Ks motorcycles K-light125 User manual

Maintenance Manual of

Two-wheeled Motorcycle

(K-LIGHT125)

KS MOTORCYCLES - https://ksmotorcycles.com

Contents

Contents.................................................................................................................................................................- 1 -

Preface...................................................................................................................................................................- 4 -

Preparatory information.........................................................................................................................................- 5 -

General safety................................................................................................................................................- 5 -

Maintenance rules..........................................................................................................................................- 6 -

Motorcycle identification.............................................................................................................................- 10 -

Important notes............................................................................................................................................- 11 -

Special tools.................................................................................................................................................- 11 -

Specification table ........................................................................................................................................- 18 -

Fault diagnosis.............................................................................................................................................- 20 -

Inspection / adjustment................................................................................................................................- 47 -

Inspection and Maintenance of Electrical System...............................................................................................- 72 -

I. Battery/Charging System..................................................................................................................................- 74 -

1.1 Preparatory Information.........................................................................................................................- 74 -

1.2 Fault Diagnosis......................................................................................................................................- 75 -

1.3 Battery ...................................................................................................................................................- 76 -

1.4 Charging System....................................................................................................................................- 77 -

1.5 Disassembly of Voltage and Current Regulator.....................................................................................- 78 -

1.6 Alternator Charging Coil .......................................................................................................................- 79 -

1.7 Disassembly of Alternator .....................................................................................................................- 79 -

II. Ignition System...............................................................................................................................................- 83 -

2.1 Preparatory Information.........................................................................................................................- 83 -

2.2 Fault Diagnosis......................................................................................................................................- 85 -

2.3 Trigger ...................................................................................................................................................- 86 -

2.4 Ignition Coil...........................................................................................................................................- 86 -

2.5 Spark Plug..............................................................................................................................................- 88 -

2.6 ECU.......................................................................................................................................................- 88 -

III. Starter System................................................................................................................................................- 90 -

3.1 Preparatory Information.........................................................................................................................- 90 -

3.2 Fault Diagnosis......................................................................................................................................- 91 -

3.3 Starter Motor..........................................................................................................................................- 91 -

3.4 Starter Relay ..........................................................................................................................................- 92 -

IV. Bulbs /Switches/Meters .................................................................................................................................- 95 -

4.1 Preparatory Information.........................................................................................................................- 95 -

4.2 Fault Diagnosis......................................................................................................................................- 96 -

4.3 Replacement of Headlight Bulb.............................................................................................................- 97 -

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 -

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4.9 Electric horn ........................................................................................................................................- 102 -

4.10 Handlebar Switch...............................................................................................................................- 104 -

Inspection and Maintenance of Chassis.............................................................................................................- 105 -

V. Brake.............................................................................................................................................................- 108 -

5.1 Preparatory Information.......................................................................................................................- 108 -

5.2 Fault Diagnosis....................................................................................................................................- 109 -

5.3 Front Brake Disc..................................................................................................................................- 109 -

5.4 Rear Brake Disc...................................................................................................................................- 111 -

5.5 CBS......................................................................................................................................................- 113 -

VII. Front Wheel/Front Suspension...................................................................................................................- 134 -

7.1 Preparatory Information.......................................................................................................................- 134 -

7.2 Fault Diagnosis....................................................................................................................................- 135 -

7.3 Front Wheel.........................................................................................................................................- 135 -

7.4 Handlebar.............................................................................................................................................- 140 -

7.5 Front Fork............................................................................................................................................- 145 -

7.6 Front Shock Absorber..........................................................................................................................- 151 -

VIII. Rear wheel/rear suspension ......................................................................................................................- 160 -

8.1 Preparation of Information-.................................................................................................................- 160 -

8.2 Fault Diagnosis....................................................................................................................................- 160 -

8.3 Rear wheel...........................................................................................................................................- 161 -

8.4 Rear shock absorber.............................................................................................................................- 166 -

8.5 Rear RockerArm.................................................................................................................................- 168 -

8.6 Chain drive ..........................................................................................................................................- 171 -

IX. Fuel Tank/Seat.............................................................................................................................................- 180 -

9.1 Preparatory information.......................................................................................................................- 180 -

9.2 Fault Diagnosis....................................................................................................................................- 180 -

9.3 Seat......................................................................................................................................................- 181 -

9.4 Fuel Tank .............................................................................................................................................- 182 -

X. Disassembly/Installation of Engine..............................................................................................................- 190 -

10.1 Preparatory information.....................................................................................................................- 190 -

10.2 Fault Diagnosis..................................................................................................................................- 190 -

10.3 Disassembly of Engine ......................................................................................................................- 191 -

10.4 Installation of Engine.........................................................................................................................- 191 -

Inspection and maintenance of engine...............................................................................................................- 193 -

XI. Lubrication System......................................................................................................................................- 195 -

11.1 Preparatory Information.....................................................................................................................- 195 -

11.2 Fault Diagnosis..................................................................................................................................- 195 -

11.3 Fuel Pump..........................................................................................................................................- 196 -

XII. Cylinder head / valve .................................................................................................................................- 201 -

12.1 Preparatory information.....................................................................................................................- 201 -

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 -

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12.7 Installation of Cylinder Head.............................................................................................................- 209 -

XIII. Cylinder Block and Piston........................................................................................................................- 211 -

13.1 Preparatory Information.....................................................................................................................- 211 -

13.2 Fault Diagnosis...............................................................................................................................- 212 -

3.3 Cylinder Block.....................................................................................................................................- 213 -

13.4 Piston.................................................................................................................................................- 214 -

13.5 Installation of Cylinder Block............................................................................................................- 218 -

XIV. Clutch / kickstarter mechanism..............................................................................................................- 221 -

14.1 Preparatory Information.....................................................................................................................- 221 -

14.2 Fault Diagnosis..................................................................................................................................- 221 -

14.3 Clutch.................................................................................................................................................- 222 -

14.4 Kickstarter Mechanism......................................................................................................................- 224 -

14.5 Disassembly of primary and auxiliary shafts.....................................................................................- 225 -

XV. Variable speed gear.....................................................................................................................................- 229 -

15.1 Preparatory Information.....................................................................................................................- 229 -

15.2 Fault Diagnosis..................................................................................................................................- 229 -

15.3 Shift mechanism................................................................................................................................- 230 -

15.4 Installation.........................................................................................................................................- 233 -

XVI. Crankcase .................................................................................................................................................- 235 -

16.1 Preparatory Information.....................................................................................................................- 235 -

16.2 Fault Diagnosis..................................................................................................................................- 235 -

16.3 Crankcase...........................................................................................................................................- 236 -

16.4 Crankshaft combination.....................................................................................................................- 239 -

XVII. Exhaust Emission Control System..........................................................................................................- 246 -

17.1 Guarantee of Exhaust Emission Control System...............................................................................- 246 -

17.2 Regular Maintenance Notice .............................................................................................................- 246 -

17.3 Mechanical Function of Exhaust Control System .............................................................................- 247 -

17.4 Catalyst Conversion System..............................................................................................................- 247 -

XVIII. Electronic Injection System...................................................................................................................- 251 -

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

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Preface

This Maintenance Manual is the explanation for the maintenance essentials of

dealers.

Preparatory information includes all matters needing attention for operation in

the Maintenance Manual. Please read this Manual carefully before operation.

Inspection and adjustment is the explanation for the essentials of inspection and

adjustment, as well as the safety of motorcycles and performance maintenance

methods of parts, which should be implemented from the time of regular inspection.

Chapter II and subsequent chapters are the explanations for the decomposition,

combination and inspection of the others of electrical equipment, motorcycle and

engine.

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.

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Preparatory information

General safety

Special tools

Maintenance rules

Specification table

Motorcycle identification

Fault diagnosis

Important notes

General safety

Carbon monoxide

If the engine must be started, ensure that the workplace is well-ventilated and do not operate the engine in a closed

place.

Notes

Exhaust gas contains

carbon monoxide, a kind of toxic gas, which may cause people to lose consciousness and

possibly lead to death.

It is necessary to operate the engine in an open place, and exhaust cleaning system should be used when the

engine is operated in a closed place.

Gasoline

Workers should operate in a well-ventilated workplace. Smoke and fire are strictly prohibited in the workplace or

the place where gasoline is stored.

Battery

Battery may emit explosive gas. Keep it away from spark, open flames and smoking area. Keep it well ventilated

when it is being charged.

Battery contains sulfuric acid (electrolyte). Burns may be caused when it contacts with skin or eyes. Therefore,

workers should wear protective clothing and mask.

——If electrolyte splashes on the skin, rinse it immediately with fresh water.

——If electrolyte splashes in the eyes, rinse them with fresh water immediately for more than 15 minutes

and consult a doctor.

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.

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Maintenance rules

During the maintenance of the motorcycle, use metric

tools as much as possible. The motor

cycle may be

damaged due to the use of incorrect tools.

Before removing or opening the fender for

maintenance, clean the dirt from the outside of part or

assembly, to prevent the dirt from falling into the

engine, chassis or brake system.

After disassembling and before measuring the wear

value, clean the parts and blow them with a compressed

air machine.

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.

Set

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Loosen parts with multiple assemblies from outside to

inside. First loosen small assemblies.

Complex assemblies such as gearboxes should be

stored in the proper assembly order for future assembly.

Complex assemblies such as gearboxes should be

stored in the proper assembly order for future assembly.

The parts that will no longer be used should be replaced

promptly before dismantling.

The lengths of bolts or screws are different for

assembly and fender, and they must be installed in the

proper positions. 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.

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Installation of rubber hose (fuel, vacuum, or coolant):

its end should be plugged into the bottom of connector,

so that there is enough place at the hose to clamp the

connector. Rubber or plastic dirt-proof boots should be

fitted at the original design position.

Disassembly of ball bearing: use tools to support one or

two (inner and outer) bearing rolling rings. If the

force is applied to only one rolling ring (either inside or

outside), the bearings may be damaged when being

disassembled and they must be replaced.

Groove

Clamp

Connector

Bearing may be damaged in the two examples

above.

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Loose cable is a potential safety hazard of electrical

safety. Check the next cable after clamping the cable, to

ensure electrical safety;

Wire clamps are not allowed to bend in the direction of

the solder joint;

Bundle the cable at the designated location;

Cables are not allowed to be placed at the end of frame

or at the corners;

Cables are not allowed to be placed at the ends of bolts

or screws;

Keep cables away from heat source or the position

where the cable may be caught during movement;

Cables should not be kept too tight or loose when being

placed along the faucet handle, and must not interfere

with adjacent parts in any steering position;

Cables should be smoothly placed and must not be

twisted or knotted;

Before con

nectors are mated, check whether the

connector sheath is damaged and the connector is

opened excessively;

If the cable is at a sharp or corner, please protect it with

tape or a hose;

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;

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