Kove 450 RALLY 2022 User manual

450 Rally Maintenance manuals
First Edition (February 2023)
This maintenance manual is copyrighted by TIBET NEW
SUMMIT MOTORCYCLE CO.,LTD.
The contents and pictures of this maintenance manual are for
reference only, please refer to the actual.
English
version
1

Introduction
This motorcycle manual provides the reader with a detailed introduction to the basic
structure, operating principles, disassembly and overhaul, and troubleshooting methods
of the 450 Rally motorcycle. It also introduces the technical specifications, performance
parameters and maintenance adjustment data of this model. It is hoped that this manual
will provide technical support and guidance to the users and after-sales service personnel
of Kaiyue motorcycles.
The technical specifications, performance parameters and maintenance adjustment
data indicated in this manual are based on the latest status. Please note that any
subsequent improvements made by the Company to this model may not be in
accordance with this manual without prior notice. We sincerely hope that you will give us
your valuable opinions and suggestions on the design, manufacture and quality of this
model, and inform us for timely improvement.
All the information, charts and various data and performance indexes published in
this manual are available until the printing of this manual. Please understand that TIBET
NEW SUMMIT MOORCYCLE CO.,LTD., reserves the right to make changes to this manual
without prior notice. Any part of this manual is the copyright of TIBET NEW SUMMIT
MOTORCYCLE CO.,LTD. Otherwise, they will be held criminally and legally responsible.
Due to the limited level of the editor, there are inevitably errors and omissions in this
manual, so please criticize and correct
TIBET NEW SUMMIT MOORCYCLE CO.,LTD.
Address: No. 2, Xiangyu Road, Shuangfengqiao Street, Yubei District, Chongqing
Customer service hotline :[phone]
For more information, please visit our website at www.colovemotor.com
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Contents
Introduction
Chapter 1 Overview ....................................................................................................... 1
Chapter 2 Basic information ....................................................................................... 3
Chapter 3 Regular maintenance and adjustment .............................................. 28
Chapter 4 Frame, body trim, exhaust system ...................................................... 72
Chapter 5 EFI ................................................................................................................... 89
Chapter 6 Fuel System .............................................................................................. 124
Chapter 7 Cooling System ........................................................................................ 139
Chapter 8 Engine ......................................................................................................... 150
Chapter 9 Cylinder head assy ................................................................................ 158
Chapter 10 Cylinder block and piston ................................................................. 169
Chapter 11 Clutch, driving gear, overrunning clutch, oil pump, gearshift
mechanism ..................................................................................................................... 175
Chapter 12 Magneto and balance driving and driven gear ......................... 187
Chapter 13 Crankcase, crankshaft, variable speed drive, balance shaft ... 193
Chapter 14 Front wheels, suspension, steering ................................................. 199
Chapter 15 Rear wheel, suspension........................................................................ 216
Chapter 16 Hydraulic brake system ....................................................................... 223
Chapter 17 ABS ............................................................................................................. 234
Chapter 18 Electrical parts ........................................................................................ 249
Chapter 19 Circuit schematic diagram ( factory ediion)..................................272
Chapter 20 Circuit schematic diagram (regular edition)..................................273
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How to use this manual
This manual describes the maintenance procedures for the 450 Rally.
Chapter 2 and 3 apply to the entire motorcycle. Chapter 4 describes the procedures for removing/installing
components that may be used to perform the services described in the following sections. Chapter 3--
Chapter 19 describe the motorcycle's components, grouped by location. If you are not familiar with this
motorcycle, please read the technical characteristics in Chapter 2. Follow the recommendations of the
maintenance schedule (Chapter 3) to ensure that the motorcycle is in optimum operating condition and that
emission levels meet domestic environmental requirements, then go to the table of contents on the first
page of that section. Most sections begin with program sets or system descriptions, maintenance
information and troubleshooting. Detailed procedures are given on the next few pages. Refer to each section
for troubleshooting based on the fault or symptom.
Your safety and the safety of others is very important. To help you make informed decisions, we have
provided safety information and other information in this manual .
You must use your own good judgment. You will find important safety information in various forms,
including.
Chapter 1
1
*Safety labels
*Safety Message - Precede the safety warning symbol with one of three signal words,
i.e., DANGER, WARNING, or CAUTION. The meaning of these signal words is:
If you do not follow the instructions, death or serious injury will result.
Failure to follow instructions may result in death or serious injury.
If you do not follow instructions, you may be injured.
Instructions - How to properly and safely service this vehicle
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Symbol
The symbols used in this manual represent specific repair procedures. If additional information
related to these symbols is required, it will be explained in detail in the text without using these
symbols
Replace parts with new parts before assembly
Use recommended oils unless otherwise explanation
Use molybdenum oil solution (oil and molybdenum grease
mixed in a ratio of 1:1)
Use multi
-purpose high temperature extreme pressure
compound lithium base grease (Youlicheng Grease SU
-
T330G/F or equivalent grease)
Molybdenum disulfide grease
Use molybdenum disulfide paste (40% or more
molybdenum disulfide, NLGI #2 or equivalent).
For example: G
-n paste made by Dow Corning USA
Honda Moly 60 (USA only). Rocol paste from Sumico
Lubricants, Japan, manufactured by Rocol Ltd.
Use of silicone grease
Apply sealant. Use a medium strength sealant unless
otherwise specified
Application of sealants
Use DOT4 brake fluid. Use recommended brake fluid unless
otherwise stated
Use shock absorbing fluid
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Basic information
1 Maintenance rules ................................................................................................. 4
2 Model identification .............................................................................................. 5
3 Basic information ................................................................................................... 6
4 Torque value - engine part ............................................................................... 13
5 Torque value - body part .................................................................................. 15
6 Lubrication and sealing point - Engine part................................................ 26
7 Lubrication and sealing point - body part................................................... 27
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Maintenance rules
1. Please use genuine or KOVE recommended parts and lubricants or their
equivalents for the KUVE. Parts that do not meet KOVE's design
specifications may damage the motorcycle.
2. Use special tools designed for this product to avoid damage and
incorrect assembly.
3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts
and bolts are not interchangeable with imperial fasteners.
4. Use new gaskets, O-rings, cotter pins and locking plates when
reassembling.
5. When tightening bolts or nuts, start with large diameter or inner bolts.
Then tighten in diagonal increments to the specified torque, unless a
specific sequence is specified.
6. Clean parts with cleaner when disassembling. Lubricate all sliding surfaces
before reassembly.
7. After reassembly, check all parts for proper installation and operation.
8. Route all wires as shown in the cable and cableway wiring.
9. Do not bend or twist control cables. Damaged control cables will not
work properly and may become stuck or tangled.
10.Abbreviations
Throughout this manual, the following abbreviations are used to identify
the respective components or systems.
Abbreviation Full Name
ABS
Anti
-lock braking system (450Rally factory version
without ABS)
CKP
sensor
crankshaft position sensor
DLC
Data link connector
DTC
Direct Torque Control
ECU
Engine control
unit
ECT
sensor
Engine coolant temperature sensor
EEP
ROM
Electrically Erasable Programmable Read
-
Only Memory
EOP
switch
Engine oil pressure switch
EVAP
Evaporative Emission Control System
IAT
sensor
intake air temperature sensor
MAP
sensor
ManifoldAbsolutePressureSensor
MCS
Motorcycle communication system
MIL
Malfunction Indicator Lamp
O
2sensor
oxygen sensor
SCS Service
connector
Service
connector
TP sensor
throttle position sensor
VS sensor
vehicle speed sensor
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Model identification
factory edition-⑴regular edition-⑵
⑴
⑵
5
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Basic information
items specification
Size
Total lenght
2190 mm
Total Width
830 mm
Total height
1487 mm
Axle distance
1475 mm
Load free seat height
960 mm
No load pedal height
360 mm
No load ground clearance
300 mm
Dry weight
155 kg
Permissible maximum front axle load
150 kg
Permissible maximum load on rear axle
210 kg
Permissible maximum weight
150 kg
Frame
Frame type
Cradle type frame
Front Suspension
Inverted telescopic fork
Front
shock absorber stroke
305 mm
Rear Suspension
External spring hydraulic
Rear shock absorber stroke
117 mm
Front tire size
90/90
-21M/C
Rear tyre size
140/80
-18M/C
Front tyre brand
Zhengxin
Rear
tyre brand
Zhengxin
Front Brake
Hydraulic single disc 298mm
Rear
Brake Hydraulic single disc 240mm
Caster angle
28
°
Towing distance
122 mm
Fuel tank capacity
31L
Engine
Cylinder alignment
1 cylinder inline, 18°
vertical
tilt
Cylinder diameter and stroke
94.5x64mm
Displacement
499cm
3
Compression ratio
12.5:1
Air distribution system
Double overhead camshaft
four-valve chain drive
intake
valve
-
5°BTDC
-
5°BTDC
35
°ABDC
35
°ABDC
exhaust
valve
33
°BBDC
33
°BBDC
-
13°ATDC
-
13°ATDC
lubricating system
Forced pressure lubrication +
splash lubrication
Oil pump type
Oscillating type
Cooling system
water cooling
Air filltration
Paper cartridge，oil-based
sponge
Engine dry weight
37kg
Ignition sequence
/
Number of cylinder
single cylinder
6
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items specification
The Fuel
Supply
System
Type
Bosch EFI
Throttle valve hole
46mm
Drive system
Clutch system
Wet multichip type
Clutch operating
system
Cable operation
Gearbox
Normal mesh two
-stage
transmission, 6
-speed
Primary drive
2.286
（69/34）
Final drive
3.769
Gear Ratio
1th
2.357
（43/15）
2th
1.824 (46/14)
3th
1.474 (40/19)
4th
1.181(32/20)
5th
1.000(26/20)
6th
0.846(23/20)
Gear Shift Mode
international
1-N-2-3-4-5-6
Electricity
Ignition system
electron ignition
Starting system
electric starter
Charging system
Three-phase output magnetic motor
Regulator/rectifier
Three
-phase full-wave rectification
Lighting System
Battery
items specification
Engine idle
1600
±100rpm
ECT Sensor resistance
（40°C/104°F
）
1.0
-1.2kΩ
IAT
Sensor resistance（20°C/68°F
）
2
-4kΩ
Fuel injector resistance
（20°C/68°F
）
11
-13Ω
Oxygen sensor heater resistance
（
20
°C/68°F）
10
-40Ω
Idle motor resistance
（25°C/77°F
）
110
-150Ω
items specification
Sparking plug
CR8E
（NGK）
Spark Plug Clearance
0.80
-0.90
Spark plug resistance
5
-8 KΩ
items Standard value limit value
Start motor brush
length
12.0-13.0（0.47-0.51）
6.5
（0.26）
EFI specification Measurement units：mm
Ignition system specification Measurement units：mm
Electric starter specifications Measurement units：mm
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