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KS Motorcycles K-LIGHT125, Maintenance Manual

The KS Motorcycles K-LIGHT125 comes with a free Maintenance Manual available for download on our website. This manual provides you with all the necessary information to keep your motorcycle running smoothly. Stay updated on maintenance tasks and download your manual today from manualshive.com.

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12.7 Installation of Cylinder Head ............................................................................................................. - 209 - 

XIII. Cylinder Block and Piston ........................................................................................................................ - 211 -

13.1 Preparatory Information ..................................................................................................................... - 211 - 

13.2  Fault Diagnosis ............................................................................................................................... - 212 - 

3.3 Cylinder Block ..................................................................................................................................... - 213 - 

13.4 Piston ................................................................................................................................................. - 214 - 

13.5 Installation of Cylinder Block ............................................................................................................ - 218 - 

XIV. Clutch / kickstarter    mechanism .............................................................................................................. - 221 -

14.1 Preparatory Information ..................................................................................................................... - 221 - 

14.2 Fault Diagnosis .................................................................................................................................. - 221 - 

14.3 Clutch ................................................................................................................................................. - 222 - 

14.4 Kickstarter Mechanism ...................................................................................................................... - 224 - 

14.5 Disassembly of primary and auxiliary shafts ..................................................................................... - 225 - 

XV. Variable speed gear ..................................................................................................................................... - 229 -

15.1 Preparatory Information ..................................................................................................................... - 229 - 

15.2 Fault Diagnosis .................................................................................................................................. - 229 - 

15.3 Shift mechanism ................................................................................................................................ - 230 - 

15.4 Installation ......................................................................................................................................... - 233 - 

XVI. Crankcase ................................................................................................................................................. - 235 -

16.1 Preparatory Information ..................................................................................................................... - 235 - 

16.2 Fault Diagnosis .................................................................................................................................. - 235 - 

16.3 Crankcase ........................................................................................................................................... - 236 - 

16.4 Crankshaft combination ..................................................................................................................... - 239 - 

XVII. Exhaust Emission Control System .......................................................................................................... - 246 -

17.1 Guarantee of Exhaust Emission Control System ............................................................................... - 246 - 

17.2 Regular Maintenance Notice ............................................................................................................. - 246 - 

17.3 Mechanical Function of Exhaust Control System ............................................................................. - 247 - 

17.4 Catalyst Conversion System .............................................................................................................. - 247 - 

XVIII. Electronic Injection System ................................................................................................................... - 251 -

18.1 Introduction of Electronic Injection System ...................................................................................... - 251 - 

18.2 EFI Parts ............................................................................................................................................ - 252 - 

18.3 Fault Maintenance and Diagnosis Method ........................................................................................ - 268 - 

18.4 Common Troubleshooting Methods .................................................................................................. - 271 - 

 Circuit Diagram

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................

............................................................................................ 277 

- 3 - 

KS MOTORCYCLES - https://ksmotorcycles.com

Summary of Contents for K-LIGHT125

Page 1: ...Maintenance Manual of Two wheeled Motorcycle K LIGHT125 KS MOTORCYCLES https ksmotorcycles com...

Page 2: ...6 Alternator Charging Coil 79 1 7 Disassembly of Alternator 79 II Ignition System 83 2 1 Preparatory Information 83 2 2 Fault Diagnosis 85 2 3 Trigger 86 2 4 Ignition Coil 86 2 5 Spark Plug 88 2 6 EC...

Page 3: ...ock absorber 166 8 5 Rear Rocker Arm 168 8 6 Chain drive 171 IX Fuel Tank Seat 180 9 1 Preparatory information 180 9 2 Fault Diagnosis 180 9 3 Seat 181 9 4 Fuel Tank 182 X Disassembly Installation of...

Page 4: ...ult Diagnosis 229 15 3 Shift mechanism 230 15 4 Installation 233 XVI Crankcase 235 16 1 Preparatory Information 235 16 2 Fault Diagnosis 235 16 3 Crankcase 236 16 4 Crankshaft combination 239 XVII Exh...

Page 5: ...nd performance maintenance methods of parts which should be implemented from the time of regular inspection Chapter II and subsequent chapters are the explanations for the decomposition combination an...

Page 6: ...d fire are strictly prohibited in the workplace or the place where gasoline is stored Battery Battery may emit explosive gas Keep it away from spark open flames and smoking area Keep it well ventilate...

Page 7: ...from the outside of part or assembly to prevent the dirt from falling into the engine chassis or brake system After disassembling and before measuring the wear value clean the parts and blow them with...

Page 8: ...r future assembly The parts that will no longer be used should be replaced promptly before dismantling The lengths of bolts or screws are different for assembly and fender and they must be installed i...

Page 9: ...uld be fitted at the original design position Disassembly of ball bearing use tools to support one or two inner and outer bearing rolling rings If the force is applied to only one rolling ring either...

Page 10: ...le may be caught during movement Cables should not be kept too tight or loose when being placed along the faucet handle and must not interfere with adjacent parts in any steering position Cables shoul...

Page 11: ...is the production factory code and a mark is added at the beginning and the end of the frame number 2 Frame nameplate riveting position as shown in the figure Frame nameplate as shown in the figure 3...

Page 12: ...dust Special tools Special tool refers to a tool specially designed for assembling or disassembling some parts of motorcycle and using it on a specific location Appropriate special tools are indispens...

Page 13: ...Fig 1 3 Fig 1 4 Fig 1 5 Fig 1 6 Fig 1 7 Fig 1 8 Feeler gauge 12 KS MOTORCYCLES https ksmotorcycles com...

Page 14: ...Fig 1 9 Fig 1 10 Handle Fig 1 11 Fig 1 12 Opening clamp Piston 13 KS MOTORCYCLES https ksmotorcycles com...

Page 15: ...h Allen wrench Socket wrench Micrometer Magnetic frame V shaped block Dial gauge Vernier caliper Spring snap ring pliers Knock on screwdriver Front fork oil seal installation tool Front fork seal driv...

Page 16: ...Fig 1 19 Fig 1 20 Fig 1 21 Fig 1 22 Fig 1 23 Fig 1 24 1 Socket head 2 Jiggle bar 3 Ratchet wrench 4 Connecting rod 15 KS MOTORCYCLES https ksmotorcycles com...

Page 17: ...Fig 1 25 Fig 1 26 Fig 1 27 Fig 1 28 2 Special tools for maintenance of chassis Front fork seal driving tool Fig 1 29 3 Steering nut wrench 16 KS MOTORCYCLES https ksmotorcycles com...

Page 18: ...nd pictures of special tools for the testing of electrical parts are shown in Table 1 31 and 1 32 Table 1 31 Name Remarks Multimeter Ignition tester Fig 1 33 Fig 1 34 Table 1 32 continued Fig 1 33 Fig...

Page 19: ...r 3XG sponge Rear tire 130 90 15 Transmission gear Clutch type Wet multi plate friction type Tank capacity 11 8L 0 5L Speed varying mode Five speed transmission Performance Throttle valve 30C 21 Drive...

Page 20: ...19 KS MOTORCYCLES https ksmotorcycles com...

Page 21: ...short circuit in the ignition switch Check whether there is any open circuit or short circuit in the line of ignition switch Check whether there is fault in the CDI ignition device Test the compressi...

Page 22: ...rter device of throttle valve 1 Check for air leakage at the joint outside the engine 2 Check whether gas distribution is conducted in correct time 3 Check whether the valve clearance is too small 4 C...

Page 23: ...ame as that of engine The temperature of radiator is low and the temperature of engine is high The working cycle of water cooling system is normal The working cycle of water cooling system is defectiv...

Page 24: ...group of spark plug is white and the engine is intermittently operate when accelerating the carburetor is tempered and engine power is insufficient Too thick combustible mixture 1 Check whether air fi...

Page 25: ...e piston ring is broken or stuck in the ring groove or in lack of elasticity 6 Check the wear of piston ring and cylinder Start the engine slowly increase the throttle and observe the changes in the e...

Page 26: ...iston ring and cylinder Readjust the idle speed of electronic fuel injector Check whether the metering hole of idle speed is too large Check whether the steel wire rope of throttle control cable can b...

Page 27: ...heck tire pressure The pressure is too low The pressure is normal Inflate as required Check fuel tank fuel pump oil pipeline throttle and other parts for oil leakage Eliminate it according to actual s...

Page 28: ...contact surface between clutch friction plate and brake shoe is excessively worn Repair or replace clutch brake shoe Supplement oil Check whether the viscosity of oil in the crankcase is too low or i...

Page 29: ...marking line 1 Check whether cylinders pistons and piston rings are excessively worn 2 Check whether the piston ring is insufficiently stretched or stuck in the ring groove 3 Check whether the piston...

Page 30: ...sh rod is not adjusted properly Readjust Check whether the elastic force of clutch spring is even Replace the whole set of clutch spring Check whether the driving and driven hub gear grooves of the cl...

Page 31: ...e free stroke of clutch grip is within the range of 10 mm 20mm 2 Check whether the elastic force of clutch spring is even 3 Check whether the driving and driven hub gear grooves of the clutch are worn...

Page 32: ...m claw at the end face of meshing gear is worn into tapered shape or a large roundness and the groove at the corresponding gear end surface is worn into a flared opening Check whether the shift fork i...

Page 33: ...her there is a sponge like feel when operating the brake grip There is residual air in the oil circuit of brake system Check whether the brake shoe has been worn to the limit mark and brake disc is ex...

Page 34: ...alue is less than the standard value Charging coil is short circuited Resistance value is infinite Resistance value meets standard value Charging coil or its output wire is short circuited Place the m...

Page 35: ...display There is voltage display The wire between connector clip and battery is open circuited Check whether there is fault in rectifier or rectifying regulator using an ohmmeter 34 KS MOTORCYCLES htt...

Page 36: ...e in the battery is insufficient 2 Check whether the density of electrolyte in the battery is too low 3 Check whether the pole plate in the battery is vulcanized or short circuited Undercharge of batt...

Page 37: ...or rotate the turn signal switch After pressing the start button you cannot hear the sound of starting relay After pressing the start button you can hear the sound of starting relay Remove the connect...

Page 38: ...he contact in clutch switch is poor 2 Check whether the contact of start button is poor 3 Check whether rectifier diode is damaged 4 Check whether the neutral switch is not working normally 5 Check wh...

Page 39: ...the starter motor connecting wire and battery connecting wire from the starter relay press the start button when the starter relay makes a sound for connection measure whether the resistance between...

Page 40: ...e generated when striking There is no power in battery All lights are out AC power lighting system DC power lighting system Disconnect the connector clip between alternator lead harness and vehicle ca...

Page 41: ...nnect the power wire and output wire of lighting switch using a wire Open circuit or short circuit between alternator or ignition switch and lighting switch Light is on when being short circuited Ligh...

Page 42: ...ty of electrolyte in the battery is too low Check whether the substrate in the battery is vulcanized or open circuited Disconnect the connector clip between rectifying regulator and vehicle cable and...

Page 43: ...disconnection The regulated voltage of rectifying regulator is too low The electric horn can make a loud sound and the turn signal light can give off a bright light Electric horn is hoarse and the tur...

Page 44: ...ght switch is turned on at the fault side using an ohmmeter The output power line at fault side is open circuited or the bond strap of lampholder is poor The contact in turn signal light switch is poo...

Page 45: ...ains off after being short circuited The contact in turn signal light switch is poor Check whether there is power output in the power input wire of turn signal light switch by light test method The li...

Page 46: ...arks are generated when striking No spark is generated when striking Connect the power wire of electric horn and connect the non power terminal of electric horn terminal connected to the button and bo...

Page 47: ...rt circuited Instantly strike the power wire of brake light switch with bond strap using a screwdriver or wire and check the conditions of spark Brake light switch is not adjusted properly or the inte...

Page 48: ...stroke of front rear brake Rim tire Inspection of brake fluid for leakage Steering column bearing and handlebar fixator Preparation standard Satisfactory Warning Before the engine is running make sur...

Page 49: ...75 88 N m Rear wheel mounting nut 100 113 N m Relevant component certifications Model Name Certification number Remarks Tire Front tire E4 75R 0009994 Use environment friendly tubeless tire Rear tire...

Page 50: ...Muffler Mark on main cylinder Mark on auxiliary cylinder Air filter e13 QJ AF M21 49 KS MOTORCYCLES https ksmotorcycles com...

Page 51: ...tion of bolt loosening at all parts I I I I I I Torque wrench Inspection of gearbox for oil leakage I I I I I I General tools Inspection or replacement of spark plug I I R R I General tools Lubricatio...

Page 52: ...eage of 1 000 kilometers I Inspection A Adjustment R Replacement C Cleaning L Lubrication Note 1 is the item in which exhaust emissions are involved Normal maintenance must be conducted in accordance...

Page 53: ...rly and add it to the appropriate location Oil capacity 1 1 0 1L when changing oil 1 2 0 1L when disassembling If the oil level is too high the operation of engine and clutch may be affected if it is...

Page 54: ...when warming up the engine and the engine should be supported on the side bracket to ensure that the oil is completely discharged When the oil drain cap is removed the oil filter and spring may pop o...

Page 55: ...ed free stroke is reached If it is screwed in the free stroke will increase if it is screwed out the free stroke will decrease Tighten the locknut After adjusting the free stroke rotate the lever to t...

Page 56: ...Remove the left protector A Remove the mounting screw A at air filter cover Remove Filter element assembly 55 KS MOTORCYCLES https ksmotorcycles com...

Page 57: ...tle and may cause the engine to overheat In addition operation without the filter element may affect subsequent adverse operation of throttle and may cause the engine to overheat Installation It shoul...

Page 58: ...Battery disassembly Remove the left protector 1 First remove the negative cable 2 Remove the positive cable Remove the air pipe of battery from the battery Remove the battery holder A Remove the batte...

Page 59: ...oltmeter Charging Connection method The positive electrode of charger is connected to the positive electrode of battery The negative electrode of charger is connected to the negative electrode of batt...

Page 60: ...lve nut Cylinder pressure Warm up the engine Insert a pressure gauge Move the choke handle to the fully open position Rotate the throttle handle to the fully open position and backflush to start the e...

Page 61: ...A at both sides of rear rocker arm until the slackness of chain is normal Note Do not install the new drive chain on a worn sprocket or install the worn chain on a new sprocket Both the sprocket and...

Page 62: ...troke will be increased Screw in or screw out it until the free stroke meets the specified value Tighten the locknut A After adjustment the brake dragging phenomenon shall be avoided Inspection of bra...

Page 63: ...62 KS MOTORCYCLES https ksmotorcycles com...

Page 64: ...ake hose 30 N m Check the winding method of brake hose If the brake hoses and brake lines models equipped with CBS are not wound correctly please discharge brake hoses and brake lines by correct windi...

Page 65: ...ou need to add brake fluid but are not sure about the type and brand of brake fluid in the brake fluid reservoir you must replace the brake fluid in the brake fluid tube After replacing brake fluid us...

Page 66: ...mm Rear wheel brake pad 6 0 mm Operating limit 3 mm Inspection of CBS Inspection of CBS Check whether the brake fluid in the CBS reservoir is above the level line Check whether there is inner leakage...

Page 67: ...light switch Open the electric door lock When the brake lever is pulled by about 15 mm the brake light is on If the brake light is off check whether the brake light switch plug is inserted properly If...

Page 68: ...ed before it can be touched Install the front headlight bulb and front position light bulb in the reverse order of disassembly Note Avoid touching the glass part of the bulb directly and do not expose...

Page 69: ...or screw out it until the free stroke meets the specified value Finally tighten the fastening nut If the specified free clearance cannot be reached by adjusting the clutch handle adjust the lower end...

Page 70: ...operation Check whether the parts of rear shock absorber are damaged and loosened Suspend the rear wheel and swing the rear wheel to check whether the engine suspension bushes are loosened Bolt nut f...

Page 71: ...ure measurement should be conducted at cold state Specified air pressure Unit Kpa Tire specifications Tire pressure Front tire 90 90 17 190 10 Rear tire 130 90 15 210 10 Notes If there is a rotation d...

Page 72: ...Mounting nut of rear wheel 100 113 m Front rim 1 85 17 Rear wheel rim 3 00 15 Steering column bearing and handlebar fixator Swing the handlebar from side to side and check whether wires are involved...

Page 73: ...tem Fastening location and fastener name Tightening torque N m Starter motor clutch cover bolt Starter motor clutch mounting bolt Rectifier bolt High voltage coil mounting bolt Flywheel mounting nut M...

Page 74: ...Charging System 1 Ignition switch 2 Electric horn 3 Ignition coil 4 Motor 5 Variable frequency flasher 6 Fuse 7 Relay 8 ECU 9 Battery 10 Voltage regulator 73 KS MOTORCYCLES https ksmotorcycles com...

Page 75: ...r fault The battery voltage will be too high and the battery life will be shortened 3 If the battery is placed for a long time the battery will discharge by itself and the power capacity will be reduc...

Page 76: ...ge coil mounting bolt 9 0 N m Flywheel puller Flywheel mounting nut 50 60N m Testing instrument Motorcycle cover bolt 9 0 N m Multimeter 1 2 Fault Diagnosis No power Discontinuous current Battery over...

Page 77: ...operation order When installing the battery first connect the positive electrode and then negative electrode 1 3 2 Battery testing Check the charging state open circuit voltage Open the battery cover...

Page 78: ...Charging time Standard 10 15 hours Quick 30 minutes Completion of charging open circuit voltage 12 8V or more 1 4 Charging System 1 4 1 Inspection of Charging State Test the battery with a multimeter...

Page 79: ...o the red terminal of regulator and connect the red probe to the white terminals white 1 white 2 white 3 of regulator respectively The pointer gauge will display a certain value otherwise it indicates...

Page 80: ...ternator Standard value 0 8 0 3 20 C Replace the alternator coil when the measured value exceeds the standard value 1 7 Disassembly of Alternator 1 7 1 Disassembly Remove the starter gear cover of eng...

Page 81: ...sal mounting wrench to fix the flywheel Remove the flywheel mounting bolt Use a flywheel puller to remove the flywheel Remove the mounting key Flywheel lock locking bolt 80 KS MOTORCYCLES https ksmoto...

Page 82: ...ic so bolt should not be installed on it Use a universal non adjustable wrench to secure the flywheel and then lock the retaining nut Install the alternator stator on the left cover of the engine inst...

Page 83: ...3 Ignition coil 4 Motor 5 Variable frequency flasher 6 Fuse 7 Relay 8 ECU 9 Battery 10 Voltage regulator ECU 1 1 White Blue Green White Trigger probe Ignition power Ignition system Black red 1 Black...

Page 84: ...poor contact 5 Check whether the heat value of spark plug is appropriate because improper spark plug may cause the engine to run unsmoothly or burn the spark plug 6 Check the main switch according to...

Page 85: ...Primary coil 4 15 Secondary coil There is a spark plug cover 18 6K 15 There is no spark plug cover 13 6K 15 Impedance of trigger 20 C 150 10 Maximum voltage in one measurement of ignition coil 15V Tri...

Page 86: ...specified value Good Not good If ignition coil fails replace it The voltage is zero or almost zero Check 1 Voltage of multimeter 2 Peak voltage of crankshaft sensor 3 Peak voltage of position sensor o...

Page 87: ...of engine Standard value 150 10 20 C If the measured resistance value is higher than the specified value the coil circuit is disconnected and needs to be replaced If the resistance value is lower tha...

Page 88: ...y to check whether the parts of wiring are loosened or in poor contact There are many brands of multimeter the internal impedances are different and the tested values are different Check the primary c...

Page 89: ...he spark plug If the spark plug is dirty or there is carbon deposit replace the spark plug Use a wire feeler to measure the gap D If the gap is incorrect replace the spark plug Spark plug gap 0 7 0 1m...

Page 90: ...coil 4 Motor 5 Variable frequency flasher 6 Fuse 7 Relay 8 ECU 9 Battery 10 Voltage regulator B G Y G Y O R O R R RELAY BATTERY B O R Gr THE ON OFF SWITCH R W G G START SWITCH FLAMEOUT SWITCH STARTOR...

Page 91: ...arter clutch should be disassembled in accordance with the working procedures Technical parameters Item Standard value Operating limit Length of starter motor brush 12 5mm 8 5mm Stater idle shaft bush...

Page 92: ...ck by foreign body Defective starter clutch Reverse rotation of starter motor Insufficient battery power 3 3 Starter Motor 3 3 1 Disassembly Note Before disassembling starter motor first turn off the...

Page 93: ...starter relay 3 4 2 Inspection of Voltage of Starter Relay Erect main foot and measure the voltage between the negative electrode green yellow of starter relay connector and bond strap of motorcycle b...

Page 94: ...ter start button is pressed When it is nonconductive check the continuity and wire of start button 3 4 4 Operation Inspection Connect the starter relay to the battery and connect the terminal of start...

Page 95: ...Bulbs Meters 1 Front headlight 2 Meter 3 Front left turn light 4 Front right turn light 5 Rear left turn light 6 Taillight 7 Reflector 8 Rear right turn light 94 KS MOTORCYCLES https ksmotorcycles com...

Page 96: ...lb 4 3 Replacement of Front Turn Signal Light Bulb 4 4 Replacement of Taillight Bulb 4 5 Replacement of License Plate Light Bulb 4 3 Meters 4 7 Ignition Switch 4 8 Electric Horn 4 9 Handlebar Switch 4...

Page 97: ...ical fault check the continuity of the circuit passing through the electronics Before performing any inspection confirm the battery status including checking whether the battery voltage is normal 4 2...

Page 98: ...because the bulb is hot and should be cooled before it can be touched 4 3 2 Installation Install the front headlight bulb and front position light bulb in the reverse order of disassembly Note Avoid...

Page 99: ...Rl0W 4 4 2 Installation The bulb should be installed in the reverse order of disassembly 4 5 Replacement of Taillight Bulb 4 5 1 Disassembly Remove Self tapping screw of taillight A Taillight cover B...

Page 100: ...cense plate light cover B License plate light holder C License light bulb D Specifications License plate light bulb W5W 4 6 2 Installation The license plate light bulb should be installed in the rever...

Page 101: ...reverse order of disassembly Torque value Meter mounting holder mounting screw 10 12N m 4 8 Ignition Switch 4 8 1 Disassembly Remove the ignition switch wire connector Check the conduction of connect...

Page 102: ...nt of Ignition Switch Remove the mounting bolt and replace the ignition switch A Red white 1 Red Red white Orange blue Gear Line color Red white 1 Red Red white Orange blue 101 KS MOTORCYCLES https ks...

Page 103: ...4 9 1 Disassembly Remove Mounting bolt A Horn B 4 9 2 Installation The horn should be installed in the reverse order of disassembly Torque value Horn mounting bolt 10 12N m 102 KS MOTORCYCLES https k...

Page 104: ...4 9 3 Inspection Remove the horn wire If the horn sounds after being connected to the battery it is in good conditions 103 KS MOTORCYCLES https ksmotorcycles com...

Page 105: ...r switch Left steering switch Light blue Yellow Blue Black Blue red Horn button Red white Brown Green Purple Red white Green yellow Dark green Orange Green white Right steering switch Orange Green w h...

Page 106: ...ding assembly mounting bolt Front axle locknut Mounting bolt of front shock absorber Rear wheel mounting nut Nut at the top of rear shock absorber Nut at the bottom of rear shock absorber Mounting bol...

Page 107: ...Front rear fluid brake 106 KS MOTORCYCLES https ksmotorcycles com...

Page 108: ...of rear brake 5 Front left brake cylinder assembly 17 Rear brake bracket assembly 29 Split pin 2 18 6 Rear fuel pump assembly 18 Fuel pump assembly 30 Mounting bolt 7 Fuel hose mounting bolt three way...

Page 109: ...ickness of rear friction pad 6 0 3 0 Torque value Front wheel axle mounting nut 75 88 N m Rear wheel axle mounting nut 100 113 N m Mounting bolt of front brake cylinder assembly 22 29 N m Mounting bol...

Page 110: ...and fluid brake disc 3 Improper installation of brake shoe and friction pad assembly Abnormal noise of brake 1 Wear of brake shoe friction pad assembly and fluid brake disc 2 Pollution of brake shoe...

Page 111: ...se specified cleaning agent to avoid reducing brake performance Note If there is grease on the brake shoe braking performance will be reduced and the brake will fail 5 3 3 Inspection of front brake di...

Page 112: ...Disc 5 3 1 Disassembly of rear brake disc Remove rear wheel See Chapter VIII Rear Wheel of this book Remove the clamp screw of rear brake disc A Note When disassembling the clamp screw of rear brake...

Page 113: ...specified cleaning agent to avoid reducing brake performance Note If there is grease on the brake shoe braking performance will be reduced and the brake will fail 5 3 3 Inspection of rear brake disc...

Page 114: ...e brake fluid spills on any plastic part it must be thoroughly rinsed immediately Remove the hollow bolt of brake hose A When removing brake hose be careful not to spill brake fluid on any painted par...

Page 115: ...brake hose 30 N m Avoid sharply bending kinking squeezing or twisting in the process of installing the brake hose Fill the brake line with brake fluid after installing brake hose See replacement of br...

Page 116: ...osition 5 5 3 Front master cylinder 5 5 3 1 Disassembly of front master cylinder Remove mounting bolt A of front master cylinder tube Remove mounting bolt B at mounting cap of front master cylinder an...

Page 117: ...all plunger assembly If the front reservoir or rear reservoir on the plunger assembly is damaged replace it with a new one Incorrect use or reverse installation of front and rear reservoirs should be...

Page 118: ...disc brake fluid isopropyl alcohol or ethanol Dot not clean the above parts with other liquid Gasoline oil or other gasoline distillates may corrode rubber parts If oil spills onto any part it will b...

Page 119: ...er parts inside the disc brake Remarks Prepare a container to hold the brake fluid Remove the plunger dust cap Remove plunger spring with a special tool inside circlip pliers and remove plunger assemb...

Page 120: ...pliers Press it into the dust cap 5 5 6 Rear Caliper 5 5 6 1 Disassembly of rear caliper Remove the hollow bolt of rear caliper A rear brake switch Release the joint bolt of caliper Remove the mountin...

Page 121: ...l brake pad pin 5 5 7 CBS pump 5 5 7 1 Assembly of CBS pump Remove the hollow bolt of brake hose A Remove the mounting bolt B at reservoir assembly of CBS pump Remove the mounting bolt C of CBS pump a...

Page 122: ...move connector snap ring with a special snap ring pliers Remove the joints and seals Remove the plug of CBS pump and remove seal and CBS plunger Loosen the lock screw A of CBS pump adjusting bolt and...

Page 123: ...seal C If the seal is damaged replace it with a new one Install the plug of CBS pump D Install joint seal E If the seal is damaged replace it with a new one Install fuel hose connector F and install t...

Page 124: ...nt of liquid and it may cause the formation of vapor bubbles king performance 5 5 8 1 Replacement and filling of front brake fluid Remove the master cylinder reservoir cap bolt A and remove reservoir...

Page 125: ...cuum pump to pump the brake fluid completely Add new brake fluid to master cylinder reservoir keep the brake fluid in the reservoir not less than 1 3 of its volume and pull the brake lever for several...

Page 126: ...G The precautions for handling disc brakes are as follows 1 It is forbidden to reuse brake fluid 2 If the container containing the brake fluid is not sealed or has been opened for a long time the brak...

Page 127: ...em If you accidentally spill any brake fluid or other oil on the brake pads or discs clean them using solvent with a high flash point Do not use any solvents that may leave oily residues If the brake...

Page 128: ...d 15 Right guard 16 Left guard cover 17 Right guard cover 18 Bolt M8 x 20 19 Aluminum washer 8 20 Seat assembly 21 Rear left fender 22 Fuel tank 23 Rear fender 24 Rear fender stiffener assembly Note D...

Page 129: ...tail cover connecting plate taillight Taillight holder rear rack assembly rear cargo box Note Do not damage the covering parts of body when disassembling Remove the body in the following order The in...

Page 130: ...heel right collar 11 Front brake disc 12 Inner hexagon screw M6 20 13 Nut M14 1 5 A Tire dimensions 90 90 17 B Rim specifications 1 85 17 aluminium alloy Rim runout limit value Vertical 2 0 mm Horizon...

Page 131: ...Console assembly A Mounting torque value of screw 8 in the figure 22 29 N m B Mounting torque value of screw 12 in the figure 10 12 N m 130 KS MOTORCYCLES https ksmotorcycles com...

Page 132: ...itch 11 Throttle handlebar assembly 12 Inner hexagon screw M6 25 13 Upper meter mounting cover 14 Nameplate of meter 15 Handlebar 16 Meter assembly 17 Meter mounting seat 18 Rubber washer of cover 19...

Page 133: ...in the figure 45 50N m E Mounting torque value of nut 11 in the figure 70 N m F Mounting torque value of bolt 19 in the figure 45 50 N m G Mounting torque value of bolt 21 in the figure 10 12 N m H Mo...

Page 134: ...r bearing 16 Upper steel bowl of lower bearing 17 Lower steel bowl of lower bearing 18 Lower bracket welding assembly 19 Inner hexagon screw M10 1 25 35 20 Clamp I 21 Bolt M6 10 22 Clamp II 23 Nut M10...

Page 135: ...owable limit mm Front wheel axle Bending degree 0 2 Front wheel Rim shimmy Vertical direction 2 0 Horizontal direction Within 1 0 2 0 Torque value Tools Front axle locknut 75 88 N m Bearing removal ro...

Page 136: ...ork and front wheel axle are bent The front wheel tire is deformed and deviates 7 2 3 Front Wheel Shimmy The rim is deformed The front wheel axle bearing is worn Detective tire 7 2 4 Rotation Difficul...

Page 137: ...Remove Front wheel axle locknut A Remove the front wheel axle A Remove the front wheel 136 KS MOTORCYCLES https ksmotorcycles com...

Page 138: ...and check the swinging amplitude of the rim Rotate the wheel with hands and read the swinging amplitude Available limit Vertical direction Replace the rim if the swinging amplitude is 2 0mm or above H...

Page 139: ...e screwdriver and the surface of rim Remove the bearing 3 with a bearing puller 7 3 3 2 Inspection of Bearing Check the rolling conditions of bearing If the bearing does not roll it may be worn or loo...

Page 140: ...ce ring 4 of bearing 7 3 4 Installation Install it in the reverse order of disassembly Notes The oil seal on the front wheel should be lubricated The engagement part or mobile part of gear seat assemb...

Page 141: ...7 4 Handlebar 7 4 1 Disassembly Disassemble Right rear view mirror assembly A Left rear view mirror assembly B Remove Primary cylinder of front brake A 140 KS MOTORCYCLES https ksmotorcycles com...

Page 142: ...Remove Left lever assembly B Remove Mounting bolt of grip end assembly A Grip end assembly B 141 KS MOTORCYCLES https ksmotorcycles com...

Page 143: ...Remove Left combination switch A Remove Right combination switch A Throttle grip B Remove Left handlebar cover A 142 KS MOTORCYCLES https ksmotorcycles com...

Page 144: ...left handlebar and left handlebar grip 1 and slowly press the left handlebar grip Remove the mounting screw at the upper seat of handlebar A Remove upper seat of handlebar B Remove the handlebar assem...

Page 145: ...andlebar 22 29N m Mounting screw of grip end 10 12 N m Mounting bolt of left lever assembly 10 12 N m Mounting bolt of primary cylinder of front brake 10 12 N m Note When installing the mounting screw...

Page 146: ...tails Remove the handlebar see this section for details Remove the front wheel see this section for details Remove the front fender see Chapter VI for details Remove the caliper of front brake see Cha...

Page 147: ...osen the clamp bolt of lower bracket A Remove the front shock absorber Disassemble Locknut A Remove Dust cap A Disassemble Upper steel bowl of upper bearing A 146 KS MOTORCYCLES https ksmotorcycles co...

Page 148: ...Disassemble Support and lower bracket 7 5 2 Inspection of Steering Column Check Steering column Deformation bending replacement 147 KS MOTORCYCLES https ksmotorcycles com...

Page 149: ...ng race of steering lever with a flat chisel and a hammer as shown in the figure Note Balls bearing races and dust seals are always replaced in sets The ball and bearing race mounted obliquely will ca...

Page 150: ...olts Ensure that the end of inner fork is flush with the head of handlebar Torque value Nut of steering axle 2 5 N m Locknut of steering axle 70 N m Upper clamp bolt of front shock absorber 22 29 N m...

Page 151: ...ck absorber spring Dust cap Oil seal clip Oil seal 37 50 11 Flat washer DU collar Piston ring Buffer spring Front branch pipe combination Outer pipe Piston pipe Positioning sleeve Sealing washer Inner...

Page 152: ...orber 7 6 1 Disassembly Disassemble Cap bolt and O ring seal Oil drainage Disassemble Plug Spring Disassemble Dust ring Wire clamp Note Do not damage the surface of inner tube 151 KS MOTORCYCLES https...

Page 153: ...absorber lever and loosen the bolts with the T shaped handle and the shock absorber clamp Disassemble Bolt Washer Disassemble Oil seal 7 6 2 Inspection Check Bending degree of inner tube 152 KS MOTOR...

Page 154: ...compressed air Note Do not attempt to straighten the bent damper bar otherwise it may seriously damage the damper rod 7 6 3 Installation Carry out assembly in the reverse process of disassembly Notes...

Page 155: ...llation Washer Bolt damper rod Note When assembling bolt add thread locking adhesive Tighten Bolt damper rod Torque value 15 20N m Notes Tighten the bolt of damper rod with the T shaped handle and the...

Page 156: ...on Dust ring Wire clamp Check Extension of inner tube Unable to extend smoothly recheck after disassembly Refuel Measuring cup Shock absorber oil 46 shock absorber oil Oil capacity 285 2ml 155 KS MOTO...

Page 157: ...absorber 1 up and down to fill the tube with oil Installation Plug Spring Installation Cap bolt and O ring seal Notes Do not damage the surface of inner tube Torque value of cap bolt 12 18 N m 156 KS...

Page 158: ...ter of rear fluid brake disc 240mm D Bending limit of rear wheel axle 0 2mm E Chain specification 428HO 1 134 F Sprocket specification 41 teeth H Mounting torque value of nut 6 in the figure 45 50N m...

Page 159: ...Chain 428HO 1 134 9 Sprocket mounting bolt M10 1 25 38 5 10 Rear wheel damper assembly 11 Rolling bearing 6303 2RS 12 Front wheel middle shaft sleeve 13 Air valve Z2 01 1 14 Rear wheel rim 15 Tubeles...

Page 160: ...bly 15 Chain adjuster retainer 7 Rear rocker arm welding assembly 16 Nut M8 8 Self locking nut M14 1 5 17 Drive chain cover 9 Washer 18 Bolt M6 10 A Mounting torque value of nut 9 in the figure 85 98...

Page 161: ...tude of rear wheel Vertical direction 2 0 Horizontal direction 2 0 Torque value Mounting nut of rear wheel 100 113 N m Nut at the top of rear shock absorber 45 50 N m Bolt at the bottom of rear shock...

Page 162: ...Brake Pedal or Slow Return Wear or break of return spring Incorrect adjustment of brake The fluid brake disc is worn or dirty Improper installation of brake friction pad 8 2 5 Abnormal sound of brake...

Page 163: ...Remove Rear brake caliper Loosen Chain adjuster bolt A Disassemble Rear wheel axle mounting nut A 162 KS MOTORCYCLES https ksmotorcycles com...

Page 164: ...isassemble rear wheel 8 3 2 Inspection 8 3 2 1 Bending Inspection of Wheel Axle Put the wheel axle on the V shaped seat and measure the eccentricity with a dial gauge Available limit Replace the wheel...

Page 165: ...ove Horizontal direction Replace the rim if the swinging amplitude is 2 0mm or above 8 3 2 3 Inspection of Rear Wheel Bearing Bearing The front wheel rotates unsmoothly or it is too loose Replace the...

Page 166: ...earing with bearing installation tools Note Do not apply pressure on the inner race ring 1 or ball bearing 2 of wheel bearing and only apply pressure to the outer race ring 3 of bearing Use the seat i...

Page 167: ...rber 8 3 1 Disassembly Firmly support the motorcycle Disassemble Lower mounting bolt of rear shock absorber A Upper mounting bolt of rear shock absorber B Rear shock absorber C 166 KS MOTORCYCLES http...

Page 168: ...ement of rear shock absorber 8 3 4 Installation Install it in the reverse order of disassembly Install the upper mounting nut and lower mounting bolt of rear shock absorber Lock it to the specified to...

Page 169: ...is chapter for details Disassemble the rear wheel see this chapter for details Disassemble Rear lower fender bracket A Disassemble Mounting nut of rear rocker arm axle A Disassemble Rear rocker arm sh...

Page 170: ...acement Check Tightness of rear rocker arm If it is loose tighten the rear rocker arm nut or replace the collar Vertical movement of rear rocker arm If the movement is not smooth or there is any bent...

Page 171: ...ghten a bent axle Check Rear rocker arm shaft sleeve assembly Damage crack Replacement Check Chain protective block Wear damage crack replacement 8 5 3 Installation Install it in the reverse order of...

Page 172: ...6 Chain drive 8 6 1 Disassembly Put the motorcycle on a flat surface and secure it Disassemble Drive sprocket cover A Disassemble the rear wheel see this chapter for details 171 KS MOTORCYCLES https...

Page 173: ...Disassemble the rear rocker arm see this section for details Remove the drive chain Disassemble Mounting nut of sprocket mounting bolt A 172 KS MOTORCYCLES https ksmotorcycles com...

Page 174: ...ote When disassembling the mounting nut of sprocket mounting bolt follow the instructions on the right figure Remove the retainer A using the retainer caliper 173 KS MOTORCYCLES https ksmotorcycles co...

Page 175: ...e chain should be replaced if the length does not match the specified value The length limit of 10 links is 127 mm Note Take measurements after stretching the chain by hands Measure the length of 10 l...

Page 176: ...ng WARNING Never use volatile substances such as steam gasoline or solvents Check rotor and side panel If it is damaged or worn replace the drive chain Lubricate the drive chain and purchase drive cha...

Page 177: ...Damage crack Replacement 8 6 3 Installation Install it in the reverse order of disassembly Adjust the drive chain slackness If the chain slackness is too smallness the engine and other important parts...

Page 178: ...Note Tighten the nut by 2 3 times in the order shown in the right figure 177 KS MOTORCYCLES https ksmotorcycles com...

Page 179: ...1 Bolt M8 20 2 Aluminum washer 8 3 Seat assembly 4 Bolt M6 10 A Mounting torque value of bolt 1 in the figure 22 29 N m B Mounting torque value of bolt 2 in the figure 10 12 N m 178 KS MOTORCYCLES htt...

Page 180: ...sensor assembly 7 Fuel tank lock 17 Self locking nut M6 8 Fuel tank assembly 18 Connecting pipe between canister and dump valve 9 Buffer rubber 19 Connecting pipe between fuel tank and dump valve 10 I...

Page 181: ...torque values during assembly Check whether all the parts are installed or operated correctly after assembly Technical parameters Item Normal Allowable limit Tank capacity 11 8L 0 5L Locking torque R...

Page 182: ...assembly Disassemble Rear mounting bolt of seat A Disassemble Lower mounting bolt of seat A two sides Seat B 9 3 2 Inspection Check Seat Cushion Breakage or damage replacement 181 KS MOTORCYCLES https...

Page 183: ...he above operations are performed in a well ventilated area and any fire source or spark is strictly prohibited including any devices with indicators No smoking Close the electric door lock Disconnect...

Page 184: ...uel hose with hands Do not remove the hose with tools forcibly Although the fuel in the fuel tank has been removed there may still be fuel residuals so be careful when disassembling the fuel hose Do n...

Page 185: ...otherwise the fuel pump may be damaged 9 4 2 Inspection Inspection Fuel tank Rust damage oil leakage replacement Inspection Rubber part Buffer rubber A Rubber cover B Sensor rubber washer C Mounting w...

Page 186: ...an it Crack damage Replace fuel pump assembly Performance inspection of fuel pump see Chapter XVII for details Inspection Fuel hose If any wear crack B or expansion C is found the fuel pipe must be re...

Page 187: ...e value Fuel tank mounting bolt 10 12 N m Fuel level sensor mounting bolt 5 9 N m Fuel pump mounting bolt 3 4 N m Note Do not damage the mounting surface of fuel tank when installing the fuel pump Use...

Page 188: ...the figure 10 12 N m C Mounting torque value of bolt 7 in the figure 10 12 N m D Mounting torque value of bolt 16 in the figure 22 29 N m E Mounting torque value of bolt 25 in the figure 22 29 N m F...

Page 189: ...7 Bolt M6 16 27 Bolt M10 1 25 10 8 Washer 28 Battery bracket mounting plate 9 Fuel inlet pipe assembly 29 Battery bracket rubber 10 Oil drain bolt 30 Battery holder 11 Front hanging board of engine 31...

Page 190: ...pedal welding assembly 18 Bolt M6 16 8 Bolt M6 25 19 Windshield 9 Shift rod assembly 20 Bolt M6 25 10 Inner hexagon screw M6 20 21 Joint M6 11 Split pin 2 25 22 Combination screw M6 16 A Mounting tor...

Page 191: ...r and transmission Specifications Oil capacity of engine 1 1 0 1L when changing oil 1 2 0 1L when disassembling Locking torque Front mounting bolt of engine 45 50N m Upper mounting bolt of engine 22 2...

Page 192: ...ch adjusting nut Remove the clutch cable from the pushing arm of clutch Remove nut and starter motor cable Remove bolt grounding cable and crankcase air pipe Remove the spark plug cap Remove the throt...

Page 193: ...perly lay wire and cable If oil has been drained fill the crankcase with recommended engine oil Conduct the following inspection and adjustment after installing the engine Engine oil level Tightness o...

Page 194: ...p Valve clearance adjusting nut Shift positioner bolt Assembling bolt Bolt at left right crankcase cover Coil screw Screw at oil filter cover Clutch push disc bolt Bolt at cylinder head cover Cylinder...

Page 195: ...n 6 Oil filter 7 Fuel pump Note After disassembling fuel pump clean the parts carefully and blow the surfaces of parts using high pressure gas During the disassembly and installation of fuel pump do n...

Page 196: ...rticles so as to reduce the wear of parts cool the parts with high heat loads absorb the impacts of bearing and other parts and reduce noise increase the sealability between the piston ring and cylind...

Page 197: ...11 3 1 Disassembly Remove the right cover remove the oil filter loosen fuel pump mounting screw remove fuel pump body driving gear and fuel pump shaft Fuel filter Fuel pump 196 KS MOTORCYCLES https ks...

Page 198: ...semble fuel pump Check the radial clearance of internal and external rotors Allowable limit 0 25mm Check the clearance between external rotor and fuel pump base Allowable limit 0 25mm Screw Screw Fuel...

Page 199: ...Check the end clearance of rotor Allowable limit 0 15mm Test gauge Panel 198 KS MOTORCYCLES https ksmotorcycles com...

Page 200: ...outer rotors should be able to rotate flexibly without clamping stagnation 10 3 2 Installation Install it in the reverse order of disassembly Fuel pump cover Outer rotor Inner rotor Fuel pump seat Dr...

Page 201: ...Cylinder head valve 1 Cylinder head cover 2 Bolt 3 Spark plug 4 Cylinder washer 5 Cylinder 200 KS MOTORCYCLES https ksmotorcycles com...

Page 202: ...high pressure gas And it can also complete the intake and exhaust through the distribution mechanism Technical parameters Unit mm Item Normal Allowable limit Planeness of cylinder head 0 03 0 05 Valve...

Page 203: ...f valve seat is not good Compression pressure is too high The washer of cylinder head is leaking There is excessive carbon deposition in the combustion chamber The spark plug is not installed properly...

Page 204: ...ket Measure the external diameter of rocker arm Allowable limit 11 95 mm Measure the inner diameter of rocker arm hole Allowable limit 12 05 mm Clearance between rocker arm hole and rocker arm shaft A...

Page 205: ...ring with valve spring compression tool QJ153 10 0104 G10 and remove valve cotter Remove the spring disc the springs of outer and inner valves the spring washer of outer valve and the valve Cylinder h...

Page 206: ...12 3 2 Valve decomposition Valve washer Inner valve spring Valve lock clamp Valve oil seal Outer valve spring Spring plate 205 KS MOTORCYCLES https ksmotorcycles com...

Page 207: ...the sandpaper and sand the surface in 8 shape Measure the free length of inner and outer valve springs Allowable limit inner spring 30mm Outer spring 39 5mm Measure the external diameter of valve ste...

Page 208: ...our Use the electric furnace or oven to heat the cylinder head to 100 150 Fix the cylinder head and remove the valve guide from the upper side of cylinder head with the valve guide disassembly tool Pu...

Page 209: ...cutter to remove the rough or uneven parts on the surface of valve seat ring Note Apply a layer of transparent or Prussia blue coating to the valve seat ring so that it can be seen more clearly Remove...

Page 210: ...ation After the valve seat ring is grinded apply polish to the valve surface and gently polish the valve 12 7 Installation of Cylinder Head Installation shall be carried out in the order contrary to t...

Page 211: ...Piston 1 Bolt 2 Cylinder block 3 Washer 4 Piston 5 Piston pin 6 Dowel pin Note Before the inspection and measurement all parts shall be cleaned and blown with high pressure air 210 KS MOTORCYCLES http...

Page 212: ...the movement of piston It can also transfer some heat in the cylinder to the surrounding cooling mediums Function of piston It can withstand the pressure generated by the combustion of combustible ga...

Page 213: ...10 Cam follower Cam follower shaft Inner diameter of cam follower hole 12 01 12 018 12 05 Outer diameter of cam follower hole 11 986 11 994 11 93 Clearance between cam follower hole and shaft 0 016 0...

Page 214: ...block with cam follower 13 3 2 Inspection of Cylinder Block Check the wear situation of inner wall of cylinder If the wear is serious please replace it Remove washer and dowel pin 13 3 3 Disassembly o...

Page 215: ...earance between cam follower hole and shaft Allowable limit 0 08 mm 13 4 Piston 13 4 1 Disassembly Remove the piston pin retainer Note During disassembly do not drop the retainer into the crankcase Ta...

Page 216: ...roove Allowable limit top ring 0 09mm Second ring 0 09mm Remove the piston ring and install the piston rings at the bottom of cylinder Note Press the piston ring in the cylinder by using the piston he...

Page 217: ...of cylinder in the upper middle and lower positions in the direction which forms a right angle 90 degrees with the piston pin Allowable limit 56 6 mm Measure the clearance between cylinder and piston...

Page 218: ...scratch the piston and do not break the piston ring After the piston ring is installed it can rotate freely in the piston ring groove Clean the washers attached to the crankcase Note Foreign matters s...

Page 219: ...et and dowel pin on the crankcase Apply oil to the inner wall of cylinder piston and piston ring Install the piston ring into the cylinder carefully Note Do not damage the piston ring Dowel pin Washer...

Page 220: ...ressure disc 13 Housing assembly Note There is no need to remove the engine from the frame when servicing the clutch Engine oil viscosity and oil level may affect clutch operation Therefore the engine...

Page 221: ...plate assembly 5 Recoil starting gear 6 Spring retainer 7 Shaft liner 8 Return spring Note During operation check whether the elasticity of kickstarter return spring and ratchet wheel is weakened or...

Page 222: ...r is too tight Clutch is sliding when accelerating Transmission is tripping from the gear Clutch cable is damaged twisted or dirty There is no clearance in the clutch push lever The elasticity of stop...

Page 223: ...enter bearing bracket of clutch Remove the active and driven friction pads of clutch Remove the pressure disc of clutch Remove the parts shown in the exploded view Lock torque of locknut 50 60N m Four...

Page 224: ...ate and center bracket for damage if any it should be replaced Measure the free length of pressure spring Allowable limit Replace it if its length is less than 34 2mm Driven friction pad Driven fricti...

Page 225: ...eturn spring and ratchet spring in case of any damage it should be replaced Check the meshing condition of starting shaft spline and spline in ratchet wheel When the meshing is loose it should be repl...

Page 226: ...1 Inspection Check the wear of gear teeth surface and drive claw respectively If the wear is serious or it is damaged please replace it Primary shaft assembly Auxiliary shaft assembly Tooth surface Dr...

Page 227: ...ce it Note The bearing disassembled cannot be reused and should be replaced with a new one Bearings and oil seals should be disassembled by using special tools Bearing QJ153 7 0101 G15 Oil seal pliers...

Page 228: ...w one Bearings and oil seals should be disassembled by using special tools 14 5 2 Combination of primary and auxiliary shafts Note When combined apply lubricating oil to all gears and shafts Ensure th...

Page 229: ...Reduction gear 1 Shifting drum 2 Shift fork 3 Shift fork shaft 4 Primary shaft assembly 5 Auxiliary shaft assembly 6 Recoil kickstarter assembly 228 KS MOTORCYCLES https ksmotorcycles com...

Page 230: ...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 brok...

Page 231: ...nd spring Remove the dowel pin Remove the parts shown in the exploded view 15 3 2 Disassembly Variable gear shaft combination Stopper lever Stopper lever spring Stopper lever Variable gear positioning...

Page 232: ...aft for bending in case of overbending replace it Check whether the elasticity of return spring is weaken and replace it if necessary Loosen the assembling bolt Separate the crankcase Note Do not dama...

Page 233: ...Allowable limit 4 7 mm Measure the outer diameter of shift drum Allowable limit 35 75 mm Measure the width of lock groove of shift drum Allowable limit 7 3 mm Remove the balancer gear Testing meter V...

Page 234: ...15 4 Installation Install it in the reverse order of disassembly 233 KS MOTORCYCLES https ksmotorcycles com...

Page 235: ...hin walled casting Heavy impact should be avoided during the operation to prevent deformation or breakage Before the inspection and measurement all parts shall be cleaned and blown with high pressure...

Page 236: ...combustion explosion impact and inertia force of movement of crankshaft mechanism and form a part of closed oil and air seal space The crankcase is also equipped with suspension holes and the engine...

Page 237: ...Remove electric starter gear needle bearing and washer Loosen the bolts on the left front cover and left rear cover of crankcase Remove the left front cover and left rear cover Remove the idle gear o...

Page 238: ...embly Remove bearing positioning device 16 3 2 Disassembly of cam component Measure the inner diameter of cam bushing Allowable limit 14 10 mm Measure cam height Allowable limit 32 5mm Flywheel assemb...

Page 239: ...rew oil filter rotor cover and oil filter rotor cover washer Remove washer and dowel pin Clamp the nut using four jaw sleeve loosen the locknut with the pneumatic tool remove the oil filter rotor and...

Page 240: ...rom right crankcase Note Do not damage washer and assembling surface Check Measure the lateral clearance of big end of connecting rod Allowable limit 0 55 mm Driving gear Locknut Fuel filter rotor Fue...

Page 241: ...t Allowable limit 0 01 mm Check whether the crankshaft bearing rotates with abnormal noise or whether it is loose If there is abnormal noise or it is loose replace the crankshaft assembly Note Cranksh...

Page 242: ...No Name 1 Air exhaust gasket 2 Cap nut M6 3 Main cylinder assembly 4 Buffer rubber 5 Clamp assembly 6 Auxiliary cylinder assembly 7 Bolt M8 30 8 Self locking nut M8 241 KS MOTORCYCLES https ksmotorcyc...

Page 243: ...Emission Control 242 KS MOTORCYCLES https ksmotorcycles com...

Page 244: ...243 KS MOTORCYCLES https ksmotorcycles com...

Page 245: ...244 KS MOTORCYCLES https ksmotorcycles com...

Page 246: ...245 KS MOTORCYCLES https ksmotorcycles com...

Page 247: ...es or frequently ridden on the roads which are applicable to non motor vehicles 6 Damage is caused due to typhoon flood and other weather disasters or damage and faults are caused due to negligence ac...

Page 248: ...of ignition system charging system or fuel system therefore please go to the dealers or service centers specified by this Company for inspection adjustment or maintenance if you feel that the engine i...

Page 249: ...hed after the engine is turned on or off because the temperature is high in a short time 2 The motorcycle with a catalytic converter should not be close to combustibles 3 The carbon monoxide in the ex...

Page 250: ...maintaining the ignition system of engine it is not allowed to start the engine to check whether the spark plug can generate sparks by removing the spark plug If it is necessary the time should not b...

Page 251: ...Electronic Injection Pars 250 KS MOTORCYCLES https ksmotorcycles com...

Page 252: ...rive signal of actuator and internal signal e g closed loop control cooling liquid temperature idle speed control battery voltage control etc Once a link is found to be faulty or a signal value is not...

Page 253: ...of space to describe how to find the true fault based on the fault information record Due to the presence of electronic control components new contents are given to the cause of engine failure In oth...

Page 254: ...ly optional 5V at supply terminal of sensor Neutral gear signal Negative electrode of battery Control terminal of main relay Positive electrode of idle motor coil A K line fault diagnosis port Negativ...

Page 255: ...confirm whether the problem is caused by calibration or software If it is caused by calibration or software please refresh the software calibration Once a problem arises it should be confirmed whethe...

Page 256: ...jector Precautions A filter is designed inside the fuel injector but it is not a maintainable part because its design function is to filter the accumulated impurities from the fuel filter in the oil l...

Page 257: ...tion Apply a small amount of lubricant to the underside of the sealing ring ISO 10 light mineral oil or equivalent product is recommended ISO 10 light mineral oil or equivalent product is not recommen...

Page 258: ...motorcycle maintenance manual and list of part number 18 2 2 6 General Failure Mode and Prevention and Solving Measures in Using Process Important note All the following decisions are based on normal...

Page 259: ...ked by dirt 18 2 3 4 Technical Parameters Measurement range Opening of 7 to 93 the actual opening from idle to full open Reference voltage of throttle position sensor 5 0 1V When the throttle is fully...

Page 260: ...amount of carbon deposits around the throttle valve plate Do not adjust the position of idle screw Replace the O ring during disassembly and assembly 18 2 3 6 Sensor fault judgement 1 Sensor inspecti...

Page 261: ...ressure at minimum installation torque the sensor is capable of sealing the engine coolant at an actual pressure of 206 8 kPa 30 psi and a temperature of 135 C Extreme working conditions only 1 hour a...

Page 262: ...eristic is also the negative temperature coefficient resistance characteristic It is also an irreparable part 18 2 5 2 Appearance of Intake Temperature Sensor Intake pressure sensor intake temperature...

Page 263: ...ltage The working DC reference voltage of sensor circuit is 5 0 1 V 18 2 6 4 Fault Determination 1 Check whether the plug in is loose 2 Check the fault or current data with a diagnostic instrument 3 V...

Page 264: ...C 18 2 7 4 Fault Determination 1 Conduct fault diagnosis with a diagnostic instrument and judge the fault type 2 Check whether pins fall off 3 Check the voltage between sensor line and signal ground w...

Page 265: ...que 8 8 11 8Nm 18 2 8 3 Inspection of Ignition Coil Line Ignition coil 1 ECU1 Standard On NG Power Open circuit Ignition coil 2 ECU13 Standard On NG Control Open circuit Ignition coil 1 2 To ground St...

Page 266: ...in D respectively with a multimeter Standard air temperature 20 30 50 10 Circuit inspection of idle speed stepper motor Stepper motor A ECU22 On NG A Open circuit Stepper motor B ECU4 On NG A Open cir...

Page 267: ...Lightly support the fuel pump strainer and carefully put the fuel pump assembly into the tank Avoid damaging the filter screen of fuel pump Installation direction of fuel pump assembly Arrange the ins...

Page 268: ...stallation Over torque an incorrect tightening order may cause washer deformation and thus result in leakage Install the fuel tank on the motorcycle Connect fuel pipe and fix it with a suitable clamp...

Page 269: ...ection of fuel pump Measure the voltage between pin 1 and pin 2 of fuel pump with a multimeter Standard Within 3S after the ignition key is inserted or during the start up process 12 2V 2 Inspection o...

Page 270: ...sensor Voltage of Engine coolant temperature sensor is higher than 4 9V 1st cycle Engine temperature sensor is short circuited to power P0117 Signal range check low for Engine coolant temperature sen...

Page 271: ...f 1st cycle Oxygen sensor heater is open circuited Ignition Coil A Primary Control P2301 Short circuit to battery for Ignition coil Output short circuit current is higher than 8 6A 1st cycle Ignition...

Page 272: ...l a Disassembly and assembly of electronic control system components common automotive mechanical parts removal tool b Electronic control system circuit and system electrical signal digital multimeter...

Page 273: ...ayed by Diagnostic Apparatus Analyze and determine engine fault using the engine working data flow displayed by the diagnostic apparatus 18 4 2 1 Step I a Engine harness and the vacuum pipeline may af...

Page 274: ...rge it may cause low intake manifold pressure and thus affect the system to determine the working state of engine thus resulting in abnormal idle speed during warm up of motorcycle In addition if the...

Page 275: ...nition coil and spark plug properly d Check oil supply system fault Check whether fuel pump is working it is able to hear the sound that the fuel pump is working near the fuel tank when starting engin...

Page 276: ...her the parameters are normal at idle speed and high idle speed b Check fuel quantity in the fuel tank and fuel filter c Check whether exhaust system is blocked for example whether three way catalytic...

Page 277: ...uld be resolved as soon as possible because some of the substances in the oil may damage the oxygen sensor and three way catalytic converter Valve clearance should not be too small if the exhaust valv...

Page 278: ...BL Gr W G W G B N B R W BL R W B Gr R W R W P P G G Y R W G B O R R R W B W B R B R O R R G Y B R R P W N W G W O B BL R Gr R G R W R W Gr W G B G W Burglar alarm Horn switch Main Relay Oxygen sensor...

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