KS Motorcycles K-LIGHT125, Maintenance Manual

Page: 230 / 278

XV. Variable speed gear
Preparatory Information ··················· 15.1
Fault Diagnosis······························ 15.2
Gearshift Mechanism ······················· 15.3
Installation ··································· 15.4
15.1 Preparatory Information
Function: Transmit torque, and decide the torque and speed of final output.
Technical parameters Unit: mm
Gearshift
Mechanism
Outer diameter of shift fork shaft 11.97-12 11.95
Diameter of inner hole of shift fork 12-12.018 12.05
Thickness of shift fork 4.93-5.0 4.7
Outer diameter of shift drum 35.8-36 35.75
Width of lock groove of shift drum 7.05-7.15 7.3
15.2 Fault Diagnosis
The gear cannot be engaged It's h ard to shift gears
Variable-speed shift fork is broken or deformed Clutch is not completely disengaged
The guide pin of shift fork is broken The return spring of transmission is not working
properly
The gear claws are worn The lock groove of shift drum is worn
The gear is out of controlled
spontaneously
Joint claws are worn and the edges become round
corners
The elasticity of return spring of transmission is
weaken
The spline teeth of spline shaft and spline grooves of
sliding gear are worn,
resulting in a great axial force when the gear is working
Shift drum or shift fork is worn
- 229 -
KS MOTORCYCLES - https://ksmotorcycles.com