Karma KS-7 Series Maintenance Manual

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Maintenance Manual

KS-7 Series

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KS-737.2

KS-737.2L

KS-747.2

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Summary of Contents for Karma KS-7 Series

Page 1 Maintenance Manual KS-7 Series □ □ □ KS-737.2 KS-737.2L KS-747.2...
Page 2 Introduction This manual contains basic detail information about the disassembly and replacement for KS-7 series to enable Karma's authorized dealers to provide better after service. It is not intended to be a comprehensive maintenance guide or provide detail assembly/disassembly of the products.
Page 3  Part name/ Description  Quantity required 4. Warranty Policy- Do use the parts provided by Karma to meet the requirement of product quality and warranty policy. For more details, please refer to the Owner's Manual / Distribution Contract. 5. Technical Data 5.1 Limited Loading Weight...
Page 5 Table of Content 1. Front Wheel ......................1 2. Rear Wheels ......................6 3. Shock Absorber ....................7 4. Controller ....................... 9 5. Motor Differential ..................... 14 6. Anti-Tipper ......................17 7. Rear Casing And Battery ................22 8. Rear Casing ......................
Page 6 1. Front Wheel 1.1 KS-737 Front Wheel Figure 1.1 1. M20 Upper Bearing Cap 2. Upper Bearing Adjustment Ring 3. Bearing 4. Top Bearing Seat 5. Bottom Bearing Cap 6. Bottom Bearing Seat 7. Front Wheel Fork 8. M10 Hex Socket Head Cap Screw 9.
Page 7 Requirements: -8 mm L-shaped Allen key -17 mm box wrench -30 mm open end wrench Instructions of Disassembly & Maintenance: 1.1.1 Use the 8 mm L-shaped Allen key and the 17 mm box wrench to remove (8) and (13). The, the the front wheel assembly can be removed. 1.1.2 Use the 30 mm open end wrench to remove M20 upper bearing cap (1).
Page 8 1.2 KS-737.2L Front Wheel Figure 1.2 1. Front Wheel Fork 2. M10 Hex Socket Head Cap Screw 3. Fixing Block of Drum Brake 4. Drum Brake Assembly 5. Front Wheel Assembly 6. M10 Nylon Insert Hex Nut...
Page 9 Requirements: -8 mm L-shaped Allen key -17 mm box wrench Instructions of Disassembly & Maintenance: 1.2.1 Use the 8 mm L-shaped Allen key and the 17 mm box wrench to remove (2) and (6). Remove these parts (3, 4, and 5) in sequence starting from (3) to remove the front wheel assembly.
Page 10 1.3 KS-747.2 Front Wheels Figure 1.3 1. M8 Hex Head Bolt 2. M8 Spring Washer 3. M8 Flat Washer 4. Front Wheel Assembly ( of Larger Inch) 5. Sleeve Requirements: -13 mm socket wrench Instructions of Disassembly & Maintenance: 1.3.1 Use the 13 mm socket wrenchto remove (1). Remove (2 and 3) in sequence, and the front wheel assembly can be removed from the side.
Page 11 2. Rear Wheels Figure 2.1 1. Tube Plug-Black 2. M10 Nylon Insert Hex Nut 3. M10 Flat Washer 4. Rear Wheel Assembly 5. Differential of Motor Requirements: -17 mm box wrench Instructions of Disassembly & Maintenance: 2.1 Remove the tube plug (1). Use the 17 mm box wrench to remove (2). Remove (3), and the rear wheel can be replaced.
Page 12 3. Shock Absorber 3.1 KS-737.2 Shock Absorber Figure 3.1 1. M10 Nylon Insert Hex Nut 2. M10 Flat Washer 3. Rear Shock Absorber 4. M10 Hex Head Bolt Requirements: -Two 17 mm box wrenches Instructions of Disassembly & Maintenance: 3.1.1 Use two 17 mm box wrenches to remove (1) and (4). After removing (2), the shock abosorber can be removed.
Page 13 3.2 KS-737.2L Shock Absorber Figure 3.2 1. Rear Shock Absorber 2. M8 Flat Washer 3. M8 Hex Head Bolt 4. M8 Nylon Insert Hex Nut Requirements: -Two 13 mm box wrenches Instructions of Disassembly & Maintenance: 3.2.1 Use two 13 mm box wrenches to remove (3) and (4). After removing (2), the shock abosorber can be removed.
Page 14 4. Controller 4.1 KS-737.2 Controller Figure 4.1 1. M5 Flat Head Socket Cap Screw (25 mm) 2. S-Drive120 Controller 3. Mounting Plate of Central Relay Box 4. M5 Nylon Insert Hex Nut 5. M5 Flat Head Socket Cap Screw (16 mm) 6.
Page 15 Requirements: -3 mm L-shaped Allen key -7 mm box wrench Instructions of Disassembly & Maintenance: 4.1.1 Use the 3 mm L-shaped Allen key to remove (5), Then (6)and (7) can be removed. 4.1.2 Use the 3 mm L-shaped Allen key and the 7 mm box wrench to remove part (1) and (4), then the controller can be removed.
Page 16 4.2 KS-737.2L Controller Figure 4.2 1. M5 Flat Head Socket Cap Screw 2. S-Drive 120 Controller 3. M5 Flat Washer 4. M5 Nylon Insert Hex Nut Requirements: - 3 mm L-shaped Allen key - 8 mm box wrench Instructions of Disassembly & Maintenance: 4.2.1 Use the 3 mm L-shaped Allen key and the 8 mm box wrench to remove (1) and (4), then (3) and the controller can be removed.
Page 17 4.3 KS-747.2 Controller Figure 4.3 1. M5 Flat Head Socket Cap Screw (25 mm) 2. S-Drive120 Controller 3. Mounting Plate of Central Relay Box 4. M5 Nylon Insert Hex Nut 5. M5 Flat Head Socket Cap Screw (16 mm) 6. M5 Spring Washer 7.
Page 18 Inspection Points: ●After the re-assembly, the cables should be plugged in properly. ●The cables and cable ties should be arranged as the original. DO NOT modify it.
Page 19 5. Motor Differential 5.1 KS-737.2 Motor Differential Figure 5.1 1. M8 Hex Head Bolt 2. M8 Flat Washer 3. Retaining Ring of Differential 4. Orange Rubber Pad 5. Reinforcement Plate of Retaining Ring 6. M8 Nylon Insert Nut 7. M6 Nylon Insert Hex Nut 8.
Page 20 Requirements: - 4 mm L-shaped Allen key - 10 mm box wrench - 13 mm box wrench Instructions of Disassembly & Maintenance: 5.1.1 Fisrt, remove the rear wheels refering to previous section. 5.1.2 Use the 4 mm L-shaped Allen key and the 10 mm box wrench to remove (7) and (10).
Page 21 5.2 KS-747.2 Motor Differential Figure 5.2 1. M8 Hex Head Bolt 2. M8 Internal Tooth Lock Washer 3. Retaining Plate of Brake 4. Retaining Ring of Brake 5. Motor Differential Assembly 6. Orange Rubber Pad Requirements: -Two 13 mm box wrenches Instructions of Disassembly &...
Page 22 6. Anti-Tipper 6.1 KS-737.2 Anti-Tipper Figure 6.1 1. M6 Hex Socket Head Cap Screw 2. M6 Flat Washer 3. Anti-Tipper Assembly 4. M6 Nylon Insert Hex Nut Requirements: -5 mm L-shaped Allen key -10 mm box wrench Instructions of Disassembly & Maintenance: 6.1.1 Use the 5 mm L-shaped Allen key and the 10 mm box wrench to remove (1) and (4).
Page 23 6.2 KS-737.2L Anti-Tipper Figure 6.2 1. M6 Hex Socket Head Cap Screw 2. 2”Anti-Tipper Wheel 3. M6 Flat Washer 4. Anti-Tipper Assembly 5. M6 Nylon Insert Hex Nut 6. M8 Hex Head Bolt 7. M8 Flat Washer 8. M8 Nylon Insert Hex Nut...
Page 24 Requirements: -5 mm L-shaped Allen key -10 mm box wrench -Two 13 mm box wrenches Instructions of Disassembly & Maintenance: 6.2.1 Use the 5 mm L-shaped Allen key and the 10 mm box wrench to remove (1) and (5). Then, remove (2) and (3). The anti-tipper can be replaced. 6.2.2 Use the two 13 mm box wrenches to remove (6) and (8).
Page 25 6.3 KS-747.2 Anti-Tipper Figure 6.3 1. M6 Hex Socket Head Cap Screw 2. M6 Flat Washer 3. Ant-Tippers Assembly 4. M6 Nylon Insert Hex Nut...
Page 26 Requirements: -5 mm L-shaped Allen key -10 mm box wrench Instructions of Disassembly & Maintenance: 6.3.1 Use the 5 mm L-shaped Allen key and the 10 mm box wrench to remove (1) and (4). Then, remove (2). The anti-tipper can be adjusted. 6.3.2 Remove the anti-tipper from the side.
Page 27 7. Rear Casing and Battery 7.1 KS-737.2 Rear Casing and Batteries Figure 7.1 1. Straight Grain Small Knob (HK25M615) 2. Rear Casing Assembly 3. Battery Assembly Instructions of Disassembly & Maintenance: 7.1.1 Loosen (1) with one hand and remove (2). Unfasten the Velcro straps which fix the batteries, and the batteries can be replaced.
Page 28 7.2 KS-747.2 Rear Casing and Batteries Figure 7.2 1. Straight Grain Small Knob (HK25M615) 2. Straight Grain Small Knob (HK20M615) 3. Rear Casing 4. Batteries Instructions of Disassembly & Maintenance: 7.2.1 Loosen (1) and (2) with one hand and remove (3). Unfasten the Velcro straps which fix the batteries, and the batteries can be replaced.
Page 29 8. Rear Casing Figure 8.1 1. Transparent Turn Signal Light 2. Rear Casing 3. M8 Spring Washer 4. Nut of Backrest Tube Base 5. M4 Flat Head Phillips Self Tapping Screw Requirements:...
Page 30 -Phillips screwdriver Instructions of Disassembly & Maintenance: 8.1 Loosen the rear casing and the batteries refering to the previous sections. 8.2 Use the Phillips screwdriver to remove (5). Remove (4) and (3) in sequence. Then, the rear lights can be removed. 8.3 Re-assembly is done in reverse order.
Page 31 9. Seat 9.1 KS-737.2L Seat Figure 9.1 1. Seat Lift Assembly 2. M10 Nylon Insert Hex Nut 3. M10 Flat Washer 4. M10 Hex Head Bolt (16 mm) 5. M10 Hex Head Bolt (50 mm) Requirements: -Two 17 mm box wrenches Instructions of Disassembly &...
Page 32 9.2 KS-737.2L Seat Figure 9.2 1. Knob Bolt Instructions of Disassembly & Maintenance: 9.2.1 Untighten (1) with one hand and the seat can be removed or the seat height can be adjusted. 9.2.2 Re-assembly is done in reverse order. Inspection Points: ●The knob bolt should be tightened.
Page 33 10. Headlight 10.1 KS-737 Headlight Figure 10.1 1. Headlight 2. M5 Flat Head Socket Cap Screw 3. M5 Spring Washer 4. M5 Flat Washer 5. Front Casing 6. M5 Nylon Insert Hex Nut 7. M6 Flat Washer 8. Long Bumper Protection Strip...
Page 34 Requirements: -3 mm L-shaped Allen key -8 mm box wrench Instructions of Disassembly & Maintenance: 10.1.1 Use the 3 mm L-shaped allen key to remove (2). Remove (3 and 4), and then the headlight can be replaced. 10.1.2 Use the 3 mm L-shaped allen keyand the 8 mm box wrench to remove (2 and 6).
Page 35 10.2 KS-747.2 Headlight Figure 10.2 1. Phillips Self Tapping Screw 2. Phillips Self Tapping Screw Requirements: -Phillips screwdriver Instructions of Disassembly & Maintenance: 10.2.1 Use the Phillips screwdriver to remove (1), and remove the light base. 10.2.2 Use the Phillips screwdriver to remove (2). Carefully remove the light bulb.
Page 36 11. Rear View Mirror and Basket Figure 11.1 1. Rear-View Mirror 2. Basket Requirements: -13 mm box wrench Instructions of Disassembly & Maintenance: 11.1 Use the 13 mm box wrench to remove (1). 11.2 Remove the basket by lifting the basket up with two hands. 11.3 Re-assembly is done in reverse order.
Page 37 12. Steering Column Figure 12.1 1. M5 Flat Head Socket Cap Screw (16 mm) 2. M5 Plastic Washer 3. Bottom Casing Complete of Steering Column 4. Rear Casing Complete of Steering Column 5. M5 Nylon Insert Hex Nut 6. Front Bottom Casing of Steering Column 7.
Page 38 Requirements: -3 mm L-shaped Allen key -8 mm box wrench Instructions of Disassembly & Maintenance: 12.1 Use the 3 mm L-shaped Allen key to remove (1) and remove (2). Then, the nameplate casing, top casing assembly, bottom casing complete, and rear casing complete can all be removed.
Page 39 13. Turn Signal Light Figure 13.1 1. Front Top Casing of Steering Column 2. M10 Nylon Insert Hex Nut 3 & 4. Turn Signal Lights 5. Soft Polyester Name Plate...
Page 40 Requirements: -17 mm box wrench Instructions of Disassembly & Maintenance: 13.1 Use the 17 mm box wrench and detach the pins to remove it. Do not over pull the wires. 13.2 Remove the light cover by opening it from the side. 13.3 Re-assembly is done in reverse order.
Page 41 14. Speed Lever Figure 14.1 1. M5 Flat Washer 2. M5 Nylon Insert Hex Nut 3. M5 Round Head Phillips Machine Screw 4. M5 Spring Washer 5. Casing Mounting Bracket 6. Variable Resistor 7. Speed Lever –Pull Type 8. Bearing RIF-814ZZ 9.
Page 42 -3 mm L-shaped Allen key -8 mm box wrench Instructions of Disassembly & Maintenance: 14.1 Remove the casing of the tiller refering to the previous sections. 14.2 Use the 3 mm L-shaped Allen key and the 8 mm box wrench to remove (2 and 10).
Page 44 15. Electronics 15.1 Error Codes and Diagnostic Codes Number of Battery & Diagnostics Indicator Bars Battery Voltage The batteries need charging or there is a bad connection to the batteries. Check the connections between the central relay box and the batteries. If the connections are good, try charging the batteries.
Page 60 104-***** Rev:00 Dec.2013...

This manual is also suitable for:

Ks-737.2 Ks-737.2l Ks-747.2