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KSR Moto T58 - ZION 125, Repair Manual

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KSR Moto T58 - ZION 125 Repair Manual Download Page 63

63

ENGINE

PART LOCATION - LUBRICATION SCHEME

PART LIST - LUBRICATION SCHEME

1. Oil 

strainer

2. Oil 

pump

3. Crankshaft
4. Camshaft

                O

LOÀRZGLUHFWLRQ

4

1

2

3

NOTE

• 

After removing the oil pump, clean the parts up and 
below the surface with high pressure air. 

• 

'RQWOHDYHDQ\IRUHLJQREMHFWLQWRWKHFUDQNFDVHGXU

-

ing the operation.

Summary of Contents for T58 - ZION 125

Page 1: ...REPAIR MANUAL T58 ZION 125 Vers 2014_06...

Page 2: ...workshop OO VSHFL FDWLRQV UHIHUV WR WKH FXUUHQW VWDWH DQG DUH QRQELQGLQJ 65 URXS PE VSHFL FDOO UHVHUYHV WKH ULJKW WR modify the information in this manual without notice and without specifying reason...

Page 3: ...CTION 30 STEERING 31 STEERING PLAY INSPECTION 31 STEERING PLAY ADJUSTMENT 31 STEERING BEARING LUBRICATION 31 ELECTRICAL SYSTEM 32 BATTERY INSPECTION CHARGING 32 LIGHT AND SWITCHES OPERATION INSPECTION...

Page 4: ...SPECTION PISTON RING INSTALLATION PISTON INSTALLATION 70 CYLINDER INSPECTION 70 CYLINDER INSTALLATION 71 CYLINDER HEAD INSPECTION 71 AIR VALVE REMOVAL 71 EXPLODED VIEW PART LOCATION AIR VALVE 71 INSPE...

Page 5: ...REPLACEMENT 114 REAR LIGHT WINKER BULB REPLACEMENT 114 REAR LIGHT BULB 115 REAR LIGHT REPLACEMENT 115 LICENSE PLATE BULB REPLACEMENT 116 TROUBLESHOOTING LIGHTNING SYSTEM 116 ELECTRICAL SYSTEM SPEEDOME...

Page 6: ...ring tube ANTI TEMPERING LABEL 7KH DQWL WHPSHULQJ ODEHO LV HG RQ WKH LQQHU VLGH RI WKH VHDW bench ENGINE NUMBER The engine number 5 is on the left side of the engine case DECRYPTING THE VEHICLE IDENTI...

Page 7: ...n Centrifugal automatic type CHASSIS Frame type Steel tube backbone TIRES Front tire Type Tubeless Pressure on cold tire 2 3 0 1 bar 6L H 5LP 07 Tire 120 70 15M C Rear tire Type Tubeless Pressure on c...

Page 8: ...H URFNHU DUP 10 12 L LQJ EROW RI KDQG EUDNH OHYHU EUDNHW Rear shock absorber Top nut of rear shock absorber 37 44 Bottom nut of rear shock absorber Front fork L LQJ QXW LQ WKH FOXWFK RI WKH VWDUWXS HO...

Page 9: ...AND LUBRICANTS Use oQO WKH IXHOV RLOV DQG OXEULFDQWV DFFRUGLQJ WR VSHFL FDWLRQV DV OLVWHG LQ WKLV PDQXDO Please consider that KSR Group GmbH give no approval for Bio Ethanol E 10 or higher fuel SPARE...

Page 10: ...YDOXH RI 5 LV WKH ORZHU WKH WRUTXH RI the bolts MAXIMUM TORQUE IN NM REFERRING ISO 898 1 FOR METRIC FASTENERS COEFFICIENT OF FRICTION 0 12 Size Strength R 3 6 Strength R 8 8 Strength R 12 9 M1 6 0 04...

Page 11: ...s Figure 6 3LVWRQ SLQ H KDXVWLRQ DSSDUDWXV Figure 7 Piston ring opening pincer Figure 8 Spark plug circular wrench LJXUH Dial dictator Measure the inner canon of piston pin Figure 10 Cylinder diameter...

Page 12: ...12 SPECIAL TOOLS Thickness gauge clearance gauge Fig 1 Fig 3 Fig 5 Fig 7 Fig 2 Fig 4 Fig 6 Fig 8...

Page 13: ...13 SPECIAL TOOLS 1 Bush head 2 Shake handle 3 Ratchet type wrench 4 Connecting rod LJ Fig 11 Fig 13 Fig 15 Fig 17 Fig 10 Fig 12 Fig 14 Fig 16 Fig 18...

Page 14: ...14 SPECIAL TOOLS LJ Fig 21a Fig 22a Fig 23a Fig 24 Fig 20 Fig 21b Fig 22b Fig 23b Fig 25...

Page 15: ...15 1 PERIODIC MAINTENANCE...

Page 16: ...lubricate Front forke Control Rear suspension Control Oil pump Control Transmission oil FKDQJH FKDQJH FKDQJH FKDQJH Variomatic belt RQWURO H FKDQJH FKDQJH Fly wheels RQWURO H FKDQJH FKDQJH Driven chai...

Page 17: ...0 35 0 60 Oil ring 0 1 0 6 Clearance between piston and piston pin 0 003 0 014 0 03 Narrow end diameter of connecting rod 14 010 14 018 14 04 Clearance between connecting rod and piston rod 0 011 0 02...

Page 18: ...amshaft Camheight IN EX Ignition Item Standard value Recommended spark plug Standard C5HSA NKG Hot C6HSA NGK Cold CHSA NGK Spark plug gap 0 6 0 7 mm Resistance value of ignition coil 20 C Primary coil...

Page 19: ...tarting idle gear bushing 8 3 OD of strting idle gear Carburettor Item Standard Main nozzle 0DLQ MHW 180 GOH MHW 37 5 Needle valve Wheels Item Standard mm Allowable limts mm Run out of wheels Vertical...

Page 20: ...ent 5 10 mm 7KH PDLQ DGMXVWLQJ SRVLWLRQ LV RQ WKH ERWWRP RI WKH WKURWWOH 7R DGMXVW WKH IUHH SOD RI WKH WKURWWOH JULS ORRVHQ WKH LQJ QXW DQG DGMXVW E WXUQLQJ DGMXVWLQJ QXW IWHU WKH DGMXVWPHQW LV GRQH W...

Page 21: ...FNZLVH WLOO WKH HQJLQH VSHHG UHDFKHV LWV XWPRVW PL WXUH 5HVHW WKH LGOH DGMXVWPHQW VFUHZ DQG VHW WKH HQJLQH VSHHG GRZQ to 1450 100 U min Pull the throttle for several times for acceleration and inspect...

Page 22: ...e RECOMMENDED ENGINE OIL Quantity 1 00 L Type CASTROL Power 1 Racing 4T 10W 40 The engine oil level must be checked before every start ENGINE OIL REPLACEMENT 1 Remove the bolt 1 on the right underside...

Page 23: ...GEAR CASE 1 Warm up the engine 2 Place the vehicle on a smooth surface on the main stand 3 Place an oil pan under the transmission release bolt 1 4 Remove the release bolt 5 Check the seal ring OIL LE...

Page 24: ...IDOOV EHORZ WKH 0 1 PDUN WKLV LQGLFDWHV D leakage in the brake system or worn out brake linings 1 0RYH WKH EUDNH XLG UHVHUYRLU PRXQWHG RQ WKH KDQGOHEDU WR D horizontal position 2 KHFN WKH EUDNH XLG OH...

Page 25: ...QO ZLWKRXW FKHFNLQJ WKH system 1 0RYH WKH EUDNH XLG UHVHUYRLU PRXQWHG RQ WKH KDQGOHEDU WR D horizontal position 2 KHFN WKH EUDNH XLG OHYHO 3 Remove the cover with membrane 2 4 GG EUDNH XLG EHWZHHQ WKH...

Page 26: ...the indicators 2 damage or cracking is visible change the front brake pads 3 Remove the two bolts 3 4 Remove the brake pads in pair 5 Reassemble in reverse order NOTE Glue in the bolts 1 FRONT REAR B...

Page 27: ...4 7DNH VSHFLDO FDUH WKDW WKH D OH VSDFHU DQG WKH VSHHGRPHWHU gear installed correct Item Torque 1 2 55 62 Nm 4 1P REAR BRAKE DISC REPLACEMENT 1 5HPRYH WKH H KDXVW WARNING IWHU GULYLQJ WKH H KDXVW LV...

Page 28: ...H 3 Remove the front and rear handlebar cover and the leg pro tection panel 4 5HPRYH WKH EDQMR EROW IURP WKH PDVWHU EUDNH F OLQGHU 5 Replace the brake hose Take care that the brake hose is in stalled...

Page 29: ...PRYH WKH IURQW DQG UHDU KDQGOHEDU FRYHU VWRUDJH ER DQG the leg protection panel 4 5HPRYH WKH EDQMR EROW IURP WKH PDVWHU EUDNH F OLQGHU 5 Replace the brake hose Take care that the brake hose is in stal...

Page 30: ...hock absorber up and down arrows to check for correct function 2 Check whether a part of the rear shock absorber is damaged or loosened 3 Put the vehicle on the main stand and move the rear wheel up d...

Page 31: ...VHWWLQJ is reached 5 Test the steering play 7KH VWHHULQJ PXVW EH DGMXVWHG LQ WKDW ZD WKDW LW LV HDV WR PRYH the handlebar and the steering is without free play 6 LQDOO NHHS WKH DGMXVWPHQW QXW ZLWK D Z...

Page 32: ...in use 7 The voltage range of the battery is 12 3 Volt DC to 13 1 Volt DC 8 To measure the Voltage of the battery use a conventional volt meter 4 Measure between the battery terminals When you charge...

Page 33: ...icator switch 4 Horn switch Switches Functions right side 5 Engine OFF ON 6 Light switch 7 Starter Button HEADLIGHT AIMING INSPECTION 1 Place the vehicle at a distance of 5 meters in front of a wall T...

Page 34: ...34 2 REPAIR AND DIAGNOSTICS...

Page 35: ...rrier 6 Protection cap 7 Buffer 8 1XW 0 Engine carrier 10 Bolt engine carrier 11 Side stand 12 Locking plate 13 Screw 14 Spring 15 Shell 16 Main stand 17 Rubber bad 18 6FUHZ 0 Washer M8 20 Bush main s...

Page 36: ...5 6FUHZ 0 6 Clamp for air pipe 7 Fuel pipe 8 Pipe clamp 8mm Fuel pump 10 Pipe clamp 11 Fuel pipe 12 Pipe clamp 13 XHO SLSH 14 Non return valve 15 Pipe clamp 16 Fuel reserve tap 17 6FUHZ 0 18 Pipe cla...

Page 37: ...uel tank 5H OO JDVROLQH DWHU LQ WKH FDUEXUHWWRU RU WKH MHW LV blocked Check the carburettor XHO OWHU LV EORFNHG OHDQ RU UHSODFH WKH IXHO OWHU Engine have no idle GOLQJ MHW EORFNHG Check the carburetto...

Page 38: ...manifold after dismounting carbu rettor to avoid other article entry RU WKH GHWDLOHG VSHFL FDWLRQ VHH SDJH DQG 3 2 1 6 7 8 5 4 PART LIST CARBURETTOR 1 Carburettor cover 2 1HHGOH MHW 3 Diaphgram 4 GOH...

Page 39: ...apours If fuel gets into your eyes rinse immediately with water and contact a doctor Wash affected skin areas imme diately with soap and water If fuel is swallowed contact a doctor immediately Change...

Page 40: ...PHWHULQJ KROH DQG the main nozzle to see if they are damaged worn down or stained If so they should be replaced DPLQH WKH SOXQJHU WR VHH LI LW LV ZRUQ GRZQ I VR LW VKRXOG be replaced 10 DPLQH WKH FDU...

Page 41: ...seals 8 Carburettor FUEL TANK REMOVAL 1 Remove the leg protection and the under vehicle protection See in the capitel CHASSIS 2 Train the fuel from the tank 3 Disconnect all cables coming from the tan...

Page 42: ...cover gasket 5 2 5LQJ 6 Collar 7 9DOYH FOHDUDQFH DGMXVW VFUHZ 8 Nut M5 Rocker arm 10 Collar 11 Camshaft housing 12 Circlip 42 13 Circlip 10 14 6KDIW IRU H KDXVW URFNHU DUP 15 Shaft for intake rocker a...

Page 43: ...ressed air before inspecting and measuring PART LIST ROCKER COVER AND CYLINDER HEAD 1 Cylinder 2 Cylinder gasket 3 Upper ring 4 Second ring 5 Oil scraper ring 6 Piston pin clip 7 Piston 8 Piston pin C...

Page 44: ...clutch 12 Spring retainer 13 Pressure spring 14 O Ring 15 Spring retaining seat 16 Distance washer 17 Spring retainer 18 Variomatic drive disc Sealing washer 20 Bearing 21 HDULQJ 22 Circlip 28 23 Dri...

Page 45: ...or water pump frive shaft 13 Impeller water pump 14 Gasket for water pump 15 Water pump housing 16 Collar 17 Sealing washer 18 ROW 0 Circlip 24 20 Stator for generator 21 Oil drain plug 22 O Ring 23 S...

Page 46: ...SION 1 8 7 6 5 4 3 2 12 11 10 PART LIST TRANSMISSION 1 Bearing 6205 2RS 2 HDUER KRXVLQJ 3 DVNHW IRU JHDUER KRXVLQJ 4 2LO VHDO 5 Output shaft 6 Bearing 6201 7 Distance washer 8 GOHU JHDU LQ JHDU ER Bea...

Page 47: ...he engine is no need to remove the whole engine from the frame SPECIFICATION ENGINE ENGINE TYPE 4 STROKE LIQUID COOLED Fuel typ Unleaded gasoline 2FW 63 63 Do not use any Bio Ethanol fuel Number of cy...

Page 48: ...the carburetor system Spark plug defective Check or replace GMXVWLQJ VFUHZ RQ FDUEXUHWRU GLVWRUWHG GMXVW WKH LGOH VSHHG Engine does not speed up DUEXUHWRU UXQQLQJ RYHU EHFDXVH RDW QHHGOH dirty or worn...

Page 49: ...Check the following items if the compression pressure is too high Combustion chamber and the carbon deposition on the top of the piston SPARK PLUG 1 Open the drop door to reach the spark plug 2 Remov...

Page 50: ...orting stand under the vehicle be cause the main stand is installed on the engine 2 5HPRYH WKH VWRUDJH ER WKH DLU OWHU ER WKH UHVRQDQFH ER VFUHZV WKH UHDU IHQGHU WKH UHDU EUDNH FDOLSHU DQG WKH H haust...

Page 51: ...VW PRYH the engine up and down 8 Pull the engine backwards Remove the rear wheel MAIN STAND REMOVAL 1 Remove the screw 1 to remove the spring 2 2 Remove the screw 3 NOTE Only the left side is illustra...

Page 52: ...1 to remove the cylinder head cover 2 TIMING CHAIN TENSIONING RAIL REMOVAL 1 Remove the two screws 1 to remove the timing chain ten sioning rail 2 CAMSHAFT SPROCKET REMOVAL 1 Remove the two screws 1...

Page 53: ...emove the camshaft 2 2 Remove the circlip 3 to remove the rocker arm shafts 4 and so to remove the rocker arms CYLINDER HEAD REMOVAL 1 To pull off the cylinder head 1 remove the two screws 2 COOLANT H...

Page 54: ...er 2 VARIOMATIC DISC WITH FAN REMOVAL 1 Remove the nut 1 with the washer to remove the variomatic disc 2 VARIOMATIC BELT REMOVAL 1 Remove the variomatic disc to remove the belt 3 VARIOMATIC DISC REMOV...

Page 55: ...EMOVAL 1 5HPRYH WKH VL VFUHZV 2 3XOO RII WKH JHDUER KRXVLQJ GEARBOX REMOVAL For more information look on the page 46 WATER PUMP HOUSING REMOVAL 1 Remove the three screws 1 to remove the water pump hou...

Page 56: ...IL SEALING OF STATOR REMOVAL INSTALLATION 1 Remove the circlip 1 and pull out the oil seal 2 2 Reassemble in reverse order IMPELLER WATER PUMP REMOVAL 1 Remove the circlip 1 2 Pull out the impeller wa...

Page 57: ...ft IDLER GEAR REMOVAL 1 Remove the woodruff key 1 to remove the idler gear 2 OIL PUMP REMOVAL 1 Remove the two screws 1 to remove the locking plate 2 2 Remove the circlip 3 3 Pull off the drive gear 4...

Page 58: ...1 to remove the locking plate 2 2 Remove the crankshaft 3 Now it is possible to pul out the oil sealing 3 of the crankshaft right TIMING CHAIN GUID RAIL REMOVAL 1 Remove the screw 1 to remove the timi...

Page 59: ...eck for remaining cases bolts or WWLQJ Don t force CRANKSHAFT REMOVAL 1 Pull out the crankshaft 1 arrow NOTE I LW LV GLI FXOW WR SXOO RXW WKH FUDQNVKDIW ORRN WR WKH WLPLQJ FKDLQ OIL SEALS REMOVAL 1 Re...

Page 60: ...DUH QRLV RU KDYH H FHVVLYH SOD 5 If the bearings didn t work correct remove the bearings off the crankshaft by using an inner bearing puller or hammer out the bearing from the backward 6 Measure the i...

Page 61: ...IWV PRYH WR WKH ULJKW SRVLWLRQ EHIRUH LQJ the crankcase 2 Tighten the three screws 1 TROUBLESHOOTING CRANKCASE FAILURE CAUSE TO DO Noise out from the crankcase Loosen or damage parts bearings gears in...

Page 62: ...ngine oil leak Check the whole lubrication system for leaks Wear and improper installation of the piston ring Check the piston rings as de scribed Engine overheated or burnt out Seized piston Absence...

Page 63: ...ICATION SCHEME 1 Oil strainer 2 Oil pump 3 Crankshaft 4 Camshaft OLO RZ GLUHFWLRQ 4 1 2 3 NOTE After removing the oil pump clean the parts up and below the surface with high pressure air RQ W OHDYH DQ...

Page 64: ...stall the starter motor pinion in reverse order See page 57 MAGNETO ROTOR STATOR AND IMPELLER WATER PUMP INSTALLATION 1 Install the parts in reverse order See page 56 GENERATOR COVER AND WATER PUMP HO...

Page 65: ...ch 125 125 2 125 5 Free length of clutch press spring 140 Outside diameter of right hemisphereshaft sleeve of drive gear Inner diameter of right hemisphere shaft sleeve of drive gear 34 00 Outside dia...

Page 66: ...ASSEMBLY 1 Assemble the driven disc in reverse order CLUTCH INSPECTION 1 Check abrasion of the friction panel of clutch 1 2 Measure the thickness A of the friction pnael Allowable limit A 1 5 mm CLUT...

Page 67: ...B 24 04 mm 3 Measure the outside diameter C of the sleeve Allowable limit C 23 98 mm VARIOMACTIC DRIVE DISC INSTALLATION 1 Install the variomatic drive disc in reverse order See page 54 BELT INSPECTI...

Page 68: ...is shaking in the movement The friction plate spring of clutch is broken out Replace the friction plate INSPECTION CYLINDER AND PISTON Item Standard mm Allowable limits mm Cylinder Inner Diameter 52...

Page 69: ...Allowable limit 0 03 mm 5 Take down the piston ring and install such rings on the bottom of the cylinder 6 Push the piston ring into the cylinder by the piston head 7 Measure the clearance of the clos...

Page 70: ...inder 2 Measure the inner diameter of the cylinder from three posi tions the upper middle and bottom A with the right angle against the piston pin as shown in picture 1 Allowable limits A 52 413 mm 3...

Page 71: ...Don t forget the guid pins on the crankcases 2 and the cylinder 4 Install the timing chain guid CYLINDER HEAD INSPECTION AIR VALVE REMOVAL 1 Press the air valve spring by special tool 1 and take down...

Page 72: ...L FH GLDPHWHU IN EX 10 00 10 015 10 10 Rocker shaft diameter IN EX Clearance between the rocker RUL FH DQG VKDIW IN EX 0 012 0 033 0 033 Camshaft Camheight IN EX AIR VALVE INSPECTION 1 Measure the fre...

Page 73: ...ins a proper width All the dents and ragged parts must be removed Standard valve race width Intake 1 0mm Exhaust 1 0mm NOTE If contacted place is the higher part of valve please use a 32 ang le plain...

Page 74: ...hten the two screws 1 NOTE Don t forget the guid pins CAMSHAFT INSPECTION 1 Check the outer circle of the bearing 1 for possible unstable RU LQ H LEOH URWDWLRQ LI VR UHSODFH LW 2 KHFN WKH LQQHU FLUFOH...

Page 75: ...rget the guid pins TORQUE LIST PART NO TORQUE 3 28 32 Nm For screws that are not listed use standard values page 10 4 Turn the crankshaft so long till the T mark an the notch in the cover are in line...

Page 76: ...sioner works alone 6 Tighten the screw 1 VALVE CLEARANCE ADJUSTMENT 1 GMXVW WKH SLVWRQ WR ULQJ 7 7 PDUNLQJ OLQH DV GHVFULEHG on page 77 2 7R DGMXVW WKH YDOYH FOHDUDQFH ORRVH WKH ORFN QXW DQG WXUQ LQ R...

Page 77: ...NSTALLATION 1 Install the engine in reverse order 2 5H OO WKH HQJLQH DQG WKH WUDQVPLVVLRQ RLO VHH SDJH TORQUE LIST ENGINE Fastening area and fastener name Tightening torque Nm Cylinder cover nut 25 28...

Page 78: ...2 11 10 PART LIST MUFFLER 1 KDXVW V VWHP FRPSOHWH 2 Nut M7 3 KDXVW JDVNHW 4 6FUHZV 0 5 Washer 6 Washer 7 Heat insulating mat 8 Screw Spring washer M6 10 Washer 11 Heat insulating mat 12 6FUHZ 0 13 KDX...

Page 79: ...VWDQGDUG RQO 3 Please maintain the motorcycle according to stipulations in the regular maintenance table 4 V WR H KDXVW FRQWURO V VWHP UDQGRP DGMXVWPHQW RU UHSODFH PHQW LQFOXGLQJ XVH RI VSDUN SOXJ LGO...

Page 80: ...ed by a vacuum device By automatic opening and closing of this membrane the air supply is regulated SECOND AIR SYSTEM INSPECTION 1 Disconnect the two hoses 1 2 Remove the two screws 2 3 Remove the thr...

Page 81: ...62 Nm For screws that are not listed use standard values page 10 PART LIST RIGHT CRANKCASE 1 OH 2 Left collar 3 Oil seal 4 Bearing 6201 5 Middle collar 6 Brake disc bolts 7 Brake disc 8 Rim Tire 10 T...

Page 82: ...WKH DLU SUHVVXUH Wheel unbalanced Rim damaged Replace the rim Tire worn Replace the tire or Balance the wheel Abnormal or scratching noise Wheel bearing loosened or worn Replace the bearing Speedomete...

Page 83: ...LWK H FHVVLYHO ZRUQ WLUHV ZLOO decrease the riding stability and can lead to loss of control Please UHSODFH WKH H FHVVLYH ZRUQ WLUHV LPPHGLDWHO NOTE Allowable tread limit X Technically 1 6 mm Legal va...

Page 84: ...ALITY Torque list Part No Torque 3 4 5 9 Nm 6 5 9 Nm 10 30 35 Nm 13 22 29 Nm For screws that are not listed use standard values page 10 PART LIST FRONT BRAKE 1 Brake system 2 Brake lever 3 Screw M6 4...

Page 85: ...ALITY Torque list Part No Torque 2 5 9 Nm 5 6 5 9 Nm 10 30 35 Nm 13 22 29 Nm For screws that are not listed use standard values page 10 PART LIST FRONT BRAKE 1 Brake system 2 6FUHZ 0 3 Bracket brake m...

Page 86: ...ar rim BRAKE LEVERS The front brake lever is located on the right side of the handlebar The rear brake lever is located on the left side of the handlebar NOTE 7KLV OHYHUV RSHUDWHG E K GUDXOLF W LV QRW...

Page 87: ...r it could be possi ble that the gaskets of the rear brake calliper defect or the brake pads are worn 1 UDLQ WKH EUDNH XLG IURP WKH K GUDXOLF EUDNH V VWHP 2 5HPRYH WKH EDQMR EROW IURP WKH PDVWHU EUDNH...

Page 88: ...caused E VSODVK RI EUDNH XLG 4 Do not allow dust or water to enter the brake system during UH OOLQJ 5 UDNH XLG VKRXOG EH UHSODFHG DW OHDVW HYHU HDUV SPECIFICATION BRAKE FLUID UDNH XLG W SH CASTROL SU...

Page 89: ...TION VALUE 9 Steel balls 4mm 25 pieces 7 Bearing 32007E PART LIST FRONT SUSPENSION 1 Shock absorber front right 2 Shock absorber front left 3 6FUHZV 0 4 Bracket speedometer cable 5 Bracket brake hose...

Page 90: ...NSION REAR SUSPENSION Torque list Part No Torque 1 37 44 Nm 3 22 29 Nm For screws that are not listed use standard values page 10 3 3 2 1 1 PART LIST REAR SUSPENSION 1 6FUHZ 0 2 Shock absorber rear 3...

Page 91: ...Gasket defect Replace the affected fork leg Weak rear shock absorber spring Spring worn or broken Replace the rear shock absorber Leaking rear shock absorber Gasket defect Replace the rear shock absor...

Page 92: ...on the lower bearing race and position the 25 steel balls as shown in the picture 1 4 GMXVW WKH VXVSHQVLRQ ZLWK WKH XSSHU EHDULQJ UDFH DGMXVW ment nut 5 Reassemble in reverse order FRONT SUSPENSION FO...

Page 93: ...ear shock absorber 3 5 Reassemble in reverse order NOTE The rear shock absorber is spring loaded The spring preload can EH QRW DGMXVWHG EXPLODED VIEW PART LOCATION STEERING SUSPENSION Torque list Part...

Page 94: ...s More troubleshooting see on page 82 STEERING REPLACEMENT 1 Follow the points of front suspension replacement 2 Remove the suspension forks HANDLEBAR REPLACEMENT 1 Remove the front rear handlebar cov...

Page 95: ...95 ELECTRICAL SYSTEM WIRING DIAGRAM...

Page 96: ...ON ELECTRICAL SYSTEM PART LIST STEERING 1 Winker relay 2 5HFWL HU 3 Horn 4 Igniter CDI 5 Main switch power lock module 6 Emergency cutout switch 7 Ignition coil 8 Wiring loom Starter relaise 10 Diode...

Page 97: ...Head light 2 Position light 3 Turn signal front 4 Rear light and brake light 5 Turn signal rear 6 Number plate light 7 5HDU UH HFWRU 8 Instrument panel and indicators Switches left 10 Switches right 1...

Page 98: ...istance of trigger 20 C 100 200 0D YROWDJH RI LJQLWLRQ FRLO 9 Voltage of trigger Above 1 7V Battery Capacity type 12V 6Ah dry charged Voltage Full charg 13 V Need to be charged 12 3V Charging current...

Page 99: ...WKDW DIWHU HDFK PDLQWHQDQFH WKH ER FRYHU LV FORVHG correct to avoid that water or others penetrate WARNING Do not use a fuse of a higher amperage rating than recommended WR DYRLG FDXVLQJ H WHQVLYH GDP...

Page 100: ...tem in accordance with the order stip ulated in the fault diagnosis table 6 If there is electric current passes through an electrical unit do not disassemble the connector otherwise over tension will...

Page 101: ...replace the battery Disconnected battery cable Connect the battery cable Fuse blown Find the cause repair it and re place the fuse Faulty main switch Replace the main switch Low power Weak battery Ch...

Page 102: ...Start the engine gradually increase engine speed to test the RXWSXW I WKH FODPSLQJ YROWDJH H FHHGV WKH VSHFL HG YDOXH range inspect the voltage regulator 6 Inspect the clamping voltage of the lighting...

Page 103: ...d body ground There being resistance in alternator coil 0 6 After checking that the main wiring end between illuminating line green red and body ground resistor plug plug of auto matic side starter re...

Page 104: ...C 4 I WKH PHDVXUHG YDOXH H FHHGV WKH VWDQGDUG YDOXH UHSODFH WKH stator NOTE Inspection to charging coil of generator can be performed on en gine GENERATOR REPLACEMENT 1 Remove the generator cover 1 wi...

Page 105: ...th might which is the main cause of fault 5 DG VRFNHW FRQWDFW LV WKH PDLQ FDXVH RI WKH LJQLWLRQ V VWHP IDXOW VR LQVSHFW ZKHWKHU WKH MRLQW RI HDFK SDUW LV LQ SRRU contact or not 6 Inspect whether the s...

Page 106: ...y of multimeter brands with dif ferent interior resistance the values tested will differ accord ingly Connect the multimeter 1 with a high voltage diverter or an electric meter with LQSXW UHVLVWDQFH D...

Page 107: ...age at the alternator is normal poor contact or broken line can be determined If both are abnormal bad act of the trigger can be determined Please refer to inspection of the troubleshooting table TRIG...

Page 108: ...The primary coil is installed in accordance with the black white wire COIL INSPECTION 1 Measure the resistance between terminals of coil between 1 and 2 6WDQGDUG YDOXH 2 If the resistance value is wi...

Page 109: ...al or when there is no spark in the spark plug Replace Normal high volt age no spark Bad act of spark plug or power leak in second ary coil Check and replace Bad act of ignition coil Check and replace...

Page 110: ...M NOTE Dismantling of the starter motor can be done conducted on the engine In case of damage the starter motor need to be replaced complete and does not need to be repaired STARTER MOTOR INSPECTION 1...

Page 111: ...line of the start relay Inspect actuation of the start relay VOLTAGE OF STARTER RELAY INSPECT 1 Disconnect the plug green yellow 2 Measure the voltage between the ground wire of the frame and the gree...

Page 112: ...of starter motor Replace Power shortage in battery or battery empty Replace or charge BULBS REPLACEMENT GENERAL INFORMATION PREPARATORY DATA Precautions on operation While trouble shooting electric f...

Page 113: ...e on page 130 131 NOTE It is not necessary to remove the sidecover HEADLIGHT BULB 1 Remove the rubber cap 1 2 Unthread the locking nut 2 3 Pull out the whole bulb 3 4 Pull out the headlight bulb 4 5 R...

Page 114: ...front sidecover 2 5HPRYH WKH YH VFUHZV DQG UHPRYH WKH ZKROH EXOE DQG poistion bulb 3 Remove the headlight 2 4 Reassemble in reverse order WINKER REPLACEMENT 1 Remove the left or right front sidecover...

Page 115: ...unterclock wise 3 Reassemble in reverse order WINKER BULB 1 To remove the bulb bracket 1 turn it counterclockwise 2 To remove the bulb 2 pull it in an turn the bulb counterclock wise 3 Reassemble in r...

Page 116: ...ch is on Burned bulb Replace bulb Faulty switch Replace switch Broken or shorted wire Check and repair Fuse blown Replace fuse Weak battery Charge battery or replace it Poor contact of connecting wire...

Page 117: ...l out the defect indicator light 1 and replace it 3 Reassemble in reverse order MAIN SWITCH INSPECTION 1 Remove the right front sidecover See on page 131 2 Disconnect the cable 1 coming from the main...

Page 118: ...rk correct replace the main switch Follow the de scription above HORN INSPECTION REPLACEMENT 1 Remove the right front sidecover 2 Disconnect the horn wires 1 3 To remove the horn remove the screw 2 4...

Page 119: ...below 4 In case of damage the handle switch need to be replaced complete and does not need to be repaired RIGHT HANDLE SWITCH INSPECTION 1 Remove the rear handlebar cover 2 Use a continuity tester to...

Page 120: ...emove the rear handlebar cover 2 Press together arrows the two clips on the side 3 Pull out the related switch 4 Assembling in reversed order NOTE Only one switch is illustrated Remove the other switc...

Page 121: ...e the resistance value between the terminals 4 If the measured values do not match the standard value replace the sensor 10 Check the gasket 5 before reassembling 11 Assembling in reversed order LEVEL...

Page 122: ...eat source or any place where may bite it when it is moving When laying a cable along a handle avoid it being strained WRR WLJKWO RU ORRVHO DQG LW FDQ QRW LQWHUIHUH ZLWK DQ DGMDFHQW part at any turnin...

Page 123: ...ER 4 Remove the two battery vables 3 to remove the battery 4 5 IWHUZDUGV RX FDQ OLIW WKH VWRUDJH ER 6 Reassemble in reverse order REAR CARRIER REMOVAL 1 5HPRYH WKH VWRUDJH ER 2 Remove the three srews...

Page 124: ...he screw 5 7 Remove the two screws 6 8 Unthread the sidecover on the frontside and backside Slide the sidecover 7 sidewards and forwards 10 Reassemble in reverse order SIDECOVER LEFT REMOVAL 1 Remove...

Page 125: ...er sidecover 4 5 Reassemble in reverse order LOWER SIDECOVER LEFT REMOVAL 1 Remove the lower sidecover left in the same way as the lower sidecover right removal REAR LIGHT COVER WITH REAR LIGHT REMOVA...

Page 126: ...e license plate bracket 2 3 Reassemble in reverse order INNER REAR FENDER REMOVAL 1 Remove the sidecover and the license plate bracket 2 Remove the two screws 1 on the right and left side 3 Unthread t...

Page 127: ...ER REMOVAL 1 Remove the two screws 1 2 Remove the three screws 2 3 Remove the screw 3 on the left and right side 4 Split the front and the rear handlebar cover 5 To remove the front handlebar cover di...

Page 128: ...the four screws 3 to remove the windshield 4 4 Remove the three screws 5 to remove the windshield bracket 6 5 Reassemble in reverse order INSTRUMENT PANEL REMOVAL 1 Remove the front handlebar cover an...

Page 129: ...ve the radiator cowling 2 FRONT COVER REMOVAL 1 Remove the front handlebar cover and the windshiel bracket and the radiator cowling 2 Remove the the four screws 1 of the instrument panel 2 NOTE It is...

Page 130: ...ecover with the headlight 1 Remove the windshield bracket the front cover and the instru ment panel 2 Remove the screw 1 3 Remove the screw 2 4 Remove the four screws 3 5 Unthread the left headlight f...

Page 131: ...left with the left headlight sidewards 10 Disconnect the cable 8 11 To remove the sidecover from the headlight remove the four VFUHZV 12 Reassemble in reverse order FRONT SIDECOVER RIGHT REMOVAL 1 Re...

Page 132: ...MOVAL 1 5HPRYH WKH VWRUDJH ER DQG WKH IXHO WDQN FRYHU 2 Remove the tank closure 1 3 Remove the blanking grommet 2 and close the tank clo sure 4 Remove the four screws 3 5 Remove the two screws 4 on th...

Page 133: ...n switch cover 1 counterclockwise arrow and pull it out 3 Remove the screw 2 4 Now it is possible to remove the leg protection 3 UNDER VEHICLE PROTECTION PANEL REMOVAL 1 5HPRYH WKH VL VFUHZV RQ WKH OH...

Page 134: ...ws 1 Remove the screw 2 on left and right side 3 To remove the front wheel arch panel 3 remove the screw 4 on the inner side LOWER COVER STEERING COLUMN REMOVAL 1 Remove the front wheel arch panel 2 R...

Page 135: ...vent damage during installation of the back view mirror con sider that on the right side is a left handed thread and vice versa MIRRORS REMOVAL 1 Push out the rubber cap 1 2 To remove the left mirror...

Page 136: ...KSR Moto is a trademark of KSR Group GmbH Gewerbeparkstrasse 11 3500 Krems Austria w w w k s r g r o u p c o m...

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