KSR Ride Speedy, Repair Manual

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INDEX 3
INTRODUCTION
………………………………2
INDEX …………………………………………3
IMPORTANT NOTES …………………………5
LOCATION OF SERIAL NUMBERS
………6
VIN (CHASSISNUMBER)……………………6
FRAME PLATE………………………………6
MOTOR NUMBER……………………………6
DECRYPTING THE VEHICLE IDENTIFICATION
NUMBER………………………………………………
6
GENERAL SPECIFICATION
…………………7
SPECIFIC TIGHTENING TORQUES ………8
TABLE OF TORQUE FORCE OF FASTENERS…
8
GENERAL TIGHTENING TORQUES/ BOLTS ……
9
SPECIAL TOOLS ……………………………10
1. TIPS FOR USING THE FOUR MAJOR
ELECTRICAL PARTS
……………………11
1. CHARGER…………………………………12
2. CONTROLLER……………………………12
3. MOTOR……………………………………12
4. BATTERY…………………………………12
2. FAILURE DIAGNOSIS …………………13
FAILURE DIAGNOSIS PROCEDURE WHEN THE
HYDRAULIC DISC BRAKE FAILS
………………14
FAILURE DIAGNOSIS PROCEDURE WHEN THE
DRUM BRAKE FAILS………………………………
15
FAILURE DIAGNOSIS PROCEDURE WHEN
MOTOR STOPS RUNNING………………………
16
MAINTENANCE PROCEDURE WHEN MOTOR
WON’T STOP RUNNING…………………………
17
MAINTENANCE PROCEDURE WHEN MOTOR
RUNS AND STOPS EVERY NOW AND THEN…
17
MAINTENANCE PROCEDURE WHEN MOTOR
RUNS SLOWLY……………………………………
18
MAINTENANCE PROCEDURE FOR BAD
CHARGING
……………………………………18
MAINTENANCE PROCEDURE WHEN BATTERY CAN’T BE
CHARGED OR CHARGED COMPLETELY
……………
19
MAINTENANCE PROCEDURE FOR NO
ELECTRICITY OF BATTERY……………………
19
MAINTENANCE PROCEDURE WHEN HORN
DOESN’T SOUND…………………………………
20
MAINTENANCE PROCEDURE WHEN HEADLAMP
OR TURN SIGNAL OFF…………………………
20
3. FAULTS AND TROUBLESHOOTING …21
FAULTS AND TROUBLESHOOTING…… 22
4. PERIODIC MAINTENANCE
…………… 25
PERIODIC MAINTENANCE CHART ……26
IMPORTANT PREPARATION
REFERENCES
………………………………27
WHEELS AND TIRES/ BRAKES
…………28
AIR PRESSURE INSPECTION……………28
WHEEL BEARING AND WHEEL AXLE
DAMAGE INSPECTION…………………… 28
BRAKE FLUID LEAK INSPECTION………28
BRAKE OPERATION INSPECTION FRONT……
28
BRAKE FLUID LEVEL INSPECTION
……
29
FRONT BRAKE PAD WEAR INSPECTION……
29
BRAKES ……………………………………29
REAR BRAKE PAD WEAR INSPECTION
……30
BRAKE DISC INSPECTION………………30
BRAKE DRUM INSPECTION………………31
BRAKE HOSE REPLACEMENT……………31
BRAKE OPERATION INSPECTION REAR
……32
REAR BRAKE SYSTEM ADJUSTMENT…32
BRAKE CABLE REPLACEMENT…………32
SUSPENSION………………………………33
FRONT FORK OPERATION INSPECTION
……33
FRONT FORK OIL LEAK INSPECTION
…………33
REAR SHOCK OPERATION INSPECTION
……33
REAR SHOCK OIL LEAK INSPECTION
………33
ELECTRICAL SYSTEM
……………………34
LIGHT AND SWITCHES OPERATION
INSPECTION…………………………………35
HEADLIGHT AIMING INSPECTION………35
5. REPAIR AND DIAGNOSTICS …………36
WHEELS AND TIRES ………………………37
EXPLODED VIEW/ PART LOCATION -
FRONT WHEEL………………………………37
EXPLODED VIEW/ PART LOCATION -
REAR WHEEL………………………………38
SPECIFICATION - FRONT/ REAR WHEEL………
38
TROUBLESHOOTING - FRONT/ REAR
WHEEL……………………………………… 38
FRONT WHEEL REPLACEMENT…………39
REAR WHEEL REPLACEMENT…………39
WHEELS (RIMS)……………………………40
TIRES…………………………………………40
WHEEL BEARING WHEEL AXLE DAMAGE
INSPECTION
…………………………………40
FRONT WHEEL BEARING INSPECTION………
40
INSPECT BENDING OF THE WHEEL
SPINDLE………………………………………40
BRAKES ………………………………………41
PART LOCATION - FRONT BRAKE……… 41
EXPLODED VIEW/ PART LOCATION - REAR
BRAKE
…………………………………………42
SPECIFICATION - FRONT/ REAR
BRAKE………………………………………42