KSR Moto T58 - ZION 125 Operating instructions

REPAIR MANUAL
T58 - ZION 125 Vers. 2014_06

2
INTRODUCTION
It is important that you read this repair manual carefully before the start of work.
Only use KSR spare parts.
KSR Moto is a registered brand by KSR Group GmbH.
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with the service schedule.
The repair manual was written to correspond to the current state of this model.
We reserve the right to make changes in this manuals in the interest of technical advancements and improvements
without a notice.
It is recommended that repair work will be done by a fully educated mechanic.
We will not provide descriptions of general workshop methods, safety rules that necessary in a workshop.
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modify the information in this manual without notice and without specifying reasons.
KSR Group GmbH accepts no liability deviations from illustrations and descriptions or misprints and other errors.
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ther the illustrations and pictures are symbolic images, and may differ from the actual components.
© 2012 by KSR Group GmbH, Krems Austria
All rights reserved
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KSR Group GmbH
A-3500 Krems, Austria

3
INTRODUCTION 2
INDEX 3
IMPORTANT NOTES 6
LOCATION OF SEVERAL NUMBERS 7
VIN (CHASSIS NUMBER) AND FRAME PLATE 7
ANTI TEMPERING LABEL 7
ENGINE NUMBER 7
DECRYPTING THE VEHICLE IDENTIFICATION NUMBER 7
GENERAL SPECIFICATION 8
SPECIFIC TIGHTNING TORQUES 9
GENERAL TIGHTNING TORQUES 10
SPECIAL TOOLS 11
1. PERIODIC MAINTENANCE 15
PERIODIC MAINTENANCE CHART 16
IMPORTANT PREPERATION REFERENCES 17
AIR SYSTEM/ FUEL SYSTEM 20
AIR FILTER 20
THROTTLE CONTROL SYSTEM 20
IDLE ADJUSTMENT 20
FUEL SYSTEM 21
ADJUSTMENT OF CARBURETTOR 21
FUEL HOSE INSPECTION 21
FUEL FILTER REPLACEMENT 21
ENGINE 22
ENGINE OIL INSPECTION 22
ENGINE OIL REPLACEMENT 22
SPARK PLUG INSPECTION 22
SPARK PLUG IMAGES ANDANALYSIS 23
SPARK PLUG REPLACEMENT 23
OIL REPLACEMENT OF THE GEAR CASE 23
OIL LEVEL INSPECTION OF THE GEAR CASE 23
WHEELS AND TIRES/ BRAKES 24
AIR PRESSURE INSPECTION 24
WHEEL BEARING AND WHEELAXLE DAMAGE
INSPECTION 24
BRAKE FLUID LEAK INSPECTION FRONTAND REAR 24
BRAKE OPERATION INSPECTION FRONT/ REAR 24
BRAKE FLUID LEVEL INSPECTION FRONT/ REAR 25
FRONT BRAKE PAD WEAR INSPECTION/
REPLACEMENT 25
REAR BRAKE PAD WEAR INSPECTION/ REPLACEMENT26
FRONT/REAR BRAKE DISC INSPECTION 26
FRONT BRAKE DISC REPLACEMENT 27
REAR BRAKE DISC REPLACEMENT 27
FRONT BRAKE HOSE REPLACEMENT 28
REAR BRAKE HOSE REPLACEMENT 
SUSPENSION 30
FRONT FORK OPERATION INSPECTION 30
FRONT FORK OIL LEAK INSPECTION 30
REAR SHOCK OPERATION INSPECTION 30
REAR SHOCK OIL LEAK INSPECTION 30
STEERING 31
STEERING PLAY INSPECTION 31
STEERING PLAYADJUSTMENT 31
STEERING BEARING LUBRICATION 31
ELECTRICAL SYSTEM 32
BATTERY INSPECTION/ CHARGING 32
LIGHTAND SWITCHES OPERATION INSPECTION 33
HEADLIGHTAIMING INSPECTION 33
2. REPAIR AND DIAGNOSTICS 34
CHASSIS 35
EXPLODED VIEW/ PARTS LOCATION - CHASSIS 35
FUEL SYSTEM/ FUEL TANK 36
EXPLODED VIEW/ PART LOCATION - FUEL SYSTEM 36
TROUBLESHOOTING - FUEL SYSTEM 37
FUEL SYSTEM/ CARBURETTOR 38
EXPLODED VIEW/ PART LOCATION - CARBURETTOR 38
CARBURETTOR REMOVAL 
CARBURETTOR UPPER COVER REMOVAL 
FUEL SYSTEM/ FUEL TANK 40
FLOAT CHAMBER REMOVAL 40
ELECTRICAL ENRICHMENT VALVE (CHOKE) REMOVAL 40
CARBURETTOR ADJUSTMENT 40
FUEL SUPPLY INSPECTION 40
FUEL TANK REMOVAL 41
ENGINE 42
EXPLODED VIEW/ PARTS LOCATION - ROCKER COVER
AND CYLINDER HEAD 42
EXPLODED VIEW/ PARTS LOCATION - CYLINDER AND
PISTON 43
EXPLODED VIEW/ PARTS LOCATION - DRIVE DISC/
CLUTCH/ DRIVEN WHEEL 44
EXPLODED VIEW/ PART LOCATION - RIGHT
CRANKCASE 45
EXPLODED VIEW/ PARTS LOCATION - TRANSMISSION 46
PART LOCATION - ENGINE 47
SPECIFICATION - ENGINE 47
TROUBLESHOOTING - ENGINE 48
CYLINDER PRESSURE INSPECTION 
SPARK PLUG 
ENGINE OVERHAUL/ REMOVAL 50
ENGINE PREPARATION 50
ENGINE REMOVAL 51
MAIN STAND REMOVAL 51
ENGINE OIL REMOVAL 51
SECONDARYAIR SYSTEM REMOVAL 51
THERMOSTAT REMOVAL 52
TOP END REMOVAL 52
CYLINDER HEAD COVER 52
TIMING CHAIN TENSIONING RAIL REMOVAL 52
CAMSHAFT SPROCKET REMOVAL 52
CAMSHAFT HOUSING REMOVAL 53
CAMSHAFT AND ROCKER ARM REMOVAL 53
CYLINDER HEAD REMOVAL 53
COOLANT HOSE REMOVAL 53
CYLINDER REMOVAL 53
PISTON REMOVAL 54
VARIOMATIC COVER REMOVAL 54
VARIOMATIC DISC WITH FAN REMOVAL 54
VARIOMATIC BELT REMOVAL 54
INDEX

4
VARIOMATIC DISC REMOVAL 54
CLUTCH DRUM AND CERTIFUGAL CLUTCH REMOVAL 54
TRANSMISSION OIL REMOVAL 55
GEARBOX HOUSING REMOVAL 55
GEARBOX REMOVAL 55
WATER PUMP HOUSING REMOVAL 55
GENERATOR COVER REMOVAL 55
STATOR FOR GENERATOR REMOVAL 56
OIL SEALING OF STATOR REMOVAL/ INSTALLATION 56
IMPELLER WATER PUMP REMOVAL 56
MAGNETO ROTOR REMOVAL 56
STATER MOTOR PINION REMOVAL 57
IDLER GEAR REMOVAL 57
OIL PUMP REMOVAL 57
EXPLODED VIEW/ PARTS LOCATION - OIL PUMP 58
STARTER REMOVAL 58
OIL SEAL CRANKSHAFT RIGHT REMOVAL 58
TIMING CHAIN GUID RAIL REMOVAL 58
CRANKCASE REMOVAL 
CRANKSHAFT REMOVAL 
OIL SEALS REMOVAL 
CRANKSHAFT INSPECTION 
CRANKSHAFT INSTALLATION 60
GASKETS 61
CRANKSCASE INSTALLATION 61
TROUBLESHOOTING - CRANKCASE 61
INSPECTION - CRANKCASE 61
OIL PUMP INSPECTION 61
OIL PUMP INSTALLATION 62
TROUBLESHOOTING - LUBRICATION 62
PART LOCATION - LUBRICATION SCHEME 63
STARTER INSTALLATION 64
IDLER GEAR INSTALLTION 64
STATER MOTOR PINION INSTALLATON 64
MAGNETO ROTOR, STATORAND IMPELLER WATER
PUMP INSTALLATION 64
GENERATOR COVERAND WATER PUMP HOUSING
INSTALLATION 64
PART LOCATION - COOLING SYSTEM 64
TRANSMISSION INSTALLATION 65
INSPECTION - VARIOMATIC 65
CLUTCH DISMANTLING 65
DRIVEN DISC DISMANTLING 65
CLUTCH SPRING INSPECTION 66
DRIVEN DISC ASSEMBLY 66
CLUTCH INSPECTION 66
CLUTCH ASSEMBLY 66
CLUTCH DRUM INSPECTION 66
CLUTCH DRUM AND CERTIFUGAL CLUTCH
INSTALLATION 67
VARIOMATIC DRIVE DISC INSPECTION 67
VARIOMACTIC DRIVE DISC INSTALLATION 67
BELT INSPECTION 67
BELT INSTALALTION 67
VARIOMATIC DISC WITH FAN INSTALLATION 68
VARIOMATIC COVER INSTALLATION 68
TROUBLESHOOTING - VARIOMATIC DISC/ CLUTCH 68
INSPECTION - CYLINDER AND PISTON 68
PISTON INSPECTION 
PISTON RING INSTALLATION 
PISTON INSTALLATION 70
CYLINDER INSPECTION 70
CYLINDER INSTALLATION 71
CYLINDER HEAD INSPECTION 71
AIR VALVE REMOVAL 71
EXPLODED VIEW/ PART LOCATION - AIR VALVE 71
INSPECTION - CYLINDER HEAD 72
AIR VALVE INSPECTION 72
AIR VALVE ADJUSTMENT 73
CYLINDER HEAD INSPECTION 74
AIR VALVE INSTALLATION 74
CYLINDER HEAD INSTALLATION 74
CAMSHAFT INSPECTION 74
VALVE TIMING ADJUSTMENT/ CAMSHAFT HOUSING
INSTALLATION 75
TIMING CHAIN TENSIONING RAIL INSTALLATION 76
VALVE CLEARANCE ADJUSTMENT 76
EXPLODED VIEW/ PART LOCATION - THERMOSTAT 77
THERMOSTATAND SECONDARYAIR SYSTEM
INSTALLATION 77
ENIGNE INSTALLATION 77
TORQUE LIST - ENGINE 77
INSPECTION - THERMOSTAT 77
EXPLODED VIEW/ PART LOCATION - MUFFLER 78
EXHAUST 
EXHAUST REMOVAL 
SECOND AIR SYSTEM 80
SECOND AIR SYSTEM INSPECTION 80
WHEELS AND TIRES 81
EXPLODED VIEW/ PART LOCATION - FRONT WHEEL 81
EXPLODED VIEW/ PARTS LOCATION - REAR WHEEL 82
SPECIFICATION - WHEELS 82
TROUBLESHOOTING - WHEELS 82
WHEELS AND TIRES 83
WHEELS (RIMS) 83
TIRES 83
WHEEL BEARING INSPECTION 83
BENDING OF THE WHEEL SPINDLE INSPECT 83
BRAKES 84
EXPLODED VIEW/ PARTS LOCATION - FRONT BRAKE 84
EXPLODED VIEW/ PARTS LOCATION - REAR BRAKE 85
TROUBLESHOOTING - BRAKES 86
BRAKE LEVERS 86
FRONT/REAR BRAKE LEVER/ MASTER BRAKE CYLINDER
REPLACEMENT 86
FRONT BRAKE CALLIPER REPLACEMENT 87
REAR BRAKE CALLIPER REPLACEMENT 87
FRONT/ REAR BRAKE PAD WEAR INSPECTION/ RE-
PLACEMENT 87
FRONT/ REAR BRAKE DISC INSPECTION 87
BRAKE FLUID 88
SPECIFICATION - BRAKE FLUID 88
BRAKE HOSE 88
SUSPENSION 89
EXPLODED VIEW/ PARTS LOCATION - FRONT
SUSPENSION 
SPECIFICATION - BEARING SUSPENSION 
REAR SUSPENSION 
TROUBLESHOOTING - SUSPENSION 
FRONT SUSPENSION REPLACEMENT 
SUSPENSION - BEARING INSPECTION/ INSTALLATION 
FRONT SUSPENSION FORK LEG REPLACEMENT 
EXPLODED VIEW/ PART LOCATION - STEERING 
TROUBLESHOOTING - STEERING 
STEERING REPLACEMENT 
HANDLEBAR REPLACEMENT 
INDEX

5
ELECTRICAL SYSTEM 95
WIRING DIAGRAM 
PART LOCATION - ELECTRICAL SYSTEM 
ELECTRICAL SYSTEM 97
PART LOCATION - LIGHTS/ INSTRUMENTS SWITCHES 
SPECIFICATION - ELECTRICAL SYSTEM 
ELECTRICAL SYSTEM/ FUSE 99
FUSE REPLACEMENT 
TROUBLESHOOTING - FUSE 
BATTERY GENERAL INFORMATION 100
BATTERY REMOVAL 100
ELECTRICAL SYSTEM/ BATTERY 101
SPECIFICATION - BATTERY 101
TROUBLESHOOTING - BATTERY/ CHARGING SYSTEM 101
ELECTRICAL SYSTEM/ CHARGING SYSTEM 102
CHARGING SCHEME 102
CHARGING PERFORMANCE TEST 102
SPECIFICATION - CHARGING SYSTEM 102
REGULATOR - RECTIFIER INSPECTION 103
CHARGE COIL OF GENERATOR INSPECTION 104
GENERATOR REPLACEMENT 104
TROUBLESHOOTING - CHARGING SYSTEM 104
ELECTRICAL SYSTEM/ IGNITION SYSTEM 105
IGNITION SCHEME 105
SPECIFICATION - IGNITION SYSTEM 106
IGNITION SYSTEM INSPECTION 106
VOLTAGE OF IGNITION COIL 106
TRIGGER (PICK UP) 107
TRIGGER (PICK UP) INSPECTION 107
CDI GROUP 107
IGNITION COIL DISASSEMBLY 108
COIL INSPECTION 108
TROUBLESHOOTING - IGNITION SYSTEM 
ELECTRICAL SYSTEM/ START UP SYSTEM 110
START UP SYSTEM 110
STARTER MOTOR INSPECTION 110
STARTER RELAY INSPECTION 111
VOLTAGE OF STARTER RELAY INSPECT 111
ACTUATION INSPECTION 111
ELECTRICAL SYSTEM/ START UP SYSTEM/
LIGHTNING SYSTEM 112
TROUBLESHOOTING - START UP SYSTEM 112
BULBS REPLACEMENT GENERAL INFORMATION 112
HEADLIGHT/ POSITION/ WINKER BULB
REPLACEMENT 113
HEADLIGHT BULB 113
POSITION BULB 113
WINKER BULB 114
HEADLIGHT REPLACEMENT 114
WINKER REPLACEMENT 114
REAR LIGHT/ WINKER BULB REPLACEMENT 114
REAR LIGHT BULB 115
REAR LIGHT REPLACEMENT 115
LICENSE PLATE BULB REPLACEMENT 116
TROUBLESHOOTING - LIGHTNING SYSTEM 116
ELECTRICAL SYSTEM/ SPEEDOMETER/
SWICHES A. SENSORS 117
SPEEDOMETER DESCRIPTION 117
SPEEDOMETER INDICATOR LIGHTS REPLACEMENT 117
MAIN SWITCH INSPECTION 117
MAIN SWITCH REPLACEMENT 117
HORN INSPECTION/ REPLACEMENT 118
HANDLE SWITCH 
HANDLE SWITCH INSPECTION 
RIGHT HANDLE SWITCH INSPECTION 
LEFT HANDLE SWITCH INSPECTION 120
HANDLE SWITCH REPLACEMENT 120
FRONT/ REAR BRAKE LIGHT SWITCH INSPECTION 120
FRONT/ REAR BRAKE LIGHT SWITCH REPLACEMENT 121
FUEL LEVEL SENSOR INSPECTION 121
EMERGENCY CUTOUT SWITCH INSPECTION/
REPLACEMENT 121
ELECTRICAL SYSTEM/ CABLES 122
CHASSIS 123
COVER REPLACEMENT 123
STORAGE BOX REMOVAL 123
REAR CARRIER REMOVAL 123
SIDECOVER RIGHT REPLACEMENT 123
SIDECOVER LEFT REMOVAL 124
LOWER SIDECOVER RIGHT REMOVAL 125
LOWER SIDECOVER LEFT REMOVAL 125
REAR LIGHT COVER WITH REAR LIGHT REMOVAL 125
LICENSE PLATE BRACKET 126
INNER REAR FENDER REMOVAL 126
REAR FENDER REMOVAL 126
FRONTAND REAR HANDLEBAR COVER REMOVAL 127
WINDSHIELD REMOVAL 128
INSTRUMENT PANEL REMOVAL 128
RADIATOR COWLING REMOVAL 
FRONT COVER REMOVAL 
FRONT SIDECOVER LEFT REMOVAL 130
FRONT SIDECOVER RIGHT REMOVAL 131
FUEL TANK COVER REMOVAL 132
MIDDLE COVER REMOVAL 132
LEG PROTECTION REMOVAL 133
UNDER VEHICLE PROTECTION PANEL REMOVAL 133
FRONT WHEELARCH PANEL REMOVAL 134
LOWER COVER STEERING COLUMN REMOVAL 134
FRONT FENDER REMOVAL 134
MIRRORS 135
BACK VIEW MIRRORS 135
MIRRORS REMOVAL 135
BACK VIEW MIRRORS INSTALLATION 135
INDEX

6
LOCATION OF SEVERAL NUMBERS
VIN (CHASSIS NUMBER) AND FRAME PLATE
Remove the ruber cover (1).
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right side of the frame.
FRAME PLATE
The frame plate (3) is located on the front side of the steering
tube.
ANTI TEMPERING LABEL
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bench.
ENGINE NUMBER
The engine number (5) is on the left side of the engine case.
DECRYPTING THE VEHICLE IDENTIFICATION NUMBER
EXAMPLE:/%%7$%
LBB - WORLD MANUFACTURER INDEX (NAME OF MANUFACTURER)
T58 - MODEL TYPE
0 - VARIANT OF MODEL
0 - VERSION OF MODEL
6 - RANDOM NUMBER
A - YEAR OF PRODUCTION (AB = 2010/ DB = 2013,.........)
B - ASSEMBLING PLANT (LOCATION OF FACTORY)
 6(5,$/180%(5
1
2
5
4
3

7
GENERAL SPECIFICATION
ENGINE
Engine type: Water cooling 4 - stroke
Cylinder arrangement: Single cylinder
Displacement: 125 cm³
Compression ratio: 10.4:1
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0D[WRUTXH1PUSP1PUSP
Starting system: Electric starter
Lubrication system: Pressure and splash lubrication
ENGINE OIL QUANTITY
4XDQWLW\5HSODFLQJ/
Dismantling: 1 L
Recommended type: Recommended type: CASTROL Power 1 - Racing
4T 10W-40
TRANSMISSION OIL
7\SH6$(:
Niveau bolt
5HFRPPHQGHGW\SH&DVWURO07;3DUW6\QWK:25(3:
AIR FILTER ELEMENT
Type: Dry
FUEL
5HFRPPHQGHGIXHO8QOHDGHGJDVROLQHRQO\!2FW6363
Do not use Bio-Ethanol fuel
Fuel tank capacity: 8.6 L ± 0.2 L
CARBURETTOR
Type/ Manufacturer: PD26JC G18/ CORUNDUM or QJ
SPARK PLUG
Manufacturer/model: NGK (CR8E)
CLUTCH
Clutch type: C.V.T. system
TRANSMISSION TYPE
V-belt automatic
Fly (roller) weights: 5.0 g
Operation: Centrifugal automatic type
CHASSIS
Frame type: Steel tube backbone
TIRES
Front tire
Type: Tubeless/ Pressure on cold tire: 2.3 ± 0.1 bar
6L]H5LP07[
Tire: 120/70-15M/C
Rear tire
Type: Tubeless/ Pressure on cold tire: 2.3 ± 0.1 bar
6L]H5LP07[
Tire: 140/60-14M/C
BRAKES
Front brake:
Type: Single Hydraulic disc brake (240 mm)/ Right hand operation
Rear brake:
Type: Single Hydraulic disc brake (220 mm)/ Left hand operation
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FLUID DOT 4.)
Cable operated
FRONT SUSPENSION
Type: Telescopic fork
Spring/shock absorber type: Coil spring/oil damper
REAR SUSPENSION
Type: Unit swing
Spring/shock absorber type: Coil spring/oil damper
ELECTRICAL SYSTEM
Ignition system: CDI
Charging system: CDI magneto
BATTERY
Model: YTX7A-BS/ 12 V, 6.0 Ah
LIGHT AND BULBS
Headlight 12 V, 35
W/35.0 W
Tail/brake light: 12 V, 5.0
W/21.0 W
Front turn signal light: 12 V, 10.0 W
Rear turn signal light: 12 V, 10.0 W
License plate light: 12 V, 5.0 W
High beam indicator light: 12 V, 3W
Turn signal indicator light: 12 V, 3 W
MAIN FUSE
15 A

8
SPECIFIC TIGHTNING TORQUES
MODULE PART TORQUE / Nm
Electrical System
Bolt in the clutch cover of the startup electrical machinery 12
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5HFWL¿HUEROW 5
)L[LQJEROWRILJQLWLRQFRLO 
)L[LQJQXWRIÀ\ZKHHO 5
Body fender bolt 
Wheel Axles )URQWZKHHOD[OHFODPSLQJQXW 55-62
5HDUZKHHO¿[HGQXW 100-113
)L[LQJEROWIRUIXHOWDQN 
)L[LQJEROWIRUUHDUFDUULHUUDFN 
)L[LQJEROWIRUUHDUUDFN 
)L[LQJEROWIRUVHDWORFN 
Front brake system
)URQWEUDNHGLVF¿[HGEROW 
Mounting bolt of front brake caliper 
)L[LQJEROWRIKDQGEUDNHOHYHUEUDNHW 
Rear brake system
5HDUEUDNHGLVF¿[HGEROW 
)L[LQJEROWRIUHDUEUDNHURFNHUDUP 10-12
)L[LQJEROWRIKDQGEUDNHOHYHUEUDNHW 
Rear shock absorber Top nut of rear shock absorber 37-44
Bottom nut of rear shock absorber 
Front fork
)L[LQJQXWLQWKHFOXWFKRIWKHVWDUWXSHOHFWULFDOPDFKLQHU\ 40-60
Mounting bolt of brake line guide clamp 
Mounting bolt of fork legs 37-44
Handlebar Mounting bolt and nut of handle bar 40-60
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)L[LQJEROWRIPXIÀHU 
)L[LQJEROWRIPXIÀHUWULPFRYHU 
)L[HGEROWRIPXIÀHUFRQQHFWRU 
Engine
Cylinder cover nut 28-28
Oil drainage bolt 22-25
Spark plug 10-15
Mould assembling bolt 10-12
Variable- speed chamber bolt 10-12
)L[LQJEROWRIHQJLQH 10-12
)L[LQJEROWRIRLOSXPS 10-12
Oil pump chain wheel bolt 10-12
/RFNQXWRIÀ\ZKHHO 50-60
Nuts of engine cooling fan 
Douple-screw bolt on right cover 10-12
Douple end stud 18-22
&KDLQUHJXODWRU¿[HGEROW 10-12
Setscrew of electric wire clamp 4-7

16
IMPORTANT NOTES
WARRANTY
The ZRUNSUHVFULEHGLQWKHVHUYLFHVFKHGXOHPXVWEHFDUULHGRXWLQDQDXWKRUL]HGZRUNVKRSDQGFRQ¿UPHGLQWKHFXV-
tomer‘s service card, otherwise no warranty claims will be recognized. No warranty claims can be considered for dam-
age resulting from manipulations and/or alterations to the vehicle.
NOTES AND WARNINGS
Pay attention to the notes/warnings in this manual.
• ,GHQWL¿HVGDQJHUVWKDWZLOOOHDGWRHQYLURQPHQWDOGDPDJHLIWKHPHDVXUHVDUHQRWWDNHQ
• ,GHQWL¿HVGDQJHUVWKDWLVOLNHO\WROHDGWRIDWDORUVHULRXVLQMXU\LIWKHPHDVXUHVDUHQRWWDNHQ
• ,GHQWL¿HVGDQJHUVWKDWZLOOOHDGWRFRQVLGHUDEOHPDFKLQHDQGPDWHULDOGDPDJHLIWKHPHDVXUHVDUHQRWWDNHQ
• ,GHQWL¿HVGDQJHUVWKDWZLOOLPPHGLDWHO\OHDGWRIDWDORUVHULRXVSHUPDQHQWLQMXU\LIWKHDSSURSULDWHPHDVXUHVDUHQRW
taken.
REPAIR MANUAL
It is important that you read this manual completely before the start of work. It contains useful information how to
repair and maintain the vehicle.
FUELAND LUBRICANTS
Use oQO\WKHIXHOVRLOVDQGOXEULFDQWVDFFRUGLQJWRVSHFL¿FDWLRQVDVOLVWHGLQWKLVPDQXDO
Please consider that KSR Group GmbH give no approval for Bio- Ethanol (E 10 or higher) fuel.
SPARE PARTS AND ACCESSORIES
Only use spare parts and accessory that have been approved or recommended by KSR Group GmbH.
PRACTICE
Special tools arHUHTXLUHGIRUVRPHZRUNEXWPRVWO\SURIHVVLRQDOZRUNVKRSHTXLSPHQWLVHQRXJKIRUVHUYLFHUHSDLUDQG
maintenance of the vehicle. Special tools mentioned inside of this manual.
When thread locker is used on connections (e.g., Loctite®), follow the instructions for use from the manufacturer.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or
worn parts.
IMPORTANT
• After each repair or maintenance work security check and a test drive must be done.
• Before you delivery the vehicle to the customer a road safety test must be done.
• 7LJKWHQWKHEROWVRIODUJHGLDPHWHURUWKHLQQHURQHV¿UVWWKHQVFUHZGRZQWRWKHUHTXLUHGRUGHUVRIGLDJRQDOXQOHVV
RWKHUZLVHVSHFL¿HG
• 5LQVHWKHSDUWVGLVDVVHPEOHZLWKFOHDQHUÀXLGOXEULFDWHDOOWKHOXEULFDWLQJVXUIDFHVUHTXLUHGEHIRUHDVVHPEO\
!WARNING

10
GENERAL TIGHTNING TORQUES
,IQRVSHFL¿FWRUTXHLVJLYHQIRUDEROWHGDVVHPEOLQJXVHWKHWDEOHEHORZWRWLJKWHQWKHVFUHZV,I\RXUHOHDVHDEROWHG
and glued assembling it must be glued in assembling again. For the bonding of screws use Loctite ® 243 ™, follow
the instructions for use from the manufacturer.
*7KHYDOXH5VWUHQJWKLQGLFDWHVWKHPDWHULDOSURSHUW\7KHORZHUWKHYDOXHRI5LVWKHORZHUWKHWRUTXHRI
the bolts.
MAXIMUM TORQUE IN NM REFERRING ISO 898/1 FOR METRIC
FASTENERS/ COEFFICIENT OF FRICTION 0.12
Size *Strength (R) 3,6 *Strength (R) 8,8 *Strength (R) 12,9
M1.6 0,047 Nm 0,169 Nm 0,285 Nm
M 2 0,10 Nm 0,35 Nm 0,60 Nm
M 2.5 0,21 Nm 0,73 Nm 0,12 Nm
M 3 0,36 Nm 0,12 Nm 0,21 Nm
M 4 0.82 Nm 3.0 Nm 5.1 Nm
M 5 1.6 Nm 5.9 Nm 10.0 Nm
M 6 2.8 Nm 10.1 Nm 17.4 Nm
M 8 6.8 Nm 24.6 Nm 42.2 Nm
M 10 13.7 Nm 48 Nm 83 Nm
M 12 23 Nm 84 Nm 144 Nm
M 14 37 Nm 133 Nm 229 Nm
M 16 57 Nm 206 Nm 354 Nm
M 18 80 Nm 295 Nm 492 Nm
M 20 112 Nm 415 Nm 692 Nm

11
SPECIAL TOOLS
Special tools arHUHTXLUHGIRUVRPHZRUNEXWPRVWO\SURIHVVLRQDOZRUNVKRSHTXLSPHQWLVHQRXJKIRUVHUYLFHUHSDLUDQG
maintenance of the vehicle.
After disassembly, clean the parts that are to be reused and check them for damage and wear. Replace damaged or
worn parts.
NAME REMARKS
)O\ZKHHOH[WUDFWRU Figure 1
Spacer gauge Figure 2
Dismounting tools for bearing Figure 3
Assembling tools for bearing Figure 4
Oil-seal dismounting tool Figure 5
Handle of dismounting tools Figure 6
3LVWRQSLQH[KDXVWLRQDSSDUDWXV Figure 7
Piston ring opening pincer Figure 8
Spark plug circular wrench )LJXUH
Dial dictator - Measure the inner canon of piston pin Figure 10
Cylinder diameter tester Figure 11
,QQHUKH[DJRQZUHQFK Figure 12
Rest wrench Figure 13
Micrometer Figure 14
Circular wrench Figure 15
Dial indicator Figure 16
Magnetic stand, V-shape block Figure 17
6TXDUHFDOLSHU Figure 18
Whack-type screw drive )LJXUH
Front fork oil seal dismounting tools Figure 20
Front part seal element driving-in tools Figure 21
Steering nut wrench Figure 22
Universal meter Figure 23
Spring clip-ring clipper Figure 24
Ignition tester Figure 25
Brake bleeder device no picture

12
SPECIAL TOOLS














Thickness
g
au
g
e
(
clearance
g
au
g
e
)

Fig. 1
Fig. 3
Fig. 5
Fig. 7
Fig. 2
Fig. 4
Fig. 6
Fig. 8

13
SPECIAL TOOLS
















1. Bush-head 2.Shake-handle
3.Ratchet type wrench 4.Connecting-rod
)LJ
Fig. 11
Fig. 13
Fig. 15
Fig. 17
Fig. 10
Fig. 12
Fig. 14
Fig. 16
Fig. 18

14
SPECIAL TOOLS



















)LJ
Fig. 21a
Fig. 22a
Fig. 23a
Fig. 24
Fig. 20
Fig. 21b
Fig. 22b
Fig. 23b
Fig. 25

15
1. PERIODIC MAINTENANCE

16
PERIODIC MAINTENANCE CHART
Important maintenance work have to be carried out by an authorized workshop.
CHECKLIST OF CONSTANT MAINTENANCE
7KHLQVSHFWLRQLQWHUYDOVDUHUHTXLUHGRWKHUZLVHQR
guarantee can be granted. 1000 km or 1. month 4.000 km or 6. month 7.000 km or 12. month 10.000 km or 18. month 13.000 km or 24. month
PART TO DO
$LU¿OWHU &OHDQH[FKDQJH ¥¥ ([FKDQJH ¥¥
Wheels, rims Control ¥¥¥¥¥
Tires Control/ tire pressure ¥¥¥¥
Wheel bearing &RQWUROH[FKDQJH ¥¥¥¥
Steering bearing Control/ clean/ lubricate ¥¥¥ Lubricate ¥
Screws Coverparts Control/ tighten ¥¥¥¥
Brake system &RQWUROFOHDQH[FKDQJH ¥¥¥¥
Main stand Control/ clean/ lubricate ¥¥¥¥
Front forke Control ¥¥¥¥
Rear suspension Control ¥¥¥¥
Oil pump Control ¥¥¥¥¥
Transmission oil ([FKDQJH ([FKDQJH ([FKDQJH ([FKDQJH
Variomatic belt &RQWUROH[FKDQJH ¥([FKDQJH ¥
Fly wheels &RQWUROH[FKDQJH ¥([FKDQJH ¥
Driven chain/ sproket &RQWUROFOHDQH[FKDQJH
Clutch Control ¥¥¥¥¥
Cable/ bowden Control/ clean/ lubricate ¥¥¥¥¥
Throttle Control/ clean/ lubricate ¥¥¥¥
Lights/ switches &RQWURODGMXVW ¥¥¥¥¥
)XHOOLQHIXHO¿OWHU &RQWUROH[FKDQJH ([FKDQJH
Idle speed &RQWURODGMXVW ¥¥¥¥¥
([KDXVWV\VWHP Control/ tighten ¥¥¥¥
Coolant Control
CAUTION:9DULRPDWLFEHOWÀ\ZKHHOVVSDUNSOXJHIXHO¿OWHUDQGDLU¿OWHUHOHPHQWKDYHWREHH[FKDQJHGHYHU\NP2QO\XVHGXUDWLRQFRRODQW
%UDNHOLQHVKDYHWREHH[FKDQJHGDWOHDVWHYHU\\HDUV)URPNPRUWKPRQWKWKHLQVSHFWLRQVKRXOGEHPDGHHYHU\NP7KHYHKLFOHLV
constantly checked for rust. The owner is responsible for rust prevention.

17
IMPORTANT PREPERATION REFERENCES
Cylinder Block / Piston Item Standard [mm] Allowable limits [mm]
Cylinder
Inner Diameter 52.40-52.413 52.413
Cylinder degree 0.004 0.004
Roundness 0.005 0.005
Flatness 0.05 0.05
Piston
Piston ring
Piston pin
Piston mark direction “IN” properly opposite
to the inlet valve --
Measuring points for piston outer diameter 52.36-52.37 (at the bottom of the piston
skirt 7mm) 52.37
3LVWRQSLQVDGGOHRUL¿FHLQQHUGLDPHWHU 14.002-14.008 14.04
Piston pin outer diameter  
Clearance between piston and cylinder 0.03-0.053 0.053
Clearance between
piston ring and ring
groove
1st Ring 0.03-0.007 0.10
2nd Ring 0.03-0.007 0.10
Clearance between
piston and piston pin
1st Ring 0.10-0.25 0.50
2nd Ring 0.20-0.35 0.60
Oil ring 0.1-0.6 --
Clearance between piston and piston pin 0.003-0.014 0.03
Narrow end diameter of connecting rod 14.010-14.018 14.04
Clearance between connecting rod and piston
rod 0.011-0.024 0.05
Variomatic drive Item Standard [mm] Allowable limits [mm]
Inner diameter of right hemisphere of drive wheel 24.00-24.02 24.04
Outside slippery sleeve  
Width of triangle belt 21.8-22.0 20.5
Thickness of clutch friction panel 1.5 1.5
Inner diameter of outside sleeve of clutch 125-125.2 125.5
Free length of clutch press spring  70
Outside diameter of right hemisphereshaft sleeve of drive gear  
Inner diameter of right hemisphere shaft sleeve of drive gear  34.00
Outside diameter of rolling ball 20-20.2 
Connection rod Item Standard [mm] Allowable limits [mm]
Crankcase
Left and right clearance of the wide end of the
connection rod 0.1-0.35 0.55
Radial clearance of the wide end of the
connection rod 0.008-0.016 0.05

18
IMPORTANT PREPERATION REFERENCES
Cylinder Cap Item Standard [mm] Allowable limits [mm]
Cylinder pressure 1.25 Mpa --
&\OLQGHUFDSÀDWQHVV 0.03 0.03
Air valve
Valve guid
Air valve
clearance IN 0.10 0.12
EX 0.13 0.14
Inner diameter of valve guid IN / EX 5.00-5.012 5.03
Clearance between the valve
pod and the valve guid IN 0.010-0.035 0.08
EX 0.030-0.05 0.10
Retainer width IN / EX 1.2 1.7
Air door spring Free length IN / EX 35.4 
Rocker
5RFNHURUL¿FHGLDPHWHU IN / EX 10.00-10.015 10.10
Rocker shaft diameter IN / EX  
Clearance between the rocker
RUL¿FHDQGVKDIW IN / EX 0.012-0.033 0.033
Camshaft Camheight IN  
EX  
Ignition Item Standard value
Recommended
spark plug
Standard C5HSA (NKG)
Hot C6HSA (NGK)
Cold CHSA (NGK)
Spark plug gap 0.6-0.7 mm
Resistance value
of ignition coil
(20°C)
Primary coil 4 ȍ± 10%
Secondary coil With spark plug cap 8-11 Kȍ
Without spark plug cap 4.5-5.5 Kȍ
Resistance of trigger (20°C) 100-200ȍ
0D[YROWDJHRILJQLWLRQFRLO 9
Voltage of trigger Above 1.7V
Electric system Item 6SHFL¿FDWLRQV
Battery
Capacity / type 12V-6Ah / dry-charged
Voltage
(20°C) Full charg 13.1V
Need to be charged 12.3V (one hour)
Charging current Normal: 0.6A, Quick: 6A
Charging time Normal: 10-15 hours, Quick: 30 Minutes
Magneto Capacity 200W/8500rpm
Coil impedance (20°C) White-black 3.3-3.5ȍ
Voltage regulator Pattem Fullwave of three phase
Charging voltage of battery 14.5 ± 0.5V / 5000 rpm

19
IMPORTANT PREPERATION REFERENCES
Starting system Item Standard value [mm] Operation limit [mm]
Length of starting motor bush 12.5 8.5
Starting idle gear bushing -- 8.3
OD of strting idle gear -- 
Carburettor Item Standard
Main nozzle %
0DLQMHW 180#
,GOHMHW 37.5#
Needle valve %
Wheels Item Standard [mm] Allowable limts [mm]
Run out of wheels
Vertical direction front wheel -- 2.0
Transverse direction front wheel -- 2.0
Vertical direction rear wheel -- 2.0
Transverse direction rear wheel -- 2.0

20
AIR SYSTEM/ FUEL SYSTEM
AIR FILTER
5HSODFHPHQWRIWKHDLU¿OWHUHOHPHQW
1. 5HPRYHWKHWKHVHYHQVFUHZVWRUHPRYHWKHDLU¿OWHU
cover (2).
2. 3XOORXWWKHDLU¿OWHUHOHPHQWFRYHU
&KHFNWR VHHLI WKH¿OWHU HOHPHQWLV SROOXWHGRU GDPDJHG,I LWLV
polluted or damaged, please replace with new one.
CHANGING INTERVALS
,I WKH PRWRUF\FOH LV IUHTXHQWO\ GULYHQ RQ EDG URDG RU LQ UDLQ LW
should be replaced early. Under normal condition replace it refer-
ring the maintenance chart.
Reassemble in reverse order.
THROTTLE CONTROL SYSTEM
,QVSHFWLRQDGMXVWPHQWRIDFFHOHUDWRU¶VSXOOZLUH
Check the smoothness of accelerator pull wire.
Free displacement: 5-10 mm
7KHPDLQDGMXVWLQJSRVLWLRQLVRQWKHERWWRPRIWKHWKURWWOH
7RDGMXVWWKHIUHHSOD\RIWKHWKURWWOHJULSORRVHQWKH¿[LQJQXW
DQGDGMXVWE\WXUQLQJDGMXVWLQJQXW
$IWHUWKHDGMXVWPHQWLVGRQHWLJKWHQWKHQXW
IDLE ADJUSTMENT
Start and warm up the engine for about 3 minutes, so that the en-
gine will operate in normal running temperature.
5HPRYHWKHVWRUDJHER[
$GMXVWWKHLGOHDGMXVWPHQWVFUHZDQGVHWWKHLGOHVSHHGWR
U/min.
Create a round and stabile engine speed, using the air control
screw (2). The air control screw is located on the bottom of the
FDUEXUHWWRU7RDGMXVWWKHDLUFRQWUROVFUHZXVDD¿VWVFUHZGULYHU
5HVHWWKHLGOHDGMXVWPHQWVFUHZDQGVHWWKHHQJLQHVSHHGGRZQ
to 1200-1500±100 U/min.
Pull the throttle for several times for acceleration and inspect
whether the idle speed is steady.
1
2
3
1
2
1
2
3