Page 1 Maintenance Manual of Two-wheeled Motorcycle (K-LIGHT125) KS MOTORCYCLES - https://ksmotorcycles.com...
Page 2: Table Of Contents
4.4 Replacement of Front Turn Signal Light Bulb ..................- 98 - 4.5 Replacement of Taillight Bulb ....................... - 98 - 4.6 Replacement of License Light Bulb ...................... - 99 - 4.7 Meters ..............................- 99 - 4.8 Ignition Switch............................. - 100 - KS MOTORCYCLES - https://ksmotorcycles.com - 1 -...
Page 3 12.2 Fault Diagnosis ..........................- 202 - 12.3 Cylinder Head ............................ - 202 - 12.4 Valve inspection ..........................- 206 - 12.5 Replacement of Valve Guide ......................- 207 - 12.6 Finishing Valve Seat Ring ........................- 208 - KS MOTORCYCLES - https://ksmotorcycles.com - 2 -...
Page 4 18.1 Introduction of Electronic Injection System ..................- 251 - 18.2 EFI Parts ............................- 252 - 18.3 Fault Maintenance and Diagnosis Method ..................- 268 - 18.4 Common Troubleshooting Methods ....................- 271 - Circuit Diagram..............................277 KS MOTORCYCLES - https://ksmotorcycles.com - 3 -...
Page 5: Preface
Exploded diagrams and system diagrams, maintenance fault diagnosis and instructions are provided above all chapters. Note: The style or structure of the motorcycle and the photographs, pictures or instructions on the Manual are subject to change without further notice. KS MOTORCYCLES - https://ksmotorcycles.com - 4 -...
Page 6: Preparatory Information
The electrolyte is toxic. If you accidentally drink electrolyte, you should immediately drink plenty of water, milk and magnesium oxide milk (a laxative antacid) or vegetable oil, and consult a doctor. Keep it out of the reach of children. KS MOTORCYCLES - https://ksmotorcycles.com - 5 -...
Page 7 The rubber parts may deteriorate due to aging and are easily damaged by solvents or oils. They should be inspected before reassembly and replaced if necessary. KS MOTORCYCLES - https://ksmotorcycles.com - 6 -...
Page 8 If they are mixed, put the bolt in the hole and check whether it is proper. Installation of oil seal: the oil seal groove should be filled with lubricating grease, check whether the oil seal is smooth and may be damaged. KS MOTORCYCLES - https://ksmotorcycles.com - 7 -...
Page 9 (either inside or outside), the bearings may be damaged when being disassembled and they must be replaced. Bearing may be damaged in the two examples above. KS MOTORCYCLES - https://ksmotorcycles.com - 8 -...
Page 10 After the cable is repaired, please bind it up reliably with tape; The control wire must not bend or twist. If the control line is damaged, inflexible operation may be caused; KS MOTORCYCLES - https://ksmotorcycles.com - 9 -...
Page 11 Frame nameplate, as shown in the figure. 3. Serial number of engine ① is marked at the housing of crankcase, as shown in the figure. Engine number: QJ157FMI-A*□□□□□□□* 黑/红1 黑/白1 白蓝绿白触发头点火电源 KS MOTORCYCLES - https://ksmotorcycles.com - 10 -...
Page 12 Piston ring opening clamp Fig. 1-12 Spark plug socket wrench Fig. 1-13 Measuring clutch thickness Fig. 1-14 Cylinder diameter tester Fig. 1-15 Dial gauge Measure inner diameter of piston pin, Fig. 1-16 Table 1-2 KS MOTORCYCLES - https://ksmotorcycles.com - 11 -...
Page 13 Fig. 1-3 Fig. 1-4 Feeler gauge Fig. 1-5 Fig. 1-6 Fig. 1-7 Fig. 1-8 KS MOTORCYCLES - https://ksmotorcycles.com - 12 -...
Page 14 Fig. 1-10 Fig. 1-9 ①Handle Fig. 1-12 Fig. 1-11 ① Opening clamp ②Piston KS MOTORCYCLES - https://ksmotorcycles.com - 13 -...
Page 15 Knock-on screwdriver Fig. 1-27 Front fork oil seal installation tool Fig. 1-28 Front fork seal driving tool Fig. 1-29 Steering nut wrench Fig. 1-30 (1) Common tools for chassis maintenance Table 1-18 (continued) KS MOTORCYCLES - https://ksmotorcycles.com - 14 -...
Page 16 Fig. 1-19 Fig. 1-20 1. Socket head 2. Jiggle bar 3. Ratchet wrench 4. Connecting rod Fig. 1-21 Fig. 1-22 Fig. 1-23 Fig. 1-24 KS MOTORCYCLES - https://ksmotorcycles.com - 15 -...
Page 17 Fig. 1-25 Fig. 1-26 Fig. 1-27 Fig. 1-28 (2) Special tools for maintenance of chassis: Front fork seal driving tool. Fig. 1-29 (3) Steering nut wrench. KS MOTORCYCLES - https://ksmotorcycles.com - 16 -...
Page 18 The list and pictures of special tools for the testing of electrical parts are shown in Table 1-31 and 1-32. Table 1-31 Name Remarks Multimeter Fig. 1-33 Ignition tester Fig. 1-34 Table 1-32 (continued) Fig. 1-33 Fig. 1-34 KS MOTORCYCLES - https://ksmotorcycles.com - 17 -...
Page 19 7.8kw/9000rev/min horsepower Alternator 100W/5000rpm capacity Compression ratio 9：1 Spark plug D7RTC Maximum speed 90km/h five-speed Spark plug gap 0.7±0.1mm Diameter of front φ280mm brake disc Ignition mode Diameter of rear brake φ240mm disc KS MOTORCYCLES - https://ksmotorcycles.com - 18 -...
Page 20 KS MOTORCYCLES - https://ksmotorcycles.com - 19 -...
Page 21 2. Check whether there is 3. Check whether there is any any open circuit or short open circuit or short circuit circuit in the trigger coil in the trigger coil KS MOTORCYCLES - https://ksmotorcycles.com - 20 -...
Page 22 It may flame out after a short-time operation There is a fault in the starter device of The inner part of throttle throttle valve valve is blocked or the float is too high KS MOTORCYCLES - https://ksmotorcycles.com - 21 -...
Page 23 Check whether the alternator flywheel and trigger coil are loosened The coolant in There is no coolant in the radiator is the radiator sufficient The coolant capacity in the system is sufficient KS MOTORCYCLES - https://ksmotorcycles.com - 22 -...
Page 24 Check whether the viscosity of oil in the crankcase is too low or it is too dirty Check whether oil filter is blocked Check whether the fuel pump is working properly Check whether the lubrication oil passage is blocked KS MOTORCYCLES - https://ksmotorcycles.com - 23 -...
Page 25 Check whether the rolling path on the 4. Check whether the throttle float inner end surface of moving friction height is improper wheel for excessive wear or pits due to squeezing KS MOTORCYCLES - https://ksmotorcycles.com - 24 -...
Page 26 Check the heat insulator of throttle valve valve opening to for cracks the standard value Check whether the mounting nut connected to the throttle valve is loosened Check fuel pump Check reed valve for air leakage KS MOTORCYCLES - https://ksmotorcycles.com - 25 -...
Page 27 Check and adjust Check whether engine ignition is conducted in carburetor correct time using ignition timing light Check whether the Check the ignition clutch drive belt is system slipping KS MOTORCYCLES - https://ksmotorcycles.com - 26 -...
Page 28 6. Check whether the driving and driven hub gear grooves of clutch have been worn to a zigzag shape KS MOTORCYCLES - https://ksmotorcycles.com - 27 -...
Page 29 3. Check whether the piston ring openings are staggered Check whether valve and valve guide Valve seal has been have been excessively worn damaged KS MOTORCYCLES - https://ksmotorcycles.com - 28 -...
Page 30 Repair or replace Check whether the driven disc of clutch is warped or deformed Check whether the parts of the clutch control mechanisms such as the push camshaft and the push rod are excessively worn KS MOTORCYCLES - https://ksmotorcycles.com - 29 -...
Page 31 5. Check whether the parts of the clutch control worn mechanisms are excessively worn 3. Check whether the shift fork is deformed 4. Check whether the shift fork shaft is deformed or excessively worn KS MOTORCYCLES - https://ksmotorcycles.com - 30 -...
Page 32 3. Check whether the transmission is installed properly KS MOTORCYCLES - https://ksmotorcycles.com - 31 -...
Page 33 Check whether the piston rubber reservoir of main brake pump is damaged, cracked or aged Check whether brake caliper seal is damaged, cracked or aged Check whether the surfaces of brake caliper piston and cylinder wall are excessively worn or damaged KS MOTORCYCLES - https://ksmotorcycles.com - 32 -...
Page 34 The line between alternator and rectifier or check the voltage between connector clip to wire end of rectifying regulator is in poor contact or open battery circuit (generally red line or red / white line) and ground KS MOTORCYCLES - https://ksmotorcycles.com - 33 -...
Page 35 There is no There is voltage voltage display display The wire between connector clip Check whether there is fault in and battery is open-circuited rectifier or rectifying regulator using an ohmmeter KS MOTORCYCLES - https://ksmotorcycles.com - 34 -...
Page 36 1. Check whether the electrolyte in the battery is insufficient coil 2. Check whether the density of electrolyte in the battery is too low 3. Check whether the pole plate in the battery is vulcanized or short-circuited KS MOTORCYCLES - https://ksmotorcycles.com - 35 -...
Page 37 After connection, the starter After connection, starter motor can work starter motor still cannot relay can work normally the starter motor work normally still does not work, and no starter relay sound is heard KS MOTORCYCLES - https://ksmotorcycles.com - 36 -...
Page 38 The line in the electric starting control The line in the electric starting control system is open-circuited or short-circuited system is open-circuited or short-circuited KS MOTORCYCLES - https://ksmotorcycles.com - 37 -...
Page 39 2. Check whether the carbon brush spring is broken or lacks elasticity 3. Check whether the armature commutator is dirty, burnt out or damaged Check whether the armature commutator is excessively worn KS MOTORCYCLES - https://ksmotorcycles.com - 38 -...
Page 40 Disassemble the headlight battery and ignition switch combination and check 3. Check whether there is any whether the headlight bulb is open circuit or short circuit burnt out in the ignition switch KS MOTORCYCLES - https://ksmotorcycles.com - 39 -...
Page 41 Light is on when being Light is still out when short circuited being short circuited The contact in the lighting The line between lighting switch switch is poor and light is open-circuited or short-circuited KS MOTORCYCLES - https://ksmotorcycles.com - 40 -...
Page 42 (generally red line or red / white line) and ground There is no There is voltage voltage display display The wire between connector Check whether there is fault and battery is open-circuited in rectifying regulator KS MOTORCYCLES - https://ksmotorcycles.com - 41 -...
Page 43 1. Check whether the internal contacts of lighting switch Replace light bulb and edge switch are in poor contact 2. Check whether the connector clip and bond strap in the system are in poor contact KS MOTORCYCLES - https://ksmotorcycles.com - 42 -...
Page 44 The turn signal light remains off The turn signal light is still on after being short-circuited after being short-circuited KS MOTORCYCLES - https://ksmotorcycles.com - 43 -...
Page 45 The power wire of turn signal light is Check whether the lines between open-circuited or short-circuited ignition switch and scintillator or scintillator and turn signal light switch are short-circuited or open-circuited KS MOTORCYCLES - https://ksmotorcycles.com - 44 -...
Page 46 The horn still does not ring Horn sounds normal after after adjustment adjustment Horn has been Horn has not been damaged damaged properly KS MOTORCYCLES - https://ksmotorcycles.com - 45 -...
Page 47 Check whether the wire Check whether the power wire between brake light switch between ignition switch and brake and brake light is light switch is open-circuited or short-circuited or short-circuited open-circuited KS MOTORCYCLES - https://ksmotorcycles.com - 46 -...
Page 48: Inspection / Adjustment
•Under certain conditions, gasoline is volatile and explosive. Workplaces must be ventilated and flame should be extinguished. Smoke and fire are strictly prohibited in the workplace or the place where gasoline is stored. KS MOTORCYCLES - https://ksmotorcycles.com - 47 -...
Page 49 E9 50R-00 11967 Rear license plate light E9 50R-00 1493 Rear view Rear view mirror E7 000501 mirror Horn Horn E4 000148 Side reflector E11 020614 Amber (round) Reflector Rear reflector E9 021664 Red (round) KS MOTORCYCLES - https://ksmotorcycles.com - 48 -...
Page 50 Mark on main cylinder: Muffler Mark on auxiliary cylinder: Air filter e13 QJ AF-M21 KS MOTORCYCLES - https://ksmotorcycles.com - 49 -...
Page 51 Side stand of main General tools footpeg Shock absorber General tools Engine bolt torque Torque wrench Front/rear brake General tools Drive chain General tools Clutch General tools Valve Feeler gauge KS MOTORCYCLES - https://ksmotorcycles.com - 50 -...
Page 52 2. When riding on gravel roads or under severe environmental pollution conditions, add the number of cleaning air filter to extend the service life. 3. Maintenance frequency should be added to the motorcycles which often run at a high speed and have a large mileage. KS MOTORCYCLES - https://ksmotorcycles.com - 51 -...
Page 53 Put the engine on a level surface, and check the oil level position at the oil level indicator. If the oil level is below or near the lower limit, add the recommended oil to the upper limit mark. KS MOTORCYCLES - https://ksmotorcycles.com - 52 -...
Page 54 When checking, the engine should stand upright on the ground. Upper limit Lower limit Make sure there is no oil leakage. KS MOTORCYCLES - https://ksmotorcycles.com - 53 -...
Page 55 Throttle cable adjusting nut throttle cable. The steps are the same as the procedures for adjusting the upper end of throttle cable. Air filter Filter element replacement KS MOTORCYCLES - https://ksmotorcycles.com - 54 -...
Page 56 Remove the left protector [A]. Remove the mounting screw [A] at air filter cover. Remove Filter element assembly KS MOTORCYCLES - https://ksmotorcycles.com - 55 -...
Page 57 If it is light gray, combustion conditions are good. If it is pale white, ignition system is out of order or the mixture is too thin. If it is damp or black with carbon deposit, the mixture is too thick. KS MOTORCYCLES - https://ksmotorcycles.com - 56 -...
Page 58 Warning! The positive and negative electrodes should be removed in the operation order. When installing the battery, first connect the positive electrode and then negative electrode. Installation KS MOTORCYCLES - https://ksmotorcycles.com - 57 -...
Page 59 •Measure the voltage 30 minutes after charging. Charging current: Standard: 0.6A Quick: 6.0A Charging time: Standard: 10-15 hours Quick: 30 minutes Completion of charging: open circuit voltage: 12.8V or more KS MOTORCYCLES - https://ksmotorcycles.com - 58 -...
Page 60 . Washer of cylinder head for damage Reasons for high pressure: .Reasons for high pressure Turn off the engine and remove the spark plug/spark plug cap It should be conducted in the reverse order of disassembly. KS MOTORCYCLES - https://ksmotorcycles.com - 59 -...
Page 61 Free stroke of brake Free stroke of front brake Measure the free stroke of front brake lever at the tip of brake lever. Free stroke: 10-20mm Free stroke of brake pedal KS MOTORCYCLES - https://ksmotorcycles.com - 60 -...
Page 62 Rotate the brake lever or pedal to check whether brake fluid leaks from the brake hose [A] and brake line [B] (model equipped with CBS). ★If brake fluid leaks from any position, check or replace the defective part. KS MOTORCYCLES - https://ksmotorcycles.com - 61 -...
Page 63 KS MOTORCYCLES - https://ksmotorcycles.com - 62 -...
Page 64 ○ When checking the brake fluid level, make the brake fluid reservoir level. ★If the level is lower than the lower limit, add brake fluid to the reservoir until the liquid level reaches the high liquid level line. KS MOTORCYCLES - https://ksmotorcycles.com - 63 -...
Page 65 [C] until you feel a little resistance, indicating that the cover has been fixed on the reservoir, then hold the reservoir [A] and rotate it by 1/6 turn [D]. KS MOTORCYCLES - https://ksmotorcycles.com - 64 -...
Page 66 If it can be screwed, there may be inner leakage, please replace CBS or CBS plunger assembly; if it cannot be screwed, there is no inner leakage in CBS. (See “disassemble and assemble CBS pump” for details) KS MOTORCYCLES - https://ksmotorcycles.com - 65 -...
Page 67 ★ If the brake light is off, check or replace the following parts: Battery; Brake light; Fuse; Front brake light switch; Rear brake light switch; Cable harness. KS MOTORCYCLES - https://ksmotorcycles.com - 66 -...
Page 68 Otherwise, it may affect the transparency, life and luminous flux of bulb. If it is stained with oil, wipe it thoroughly with a cloth dampened with alcohol or volatile rubber water. KS MOTORCYCLES - https://ksmotorcycles.com - 67 -...
Page 69 The steps are the same as the process of adjusting the clutch handle end. Clutch cable Adjusting nut Front/rear suspension system Front part KS MOTORCYCLES - https://ksmotorcycles.com - 68 -...
Page 70 Bolt/nut/fixture Check whether the bolts, nuts and fixtures of various parts of motorcycle are loosened. If they are loosened, tighten it to the specified torque value. KS MOTORCYCLES - https://ksmotorcycles.com - 69 -...
Page 71 If there is a rotation direction at the tire, mark it with “1”  Point the mark to the rotation direction when installing the tire.  Align mark “2” to the installation position of rim valve KS MOTORCYCLES - https://ksmotorcycles.com - 70 -...
Page 72 Swing the handlebar from side to side, and check whether wires are involved. Rotate the front wheel, and freely swing the handlebar to confirm. If the handlebar cannot be swung smoothly, check the steering column bearing when it is loosened. KS MOTORCYCLES - https://ksmotorcycles.com - 71 -...
Page 73: Inspection And Maintenance Of Electrical System
Torque Table of Fastener of Electrical System Tightening torque (N•m) Fastening location and fastener name Starter motor clutch cover bolt Starter motor clutch mounting bolt Rectifier bolt High-voltage coil mounting bolt Flywheel mounting nut 50～60 Motorcycle protector bolt KS MOTORCYCLES - https://ksmotorcycles.com - 72 -...
Page 74 Charging System 1 Ignition switch 2 Electric horn 3 Ignition coil 4 Motor 5 Variable-frequency flasher 6 Fuse 7 Relay 8 ECU 9 Battery 10 Voltage regulator KS MOTORCYCLES - https://ksmotorcycles.com - 73 -...
Page 75: Battery/Charging System
9. When the battery is charged in an emergency, the battery must be removed from the motorcycle before charging. 10. Do not use liquid-filled batteries when the batteries are exchanged. 11. Use a voltmeter when checking the charging state of battery. KS MOTORCYCLES - https://ksmotorcycles.com - 74 -...
Page 76: Fault Diagnosis
Low voltage Defective charging system Defective battery charging Defective contact, short wire or short circuit of wire connector Defective contact Defective voltage and current regulator Defective charging system Defective alternator Defective rectifying voltage regulator KS MOTORCYCLES - https://ksmotorcycles.com - 75 -...
Page 77: Battery
Remove the battery connector wire. Measure the voltage between battery terminals. Fully charged: 13.1V Undercharge: 12.3V (the battery has not worked for 1 hour) *Note Check the charging state using a voltmeter. KS MOTORCYCLES - https://ksmotorcycles.com - 76 -...
Page 78: Charging System
The multimeter is set to the position of DC voltage during voltage detection, and the limiting voltage will change slightly when the lighting system is turned on. Charging simple function diagram (general version) KS MOTORCYCLES - https://ksmotorcycles.com - 77 -...
Page 79: Disassembly Of Voltage And Current Regulator
•Use a multimeter to check. The impedance values may be different when different multimeters are used, so the check may not be correct. The voltage regulator should be replaced when the impedance between the terminals is abnormal. KS MOTORCYCLES - https://ksmotorcycles.com - 78 -...
Page 80: Alternator Charging Coil
White White / green White 1.7 Disassembly of Alternator 1.7.1 Disassembly Remove the starter gear cover of engine. Starter gear cover locking bolt Remove the left cover of engine. Left cover locking bolt KS MOTORCYCLES - https://ksmotorcycles.com - 79 -...
Page 81 Use a universal mounting wrench to fix the flywheel. Remove the flywheel mounting bolt. Use a flywheel puller to remove the flywheel. Remove the mounting key. Flywheel lock locking bolt KS MOTORCYCLES - https://ksmotorcycles.com - 80 -...
Page 82 Flywheel locking torque value: 50-60 N·m Stator and box cover locking torque value: 10-12N·m Trigger locking torque value: 6-9N·m KS MOTORCYCLES - https://ksmotorcycles.com - 81 -...
Page 83 触发头 Trigger probe 点火电源 Ignition power Ignition system 1 Ignition switch 2 Electric horn 3 Ignition coil 4 Motor 5 Variable-frequency flasher 6 Fuse 7 Relay 8 ECU 9 Battery 10 Voltage regulator KS MOTORCYCLES - https://ksmotorcycles.com - 82 -...
Page 84: Preparatory Information
This is to prevent damage to ECU. Do not reverse the electrodes of battery. The side of negative electrode should be grounded. This is to prevent damage to ECU. KS MOTORCYCLES - https://ksmotorcycles.com - 83 -...
Page 85 (20°C) Secondary coil There is no 13.6KΩ±15％ spark plug cover 150±10Ω Impedance of trigger (20°C) Maximum voltage in one measurement of ignition coil Trigger voltage Above 1.7V Tools Accessories of maximum voltmeter Multimeter KS MOTORCYCLES - https://ksmotorcycles.com - 84 -...
Page 86: Fault Diagnosis
2. Ignition switch and engine switch flames out 3. Peak voltage of crankshaft sensor 4. Peak voltage of position sensor of camshaft Good Replace faulty parts If electronic control unit is faulty, replace it KS MOTORCYCLES - https://ksmotorcycles.com - 85 -...
Page 87: Trigger
★If the resistance value is lower than the specified value, the coil is short-circuited and must be replaced. 2.4 Ignition Coil 2.4.1 Disassembly of ignition coil: ●Remove the fuel tank (see Chapter IX “Disassembly of Fuel Tank” for details). KS MOTORCYCLES - https://ksmotorcycles.com - 86 -...
Page 88 ★The impedance value is good in the standard value. ★If the impedance value is “∞”, it indicates that the wire in the coil is disconnected and the ignition coil needs to be replaced. KS MOTORCYCLES - https://ksmotorcycles.com - 87 -...
Page 89: Spark Plug
○Use standard spark plugs or their equivalents Spark plug: D7RTC 2.6 ECU ●System inspection ●Remove ECU and check the parts at wiring terminal related to ignition system. (See section “ECU” of electronic injection system for details) KS MOTORCYCLES - https://ksmotorcycles.com - 88 -...
Page 90 FLAMEOUT SWITCH START SWITCH STARTOR MOTOR MAIN SWITCH 1 Ignition switch 2 Electric horn 3 Ignition coil 4 Motor 5 Variable-frequency flasher 6 Fuse 7 Relay 8 ECU 9 Battery 10 Voltage regulator KS MOTORCYCLES - https://ksmotorcycles.com - 89 -...
Page 91: Preparatory Information
Length of starter motor brush 12.5mm 8.5mm Stater idle shaft bushing 8.3mm Outer diameter of starter idle shaft 7.94mm Lock torque value Starter motor clutch cover bolt 12 N•m Tools Mounting nut wrench Universal fixing wrench KS MOTORCYCLES - https://ksmotorcycles.com - 90 -...
Page 92: Fault Diagnosis
[B] connector. Remove the starter motor mounting bolt [A], and remove the starter motor. 3.3.2 Installation Install the starter motor in the reverse order of disassembly. Torque value Starter motor mounting bolt 10-12 N•m KS MOTORCYCLES - https://ksmotorcycles.com - 91 -...
Page 93: Starter Relay
Black the regulations. Green / When no voltage is applied to the starter relay wire, yellow check the continuity and wire of brake switch. Bond strap Starter relay KS MOTORCYCLES - https://ksmotorcycles.com - 92 -...
Page 94 Connect the fully charged battery between the black and green/yellow wires of the relay. At this point, “Da” sound is made in the relay and the resistance indication of multimeter is “zero”. KS MOTORCYCLES - https://ksmotorcycles.com - 93 -...
Page 95 Bulbs/Meters 1 Front headlight 2 Meter 3 Front left turn light 4 Front right turn light 5 Rear left turn light 6 Taillight 7 Reflector 8 Rear right turn light KS MOTORCYCLES - https://ksmotorcycles.com - 94 -...
Page 96: Bulbs /Switches/Meters
Replacement of Taillight Bulb ································· 4.5 Replacement of License Plate Light Bulb ···················· 4.3 Meters ····························································· 4.7 Ignition Switch ··················································· 4.8 Electric Horn ····················································· 4.9 Handlebar Switch ················································ 4.10 4.1 Preparatory Information Precautions for operation KS MOTORCYCLES - https://ksmotorcycles.com - 95 -...
Page 97: Fault Diagnosis
The “ON” light of main switch is off. • Defective light bulb. • Defective switch. • The connector is in poor contact or disconnected. • The power of battery is weak or there is no voltage. KS MOTORCYCLES - https://ksmotorcycles.com - 96 -...
Page 98: Replacement Of Headlight Bulb
Otherwise, it may affect the transparency, life and luminous flux of bulb. If it is stained with oil, wipe it thoroughly with a cloth dampened with alcohol or volatile rubber water. KS MOTORCYCLES - https://ksmotorcycles.com - 97 -...
Page 99: Replacement Of Front Turn Signal Light Bulb
Remove Self-tapping screw of taillight [A] Taillight cover [B] Taillight bulb [B] Specifications Turn signal light bulb P21/5W 4.5.2 Installation The taillight bulb should be installed in the reverse order of disassembly. *Note KS MOTORCYCLES - https://ksmotorcycles.com - 98 -...
Page 100: Replacement Of License Light Bulb
The license plate light bulb should be installed in the reverse order of disassembly. 4.7 Meters 4.7.1 Disassembly Remove: Inner hexagon screw M6×25[F] Upper meter mounting cover [E] Meter mounting holder [C] Bolt M6×20[A] Rear meter cover [B] Meter assembly [D] KS MOTORCYCLES - https://ksmotorcycles.com - 99 -...
Page 101: Ignition Switch
The meter should be installed in the reverse order of disassembly. Torque value: Meter mounting holder mounting screw 10～12N·m 4.8 Ignition Switch 4.8.1 Disassembly Remove the ignition switch wire connector. Check the conduction of connector terminal. KS MOTORCYCLES - https://ksmotorcycles.com - 100 -...
Page 102 Red / white 1 Red / white Orange / blue Gear Orange / Red /white Red /white Line color blue 4.8.2 Replacement of Ignition Switch Remove the mounting bolt and replace the ignition switch [A] . KS MOTORCYCLES - https://ksmotorcycles.com - 101 -...
Page 103: Electric Horn
4.9 Electric horn 4.9.1 Disassembly Remove Mounting bolt [A] Horn [B] 4.9.2 Installation The horn should be installed in the reverse order of disassembly. Torque value: Horn mounting bolt 10～12N.m KS MOTORCYCLES - https://ksmotorcycles.com - 102 -...
Page 104 4.9.3 Inspection Remove the horn wire. If the horn sounds after being connected to the battery, it is in good conditions. KS MOTORCYCLES - https://ksmotorcycles.com - 103 -...
Page 105: Handlebar Switch
Green Red/ Green/ Purple white yellow Dark Orange Green / green white Right steering switch Orange Green/w Starting switch Stop switch hite Green/ Red/ Green Dark yellow white green Purple Red/ white Brake KS MOTORCYCLES - https://ksmotorcycles.com - 104 -...
Page 106: Inspection And Maintenance Of Chassis
Nut at the bottom of rear shock absorber 22-29 Mounting bolt of rear grab rail 22-29 Fuel tank mounting bolt Helmet barrel mounting bolt Muffler mounting bolt 22-29 Muffler connector mounting bolt Mounting nut of rear rocker arm axis 70-83 KS MOTORCYCLES - https://ksmotorcycles.com - 105 -...
Page 107 Front / rear fluid brake KS MOTORCYCLES - https://ksmotorcycles.com - 106 -...
Page 108 Spring Gasket 10 Rear linkage brake hose Brake pad assembly (front) assembly I CBS fuel pump assembly Brake pad assembly (rear) Fluid brake bolt Fuel hose mounting bolt M10×1.25×43 Bleed screw Bolt M6×16 KS MOTORCYCLES - https://ksmotorcycles.com - 107 -...
Page 109: Brake
5-9 N•m Mounting bolt of rear fuel pump 5-9 N•m Mounting bolt of front fluid brake disc 10-12 N·m Mounting bolt of rear fluid brake disc 10-12 N·m Brake tube mounting bolt 30 N·m KS MOTORCYCLES - https://ksmotorcycles.com - 108 -...
Page 110: Fault Diagnosis
Remove the front wheel. (See Chapter 7 “Front wheel” of this book) Remove the clamp screw [A] of front brake disc Note: When disassembling the clamp screw of front brake disc, follow the instructions on the right figure KS MOTORCYCLES - https://ksmotorcycles.com - 109 -...
Page 111 Specifications φ280mm Diameter of front fluid brake disc Thickness of front brake disc 4.0mm Allowable limit: Thickness of front fluid brake disc *Note • Use a micrometer for measurement. KS MOTORCYCLES - https://ksmotorcycles.com - 110 -...
Page 112: Rear Brake Disc
Remove rear wheel. (See Chapter VIII “Rear Wheel” of this book) Remove the clamp screw of rear brake disc [A] Note: When disassembling the clamp screw of rear brake disc, follow the instructions on the right figure. KS MOTORCYCLES - https://ksmotorcycles.com - 111 -...
Page 113 Specifications φ240mm Diameter of rear fluid brake disc Thickness of rear fluid brake disc 5.0mm Allowable limit: Thickness of rear fluid brake disc *Note • Use a micrometer for measurement. KS MOTORCYCLES - https://ksmotorcycles.com - 112 -...
Page 114: Cbs
●When removing brake hose [B], temporarily fix the end of brake hose in a high place to minimize the loss of brake fluid. ●If brake fluid overflows, clean it immediately. KS MOTORCYCLES - https://ksmotorcycles.com - 113 -...
Page 115 ●Fill the brake line with brake fluid after installing brake hose. (See “replacement of brake fluid” for details). 5.5.2 Adjustment of brake stroke Front brake The stroke of front brake is nonadjustable KS MOTORCYCLES - https://ksmotorcycles.com - 114 -...
Page 116 ●Remove lever locknut and remove lever bolt. ●Remove plunger dust cap. ●Remove plunger spring with a special tool—inside circlip pliers, and remove plunger assembly. KS MOTORCYCLES - https://ksmotorcycles.com - 115 -...
Page 117 Loosen front caliper brake pin [A] and hollow bolt [B], and then gently tighten them (Tighten them a little bit, and do not tighten too much). Mounting bolt of front caliper [C]. Remove front caliper ●Remove hollow bolt [B] KS MOTORCYCLES - https://ksmotorcycles.com - 116 -...
Page 118 ● Install piston ● Install spring ●Install front brake mounting bracket ●Install brake pad ●Install brake pad pin KS MOTORCYCLES - https://ksmotorcycles.com - 117 -...
Page 119 ●Press it into the reservoir hose joint ● Use a special tool - inner circlip pliers to install the reservoir joint circlip and the reservoir joint dust cap KS MOTORCYCLES - https://ksmotorcycles.com - 118 -...
Page 120 ●Remove the piston with compressed air. ● Remove dust ring and seal 5.5.6.2 Assembly of rear caliper ●Install dust ring and seal. If seal and dust rings are damaged, replace it with a new one. ● Install piston KS MOTORCYCLES - https://ksmotorcycles.com - 119 -...
Page 121 ●Remove the hollow bolt of brake hose [A] ●Remove the mounting bolt [B] at reservoir assembly of CBS pump ●Remove the mounting bolt [C] of CBS pump, and remove CBS pump Notes If brake fluid spills out, rinse it immediately! KS MOTORCYCLES - https://ksmotorcycles.com - 120 -...
Page 122 CBS plunger. ●Loosen the lock screw [A] of CBS pump adjusting bolt, and remove CBS pump adjusting bolt. ●Insert a round bar into CBS pump adjusting bolt to pull out adjusting valve element assembly. KS MOTORCYCLES - https://ksmotorcycles.com - 121 -...
Page 123 ●Install the dust cap of fuel hose connector [H] ●Insert fuel hose. If fuel hose is damaged, replace it with a new one. ●Move the CBS pump reservoir hose clamp to the joint locking position. KS MOTORCYCLES - https://ksmotorcycles.com - 122 -...
Page 124 [B]. ○Operate the brake lever and feel. If you feel that it is softer than before, please repeat the above actions to refill. KS MOTORCYCLES - https://ksmotorcycles.com - 123 -...
Page 125 [B]. ○Operate the brake lever and feel. If you feel that it is softer than before, please repeat the above actions to refill. 。 KS MOTORCYCLES - https://ksmotorcycles.com - 124 -...
Page 126 6. In addition to brake pads and brake discs, only disc brake fluid, isopropyl alcohol or alcohol can be used to clean the brake parts. Do not clean the above parts with any other liquid! Gasoline, oil or other KS MOTORCYCLES - https://ksmotorcycles.com - 125 -...
Page 127 9. The air in the brake line must be drained whenever the brake line connector or exhaust valve is opened! KS MOTORCYCLES - https://ksmotorcycles.com - 126 -...
Page 128 12 Left rear cover 13. Bolt M6 x 28 14. Left guard 15. Right guard 16. Left guard cover 17. Right guard cover 18. Bolt M8 x 20 19. Aluminum washer 8 20. Seat assembly 21. Rear left fender 22. Fuel tank 23. Rear fender 24. Rear fender stiffener assembly KS MOTORCYCLES - https://ksmotorcycles.com - 127 -...
Page 129 The insert plate and cover plate of body are aligned with their slots respectively. The hooks of parts should be installed correctly when assembling. Do not damage the fittings when installing covering parts. KS MOTORCYCLES - https://ksmotorcycles.com - 128 -...
Page 130 Rolling bearing 6202-2RS Front wheel middle shaft sleeve Front wheel oil seal assembly Air valve Z2-01-1 Front rim Tubeless tire 90/90-17 Front wheel right collar Front brake disc Inner hexagon screw M6×20 Nut M14×1.5 KS MOTORCYCLES - https://ksmotorcycles.com - 129 -...
Page 131 Console assembly Mounting torque value of screw 8 in the figure: 22∼29 N·m Mounting torque value of screw 12 in the figure: 10∼12 N·m KS MOTORCYCLES - https://ksmotorcycles.com - 130 -...
Page 132 Meter mounting seat Rubber washer of cover Upper collar of radiator Rear meter cover Bolt M6×25 Bolt M6×20 Self-locking nut M8 Throttle cable assembly Clutch cable assembly Left lever assembly Spring washer φ8 KS MOTORCYCLES - https://ksmotorcycles.com - 131 -...
Page 133 Mounting torque value of nut 10 in the figure:37-44 N·m Mounting torque value of bolt 25 in the figure: 10-12 N·m Number of upper steel balls: 21 Number of lower steel balls: 17 KS MOTORCYCLES - https://ksmotorcycles.com - 132 -...
Page 134 Front right shock absorber assembly Front left shock absorber assembly Front left turn signal light Inner hexagon screw M6×20 Nut M6 Front steering light stop plate welding assembly Clamp Front right turn signal light KS MOTORCYCLES - https://ksmotorcycles.com - 133 -...
Page 135: Front Wheel/Front Suspension
Steering column bearing locknut 70 N·m Steering column bearing nut 2 N·m Upper clamp bolt of shock absorber 22∼29 N·m Lower clamp bolt of shock absorber 45∼50 N·m Headlight bracket locknut 37∼44 N·m KS MOTORCYCLES - https://ksmotorcycles.com - 134 -...
Page 136: Fault Diagnosis
7.2.5 Abnormal Sound of Front Shock Absorber Friction sound of shock absorber guard. The bolts of all parts of shock absorber are loose. 7.3 Front Wheel 7.3.1 Disassembly Note: The motorcycle must be firmly supported. KS MOTORCYCLES - https://ksmotorcycles.com - 135 -...
Page 137 Remove Front wheel axle locknut [A]. Remove the front wheel axle [A] Remove the front wheel KS MOTORCYCLES - https://ksmotorcycles.com - 136 -...
Page 138 Horizontal direction: Replace the rim if the swinging amplitude is 2.0mm or above. 7.3.2.3Inspection of Front Wheel Bearing  Bearing The front wheel rotates unsmoothly or it is too loose→Replace the bearing  Oil Seal Damage/wear→Replacement KS MOTORCYCLES - https://ksmotorcycles.com - 137 -...
Page 139 Check the rolling conditions of bearing. Clearance If the bearing does not roll, it may be worn or loose and thus it should be replaced with a new one. Clearance Axial direction Radial direction KS MOTORCYCLES - https://ksmotorcycles.com - 138 -...
Page 140 • After the wheel axle is installed, rotate the wheel to confirm whether the speedometer drive shaft rotates. Torque value: Front wheel axle locknut 75-88 N·m KS MOTORCYCLES - https://ksmotorcycles.com - 139 -...
Page 141: Handlebar
7.4 Handlebar 7.4.1 Disassembly Disassemble Right rear view mirror assembly [A] Left rear view mirror assembly [B] Remove Primary cylinder of front brake [A] KS MOTORCYCLES - https://ksmotorcycles.com - 140 -...
Page 142 Remove Left lever assembly [B] Remove Mounting bolt of grip end assembly [A] Grip end assembly [B] KS MOTORCYCLES - https://ksmotorcycles.com - 141 -...
Page 143 Remove Left combination switch [A] Remove Right combination switch [A] Throttle grip [B] Remove Left handlebar cover [A] KS MOTORCYCLES - https://ksmotorcycles.com - 142 -...
Page 144 [1] and slowly press the left handlebar grip. Remove the mounting screw at the upper seat of handlebar [A] Remove upper seat of handlebar [B] Remove the handlebar assembly KS MOTORCYCLES - https://ksmotorcycles.com - 143 -...
Page 145 10-12 N•m *Note: When installing the mounting screw at the upper seat of handlebar, finally fix the 2 screws [A] below *Note: When installing the left lever assembly, first fix the screw [A] below KS MOTORCYCLES - https://ksmotorcycles.com - 144 -...
Page 146: Front Fork
Remove the front fender (see Chapter VI for details) Remove the caliper of front brake (see Chapter V “Brake” for details) Loosen the clamp bolt of upper bracket [A] Disassemble Supporting bolt [A] Upper bracket [B] KS MOTORCYCLES - https://ksmotorcycles.com - 145 -...
Page 147 Loosen the clamp bolt of lower bracket[A] Remove the front shock absorber Disassemble Locknut [A] Remove Dust cap [A] Disassemble Upper steel bowl of upper bearing [A] KS MOTORCYCLES - https://ksmotorcycles.com - 146 -...
Page 148 Disassemble Support and lower bracket 7.5.2 Inspection of Steering Column Check Steering column Deformation / bending→replacement KS MOTORCYCLES - https://ksmotorcycles.com - 147 -...
Page 149 Do not strike the surfaces of ball and direction axle. 7.5.3 Installation Carry out assembly in the reverse process of disassembly *Note KS MOTORCYCLES - https://ksmotorcycles.com - 148 -...
Page 150 [2]. Note:  Make the torque wrench perpendicular to the steering nut wrench.  Rotate the direction axle left and right several times to check whether it rotates smoothly. KS MOTORCYCLES - https://ksmotorcycles.com - 149 -...
Page 151 Shock absorber spring Dust cap Oil seal clip Oil seal 37×50×11 Flat washer DU collar Piston ring Buffer spring Front branch pipe combination Outer pipe Piston pipe Positioning sleeve Sealing washer Inner hexagon screw M10×30 KS MOTORCYCLES - https://ksmotorcycles.com - 150 -...
Page 152: Front Shock Absorber
7.6 Front Shock Absorber 7.6.1 Disassembly Disassemble Cap bolt ① and O-ring seal Oil drainage Disassemble Plug ① Spring ② Disassemble Dust ring ① Wire clamp ② Note: Do not damage the surface of inner tube KS MOTORCYCLES - https://ksmotorcycles.com - 151 -...
Page 153 Hold the shock absorber lever and loosen the bolts with the T-shaped handle ② and the shock absorber clamp. Disassemble Bolt ① Washer ② Disassemble Oil seal ① 7.6.2 Inspection Check Bending degree of inner tube KS MOTORCYCLES - https://ksmotorcycles.com - 152 -...
Page 154 Be sure to use the following new parts when reassembling the shock absorber  Oil Seal  Dust ring Ensure that parts clean before re-installation Installation Shock absorber piston ring ① Spring ② KS MOTORCYCLES - https://ksmotorcycles.com - 153 -...
Page 155 Note: When assembling bolt ②, add thread-locking adhesive Tighten Bolt (damper rod) ① Torque value: 15-20N•m Notes Tighten the bolt ① of damper rod with the T-shaped handle ② and the shock absorber clamp. KS MOTORCYCLES - https://ksmotorcycles.com - 154 -...
Page 156 Dust ring ① Wire clamp ② Check Extension of inner tube Unable to extend smoothly - recheck after disassembly Refuel Measuring cup ① Shock absorber oil: 46# shock absorber oil Oil capacity: 285±2ml KS MOTORCYCLES - https://ksmotorcycles.com - 155 -...
Page 157 Installation Plug ① Spring ② Installation Cap bolt ① and O-ring seal Notes Do not damage the surface of inner tube Torque value of cap bolt: 12-18 N·m KS MOTORCYCLES - https://ksmotorcycles.com - 156 -...
Page 158 Sprocket specification: 41 teeth Mounting torque value of nut 6 in the figure: 45-50N·m Mounting torque value of nut 19 in the figure: 100-113 N·m Mounting torque value of screw 18 in the figure:10-12 N•m KS MOTORCYCLES - https://ksmotorcycles.com - 157 -...
Page 159 Rear wheel damper assembly Rolling bearing 6303-2RS Front wheel middle shaft sleeve Air valve Z2-01-1 Rear wheel rim Tubeless tire 130/90-15 Right collar of rear wheel Rear brake disc Inner hexagon screw M6×20 Nut M16×1.5 KS MOTORCYCLES - https://ksmotorcycles.com - 158 -...
Page 160 Rear shock absorber assembly Clamp Chain adjuster assembly Rear rocker arm shaft sleeve assembly Chain adjuster retainer Rear rocker arm welding assembly Nut M8 Self-locking nut M14×1.5 Drive chain cover Washer Bolt M6×10 KS MOTORCYCLES - https://ksmotorcycles.com - 159 -...
Page 161: Rear Wheel/Rear Suspension
8.2.1 Rear Wheel Shimmy Deformation of rim Wear of rear wheel bearing Tire fault Wear or damage of rocker arm pivot shaft bearing Improper adjustment of drive chain adjuster Bent frame or rocker arm KS MOTORCYCLES - https://ksmotorcycles.com - 160 -...
Page 162: Rear Wheel
The friction pad of brake is dirty The fluid brake disc is dirty 8.3 Rear wheel 8.3.1 Disassembly Firmly support the motorcycle so that the rear wheel of motorcycle is lifted from the ground. KS MOTORCYCLES - https://ksmotorcycles.com - 161 -...
Page 163 Remove Rear brake caliper Loosen Chain adjuster bolt [A] Disassemble Rear wheel axle mounting nut [A] KS MOTORCYCLES - https://ksmotorcycles.com - 162 -...
Page 164 8.3.2.1 Bending Inspection of Wheel Axle Put the wheel axle on the V-shaped seat and measure the eccentricity with a dial gauge. Available limit: Replace the wheel axle if the eccentricity is 0.2mm above Axle KS MOTORCYCLES - https://ksmotorcycles.com - 163 -...
Page 165 Damage/wear→Replacement 8.3.3 Replacement of Bearing 8.3.3.1 Disassembly of Bearing Remove the oil seal [1]. Note: To avoid damaging the rim, please put a cloth [2] between the screwdriver and the surface of rim KS MOTORCYCLES - https://ksmotorcycles.com - 164 -...
Page 166 [4] of bearing 8.4.4 Installation Install it in the reverse order of disassembly. Notes The oil seal on the rear wheel should be lubricated. Torque value: Rear wheel axle locknut 85-98 N•m KS MOTORCYCLES - https://ksmotorcycles.com - 165 -...
Page 167: Rear Shock Absorber
8.4 Rear shock absorber 8.3.1 Disassembly Firmly support the motorcycle Disassemble Lower mounting bolt of rear shock absorber [A] Upper mounting bolt of rear shock absorber [B] Rear shock absorber [C] KS MOTORCYCLES - https://ksmotorcycles.com - 166 -...
Page 168 Lock it to the specified torque value. Torque value: Nut at the top of rear shock absorber 45-50 N·m Bolt at the bottom of rear shock absorber 22-29 N·m KS MOTORCYCLES - https://ksmotorcycles.com - 167 -...
Page 169: Rear Rocker Arm
Disassemble Rear lower fender bracket [A] Disassemble Mounting nut of rear rocker arm axle [A] Disassemble Rear rocker arm shaft Pull out the rear rocker arm shaft from right side to left side KS MOTORCYCLES - https://ksmotorcycles.com - 168 -...
Page 170 If it is loose→tighten the rear rocker arm nut or replace the collar  Vertical movement of rear rocker arm If the movement is not smooth, or there is any bent or rough parts → replace the axle sleeve KS MOTORCYCLES - https://ksmotorcycles.com - 169 -...
Page 171 Install it in the reverse order of disassembly. Clean the mounting axle parts of rear rocker arm in the solvent, and apply grease to the mounting shaft. Torque value: Mounting nut of rear 85～98 N·m KS MOTORCYCLES - https://ksmotorcycles.com - 170 -...
Page 172: Chain Drive
8.6 Chain drive 8.6.1 Disassembly Put the motorcycle on a flat surface and secure it. Disassemble Drive sprocket cover [A] Disassemble the rear wheel (see this chapter for details) KS MOTORCYCLES - https://ksmotorcycles.com - 171 -...
Page 173 Disassemble the rear rocker arm (see this section for details) Remove the drive chain Disassemble Mounting nut of sprocket mounting bolt [A] KS MOTORCYCLES - https://ksmotorcycles.com - 172 -...
Page 174 Note: When disassembling the mounting nut of sprocket mounting bolt, follow the instructions on the right figure. Remove the retainer [A] using the retainer caliper. KS MOTORCYCLES - https://ksmotorcycles.com - 173 -...
Page 175  Measure the length of 10 links within the range from the link roller ① to the inside of roller○  Measure the length of 10 links in different positions for 2-3 times. KS MOTORCYCLES - https://ksmotorcycles.com - 174 -...
Page 176 If it is damaged or worn, replace the drive chain. Lubricate the drive chain and purchase drive chain lubricants from the store. Check drive chain hardness If it is hard, clean, lubricate or replace. KS MOTORCYCLES - https://ksmotorcycles.com - 175 -...
Page 177 If the chain slackness is too smallness, the engine and other important parts may be overloaded. The chain slackness should be kept within the specified limits. Torque value: Locknut of sprocket bolt 45～50 N·m KS MOTORCYCLES - https://ksmotorcycles.com - 176 -...
Page 178 *Note Tighten the nut by 2-3 times in the order shown in the right figure. KS MOTORCYCLES - https://ksmotorcycles.com - 177 -...
Page 179 Seat Cushion Mounting torque value of bolt 1 in the figure: 22-29 N·m Mounting torque value of bolt 2 in the figure: 10-12 N·m Name Bolt M8×20 Aluminum washer 8 Seat assembly Bolt M6×10 KS MOTORCYCLES - https://ksmotorcycles.com - 178 -...
Page 180 Fuel tank lock Self-locking nut M6 Fuel tank assembly Connecting pipe between canister and dump valve Connecting pipe between fuel tank and dump Buffer rubber valve Inner hexagon screw M6×35 Dump valve assembly KS MOTORCYCLES - https://ksmotorcycles.com - 179 -...
Page 181: Fuel Tank/Seat
10-12 N·m Fuel tank mounting bolt 10-12 N·m Fuel level sensor mounting bolt 5–9 N·m Fuel pump mounting bolt 3-4 N·m 9.2 Fault Diagnosis Reduction of gasoline quantity Natural consumption of gasoline Gasoline leakage KS MOTORCYCLES - https://ksmotorcycles.com - 180 -...
Page 182: Seat
9.3 Seat 9.3.1 Disassembly Disassemble Rear mounting bolt of seat [A] Disassemble Lower mounting bolt of seat [A] (two sides) Seat [B] 9.3.2 Inspection Check Seat Cushion Breakage or damage → replacement KS MOTORCYCLES - https://ksmotorcycles.com - 181 -...
Page 183: Fuel Tank
If some fuel spills, it must be thoroughly cleaned. Disassemble Bolt [A] Remove fuel level sensor wire connector. KS MOTORCYCLES - https://ksmotorcycles.com - 182 -...
Page 184 Do not remove the fuel hose from the fuel hose connector. Remove the connector from the fuel pump interface. Remove the fuel tank from the frame Disassemble Nut [A] Fuel level sensor assembly [A] Sensor rubber washer [B] KS MOTORCYCLES - https://ksmotorcycles.com - 183 -...
Page 185 Fuel tank Rust / damage / oil leakage→replacement ● Inspection Rubber part Buffer rubber [A] Rubber cover [B] Sensor rubber washer [C] Mounting washer of fuel tank [D] Rubber washer of guard [E] Crack/damage→Replacement KS MOTORCYCLES - https://ksmotorcycles.com - 184 -...
Page 186 Crack/damage→Replace fuel pump assembly  Performance inspection of fuel pump (see Chapter XVII for details) ● Inspection Fuel hose If any wear, crack [B] or expansion [C] is found → the fuel pipe must be replaced. KS MOTORCYCLES - https://ksmotorcycles.com - 185 -...
Page 187 3-4 N·m Note: Do not damage the mounting surface of fuel tank when installing the fuel pump Use new fuel pump seal ring Note: See Chapter XVIII for the details of fuel pump KS MOTORCYCLES - https://ksmotorcycles.com - 186 -...
Page 188 Mounting torque value of bolt 16 in the figure: 22-29 N·m Mounting torque value of bolt 25 in the figure: 22-29 N·m Mounting torque value of bolt 27 in the figure: 45-50 N·m KS MOTORCYCLES - https://ksmotorcycles.com - 187 -...
Page 189 Bolt M8×16 Wire box mounting plate welding assembly Self-locking nut M8 Nut M6 Guard bush Rubber cover II Bolt M8×65 Upper hanging panel of engine Washer 8 Nut M8 Rivet for nameplate 3×6 KS MOTORCYCLES - https://ksmotorcycles.com - 188 -...
Page 190 Right pedal assembly Brake return spring Self-locking nut M6 Brake pedal welding assembly Bolt M6×16 Bolt M6×25 Windshield Shift rod assembly Bolt M6×25 Inner hexagon screw M6×20 Joint M6 Split pin 2×25 Combination screw M6×16 KS MOTORCYCLES - https://ksmotorcycles.com - 189 -...
Page 191: Disassembly/Installation Of Engine
Wear or damage of cylinder and piston Breakage fork guide Defective operation of return spring of transmission Abnormal sound of crankcase Automatic shutdown of engine Scattered or broken parts in the crankcase Stuck clutch KS MOTORCYCLES - https://ksmotorcycles.com - 190 -...
Page 192: Disassembly Of Engine
Note: Ensure that the usage position of engine mounting bolt is correct. Replace them with new O-ring of throttle body and isolator. Install the engine on the frame and tighten the mounting nut. KS MOTORCYCLES - https://ksmotorcycles.com - 191 -...
Page 193 Conduct the following inspection and adjustment after installing the engine； —Engine oil level. —Tightness of driving chain. —Clearance of rear brake pedal. —Clearance of clutch push lever. —Clearance of throttle cable. KS MOTORCYCLES - https://ksmotorcycles.com - 192 -...
Page 194: Inspection And Maintenance Of Engine
Clutch push disc bolt 10～16 9.8～11 Bolt at cylinder head cover 9.8～11 Cylinder block clamp bolt 40～50 Oil filter rotor nut 10～16 Driving sprocket bolt 9.8～11 Fuel pump screw 10～16 Shift positioner bolt 15～26 Spark plug KS MOTORCYCLES - https://ksmotorcycles.com - 193 -...
Page 195 1 Rocker arm 2 Cam mechanism 3 Crankshaft 4 Oil filter mesh 5 Piston 6 Oil filter 7 Fuel pump KS MOTORCYCLES - https://ksmotorcycles.com - 194 -...
Page 196: Lubrication System
Rotor end gap 0.07-0.12 0.15 11.2 Fault Diagnosis Reduced oil level Burning of engine Natural consumption of oil There is no oil pressure or oil pressure is too low Oil leakage Oil path is blocked KS MOTORCYCLES - https://ksmotorcycles.com - 195 -...
Page 197: Fuel Pump
11.3 Fuel Pump 11.3.1 Disassembly Remove the right cover, remove the oil filter loosen fuel pump mounting screw, remove fuel pump body, driving gear and fuel pump shaft. Fuel filter Fuel pump KS MOTORCYCLES - https://ksmotorcycles.com - 196 -...
Page 198 Fuel pump cover Check the radial clearance of internal and external Test gauge rotors. Allowable limit: 0.25mm. Check the clearance between external rotor and fuel pump base. Test gauge Allowable limit: 0.25mm. KS MOTORCYCLES - https://ksmotorcycles.com - 197 -...
Page 199 Check the end clearance of rotor. Allowable limit: 0.15mm. Panel Test gauge KS MOTORCYCLES - https://ksmotorcycles.com - 198 -...
Page 200 Outer rotor Fuel pump shaft Inner rotor *Note: After assembly, the inner and outer rotors should be able to rotate flexibly without clamping stagnation. 10.3.2 Installation Install it in the reverse order of disassembly. KS MOTORCYCLES - https://ksmotorcycles.com - 199 -...
Page 201 Cylinder head / valve 1 Cylinder head cover 2 Bolt 3 Spark plug 4 Cylinder washer 5 Cylinder KS MOTORCYCLES - https://ksmotorcycles.com - 200 -...
Page 202: Preparatory Information
Intake / 11.98-11.988 11.95 shaft exhaust Inner diameter of rocker arm Intake / Rocker arm 12-12.018 12.05 hole exhaust Clearance between rocker arm Intake / 0.012-0.038 0.08 shaft and rocker arm hole exhaust KS MOTORCYCLES - https://ksmotorcycles.com - 201 -...
Page 203: Fault Diagnosis
The spark plug is not installed properly 12.3 Cylinder Head 12.3.1 Disassembly Loosen bolt and remove the luxury housing. Bolt Luxury housing Loosen three mounting bolts and remove the cylinder Cylinder head cover Bolt head cover. KS MOTORCYCLES - https://ksmotorcycles.com - 202 -...
Page 204 Measure the external diameter of rocker arm. Allowable limit: 11.95 mm. Micrometer Measure the inner diameter of rocker arm hole. Allowable limit:12.05 mm. Clearance between rocker arm hole and rocker arm shaft. Allowable limit: 0.08 mm. Testing meter KS MOTORCYCLES - https://ksmotorcycles.com - 203 -...
Page 205 Compress the valve spring with  valve spring compression tool (QJ153-10-0104/G10) and remove valve cotter. Remove the spring disc, the springs of outer and inner valves, the spring washer of outer valve and the valve. Valve lock clamp KS MOTORCYCLES - https://ksmotorcycles.com - 204 -...
Page 206 12.3.2 Valve decomposition Valve lock clamp Inner valve spring washer Valve Spring plate Outer valve spring Valve oil seal KS MOTORCYCLES - https://ksmotorcycles.com - 205 -...
Page 207: Valve Inspection
Allowable limit: 5.40 mm. Check the valve guide and remove the carbon deposits Valve reamer in the valve guide with a reamer before check. Note: Rotate the reamer clockwise and do not rotate the reamer counterclockwise. KS MOTORCYCLES - https://ksmotorcycles.com - 206 -...
Page 208: Replacement Of Valve Guide
After the valve guide is embedded, carry out the Valve reamer finishing by using the valve guide reamer. *Note: Add an appropriate amount of cutting oil during cutting with a reamer. The reamer shall be rotated clockwise. KS MOTORCYCLES - https://ksmotorcycles.com - 207 -...
Page 209: Finishing Valve Seat Ring
Remove 1/4 of outer end of valve seat ring with a 32° cutter. Remove 1/4 of bottom end of valve seat ring with a 60° cutter. Remove the cutter, and check the places that have been handled. KS MOTORCYCLES - https://ksmotorcycles.com - 208 -...
Page 210: Installation Of Cylinder Head
(QJ153-10-0104/G10) for installation. When the valve is installed, apply appropriate amount of engine oil to the surface of the valve stem and then install the valve stem into the valve guide. KS MOTORCYCLES - https://ksmotorcycles.com - 209 -...
Page 211 Cylinder Block and Piston Note: Before the inspection and measurement, all parts shall be cleaned and blown with high-pressure air. 1 Bolt 2 Cylinder block 3 Washer 4 Piston 5 Piston pin 6 Dowel pin KS MOTORCYCLES - https://ksmotorcycles.com - 210 -...
Page 212: Preparatory Information
Acting as a slide valve for opening and closing air, the fresh mixed gas in crankcase is pressed into the cylinder regularly and the exhaust gas after burning in the cylinder is discharged timely. KS MOTORCYCLES - https://ksmotorcycles.com - 211 -...
Page 213: Fault Diagnosis
Compression pressure is too high Abnormal sound of piston Too much carbon is accumulated in the combustion chamber Damage of cylinder, piston and piston ring Wear of piston pin hole and piston pin KS MOTORCYCLES - https://ksmotorcycles.com - 212 -...
Page 214: Cylinder Block
13.3.2 Inspection of Cylinder Block Check the wear situation of inner wall of cylinder. If the wear is serious, please replace it. Remove washer and dowel pin. Dowel pin Washer 13.3.3 Disassembly of Cam Follower KS MOTORCYCLES - https://ksmotorcycles.com - 213 -...
Page 215: Piston
13.4 Piston 13.4.1 Disassembly Remove the piston pin retainer. *Note: During disassembly, do not drop the retainer into the crankcase. Take out the piston pin and remove piston. Piston pin retainer, piston pin KS MOTORCYCLES - https://ksmotorcycles.com - 214 -...
Page 216 Press the piston ring in the cylinder by using the piston head. Piston ring Measure the piston ring joint clearance. Allowable limit: 0.5mm. Measure the inner diameter of piston pin hole. Allowable limit:13.04 mm. Testing meter KS MOTORCYCLES - https://ksmotorcycles.com - 215 -...
Page 217 X and Y directions). Allowable limit: 0.05mm. Measure the cylindricity of inner wall of cylinder (inner Upper diameter difference between X and Y directions Middle in upper, middle and lower positions). Allowable limit: 0.05mm. Lower KS MOTORCYCLES - https://ksmotorcycles.com - 216 -...
Page 218 Foreign matters shall not fall into the crankcase. Install the piston, piston pin and piston pin retainer. “IN” mark *Note: Install the piston into the intake valve according to the “IN” mark at the top. KS MOTORCYCLES - https://ksmotorcycles.com - 217 -...
Page 219: Installation Of Cylinder Block
Install the gasket and dowel pin on the crankcase. Dowel pin Washer Apply oil to the inner wall of cylinder, piston and piston ring. Install the piston ring into the cylinder carefully. *Note: Do not damage the piston ring. Cylinder KS MOTORCYCLES - https://ksmotorcycles.com - 218 -...
Page 220 1 Adjusting bolt 2 Push lever 3 Push disc 4 Axle sleeve 5 Bearing 6 Pressure spring 7 Center bearing bracket 8 Active friction pad 9 Driven friction pad 10 Locknut 11 Sliding key washer 12 Pressure disc 13 Housing assembly KS MOTORCYCLES - https://ksmotorcycles.com - 219 -...
Page 221 1 Recoil starting shaft 2 Recoil starting ratchet wheel 3 Ratchet wheel spring 4 Ratchet wheel guide plate assembly 5 Recoil starting gear 6 Spring retainer 7 Shaft liner 8 Return spring KS MOTORCYCLES - https://ksmotorcycles.com - 220 -...
Page 222: Clutch / Kickstarter Mechanism
The clearance of clutch push lever is too large Variable-speed mandrel is bent Clutch disc is warping Variable-speed cam is damaged Clutch pusher fails Variable-speed plate is bent or Engine oil and oil level are damaged abnormal KS MOTORCYCLES - https://ksmotorcycles.com - 221 -...
Page 223: Clutch
Remove the parts shown in the exploded view. Lock torque of locknut: 50-60N.m Four-claw socket wrench: QJ157-0110/G20 Universal fixer Universal fixer: QJ157-0111/G20 Remove the spline washer. Housing assembly Remove housing assembly. Install the clutch in the reverse order of disassembly. KS MOTORCYCLES - https://ksmotorcycles.com - 222 -...
Page 224 Center bearing Pressure plate bracket Measure the free length of pressure spring. Allowable limit: Replace it if its length is less than 34.2mm. Free length KS MOTORCYCLES - https://ksmotorcycles.com - 223 -...
Page 225: Kickstarter Mechanism
Check the meshing condition of starting shaft spline and spline in ratchet wheel. When the meshing is loose, it should be replaced. 14.4.3 Assembly Install it in the reverse order of decomposition and disassembly. Remove primary shaft assembly. Primary shaft Remove auxiliary shaft assembly. assembly Auxiliary shaft assembly KS MOTORCYCLES - https://ksmotorcycles.com - 224 -...
Page 226: Disassembly Of Primary And Auxiliary Shafts
Auxiliary shaft assembly 14.5.1 Inspection Check the wear of gear teeth surface and drive claw Tooth respectively. surface If the wear is serious or it is damaged, please replace it. Driving claw KS MOTORCYCLES - https://ksmotorcycles.com - 225 -...
Page 227 The bearing disassembled cannot be reused and should be replaced with a new one; Bearings and oil seals should be disassembled by using special tools. Bearing: QJ153-7-0101/G15 Oil seal pliers: QJ157-0112/G15 Bearing puller Oil seal pliers KS MOTORCYCLES - https://ksmotorcycles.com - 226 -...
Page 228 14.5.2 Combination of primary and auxiliary shafts *Note: When combined, apply lubricating oil to all gears and shafts. Ensure that the gears are not jammed after combination. Notes: Install the crankcase in the reverse order of disassembly. KS MOTORCYCLES - https://ksmotorcycles.com - 227 -...
Page 229 Reduction gear 1 Shifting drum 2 Shift fork 3 Shift fork shaft 4 Primary shaft assembly 5 Auxiliary shaft assembly 6 Recoil kickstarter assembly KS MOTORCYCLES - https://ksmotorcycles.com - 228 -...
Page 230: Variable Speed Gear
The spline teeth of spline shaft and spline grooves of sliding gear are worn, resulting in a great axial force when the gear is working Shift drum or shift fork is worn KS MOTORCYCLES - https://ksmotorcycles.com - 229 -...
Page 231: Shift Mechanism
Remove the parts shown in the exploded view. Variable gear shaft Stopper lever combination 15.3.2 Disassembly Stopper lever spring Stopper lever Variable gear positioning plate Gearshift plate Gearshift plate spring Gearshift return spring Gearshift shaft assembly KS MOTORCYCLES - https://ksmotorcycles.com - 230 -...
Page 232 Remove the left case. Shift fork shaft Pull out the shift fork shaft. Remove shift drum. Remove the shift fork. Shift drum fork Measure the outer diameter of shift fork shaft. Allowable limit: 11.95 mm. Micrometer KS MOTORCYCLES - https://ksmotorcycles.com - 231 -...
Page 233 Vernier caliper Measure the outer diameter of shift drum. Allowable limit:35.75 mm. Measure the width of lock groove of shift drum. Lock groove width Allowable limit: 7.3 mm. Remove the balancer gear Balancer gear KS MOTORCYCLES - https://ksmotorcycles.com - 232 -...
Page 234: Installation
15.4 Installation Install it in the reverse order of disassembly. KS MOTORCYCLES - https://ksmotorcycles.com - 233 -...
Page 235: Crankcase
Before the inspection and measurement, all parts shall be cleaned blown with high-pressure air. Before operation, lubricant crankcase should be released. 1 Right crankcase 2 Left crankcase 3 Crankshaft combination 4 Balancer 5 Bolt KS MOTORCYCLES - https://ksmotorcycles.com - 234 -...
Page 236: Preparatory Information
Universal fixer Clutch spring compressor Screwdriver rod Socket wrench Guide rod Bearing screwdriver 16.2 Fault Diagnosis Abnormal sound of crankcase Automatic shutdown of engine Scattered or broken parts in the crankcase Stuck clutch KS MOTORCYCLES - https://ksmotorcycles.com - 235 -...
Page 237 Remove the left front cover and left rear cover. Left front cover Left rear cover Remove the idle gear of starter motor. Washer Remove washer and dowel pin. Motor idle gear Dowel pin KS MOTORCYCLES - https://ksmotorcycles.com - 236 -...
Page 238 Gear display 16.3.2 Disassembly of cam component Camshaft gear Cam mechanism shaft Camshaft spring Measure the inner diameter of cam bushing. Allowable limit:14.10 mm. Measure cam height Allowable limit: 32.5mm. Testing meter KS MOTORCYCLES - https://ksmotorcycles.com - 237 -...
Page 239 Clamp the nut using four-jaw sleeve, loosen the locknut with the pneumatic tool, remove the oil filter rotor and remove the driving gear. loosen fuel pump mounting screw, and remove fuel pump assembly. KS MOTORCYCLES - https://ksmotorcycles.com - 238 -...
Page 240: Crankshaft Combination
Dowel Note: Do not damage washer and assembling surface. Washer Check Measure the lateral clearance of big end of connecting rod. Allowable limit: 0.55 mm. Measurement position of big end of connecting rod KS MOTORCYCLES - https://ksmotorcycles.com - 239 -...
Page 241 Check whether the crankshaft bearing rotates with abnormal noise or whether it is loose. If there is abnormal noise or it is loose, replace the crankshaft assembly. *Note: Crankshaft combination and transmission Installed on the crankcase. KS MOTORCYCLES - https://ksmotorcycles.com - 240 -...
Page 242 Muffler Name Air exhaust gasket Cap nut M6 Main cylinder assembly Buffer rubber Clamp assembly Auxiliary cylinder assembly Bolt M8×30 Self-locking nut M8 KS MOTORCYCLES - https://ksmotorcycles.com - 241 -...
Page 243 Emission Control KS MOTORCYCLES - https://ksmotorcycles.com - 242 -...
Page 244 KS MOTORCYCLES - https://ksmotorcycles.com - 243 -...
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Page 246 KS MOTORCYCLES - https://ksmotorcycles.com - 245 -...
Page 247: Exhaust Emission Control System
To ensure normal emission, the users should carry out inspection, adjustment or maintenance in accordance with the specified time. For other individual problems on use, please ask the dealers .   The relevant emission provisions are shown below: KS MOTORCYCLES - https://ksmotorcycles.com - 246 -...
Page 248: Mechanical Function Of Exhaust Control System
Device Constituent part Function The canned oxydic catalyst installed in the Exhaust Catalyst device Catalyst convertor middle of exhaust pipe will oxidize CO, system HC and NOX. 17.4 Catalyst Conversion System 17.4.1 Construction: KS MOTORCYCLES - https://ksmotorcycles.com - 247 -...
Page 249 Do not start the engine by pushing the motorcycle. If necessary, start the engine by pushing the motorcycle after the temperature of the engine and catalytic converter is reduced. Do not ride the motorcycle by putting into gear or turning off the motorcycle during downhill running. KS MOTORCYCLES - https://ksmotorcycles.com - 248 -...
Page 250 When maintaining the ignition system of engine, it is not allowed to start the engine to check whether the spark plug can generate sparks by removing the spark plug. If it is necessary, the time should not be too long. KS MOTORCYCLES - https://ksmotorcycles.com - 249 -...
Page 251 Electronic Injection Pars KS MOTORCYCLES - https://ksmotorcycles.com - 250 -...
Page 252: Electronic Injection System
OEMs to understand the electronic control systems of engine more deeply; on the other hand, help the maintenance personnel in various KS MOTORCYCLES - https://ksmotorcycles.com - 251 -...
Page 253: Efi Parts
The engine controller can also wake up the self-diagnosis when the system is faulty. 18.2.1.1 ECU Appearance KS MOTORCYCLES - https://ksmotorcycles.com - 252 -...
Page 254 “-” terminal of intake ECU harness “-” terminal of sensor temperature and pressure connector sensor Diagonal stop switch Oxygen sensor signal “+” signal (highly effectively; optional) 5V+ at supply terminal of Intake pressure signal + sensor KS MOTORCYCLES - https://ksmotorcycles.com - 253 -...
Page 255 (300Kpa) in the fuel pipe can flow through the nozzle plate KS MOTORCYCLES - https://ksmotorcycles.com - 254 -...
Page 256 Impurities can cause the cohesion, flow deviation, leakage and other faults of fuel injector, so the fuel filter is very significant.  The fuel injector should be replaced with that with the same part number only, KS MOTORCYCLES - https://ksmotorcycles.com - 255 -...
Page 257 When installing the fuel injector connector, do not rotate the fuel injector. This may cause fuel injection target to shift. 18.2.2.5 Replacement Method The following is the disassembly and replacement method of fuel injector. Note: The injector and the surrounding objects are very hot.  Turn off the motorcycle. KS MOTORCYCLES - https://ksmotorcycles.com - 256 -...
Page 258 The throttle body position sensor provides the ECU with a throttle opening; Note: The engine idle speed is automatically controlled by the EFI system within the normal range. Do not adjust the idle screw with a great force. KS MOTORCYCLES - https://ksmotorcycles.com - 257 -...
Page 259 When the throttle is fully opened, the normal output is between 70% and 80% of the reference voltage. The impedance between the T1 and T2 terminals is 0kΩ to 5kΩ.   Adaptive temperature of working conditions: –40ºC ~ 125ºC. KS MOTORCYCLES - https://ksmotorcycles.com - 258 -...
Page 260 Standard: throttle idle position: 0.5 - 0.9V Full-open position of throttle: about 3.5-4V 2. Sensor circuit inspection Sensor NG: Sensor Standard: On 1—ECU29 1—ECU29 Sensor 1—to NG: Sensor 1—to Standard: Off ground ground KS MOTORCYCLES - https://ksmotorcycles.com - 259 -...
Page 261 General faults are caused by the looseness of connection plug-in or the falling of the pin on the plug-in. The sensor can only be replaced with that of the same model. KS MOTORCYCLES - https://ksmotorcycles.com - 260 -...
Page 262 Inspection point: connect it to the cable and turn on the power; measure the voltage between pin 2 and pin 4 with multimeter; Stanard: 4.75-5.25V Inspection of resistance: 5.5954 kilohm at 0° 2.0000 kilohm at 25° Otherwise, the sensor fails. KS MOTORCYCLES - https://ksmotorcycles.com - 261 -...
Page 263 4. Inspection of sensor: Connect with cable and power on; measure the voltage between pin 2 and pin 3 with a multimeter; in the standard case, the voltage is 4.25-4.75V under the air pressure of 100kPa when the sensor is not started. Otherwise, the sensor fails. The measurement diagram is as follows: KS MOTORCYCLES - https://ksmotorcycles.com - 262 -...
Page 264 Otherwise, the sensor fails. 4.Determination of oxygen sensor heating: measure the resistance between two pins (two white lines) of sensor heating rod with multimeter; Standard: 9.6±1.5Ω (measured at 21 ℃) The measurement diagram is as follows: KS MOTORCYCLES - https://ksmotorcycles.com - 263 -...
Page 265 The function of idle speed control valve is to control the flow area of bypass air passage of throttle body, so as to adjust the air volume of engine and control the idle speed of engine. KS MOTORCYCLES - https://ksmotorcycles.com - 264 -...
Page 266 18.2.10.1 Working Principle of Fuel Pump Assembly The electric fuel pump and pressure regulator work together to provide 300Kpa gasoline pressure to the engine and the fuel pump is installed at the bottom of fuel tank. KS MOTORCYCLES - https://ksmotorcycles.com - 265 -...
Page 267 Installation direction of fuel pump assembly: Arrange the installing screw holes of fuel pump assembly asymmetrically, and installed it in the specified direction. The pressure regulator should KS MOTORCYCLES - https://ksmotorcycles.com - 266 -...
Page 268 After it is unlocked with a key, the fuel pump will run for about 3 seconds. If you can hear the rotation sound of fuel pump, perform the operations according to the requirements in Article d. KS MOTORCYCLES - https://ksmotorcycles.com - 267 -...
Page 269: Fault Maintenance And Diagnosis Method
Code Criteria description Throttle position Signal range check high for Voltage of throttle position Throttle sensor is P0123 1st cycle Position Sensor throttle Position Sensor sensor is higher than 4.9V. short-circuited to power KS MOTORCYCLES - https://ksmotorcycles.com - 268 -...
Page 270 Fuel injector is Short circuit to battery for Output short circuit current Injector P0262 1st cycle short-circuited to Injector. is higher than 5A. power KS MOTORCYCLES - https://ksmotorcycles.com - 269 -...
Page 271 Internal Control The calculated check sum is Module ECU internal fault P0601 Check sum error not equal to the check sum 1st cycle Memory Check - checksum error in the flash memory. Sum Error KS MOTORCYCLES - https://ksmotorcycles.com - 270 -...
Page 272: Common Troubleshooting Methods
Electronic control system circuit and system electrical signal - digital multimeter (with buzzer) Electric control system fault diagnosis and engine working condition detection  Electronic control system fault diagnostic apparatus (recommended) electronic control system fault code table (emergency use) fuel pressure gauge, range: 0-600kP KS MOTORCYCLES - https://ksmotorcycles.com - 271 -...
Page 273 Engine harness and the vacuum pipeline—may affect the system to control air flow and fuel supply Whether oxygen sensor is assembled in place—may affect the system to determine the air to fuel ratio Engine fault indicator—may affect the system to give an alarm for fault KS MOTORCYCLES - https://ksmotorcycles.com - 272 -...
Page 274 Under normal conditions of use, clean the throttle body every 10,000 km or 1 year. 18.4.3.2 Fault phenomenon-Start Fault Rotate ignition switch to “On” position, and check whether engine fault lamp is on. KS MOTORCYCLES - https://ksmotorcycles.com - 273 -...
Page 275 Confirm whether cylinder is submerged  After completely opening the throttle and turning on starting motor, there should be working If yes: sign in engine after several seconds Check whether crankshaft position sensor clearance is too large KS MOTORCYCLES - https://ksmotorcycles.com - 274 -...
Page 276 After confirming that the engine mechanical parts and oxygen sensor are in normal conditions, run the engine to observe the oxygen sensor reading. If the reading is always greater than 500 mV at normal water temperature, check whether there is leakage in fuel injector. KS MOTORCYCLES - https://ksmotorcycles.com - 275 -...
Page 277 It will be eliminated after a period of high-speed operation, or appropriate means should be taken to keep the engine coolant temperature within the specified temperature range. KS MOTORCYCLES - https://ksmotorcycles.com - 276 -...
Page 278: Circuit Diagram
Circuit Diagram ignition coil Engine stop Brake switch Fuel meter Start swtich Clutch switch Speed sensor Main swtich Meter Start relay Battery Cylinder temperature sensor COLOR CODE W/BL MAP/ITA Gr/W Black Blue B/BL R/Gr Light blue Brown Green Orange FUSE Yellow FUSE FUSE...