KYMCO CK 1 Manual Download Page 1

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. GENERAL INFORMATION

CK 1

ENGINE SERIAL NUMBER

ENGINE SERIAL NUMBER ................ 1- 0

LUBRICATION POINTS ....................... 1-12

SPECIFICATIONS ................................ 1- 1

CABLE & HARNESS ROUTING ............ 1-13

SERVICE PRECAUTIONS .................. 1- 2

WIRING DIAGRAM .............................. 1-15

TORQUE VALUES .............................. 1-10

TROUBLESHOOTING .......................... 1-16

SPECIAL TOOLS ................................. 1-11

Location of Engine Serial Number

Location of Frame Serial Number

1-0

Summary of Contents for CK 1

Page 1: ...SERIAL NUMBER 1 0 LUBRICATION POINTS 1 12 SPECIFICATIONS 1 1 CABLE HARNESS ROUTING 1 13 SERVICE PRECAUTIONS 1 2 WIRING DIAGRAM 1 15 TORQUE VALUES 1 10 TROUBLESHOOTING 1 16 SPECIAL TOOLS 1 11 Location...

Page 2: ...Intake 0 06mm Exhaust 0 06mm Idle speed rpm 1700 Lubrication System Lubrication type Forced pressure wet sump Oil pump type Inner outer rotor Oil filter type Wire gauze filter Oil capacity 0 9 liter C...

Page 3: ...bolts or nuts begin with larger diameter to smaller ones at several times and tighten to the specified torque diagonally Use genuine parts and lubricants When servicing the motorcycle be sure to use...

Page 4: ...l working safety Disconnect the battery negative terminal before operation When using a spanner or other tools make sure not to damage the motorcycle surface After operation check all connecting point...

Page 5: ...capacity After operation terminal caps shall be installed securely When taking out the connector the lock on the connector shall be released before operation Hold the connector body when connecting o...

Page 6: ...inal cover or loose negative terminal Check the double connector cover for proper coverage and installation Insert the terminal completely Check the terminal cover for proper coverage Do not make the...

Page 7: ...e that it is not interfering with any moving or sliding parts When fixing the wire harnesses do not make it contact the parts which will generate high heat Route wire harnesses to avoid sharp edges or...

Page 8: ...sharp edge or corner When rubber protecting cover is used to protect the wire harnesses it shall be installed securely Do not break the sheath of wire If a wire or harness is with a broken sheath rep...

Page 9: ...ns When a testing device is used make sure to understand the operating methods thoroughly and operate according to the operating instructions Be careful not to drop any parts When rust is found on a t...

Page 10: ...ls represent the servicing methods and cautions included in this service manual Apply engine oil to the specified points Use designated engine oil for lubrication Apply grease for lubrication Use spec...

Page 11: ...der head lock bolt Cylinder bolt Crankcase assembly bolt Crankshaft damper bolt Right crankcase cover bolt Left crankcase cover bolt A C generator coil lock bolt Starter gear set plate bolt Carburetor...

Page 12: ...Page Valve adjuster E036 Valve spring compressor attachment E040 Clutch holder E013 Flywheel puller E005 Flywheel holder E021 Lock nut socket wrench E010 Bearing remover E037 Oil seal Bearing install...

Page 13: ...1 GENERAL INFORMATION CK 1 LUBRICATION POINTS Throttle Cable Speedometer Cable Clutch Cable Front Brake Fluid Tube 1 12...

Page 14: ...1 GENERAL INFORMATION CK 1 CABLE HARNESS ROUTING Taillight Wire Connector Wire Harness CDI Unit Ignition Coil 1 13...

Page 15: ...1 GENERAL INFORMATION CK 1 Starter Relay Throttle Cable Positive Cable Battery Negative Cable Ignition Coil Wire Clutch Cable Winker Regulator Rectifier Fuse Box 1 14...

Page 16: ...1 GENERAL INFORMATION CK 1 WIRING DIAGRAM 1 15...

Page 17: ...and piston rings Leaking cylinder head gasket Faulty choke control system Leaking intake manifold Incorrect ignition timing Incorrectly adjusted air screw Flooded carburetor Throttle valve excessivel...

Page 18: ...n timing too advanced Excessive carbon build up in combustion chamber Poor quality fuel Clutch slipping Mixture too lean Start engine and accelerate lightly for observation Inspection Adjustment Sympt...

Page 19: ...Faulty CDI unit Faulty A C generator Faulty ignition coil Faulty ignition switch Faulty A C generator Damaged vacuum tube Clogged air vent hole Remove spark plug and install it into spark plug cap to...

Page 20: ...lean and unclog Cam timing gear aligning marks not aligned Faulty spring Inspection Adjustment Symptom Probable Cause Check ignition timing Check carburetor for clogged jets Check fuel filter for fuel...

Page 21: ...tor rectifier coupler red wire and battery wire to ground and test voltage Inspection Adjustment Inspection Adjustment Symptom Symptom Probable Cause Probable Cause Normal voltage Battery has voltage...

Page 22: ...n coil Replace with a new spark plug and inspect again Check CDI unit coupler for looseness Inspection Adjustment Symptom Probable Cause Normal Abnormal Normal Abnormal Normal Abnormal Abnormal Measur...

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KYMCO CK 1, Manual

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Summary of Contents for CK 1

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