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1

. GENERAL INFORMATION

 

 

CK 1 

 

 
 
 

POOR PERFORMANCE (ENGINE LACKS POWER)

 

 
 
 

 
 

Clogged air cleaner 
Poor fuel flow (Restricted) 
Clogged fuel tank cap breather hole 
Clogged exhaust muffler 
Carburetor fuel level too low 
Clogged carburetor high speed fuel 
passage 
 
 
Faulty CDI unit     
Faulty pulser coil   

 
 
 
 
Improper valve clearance 
adjustment 
Excessively worn valve seat 
(protruded valve stem) 
 
 
Improper valve and seat contact 
Worn cylinder and piston rings 
Leaking cylinder head gasket 
Improper valve timing 
 
 
 
 
Clean and unclog   
 
 
 
 

 

Fouled spark plug   
Incorrect heat range plug 
 
 
 
Oil level too high 
Oil level too low 
Oil not changed 
 
 
 
 
Clogged oil line

 

 

Faulty oil pump 
 
 
 
Worn cylinder and piston rings 
Mixture too lean   
Poor quality fuel 
Excessive carbon buildup in 
combustion chamber

 

 

Ignition 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

 

Symptom

 

Probable Cause

 

  Engine speed 
  increases

 

Correct

 

Engine speed does not 
increase sufficiently

 

Incorrect

 

Check ignition timing 
using a timing light

 

Test cylinder compression

 

Check carburetor for 
clogging

 

Rapidly accelerate or run 
at high speed

 

Remove spark plug and 
inspect

 

Check for engine overheating

 

Check valve clearance

 

Correct

 

Incorrect

 

   

Normal   

   compression

 

Low compression

 

Check crankcase for oil 
level and condition

 

Check cylinder head for oil 
lubrication

 

Engine overheats

 

  Engine does not 
  overheats

 

  Plug not fouled or 
  discolored

 

  Plug fouled or   
  discolored

 

  Correct and not 
  contaminated

 

   Incorrect or 
   contaminated

 

Valve train lubricated 
properly

 

Valve train not 
lubricated properly

 

Engine does not knock

 

Engine knocks

 

Not clogged

 

Clogged

 

 

1-17

 

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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