KSR Moto T58 - ZION 125 Repair Manual
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KSR Moto T58 - ZION 125 Repair Manual

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REPAIR MANUAL
T58 - ZION 125
Vers. 2014_06

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Summary of Contents for KSR Moto T58 - ZION 125

  • Page 1 REPAIR MANUAL T58 - ZION 125 Vers. 2014_06...

  • Page 2: Introduction

    It is important that you read this repair manual carefully before the start of work. Only use KSR spare parts. KSR Moto is a registered brand by KSR Group GmbH. with the service schedule. The repair manual was written to correspond to the current state of this model.

  • Page 3: Table Of Contents

    INDEX INTRODUCTION STEERING STEERING PLAY INSPECTION INDEX STEERING PLAY ADJUSTMENT STEERING BEARING LUBRICATION IMPORTANT NOTES ELECTRICAL SYSTEM LOCATION OF SEVERAL NUMBERS BATTERY INSPECTION/ CHARGING VIN (CHASSIS NUMBER) AND FRAME PLATE LIGHT AND SWITCHES OPERATION INSPECTION ANTI TEMPERING LABEL HEADLIGHT AIMING INSPECTION ENGINE NUMBER 2.
  • Page 4 INDEX VARIOMATIC DISC REMOVAL INSPECTION - CYLINDER HEAD CLUTCH DRUM AND CERTIFUGAL CLUTCH REMOVAL 54 AIR VALVE INSPECTION TRANSMISSION OIL REMOVAL AIR VALVE ADJUSTMENT GEARBOX HOUSING REMOVAL CYLINDER HEAD INSPECTION GEARBOX REMOVAL AIR VALVE INSTALLATION WATER PUMP HOUSING REMOVAL CYLINDER HEAD INSTALLATION GENERATOR COVER REMOVAL CAMSHAFT INSPECTION STATOR FOR GENERATOR REMOVAL...
  • Page 5 INDEX ELECTRICAL SYSTEM ELECTRICAL SYSTEM/ SPEEDOMETER/ WIRING DIAGRAM SWICHES A. SENSORS PART LOCATION - ELECTRICAL SYSTEM SPEEDOMETER DESCRIPTION SPEEDOMETER INDICATOR LIGHTS REPLACEMENT ELECTRICAL SYSTEM MAIN SWITCH INSPECTION PART LOCATION - LIGHTS/ INSTRUMENTS SWITCHES MAIN SWITCH REPLACEMENT SPECIFICATION - ELECTRICAL SYSTEM HORN INSPECTION/ REPLACEMENT HANDLE SWITCH ELECTRICAL SYSTEM/ FUSE...

  • Page 6: Location Of Several Numbers

    LOCATION OF SEVERAL NUMBERS VIN (CHASSIS NUMBER) AND FRAME PLATE Remove the ruber cover (1). right side of the frame. FRAME PLATE The frame plate (3) is located on the front side of the steering tube. ANTI TEMPERING LABEL bench. ENGINE NUMBER The engine number (5) is on the left side of the engine case.

  • Page 7: General Specification

    GENERAL SPECIFICATION ENGINE Engine type: Water cooling 4 - stroke Cylinder arrangement: Single cylinder Displacement: 125 cm³ Compression ratio: 10.4:1 Starting system: Electric starter Lubrication system: Pressure and splash lubrication ENGINE OIL QUANTITY Dismantling: 1 L Recommended type: Recommended type: CASTROL Power 1 - Racing 4T 10W-40 TRANSMISSION OIL Niveau bolt...

  • Page 8: Specific Tightning Torques

    SPECIFIC TIGHTNING TORQUES TORQUE / Nm MODULE PART Bolt in the clutch cover of the startup electrical machinery Electrical System Body fender bolt 55-62 Wheel Axles 100-113 Mounting bolt of front brake caliper Front brake system 10-12 Rear brake system Top nut of rear shock absorber 37-44 Rear shock absorber...

  • Page 9: Important Notes

    IMPORTANT NOTES WARRANTY tomer‘s service card, otherwise no warranty claims will be recognized. No warranty claims can be considered for dam- age resulting from manipulations and/or alterations to the vehicle. NOTES AND WARNINGS Pay attention to the notes/warnings in this manual. WARNING •...

  • Page 10: General Tightning Torques

    GENERAL TIGHTNING TORQUES and glued assembling it must be glued in assembling again. For the bonding of screws use Loctite ® 243 ™, follow the instructions for use from the manufacturer. 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...

  • Page 11: Special Tools

    SPECIAL TOOLS Special tools ar maintenance of the vehicle. After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or worn parts. NAME REMARKS Figure 1 Spacer gauge Figure 2 Dismounting tools for bearing Figure 3 Assembling tools for bearing Figure 4...
  • Page 12 SPECIAL TOOLS Thickness gauge (clearance gauge) Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8...
  • Page 13 SPECIAL TOOLS Fig. 10 Fig. 11 Fig. 12 Fig. 13 Fig. 14 1. Bush-head 2.Shake-handle 3.Ratchet type wrench 4.Connecting-rod Fig. 15 Fig. 16 Fig. 18 Fig. 17...
  • Page 14 SPECIAL TOOLS Fig. 20 Fig. 21a Fig. 21b Fig. 22a Fig. 22b Fig. 23a Fig. 23b Fig. 24 Fig. 25...

  • Page 15: Periodic Maintenance

    1. PERIODIC MAINTENANCE...

  • Page 16: Periodic Maintenance Chart

    PERIODIC MAINTENANCE CHART Important maintenance work have to be carried out by an authorized workshop. CHECKLIST OF CONSTANT MAINTENANCE 1000 km or 4.000 km or 7.000 km or 10.000 km or 13.000 km or guarantee can be granted. 1. month 6.

  • Page 17: Important Preperation References

    IMPORTANT PREPERATION REFERENCES Cylinder Block / Piston Item Standard [mm] Allowable limits [mm] Inner Diameter 52.40-52.413 52.413 Cylinder degree 0.004 0.004 Cylinder Roundness 0.005 0.005 Flatness 0.05 0.05 “IN” properly opposite Piston mark direction to the inlet valve 52.36-52.37 (at the Measuring points for piston outer diameter bottom of the piston 52.37...
  • Page 18 IMPORTANT PREPERATION REFERENCES Cylinder Cap Item Standard [mm] Allowable limits [mm] Cylinder pressure 1.25 Mpa 0.03 0.03 Air valve 0.10 0.12 clearance 0.13 0.14 Inner diameter of valve guid IN / EX 5.00-5.012 5.03 Air valve Valve guid Clearance between the valve 0.010-0.035 0.08 pod and the valve guid...
  • Page 19 IMPORTANT PREPERATION REFERENCES Starting system Item Standard value [mm] Operation limit [mm] Length of starting motor bush 12.5 Starting idle gear bushing OD of strting idle gear Carburettor Item Standard Main nozzle 180# 37.5# Needle valve Wheels Item Standard [mm] Allowable limts [mm] Vertical direction front wheel Transverse direction front wheel...

  • Page 20: Air System/ Fuel System

    AIR SYSTEM/ FUEL SYSTEM AIR FILTER cover (2). polluted or damaged, please replace with new one. CHANGING INTERVALS should be replaced early. Under normal condition replace it refer- ring the maintenance chart. Reassemble in reverse order. THROTTLE CONTROL SYSTEM Check the smoothness of accelerator pull wire. Free displacement: 5-10 mm IDLE ADJUSTMENT Start and warm up the engine for about 3 minutes, so that the en-...

  • Page 21: Fuel System

    FUEL SYSTEM ADJUSTMENT OF CARBURETTOR Attention: of the bolts should be recorded because this is very helpful during the installation. Switch on and warm up the machine for about 3 minutes, so that the engine will operate in normal running temperature; U/min.

  • Page 22: Engine

    ENGINE ENGINE OIL INSPECTION 1. The vehicle shall be parked on a even ground when checking the oil level. 2. Run the engine for 2-3 minutes and afterwards wait for 2-3 minutes. 3. The engine oil tank cap (1) is located on the right side of the engine.

  • Page 23: Spark Plug Images And Analysis

    ENGINE SPARK PLUG IMAGES AND ANALYSIS Colour: 1. Gray/ 2. Light brown Analysis: Engine management ok Colour: 3. Matt black/ 4. Velvety coating Colour: 5. Oily soot/ 6. Oil coal Analysis: Too much oil. SPARK PLUG REPLACEMENT 1. Follow the steps 1-3 of “SPARK PLUG INSPECTION” 2.

  • Page 24: Wheels And Tires/ Brakes

    WHEELS AND TIRES/ BRAKES AIR PRESSURE INSPECTION WARNING Low tire air pressure leads to abnormal wear and overheating of the tire. The tire pressure should be measured under cold condi- tion. Use a conventional pressure gauge (1) to test the tire pressure. mum tire service life.

  • Page 25: Brake Fluid Level Inspection Front/ Rear

    BRAKES WARNING Always keep the brake discs free of oil and grease, and clean them with brake cleaner when necessary. Please consider that a Please consider that the front/ rear brake lever free play is not ad- BRAKE FLUID LEVEL INSPECTION FRONT/ REAR After a certain time the brake pads start to wear out and the MIN (1) mark, check the brake pads or and the brake system for system.

  • Page 26: Rear Brake Pad Wear Inspection/ Replacement

    BRAKES 3. Remove the two bolts (3). 4. Remove the brake pads in pair. 5. Reassemble in reverse order. NOTE Glue in the bolts (1). REAR BRAKE PAD WEAR INSPECTION/ REPLACEMENT Change worn brake pads immediately. Always replace the brake pads in pair.

  • Page 27: Front Brake Disc Replacement

    BRAKES FRONT BRAKE DISC REPLACEMENT 1. Remove the two bolts of the front brake calliper to fold on the side. 2. Place an appropriate supporting stand to raise the front wheel wheel (3). 4. Remove the four bolts (3) to remove the front brake disc and mount a new one if the old one is worn.

  • Page 28: Front Brake Hose Replacement

    BRAKES FRONT BRAKE HOSE REPLACEMENT When the front brake hose is leaking, cracked or worn you must replace it. NOTE Please consider that there is no need to remove the brake calliper when you need to replace the brake hose. WARNING Avoid contact with skin and eyes, and keep out of the reach of children.
  • Page 29 BRAKES REAR BRAKE HOSE REPLACEMENT When the front brake hose is leaking, cracked or worn you must replace it. NOTE Please consider that there is no need to remove the brake calliper when you need to replace the brake hose. WARNING Avoid contact with skin and eyes, and keep out of the reach of children.

  • Page 30: Front Fork Operation Inspection

    SUSPENSION FRONT FORK OPERATION INSPECTION At every inspection the fork should be controlled. 1. Apply the front brake and compress the front shock absorber up and down (arrows) to check for correct operation. 2. When the fork stick, feel spongy or the free play between the fork tubes is too big replace the defect fork leg.

  • Page 31: Steering

    STEERING STEERING PLAY INSPECTION Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the in- 1. Place a stand under the vehicle to raise the front wheel off the ground.

  • Page 32: Electrical System

    ELECTRICAL SYSTEM BATTERY INSPECTION/ CHARGING Take care that after each maintenance the lid is closed correct to avoid that water or others penetrate. 1. Please consider that the vehicle will be delivered with a main- tenance free battery. Do no more remove the cover (3) after with the battery.

  • Page 33: Light And Switches Operation Inspection

    ELECTRICAL SYSTEM LIGHT AND SWITCHES OPERATION INSPECTION 1. Place the vehicle on the main stand and start the engine. NOTE Some functions do not work as long the engine is not running. 2. Now you can test one by one the functions of all switches, the function of the rear and front light and the brake light.

  • Page 34: Repair And Diagnostics

    2. REPAIR AND DIAGNOSTICS...

  • Page 35: Chassis

    CHASSIS EXPLODED VIEW/ PARTS LOCATION - CHASSIS PART LIST - CHASSIS 10. Bolt engine carrier 21. Snap ring 11. Side stand 22. Spring 1. Frame 12. Locking plate 2. Footrest left rear 13. Screw 24. Bracket 14. Spring 25. Nut M8 15.

  • Page 36: Fuel System/ Fuel Tank

    FUEL SYSTEM/ FUEL TANK EXPLODED VIEW/ PART LOCATION - FUEL SYSTEM PART LIST - FUEL SYSTEM 8. Pipe clamp 8mm Fuel pump 18. Pipe clamp 1. Fuel tank 10. Pipe clamp Fuel pipe 11. Fuel pipe 20. Vacuum pipe 3. Fuel tank sensor 12.

  • Page 37: Troubleshooting - Fuel System

    FUEL SYSTEM/ FUEL TANK SPECIFICATION - FUEL Recommended fuel: Do not use any Bio-Ethanol fuel. Fuel tank capacity: 8.6L ± 0.2L SYSTEM Pressurized system (vacuum fuel tap) SPECIAL TOOLS See page 11 - 14 TROUBLESHOOTING - FUEL SYSTEM FAILURE CAUSE TO DO Idle speed is not set correctly No gasoline in the fuel tank...

  • Page 38: Fuel System/ Carburettor

    FUEL SYSTEM/ CARBURETTOR EXPLODED VIEW/ PART LOCATION - CARBURETTOR PART LIST - CARBURETTOR 1. Carburettor cover 3. Diaphgram 6. Floater 7. Floater chamber gasket 8. Floater chamber Electrical enrichment vlave (Choke) NOTE Use a cloth to block the intake manifold after dismounting carbu- rettor to avoid other article entry.

  • Page 39: Carburettor Removal

    FUEL SYSTEM/ CARBURETTOR CARBURETTOR REMOVAL 2. Loosen the hose clamp of the intake manifold (1), and the two 4. Disconnect electrical enrichment valve cable (5). 5. Disconnect the throttle cable (6). 6. Disconnect the hoses coming from the carburettor. It is not necessary to disconnect all hoses.

  • Page 40: Fuel System/ Fuel Tank

    FUEL SYSTEM/ FUEL TANK FLOAT CHAMBER REMOVAL components are damaged or worn. 4. If the needle valve core is damaged or worn down, it should replaced. 5. If the needle valve seat is worn down, then the carburettor body should be replaced. aged or worn down.

  • Page 41: Fuel Tank Removal

    FUEL SYSTEM/ FUEL TANK PARTS WHICH MUST BE CHECKED 1. Fuel tank 2. Fuel pump 3. Fuel tubes 4. Hose clamps 6. Fuel sensor 7. Gaskets and seals 8. Carburettor FUEL TANK REMOVAL 1. Remove the leg protection and the under vehicle protection. See in the capitel: CHASSIS 2.

  • Page 42: Engine

    ENGINE EXPLODED VIEW/ PARTS LOCATION - ROCKER COVER AND CYLINDER HEAD PART LIST - ROCKER COVER AND 12. Circlip 42 26. Valve spring seat CYLINDER HEAD 13. Circlip 10 27. Intake valve 1. Bolt 15. Shaft for intake rocker arm Spark plug 2.

  • Page 43: Exploded View/ Parts Location - Cylinder And Piston

    ENGINE EXPLODED VIEW/ PARTS LOCATION - CYLINDER AND PISTON PART LIST - ROCKER COVER AND CYLINDER HEAD 1. Cylinder 8. Piston pin 2. Cylinder gasket Collar 3. Upper ring 10. Chain guid 4. Second ring 11. Chain guid 5. Oil scraper ring 12.

  • Page 44: Exploded View/ Parts Location - Drive Disc Clutch/ Driven Wheel

    ENGINE EXPLODED VIEW/ PARTS LOCATION - DRIVE DISC/ CLUTCH/ DRIVEN WHEEL PART LIST - DRIVE DISC/ CLUTCH/ 11. Certifugal clutch 24. Bushing DRIVEN WHEEL 12. Spring retainer 25. Dowel 13. Pressure spring 26. Certifugal clutch complete 1. Variomatic disc with fan 14.

  • Page 45: Exploded View/ Part Location - Right Crankcase

    ENGINE EXPLODED VIEW/ PART LOCATION - RIGHT CRANKCASE PART LIST - RIGHT CRANKCASE 12. Seal for water pump frive shaft 25. Pipe clamp 13. Impeller water pump 26. Collant hose 14. Gasket for water pump 27. Pipe bend 15. Water pump housing 28.

  • Page 46: Exploded View/ Parts Location - Transmission

    ENGINE EXPLODED VIEW/ PARTS LOCATION - TRANSMISSION PART LIST - TRANSMISSION 6. Bearing 6201 7. Distance washer 1. Bearing 6205-2RS Bearing 6301 11. Washer 5. Output shaft...

  • Page 47: Part Location - Engine

    ENGINE PART LOCATION - ENGINE To reach the top end of the engine proceed as follow. 1. Remove the seat assembly to reach the top engine. To work on the top end of the engine is no need to remove the whole engine from the frame.

  • Page 48: Troubleshooting - Engine

    ENGINE TROUBLESHOOTING - ENGINE FAILURE CAUSE TO DO Charge the battery Check the charging of the battery Battery discharged Engine does not start when Check if the generator is working the electric starter button is correctly pushed Fuse is blown Check or replace Starter relay defective Check the starter relay...

  • Page 49: Cylinder Pressure Inspection

    ENGINE CYLINDER PRESSURE INSPECTION The pressure inspection should be made when the engine is warm. 2. Remove the spark plug from the engine. 3. Install cylinder pressure meter (1) in the spark plug hole. 4. Pull full throttle and press “Start” to run the engine. 5.

  • Page 50: Engine Preparation

    ENGINE ENGINE OVERHAUL/ REMOVAL NOTE It´s not necessary to remove the engine in order to remove the following components: • Fan cover • Magneto rotor • Stator • Drive gear • Variomatic The engine should removed by following parts: • Cylinder cover •...

  • Page 51: Engine Removal

    ENGINE ENGINE REMOVAL Follow the points 1-5 below and go ahead with point 6. 6. It is not necessary to remove the rear wheel. It can ease the transportation. 7. Remove the engine mounting bolt (1). NOTE the engine up and down. 8.

  • Page 52: Thermostat Removal

    ENGINE THERMOSTAT REMOVAL 1. Remove the two screws (1). 2. Pull out the thermostat (2). TOP END REMOVAL CYLINDER HEAD COVER 1. Remove the two screws (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).

  • Page 53: Camshaft Housing Removal

    ENGINE CAMSHAFT HOUSING REMOVAL 1. Remove the four nuts (1) with theire washers. 2. Pull of the camshaft housing (2) with the camshaft. CAMSHAFT AND ROCKER ARM REMOVAL 1. Remove the circlip (1) to remove the camshaft (2). 2. Remove the circlip (3) to remove the rocker arm shafts (4) and so to remove the rocker arms.

  • Page 54: Piston Removal

    ENGINE PISTON REMOVAL 1. Remove the C-type piston pin clip (1). 2. Push out the piston pin (2) and remove the piston (3). VARIOMATIC COVER REMOVAL 1. Remove the three screws (1) to remove the variomatic cover (2). VARIOMATIC DISC WITH FAN REMOVAL 1.

  • Page 55: Transmission Oil Removal

    ENGINE TRANSMISSION OIL REMOVAL 1. Remove the screw and drain the transmission oil. GEARBOX HOUSING REMOVAL 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 hous- ing (2).

  • Page 56: Stator For Generator Removal

    ENGINE STATOR FOR GENERATOR REMOVAL 1. To remove the stator, remove the three allen head screws (2) and the two screws (3). OIL SEALING OF STATOR REMOVAL/ INSTALLATION 1. Remove the circlip (1) and pull out the oil seal (2). 2.

  • Page 57: Stater Motor Pinion Removal

    ENGINE STATER MOTOR PINION REMOVAL 1. Pull off the stater motor pinion (1) with the shaft. 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.

  • Page 58: Exploded View/ Parts Location - Oil Pump

    ENGINE EXPLODED VIEW/ PARTS LOCATION - OIL PUMP PART LIST - TRANSMISSION 5. Pump body 1. Screws 6. Dowel pin 2. Pump cover 7. Oil pump sprocket 3. Outside runner 8. Circlip 4. Inner runner Pump shaft STARTER REMOVAL 1. Remove the two bolts (1). 2.

  • Page 59: Crankcase Removal

    ENGINE CRANKCASE REMOVAL 1. Remove the three screws (1). 2. Pull off the right crankcase. NOTE • If it is necessary usa a soft hammer to top on the case half. • Tap only on reinforced portions of case • Work slowly and carefully •...
  • Page 60 ENGINE 3. Measure the run-out at the bearing pins of the crankshaft. Allowable Limit (A/B): 0.1 mm 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.

  • Page 61: Gaskets

    ENGINE 3. Push in the crankshaft (3) (arrow). NOTE Installation of the crankshaftshould work smooth without force. If the installation works not smooth, check the timing chain and their position. GASKETS 1. Replace all gaskets. CRANKSCASE INSTALLATION 1. Replace the oil sealing. NOTE Installation the crankcase should work smooth and with additional the crankcase.

  • Page 62: Oil Pump Installation

    ENGINE 2. Check the cearance between the outside runner (2) and the pump body (3). Allowable Limit: 0.21 mm 3. Check clearance of runners (4). Allowable Limit: 0.18 mm OIL PUMP INSTALLATION TORQUE LIST PART NO. TORQUE 5-9 Nm For screws that are not listed use standard values (page 10). TROUBLESHOOTING - LUBRICATION FAILURE CAUSE...

  • Page 63: Part Location - Lubrication Scheme

    ENGINE PART LOCATION - LUBRICATION SCHEME NOTE PART LIST - LUBRICATION SCHEME • After removing the oil pump, clean the parts up and 1. Oil strainer below the surface with high pressure air. 2. Oil pump • 3. Crankshaft ing the operation. 4.

  • Page 64: Starter Installation

    ENGINE STARTER INSTALLATION 1. Install the starter in reverse order. See page: 58 IDLER GEAR INSTALLTION 1. Install the idler gear (1) in reverse order. NOTE Don´t forget the woodruff key (2) on the crankshaft. STATER MOTOR PINION INSTALLATON 1. Install the starter motor pinion in reverse order. See page: 57 MAGNETO ROTOR, STATOR AND IMPELLER WATER PUMP INSTALLATION...

  • Page 65: Transmission Installation

    ENGINE TRANSMISSION INSTALLATION 1. Controll the shafts and the gears if the work correct. 2. IF the shafts or gears are worn, replace it. 3. Install the transmission in reverse order. See page: 55 INSPECTION - VARIOMATIC Item Standard [mm] Allowable limits [mm] Inner diameter of right hemisphere of drive wheel 24.00-24.02...

  • Page 66: Clutch Spring Inspection

    ENGINE 3. Dismantle the guide pin (3). 4. Take off the oil seal (4). 5. Take down the left driven wheel (5). CLUTCH SPRING INSPECTION 1. Measure the free length (C) of the clutch spring. Allowable limit (C): 140 mm DRIVEN DISC ASSEMBLY 1.

  • Page 67: Clutch Drum And Certifugal Clutch Installation

    ENGINE CLUTCH DRUM AND CERTIFUGAL CLUTCH INSTALLATION 1. Install the clutch drum (1) and the certifugal clutch (2) in re- verse order. 2. Tighten the nut (3). NOTE Stick in the nut (3). VARIOMATIC DRIVE DISC INSPECTION 1. Measure the outside diameter (A) of the rolling balls. Allowable limit (A): 19.5 mm 2.

  • Page 68: Variomatic Disc With Fan Installation

    ENGINE VARIOMATIC DISC WITH FAN INSTALLATION 1. Push up the disc with fan (1). 2. Tighten the nut (2). NOTE Stick in the nut (2). VARIOMATIC COVER INSTALLATION 1. Install the variomatic cover in reverse order. See page: 54 TROUBLESHOOTING - VARIOMATIC DISC/ CLUTCH FAILURE CAUSE TO DO...

  • Page 69: Piston Inspection

    ENGINE PISTON INSPECTION 1. Measure the bore diameter of the piston pin hole. Measure both X and Y directions. Allowable limit: 14.04 mm 2. Measure the outer diameter of the piston at two levels of A and B. Measure about (Y) 11 mm below the skirt of the piston. Allowable limit (A,B): 52.37 mm 3.

  • Page 70: Cylinder Inspection

    ENGINE 4. Measure the clearance between the piston ring (1) and the piston ring groove (2). Allowable limits: Upper ring: 0.10 mm Second ring: 0.10 mm PISTON INSTALLATION 1. Install the “IN” mark (1) on the top of the piston toward the air intake.

  • Page 71: Cylinder Installation

    ENGINE Allowable limit (C): 0.05 mm CYLINDER INSTALLATION 1. Controll that the timing chain ist installed correct on the crank- shaft, befor you install the cylinder. 2. Renew the gasket (1). 3. Install the cylinder in reverse order. NOTE Don´t forget the guid pins on the crankcases (2) and the cylinder. 4.

  • Page 72: Inspection - Cylinder Head

    ENGINE INSPECTION - CYLINDER HEAD Item Standards [mm] Allowable limits [mm] Air valve 0.10 0.12 clearance 0.13 0.14 Inner diameter of valve guid IN / EX 5.00-5.012 5.03 Air valve Valve guid Clearance between the valve 0.010-0.035 0.08 pod and the valve guid 0.030-0.05 0.10 Retainer width...

  • Page 73: Air Valve Adjustment

    ENGINE AIR VALVE ADJUSTMENT 1. Remove ragged residues (1) on the valve race with a 45°angled milling cutter. NOTE race so that it can be observed clearly. milling cutter. 32° 3. Remove 1/4 of bottom of valve race with a 60° angle milling cutter.

  • Page 74: Cylinder Head Inspection

    ENGINE CYLINDER HEAD INSPECTION face. Allowable limit (A): 0.05 mm AIR VALVE INSTALLATION 1. Install the air valve in reverse order. CYLINDER HEAD INSTALLATION 1. Thread in the timing chain. 2. Renew the gasket. 3. Install the cylinder in reverse order. 4.

  • Page 75: Valve Timing Adjustment/ Camshaft Housing Installation

    ENGINE the picture (1). Allowable limit: 10.10 mm 6. Measure the clearance between the rocker shaft and the or- Allowable limit: 0.033 mm VALVE TIMING ADJUSTMENT/ CAMSHAFT HOUSING INSTALLATION 1. Remove the screw (1) on the right engine side. 2. Install the camshaft housing (2) in reverse order. 3.

  • Page 76: Timing Chain Tensioning Rail Installation

    ENGINE TIMING CHAIN TENSIONING RAIL INSTALLATION 1. Remove the screw (1). 2. Screw the inner screw clockwise to tighten the stretcher. 3. Install the timing chain tensioning rail in reverse order. 4. Tighten the two screws (2). 5. To activate the tensioner, screw the inner screw to the left till the tensioner works alone.

  • Page 77: Exploded View/ Part Location - Thermostat

    ENGINE EXPLODED VIEW/ PART LOCATION - THERMOSTAT PART LIST - THERMOSTAT 1. Screws 2. Bleed screw 3. Thermostat-room body 4. Sealing ring 5. Thermostat component 6. O-type ring 7. Sensor component 8. Upper cover of thermostate room INSPECTION - THERMOSTAT Initial startup temperature 72-84°C Full-open temperature...

  • Page 78: Exploded View/ Part Location - Muffler

    MUFFLER EXPLODED VIEW/ PART LOCATION - MUFFLER PART LIST - MUFFLER 6. Washer 7. Heat insulating mat 14. Collar 8. Screw 15. Rubber collar 2. Nut M7 Spring washer M6 16. Ruber washer 10. Washer 11. Heat insulating mat 5. Washer...

  • Page 79: Exhaust

    MUFFLER EXHAUST WARNING cool down before maintain it. EXHAUST REMOVAL 1. Disconnect the hose (1) from the second air system. NOTE and replace them if necessary. ENSURE THE EMISSION STANDARDS AND PAY ATTENTION TO THE FOLLOWING MATTERS 1. Please use recommended unleaded gasoline only. 3.

  • Page 80: Second Air System Inspection

    MUFFLER SECOND AIR SYSTEM The function of the second air system is to achieve the emission with fresh air. The second air system is controlled by a vacuum device. By automatic opening and closing of this membrane the air supply is regulated. SECOND AIR SYSTEM INSPECTION 1.

  • Page 81: Wheels And Tires

    WHEELS AND TIRES EXPLODED VIEW/ PART LOCATION - FRONT WHEEL PART LIST - RIGHT CRANKCASE 7. Brake disc 8. Rim Tire 2. Left collar 10. Tire valve cap 3. Oil seal 11. Tire valve 4. Bearing 6201 12. Speedometer drive 5.

  • Page 82: Exploded View/ Parts Location - Rear Wheel

    WHEELS AND TIRES EXPLODED VIEW/ PARTS LOCATION - REAR WHEEL PART LIST - RIGHT CRANKCASE Torque list 11. Washer Part No. Torque 1. Splint 12. Bearing 6003 100-113 Nm 13. Bushing 37-44 Nm 3. Bushing 15. Tire 5-9 Nm 5. Spring washer M10 16.

  • Page 83: Wheels And Tires

    WHEELS AND TIRES WHEELS (RIMS) The wheel rims should be checked for cracks, bends. If any dam- age is found replace the rim. Do not attempt even the smallest re- pair of the wheel. The wheel should be balanced whenever either the tire or the rim has been changed or replaced.

  • Page 84: Brakes

    BRAKES EXPLODED VIEW/ PARTS LOCATION - FRONT BRAKE WARNING THE BRAKING COMPONENTS MAY NOT BE SPOIL BY OIL DURING INSTALLATION OR DISASSEMBLY. RINSE WITH STIPULATED CLEANING AGENT IN ORDER TO AVOID REDUCTION OF BRAKING QUALITY. PART LIST - FRONT BRAKE 7.

  • Page 85: Exploded View/ Parts Location - Rear Brake

    BRAKES EXPLODED VIEW/ PARTS LOCATION - REAR BRAKE WARNING THE BRAKING COMPONENTS MAY NOT BE SPOIL BY OIL DURING INSTALLATION OR DISASSEMBLY. RINSE WITH STIPULATED CLEANING AGENT IN ORDER TO AVOID REDUCTION OF BRAKING QUALITY. PART LIST - FRONT BRAKE 7.

  • Page 86: Troubleshooting - Brakes

    BRAKES SPECIAL TOOLS See page 11 - 14. TROUBLESHOOTING - BRAKES FAILURE CAUSE TO DO Brake pads worn Replace the brake pads Brake pads installed improperly Install the brake pads proper Poor brake performance Clean or replace the brake pads Brake pads or brake disc contaminated and clean the brake disc/ drum Air in the front brake hose...

  • Page 87: Front Brake Calliper Replacement

    BRAKES FRONT BRAKE CALLIPER REPLACEMENT When the performance of the front brake is poor it could be possi- ble that the gaskets of the front brake calliper defect or the brake pads are worn. 3. Remove the two bolts (2) attaching the brake calliper. 4.

  • Page 88: Brake Fluid

    WHEELS AND TIRES BRAKE FLUID WARNING the braking effect. Clean the brake pads and brake disc with 3. When servicing the brake system, use shop towels to cover plastic parts and coated surfaces to avoid damage caused 4. Do not allow dust or water to enter the brake system during SPECIFICATION - BRAKE FLUID CASTROL SUPER DISC BRAKE FLUID DOT 4 >...

  • Page 89: Suspension

    SUSPENSION EXPLODED VIEW/ PARTS LOCATION - FRONT SUSPENSION PART LIST - FRONT SUSPENSION 8. Bearing race lower Ball bearing set 1. Shock absorber front right 2. Shock absorber front left nut) 11. Locking plate 4. Bracket speedometer cable 12. Nut 5.
  • Page 90 SUSPENSION REAR SUSPENSION PART LIST - REAR SUSPENSION 2. Shock absorber rear Torque list Part No. Torque 37-44 Nm 22-29 Nm For screws that are not listed use standard values (page 10).
  • Page 91 SUSPENSION SPECIAL TOOLS There are no special tools recommended because defect sus- pension elements may not be dissembled. Always´s replace defect suspension elements. TROUBLESHOOTING - SUSPENSION FAILURE CAUSE TO DO Broken or bent fork leg Replace the affected fork leg Uneven front shock absorbers fected fork leg Weak shock spring...
  • Page 92 SUSPENSION 6. Open the secure washer (4) to remove the nut (5) and the 7. Remove the steel-balls. WARNING Be careful not to lose the steel-balls . 8. To remove the front suspension pull the suspension down (ar- row). SUSPENSION - BEARING INSPECTION/ INSTALLATION 1.
  • Page 93 SUSPENSION 3. Remove the two screws (1). NOTE Only one side (left side) is illustrated. REAR SUSPENSION REPLACEMENT 1. Place an appropriate supporting stand under the engine in or- der to raise the rear wheel up. 3. Remove the Upper bolt M8×1.25×40 (1) and the lower bolt M8×30 (2).
  • Page 94 SUSPENSION TROUBLESHOOTING - STEERING FAILURE CAUSE TO DO Steering bearing loose Retighten the bearing Steering bearing worn Replace the steering components Bearing balls lost or broken Replace the steering components More troubleshooting see on page 82. STEERING REPLACEMENT 1. Follow the points of front suspension replacement. 2.

  • Page 95: Electrical System

    ELECTRICAL SYSTEM WIRING DIAGRAM...

  • Page 96: Part Location - Electrical System

    ELECTRICAL SYSTEM PART LOCATION - ELECTRICAL SYSTEM PART LIST - STEERING 1. Winker relay 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 11. Battery...

  • Page 97: Electrical System

    ELECTRICAL SYSTEM PART LOCATION - LIGHTS/ INSTRUMENTS SWITCHES PART LIST - LIGHTS/ INSTRUMENTS SWITCHES CERTIFICATION NO. PART NO. CE NO. 1. Head light 2. Position light No. 1 3. Turn signal front 4. Rear light and brake light 5. Turn signal rear No.
  • Page 98 ELECTRICAL SYSTEM/ GENERAL SPECIFICATION - ELECTRICAL SYSTEM Item Standard value Standard C5HSA (NKG) Recommended C6HSA (NGK) spark plug Cold CHSA (NGK) Spark plug gap 0.6-0.7 mm Primary coil ± 10% Resistance value of ignition coil With spark plug cap 8-11 K Secondary coil (20°C) Without spark plug cap...

  • Page 99: Fuse Replacement

    ELECTRICAL SYSTEM/ FUSE FUSE REPLACEMENT 1. Turn the main switch off. 4. Replace the blown fuse (3) and then install a new fuse of the NOTE correct to avoid that water or others penetrate. WARNING Do not use a fuse of a higher amperage rating than recommended SPECIFICATION - FUSE ITEM DESCRIPTION...

  • Page 100: Battery Removal

    ELECTRICAL SYSTEM/ BATTERY BATTERY GENERAL INFORMATION Take care that after each maintenance the lid is closed correct to avoid that water or others penetrate. NOTE 1. The battery can be charged and discharged over again. If the battery is unused after discharge the service life will shorten and the performance will degrade.

  • Page 101: Electrical System/ Battery

    ELECTRICAL SYSTEM/ BATTERY • Keep the battery away from ignition sources. • interconnecting part. • Charge operation must follow the marked time on the battery. • tions. • Do not measure the voltage until 30 minutes after the charge. SPECIFICATION - BATTERY ITEM STANDARD VALUE Type...

  • Page 102: Electrical System/ Charging System

    ELECTRICAL SYSTEM/ CHARGING SYSTEM CHARGING SCHEME CHARGING PERFORMANCE TEST 1. Remove the battery cover. 3. Disconnect the wire from the fuse terminal. Connect an am- meter (A) between the wire and fuse terminal. 4. Connect the battery positive (+) terminal to the voltmeter (V) positive (+) probe and battery negative (-) terminal to the volt- meter negative (-) probe.

  • Page 103: Regulator - Rectifier Inspection

    ELECTRICAL SYSTEM/ CHARGING SYSTEM REGULATOR - RECTIFIER INSPECTION 1. Remove the tachometer. (2). 3. Measure the resistances between the terminals. values in the table below. Multimeter White (W) Red (R) Black (B) White (W) 0.64 Red (R) Black (B) 0.64 1.017 ITEM (WIRE COLOUR) JUDGING METHOD...

  • Page 104: Charge Coil Of Generator Inspection

    ELECTRICAL SYSTEM/ CHARGING SYSTEM CHARGE COIL OF GENERATOR INSPECTION 1. Remove the center body. 2. Disassemble 3P plug (1) of the generator. 3. Measure the resistance value between each white (W) coil of the plug with an multimeter. Standard value: (20°C) stator.

  • Page 105: Electrical System/ Ignition System

    ELECTRICAL SYSTEM/ IGNITION SYSTEM IGNITION SCHEME NOTE 1. Inspect the ignition system in accordance with the order stipulated in the fault diagnosis table. 2. The ignition system is an electronic auto-advance device integrated in the CDI group, therefore the ignition time 3.

  • Page 106: Specification - Ignition System

    ELECTRICAL SYSTEM/ IGNITION SYSTEM SPECIFICATION - IGNITION SYSTEM ITEM NOMINAL VALUE/ TESTIN TERMINAL Spark plug TORCH/A8RTC Spark plug gap 0.6-0.7 mm Coil black/ white - black Resistance value of ignition coil (20°C) With spark plug cover Coil black - spark plug cover Without spark plug cover Resistance value of trigger (20°C) Blue/ white - body ground...

  • Page 107: Trigger (Pick Up)

    ELECTRICAL SYSTEM/ IGNITION SYSTEM TRIGGER (PICK UP) NOTE Install the spark plug on the air cylinder head and inspect with normal compression pressure. 1. Remove the plugs ( 2P and 3P) of CDI group and connect a peak voltage diverter between the trigger of 2P plug (blue/ white terminal - positive) to the wire and the 2P plug (white/ green terminal - negative).

  • Page 108: Ignition Coil Disassembly

    ELECTRICAL SYSTEM/ IGNITION SYSTEM INSPECTION ITEM TESTING TERMINAL STANDARD VALUE (25 °C) Main switch red/white - red Conducted main switch at off Trigger blue/ white - white/ green Primary ignition coil black/ white - black Secondary ignition coil black/white - spark plug cover Ground black and ground Conducted...

  • Page 109: Troubleshooting - Ignition System

    ELECTRICAL SYSTEM/ IGNITION SYSTEM TROUBLESHOOTING - IGNITION SYSTEM ITEM FAILURE CAUSE TO DO The interior resistance is too low and test it Replace with a designated tester. The cranking speed is too low. Search for error and repair If the voltage measured for sev- High voltage to The tester is disturbed eral times is above standard,...

  • Page 110: Electrical System/ Start Up System

    ELECTRICAL SYSTEM/ START UP SYSTEM START UP SYSTEM 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...

  • Page 111: Starter Relay Inspection

    ELECTRICAL SYSTEM/ START UP 3. Remove the screw (3) to disconnect the starter cable (4). 4. Remove the two screws (5) and pull the starter motor (6) sidewards (arrow). 5. Connect a full charged battery to the starter motor and check for operation.

  • Page 112: Troubleshooting - Start Up System

    ELECTRICAL SYSTEM/ START UP S./ LIGHTNING S. TROUBLESHOOTING - START UP SYSTEM FAILURE CAUSE TO DO Fuse blown Replace fuse Power shortage in battery Replace battery Bad acts of main switch Check and replace Bad act of startup clutch Check and repair/ replace Unable to start up Bad act of brake switch Check and replace...

  • Page 113: Headlight/ Position/ Winker Bulb Replacement

    ELECTRICAL SYSTEM/ LIGHTNING SYSTEM HEADLIGHT/ POSITION/ WINKER BULB REPLACEMENT 1. Remove the left or the right front sidecover with the headlight. See on page: 130-131 NOTE It is not necessary to remove the sidecover. HEADLIGHT BULB 1. Remove the rubber cap (1). 2.

  • Page 114: Winker Bulb

    ELECTRICAL SYSTEM/ LIGHTNING SYSTEM WINKER BULB 1. To remove the bulb bracket (1) turn it counterclockwise. 2. Pull the winker bulb (2) in and turn it counterclockwise. 3. Reassemble in reverse order. HEADLIGHT REPLACEMENT 1. Remove the left or right front sidecover. poistion bulb.

  • Page 115: Rear Light Bulb

    ELECTRICAL SYSTEM/ LIGHTNING SYSTEM REAR LIGHT 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 reverse order. WINKER BULB 1. To remove the bulb bracket (1) turn it counterclockwise. 2.

  • Page 116: License Plate Bulb Replacement

    ELECTRICAL SYSTEM/ LIGHTNING SYSTEM LICENSE PLATE BULB REPLACEMENT 1. Remove the screw (1) to remove the license plate light (2). 2. Pull out the rubber (3). 3. Pull out the license plate bulb (4). 4. Reassemble in reverse order. TROUBLESHOOTING - LIGHTNING SYSTEM FAILURE CAUSE TO DO...

  • Page 117: Speedometer Description

    ELECTRICAL SYSTEM/ SPEEDOM./ SWI. A. SENS. SPEEDOMETER DESCRIPTION 1. Speedometer 2. Odometer 3. Fuel gauge 4. Winker indicator right 5. Low beam indicator 6. Water thermometer 7. High beam indicator 8. Winker indicator left Rev meter SPEEDOMETER INDICATOR LIGHTS REPLACEMENT 1.

  • Page 118: Horn Inspection/ Replacement

    ELECTRICAL SYSTEM/ SWITCHES AND SENSORS 3. Unthread the seat lock cable (2). 4. Remove the two screws (3) to remove the main switch (4). NOTE The main switch is combined with the steering lock. When you turn the handle bar to the left, pull in the key and turn the key of the main switch to the lock symbol and pull the key out.

  • Page 119: Handle Switch

    ELECTRICAL SYSTEM/ SWITCHES AND SENSORS HANDLE SWITCH Left side Dimmer switch 2. Passing Pass light switch Turn signal switch Horn switch Right side Engine “stop switch” Light switch Starter button NOTE As long the engine stop switch is “ON” ( ) the vehicle cannot be started.

  • Page 120: Handle Switch Replacement

    ELECTRICAL SYSTEM/ SWITCHES AND SENSORS LEFT HANDLE SWITCH INSPECTION 1. Remove the rear handlebar cover. 2. Use a continuity tester to measure the switches as shown in the illustrations below. 3. In case of damage the handle switch need to be replaced. Horn switch (1) Horn switch Horn switch pressed...

  • Page 121: Front/ Rear Brake Light Switch Replacement

    ELECTRICAL SYSTEM/ SWITCHES AND SENSORS FRONT/ REAR BRAKE LIGHT SWITCH REPLACEMENT 1. Remove the front handlebar cover. 2. Disconnect the cables of the front/ rear brake light switch. 3. Before replacing the front brake switch, double check its function (See above). 4.

  • Page 122: Electrical System/ Cables

    ELECTRICAL SYSTEM/ CABLES NOTE • Loose cable is a hidden trouble to electrical safety. After clamped check each cable to ensure electrical safety. • It is not allowed to leave any wire clip bending towards bond- ing points. • Bind each cable to its designated position. •...

  • Page 123: Chassis

    CHASSIS COVER REPLACEMENT STORAGE BOX REMOVAL 1. Open the seat bench. 4. Remove the two battery vables (3) to remove the battery (4). 6. Reassemble in reverse order. REAR CARRIER REMOVAL 2. Remove the three srews (1) to remove the rear carrier (2). SIDECOVER RIGHT REPLACEMENT 2.

  • Page 124: Sidecover Left Removal

    CHASSIS 4. Remove the two screws (3). 5. Remove the three screws (4). 6. Remove the 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.

  • Page 125: Lower Sidecover Right Removal

    CHASSIS LOWER SIDECOVER RIGHT REMOVAL 1. Remove the sidecover right. 2. Remove the two screws (1). 3. Also remove the two screws (2) of the middle body cover. 4. Push down the under vehicle protection panel (3) and un- thread the lower sidecover (4). 5.

  • Page 126: License Plate Bracket

    CHASSIS LICENSE PLATE BRACKET 1. Remove the rear light cover with the rear light. 2. Remove the two screws (1) to remove the whole license plate bracket (2). 3. Reassemble in reverse order. INNER REAR FENDER REMOVAL 1. Remove the sidecover and the license plate bracket. 2.

  • Page 127: Front And Rear Handlebar Cover Removal

    CHASSIS FRONT AND REAR HANDLEBAR COVER 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, disconnect the handle- bar cables (4).

  • Page 128: Windshield Removal

    CHASSIS WINDSHIELD REMOVAL 1. Remove the two screws (1). 2. Now remove the two protections (2). 3. Remove 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.

  • Page 129: Radiator Cowling Removal

    CHASSIS 3. Disconnect the cables (3) of the instrument panel. 4. Reassemble in reverse order. RADIATOR COWLING REMOVAL 1. Remove the three screws (1) to remove the radiator cowling (2). FRONT COVER REMOVAL 1. Remove the front handlebar cover and the windshiel bracket and the radiator cowling.
  • Page 130 CHASSIS FRONT SIDECOVER LEFT REMOVAL NOTE It is necessary to remove the front sidecover 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.

  • Page 131: Front Sidecover Right Removal

    CHASSIS 7. Now remove the two screws (6). 8. Remove the two screws (7). Slide the front cover left with the left headlight sidewards. 10. Disconnect the cable (8). 11. To remove the sidecover from the headlight, remove the four 12.

  • Page 132: Fuel Tank Cover Removal

    CHASSIS FUEL TANK COVER REMOVAL 2. Remove the splint (1). 3. Open the fuel tank cover (2) and remove the bolt (3). 4. Unthread the fuel tank cover. NOTE It is not necessary to remove the spring. MIDDLE COVER REMOVAL 2.

  • Page 133: Leg Protection Removal

    CHASSIS LEG PROTECTION REMOVAL 1. Remove the middle cover and the front sidecovers. 2. Turn the ignition 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 2.

  • Page 134: Front Wheel Arch Panel Removal

    CHASSIS FRONT WHEEL ARCH PANEL REMOVAL 1. Remove the left and right front sidecover, the under vehicle protection panel and the leg protection. 2. Remove the two screws (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.

  • Page 135: Mirrors

    MIRRORS 2. Unthread the front fender from the bracket. 3. Remove the three screws (2) to split the front fender (3). BACK VIEW MIRRORS NOTE At all repairs in the area of the handle bar is advised to remove the back view mirrors.
  • Page 136 KSR Moto is a trademark of Group GmbH Gewerbeparkstrasse 3500 Krems, Austria w w w . k s r - g r o u p . c o m...

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