 18 5 mm Inspect the float for any damage and inspect the float valve for excess wear Confirm the up and down movement of the float is normal CARBURETOR INSTALLATION Reverse the removal procedure for installation After installing ma...

Page 37: ...NSTALLATION Reverse the procedure for removal TRANSMISSION COMPONENTS INSPECTION AND SERVICING STARTING MECHANISM INSPECTION AND SERVICING The starting mechanism can be divided into two types kick starting and electric starting SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM REMOVAL Remove the left crankcase cover Remove the crankcase gasket dowel pins Remove the movable driving plate the whol...

Page 38: ...le shaft Disassemble the starting spindle Disassemble the starting idle shaft SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM INSPECTION Inspect if there is any abrasion or damage of the starting spindle Inspect if there is any abrasion or damage of the starting idle shaft Inspect if there is any abrasion or damage of the starting spindle bushing and starting idle shaft hole ...

Page 39: ...oove of the crankcase then put it in Align the scribing mark of the starting spindle with the punching mark of the idle shaft and then assemble the starting spindle Hook on the two ends of the return spring Install the return spring stopping plate Install the crankcase dowel pin gasket Install the driven belt the driving plate Install the left crankcase cover and lock tightly Install the starting ...

Page 40: ...attached to the gap of the armature surface use a cleaning cloth to remove them Measure the conducting condition of the armature coil according to the picture It should be conductive Measure the conducting condition between the armature coil and the armature according to the right picture It should be non conductive If not it should be replaced z Before removal first shut off the main switch and d...

Page 41: ...n of the carbon brush bracket and it should be non conductive If not it should be replaced Inspect the needle bearing in the carbon brush base It should be able to move smoothly with no play Inspect the dust seal for wear and damage If so it should be replaced STARTER MOTOR INSTALLATION Apply some oil on the dust seal Install the carbon brush on the carbon brush base Apply a little oil on the movi...

Page 42: ...the reduction mechanism 1 Starter reduction gear 11 Clamp 2 Starter reduction gear shaft 12 Bolt 3 Starting clutch gear comp 13 Nut 4 Starting clutch outer comp 14 Washer 5 Flange starting clutch 15 Dowel pin 6 Starting clutch roller spring 16 Key woodruff 7 Spring holder 17 Roller 8 Starter motor 18 Needle bearing z Make sure the starter motor case is free of metal particles because it is magneti...

Page 43: ...tion gear shaft It should be replaced when the diameter is less than 9 94mm ENGAGING MECHANISM STARTING CLUTCH REMOVAL Remove the right crankcase cover Remove the left crankcase cover Hold the drive face with the universal set wrench Remove the starting clutch fixing nut Remove the starting clutch the whole set STARTING CLUTCH INSPECTIN Inspect if the movement between the clutch and the driving ge...

Page 44: ...he damage is serious it should be replaced Measure the inner diameter of the flange clutch It should be replaced when the diameter is more than 27 94mm STARTING CLUTCH INSTALLATION Install the spring the roller and the top pin on the body of the clutch Align the dowel pin on the flange clutch with the hole on the clutch body then install Apply some thread lock on the outer clutch component bolt an...

Page 45: ...r reading should be close to the magnitude of voltage between the two ends of the battery If not the brake switch its wire or the wire connector is not good Inspect if the start button is conductive At this time remove the starting relay inlet line the green yellow line Connect the yellow red line with the ground wire and press the start button It should be conductive between the yellow red line a...

Page 46: ...ed on the engine crankshaft and the driven belt pulley connects with the rear driven mechanism Its basic operational principle is to realize automatic CVT by the diameter changes the transmission ratio changes of the driving and driven belt pulley When the diameter of the driving belt pulley changes form small to big proportionally the diameter of the driven belt pulley changes from big to small b...

Page 47: ...cture of the driving belt pulley is shown in the picture The picture shows the working theory of the driving belt pulley The picture shows the structure of the driven belt pulley The clutch showed in the picture is the automatic dry centrifugal weight clutch ...

Page 48: ...ve the left crankcase fixing bolt Remove the left crankcase cover Hold the drive plate with a universal wrench and then remove the nuts and gasket on the drive plate shaft Remove the drive plate Remove the driven belt from the drive plate Remove the gasket and the dowel pin Remove the movable drive plate the whole set Remove the ramp plate Remove the centrifugal rollers ...

Page 49: ...f the movable drive plate Service limit 24 06mm Inspect if there is any abrasion or damage of the drive plate hub Measure the outer diameter of the drive plate hubs movable surface Service limit 23 94mm DRIVE BELT PULLEY INSTALLATION Apply some grease evenly in the movable drive plate Put the centrifugal rollers into the movable drive plate Install the ramp plate Put the drive plate hub into the d...

Page 50: ...e plate the drive plate washer and nut Hold the drive plate with a multiuse holder to make it unmovable At the same time fasten the nut on the shaft CLUTCH CLUTCH REMOVAL Remove the left crankcase cover Remove the drive plate and the driven belt Hold the clutch friction plate with a multiuse holder and remove the nut Remove the clutch friction plate z Do not allow any grease or oil on the surface ...

Page 51: ...on piece Service limit 1 5mm CLUTCH DISASSEMBLING If it is needed to replace the centrifugal weight set you must disassemble the clutch Remove the clutch friction plate Remove the whole set of clutch driven plate Compress the driven pulley spring with the clutch spring compressor and at the same time remove the nut on the shaft Disassemble the clutch with the driven pulley Remove the circlip and r...

Page 52: ...ip and the bottom plate Reverse the removal procedure for installation DRIVEN BELT PULLEY DRIVEN BELT PULLY REMOVAL After removing the clutch friction plate remove the guide pin the roller and the movable driven plate Remove the oil seal on the movable driven plate z When assembling the clutch and the driven plate you must use a clutch spring compressor otherwise it will damage this spring z No gr...

Page 53: ... 33 94mm Inspect if there is any abrasion or damage of the movable driven plate Measure the inner diameter of the movable driven plate Service limit 34 06mm Inspect if the groove of the guide pin is worn DRIVEN PLATE BEARING REPLACEMENT Remove the needle bearing from the driven plate Service limit 163 7mm z If the driven plate needle bearing and the ball bearing are loose damaged or have some unus...

Page 54: ...pply grease around the bearing DRIVE BELT PULLEY INSTALLATION Remove the grease on the driven plate Assemble the oil seal Apply a little grease on the O ring Assemble the movable driven plate into the driven plate After applying some grease on the roller and the guide pin assemble them into the driven plate hole Install the oil seal collar Remove the excessive grease Assemble with the clutch and i...

Page 55: ...ankcase cover Inspect if the transmission belt is chapped or worn Measure the width of the belt Service limit 19 0mm Replace the belt if its width is less than the above limitation See the drive pulley removal and installation procedure for the replacement z When replacing you must use the OEM part for correct fit ...

Page 56: ...NG RADIAL BALL 5 BEARING RADIAL BALL 6 BOLT SPECIAL 7 WASHER 8 OIL SEAL 9 GEAR FINAL 10 ClRCLIP EXTERNAL 11 SHAFT FINAL 12 SHAFT COMP COUNTER 13 NUT 14 WASHER 15 SHAFT DRIVE TRANSMISSION CASE OIL REPLACEMENT TRANSMISSION CASE OIL INSPECTION Inspect if there is oil leakage around the transmission case After the engine stops remove the transmission case oil level bolt z When inspecting the oil level...

Page 57: ... bolt and its oil seal and fasten Supply the oil with the prescribed specification and oil level Mount the level bolt After replacing the oil inspect for any oil leakage TRANSMISSION CASE TRANSMISSION CASE REMOVAL Remove the driven belt pulley Drain out the oil in the transmission case Remove the drive sprocket Remove the bolt and remove the transmission case cover Remove the gasket and the dowel ...

Page 58: ...ear the final gear shaft is damaged or worn BEARING ON THE TRANSMISSION CASE COVER REPLACEMENT Press the driven belt pulley shaft out of the transmission cover Remove the oil seal and drive out the bearing Remove the final gear shaft bearing z When removing or installing the bearing on the transmission case cover you must use the special tool shown in the picture ...

Page 59: ...ENT Inspect if the bearing and oil seal on the left crankcase for wear or damage If it is damaged it must be replaced Remove the oil seal Drive out the final gear shaft bearing z When driving in the final gear shaft bearing keep the bearing parallel The same is required when installing the sub shaft bearing and the driven pulley shaft bearing z When removing or installing the bearing on the left c...

Page 60: ...UAL VERSION 1 DEC 2005 61 Remove the sub shaft bearing Remove the driven belt pulley shaft bearing Drive in the new driven belt pulley shaft bearing Drive in the new sub shaft bearing Drive in the new final gear shaft bearing ...

Page 61: ...iven belt pulley shaft on the transmission case cover Drive in the transmission case cover oil seal Mount the sub shaft sub shaft gear and the final gear shaft into the left crankcase Mount the final gear on the final gear shaft Install the new dowel pin and gasket ...

Page 62: ...MANUAL VERSION 1 DEC 2005 63 Install the transmission case cover and bolt Mount the driven pulley the clutch set Mount the drive pulley the transmission belt and the left crankcase cover Fill the transmission case with oil ...

Page 63: ...lowly measure the charging voltage and current Charging voltage V 13 5 15 5 Charging current A 0 5 Measuring condition 5000 r min If the voltage is not in the range of the above specified value please inspect the voltage regulator BATTERY The battery is an important component of the electric system This battery used on the vehicle is a maintenance free battery For long period of storage the batter...

Page 64: ...of the charger with the negative pole of the battery Charge the battery for the charging time marked on the battery Measure the voltage 30 minutes after charging is finished and it should reach the specified value otherwise it needs recharging Normal 0 7A Charging current Fast 3 0A Normal 5 10 hours Charging time Fast 30 minutes Charging result Open circuit voltage 12 8V PRIMARY COIL z Disconnect ...

Page 65: ...Y COIL INSPECTION Remove the 4 core connector of the generator Measure the resistance value between the white wire of the generator and connecting wire of the vehicle body Standard value 0 2 0 4 Ω 20 When the actual value is more than the standard value the coil should be replaced GENERATOR REMOVAL AND INSPECTION z The inspection work can be done on the engine and there is no need to remove the ge...

Page 66: ...the flywheel with a universal holding wrench at the same time remove the flywheel nut Remove the flywheel with a flywheel puller and remove the solid key Remove the generator wire connector Remove the generator wire holder Remove the generator coil bolt Remove the generator wire rubber bushing from the right crankcase Remove the coil set GENERATOR INSTALLATION z Do not damage the coil when removin...

Page 67: ...Lighting wire the yellow wire Vehicle body remove the resistor side auto starter plug and turn the lighting switch to OFF Generally is 0 1 0 8Ω Charging wire the white wire Vehicle body Generally is 0 2 2 0Ω W White Y Yellow R Red G Green z When installing the flywheel make sure there are no metal pieces such as bolts or nuts attaching to the inner wall of the flywheel z After the installation is ...

Page 68: ...when the actual value is in the range of 1Ω value marked on the diagram or the resistor if not it should be replaced IGNITION SYSTEM INSPECTION AND SERVICING The circuit working principle is shown in the picture IGNITION TIME INSPECTION Remove the ignition timing hole cover or remove the fan cover Rotate the generator rotor and align the F mark on the motor with the crankcase timing ignition mark ...

Page 69: ...f the plug is bad Connect the negative end of the multimeter with the positive connecting iron of the primary ignition coil black yellow wire Press the starting button or use the kick starter and read the voltage value on the multimeter The highest voltage value should be above 112V Remove the 4 core and 2 core connector of the CDI component Connect the positive end of the multimeter with the igni...

Page 70: ... value is more than the standard value it should be replaced TRIGGER WINDING Remove the connector of the trigger winding wire Measure the resistance value between the trigger winding green red wire and the body ground wire When the actual value is more than the standard value it should be replaced Standard value 4 300Ω 20 CDI COMPONENT Remove the CDI component Inspect if the connector is loose or ...

Page 71: ... it is good however indicates the coil is bad Remove the spark plug cap and measure the resistance value of the secondary ignition coil Standard value 2 4 kΩ 20 If the resistance value is in the standard range it indicates it is good however indicates the coil is bad The ignition coil also can be inspected and measured with the ignition testing instrument Set the measuring switch of the ignition c...

Page 72: ...on the spark plug with a steel brush or a blade Inspect the spark plug gap In general it should be about 0 6 0 7mm When the carbon accumulation and wear of the spark plug are too much replace the spark plug Replace with the spark plug of the same specification z When installing connect the black yellow wire of the primary ignition coil with the black yellow connector of CDI and the green wire with...

Page 73: ... Remove the chain z Loosen nuts on bearing carrier and remove bolts z Remove axle and bearing carriers as a unit REAR SWING ARM z Remove Rear Shock z Remove rear brake caliper and set aside Do not remove brake hose z Unplug brake light wiring from the electrical box z Remove throttle cable z Remove bolts from swing arm pivot z Check Buffer Rubber Bushing for wear If wear is present on bushing it s...

Page 74: ...ENT z Do not disassemble the castle nuts when you replace the front wheels z It is only necessary to tighten the nuts so that the wheel turns freely on the axle with minimum end play Please tighten the nuts after replacing the wheels FRONT HUBS z Check seals for rips or tears and replace if any exist z Remove bearings with a punch from the opposite side z Inspect bearings for ease of movement If d...

Page 75: ...aft STEERING GEAR BOX AND BALL HEAD STEERING GEAR BOX z Remove four bolts on LH RH Clamp Nut Steering Gear Box z Remove and check Ball Head Dust Cover Steering Gear Box for wear z Check Steering Cover on both sides of Steering Gear Box and Grease the Ball Head z Steering Gear Box fill with Grease after cleaning the dust It is recommended to replace the Ball Joint if it is loose or not smooth THROT...

Page 76: ...FR Wheel z Check the Nylon Bushing of Upper Lower A Arm FR Wheel for wear Replace them immediately if wear is present STEERING KNUCKLE SUPPORT z Remove Rubber Dust Cover of the knuckle Support z Check the grease of Ball Joint Clean it if dirty and fill with grease z Replace the Steering knuckle support if the Ball Joint is loose or steering isn t flexible ...

Page 77: ...backward 2 Adjusting Nut 1 on the top of the reverse cable can adjust the mesh status inside the reverse gear box In the forward position there should be about 1 4 inch play in the cable for the correct adjustment SERVICE AIR CLEANER Service every 100 hours Note Service more often under dusty conditions 1 Remove cleaner cover 2 Remove air cleaner element 2 3 TO SERVICE PRE CLEANER 1 Clean foam fil...

Page 78: ...e the spark plug needs inspection c It is advisable to replace the spark plug at least once a year to insure easy starting and good engine performance FRONT WHEEL ALIGNMENT 1 The front wheels should be toed in from 1 8 to 1 4 To check alignment measure distance from A to B to the centerline CL of the tires with the wheels pointed straight ahead For the proper toe in dimension A should be 1 8 1 4 g...

Page 79: ...IN ADJUSTMENT After the first two hours of operation check the chain adjustment and readjust if it has more than 1 2 flex 1 Loosen Nut 1 2 Adjust Nut 2 3 Tighten Nut 1 Verify if the chain is loose Repeat the above mentioned steps until it is good enough ...

Page 80: ...KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 81 ...

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