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1
. GENERAL INFORMATION
ENGINE SERIAL NUMBER ................ 1- 0
1
SPECIFICATIONS ................................ 1- 1
SERVICE PRECAUTIONS .................. 1- 2
TORQUE VALUES .............................. 1-10
SPECIAL TOOLS ................................. 1-11
ENGINE SERIAL NUMBER
Location of Engine Serial Number
Location of Frame Serial Number
LUBRICATION POINTS ....................... 1-12
CABLE & HARNESS ROUTING ............ 1-13
WIRING DIAGRAM .............................. 1-15
TROUBLESHOOTING .......................... 1-16
CK 1
1
1-0
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Summary of Contents for KYMCO CK 1
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Page 1: Table Of Contents
. GENERAL INFORMATION CK 1 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 ......... -
Page 2: Specifications
. GENERAL INFORMATION CK 1 SPECIFICATIONS Air cleaner type Paper element Motorcycle name & Model No. CK 1 Fuel capacity 12.5liter Chassis name & Model No. LKH3 Type Overall length (mm) 2030 φ23 Piston dia. (mm) Overall width (mm) 1050 φ25 equivalent... - Page 3 . GENERAL INFORMATION CK 1 SERVICE PRECAUTIONS Make sure to install new gaskets, O-rings, circlips, cotter pins, etc. when reassembling. When tightening bolts or nuts, begin with larger-diameter to smaller ones at several times, and tighten to the specified torque diagonally.
- Page 4 . GENERAL INFORMATION CK 1 Apply or add designated greases and lubricants to the specified lubrication points. After reassembly, check all parts for proper tightening and operation. When two persons work together, pay attention to the mutual working safety.
- Page 5 . GENERAL INFORMATION CK 1 If the fuse is burned out, find the cause and repair it. Replace it with a new one Confirm according to the specified capacity. Capacity After operation, terminal caps shall be installed securely.
- Page 6 . GENERAL INFORMATION CK 1 The connector shall be inserted completely. If the double connector has a lock, lock Snapping! it at the correct position. Check if there is any loose wire. Before connecting a terminal, check for damaged terminal cover or loose negative terminal.
- Page 7 . GENERAL INFORMATION CK 1 After clamping, check each wire to make sure it is secure. Do not squeeze wires against the weld or its clamp. After clamping, check each harness to make sure that it is not interfering with any moving or sliding parts.
- Page 8 . GENERAL INFORMATION CK 1 Route harnesses so they are neither pulled tight nor have excessive slack. Do not pull too tight! Protect wires and harnesses with electrical tape or tube if they contact a sharp edge or corner.
- Page 9 . GENERAL INFORMATION CK 1 After routing, check that the wire harnesses are not twisted or kinked. Wire harnesses routed along with handlebar should not be pulled tight, have excessive slack or interfere with adjacent or surrounding parts in all steering positions.
- Page 10 . GENERAL INFORMATION CK 1 Symbols: The following symbols represent the servicing methods and cautions included in this service manual. : Apply engine oil to the specified points. (Use designated engine oil for lubrication.) Engine Oil : Apply grease for lubrication.
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Page 11: Torque Values
. GENERAL INFORMATION CK 1 TORQUE VALUES STANDARD TORQUE VALUES Item Torque (kg-m) Item Torque (kg-m) 5mm bolt, nut 0.45～0.6 5mm screw 0.35～0.5 6mm bolt, nut 0.8～1.2 6mm nut, SH bolt 0.7～1.1 8mm bolt, nut 1.8～2.0 6mm flange bolt, nut 1.0～1.4... -
Page 12: Special Tools
. GENERAL INFORMATION CK 1 SPECIAL TOOLS Tool Name Tool No. Remarks Ref. 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: Lubrication Points
. GENERAL INFORMATION CK 1 LUBRICATION POINTS Throttle Cable Speedometer Cable Clutch Cable Front Brake Fluid Tube 1-12... -
Page 14: Cable & Harness Routing
. GENERAL INFORMATION CK 1 CABLE & HARNESS ROUTING Wire Harness Ignition Coil Taillight Wire Connector CDI Unit 1-13... - Page 15 . GENERAL INFORMATION CK 1 Throttle Cable Ignition Coil Wire Clutch Cable Regulator/Rectifier Battery Negative Cable Positive Cable Starter Relay Winker Fuse Box 1-14...
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Page 16: Wiring Diagram
. GENERAL INFORMATION CK 1 WIRING DIAGRAM 1-15... -
Page 17: Troubleshooting
. GENERAL INFORMATION CK 1 TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START Inspection/Adjustment Probable Cause Symptom Check if fuel reaches carburetor by loosening drain screw Empty fuel tank Clogged fuel line between fuel tank and carburetor Clogged float valve... - Page 18 . GENERAL INFORMATION CK 1 POOR PERFORMANCE (ENGINE LACKS POWER) Inspection/Adjustment Probable Cause Symptom Start engine and accelerate lightly for observation Clogged air cleaner Poor fuel flow (Restricted) Clogged fuel tank cap breather hole Engine speed Engine speed does not...
- Page 19 . GENERAL INFORMATION CK 1 Ignition timing too advanced POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct Incorrect Faulty pulser coil Check carburetor air screw adjustment Mixture too lean (turn screw in)
- Page 20 . GENERAL INFORMATION CK 1 POOR PERFORMANCE (AT HIGH SPEED) Inspection/Adjustment Symptom Probable Cause Check ignition timing Faulty CDI unit Correct Incorrect Faulty pulser coil Check valve clearance Improperly adjusted valve clearance Correct Incorrect Worn valve seat Check fuel filter for...
- Page 21 . GENERAL INFORMATION CK 1 POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging Inspection/Adjustment Symptom Probable Cause Start engine and test limit voltage between battery terminals Dead battery Voltage does not Normal voltage increase Faulty battery Measure resistance between AC generator...
- Page 22 . GENERAL INFORMATION CK 1 NO SPARK AT SPARK PLUG Inspection/Adjustment Symptom Probable Cause Replace with a new spark plug and inspect again Weak or no spark Good spark Faulty old spark plug Check spark plug cap and ignition coil wire...