KYMCO CK 1 User manual

1. GENERAL INFORMATION
CK 1
1
ENGINE SERIAL NUMBER
1
ENGINE SERIAL NUMBER................1- 0 LUBRICATION POINTS....................... 1-12
SPECIFICATIONS................................1- 1 CABLE & HARNESS ROUTING ............ 1-13
SERVICE PRECAUTIONS..................1- 2 WIRING DIAGRAM.............................. 1-15
TORQUE VALUES ..............................1-10 TROUBLESHOOTING.......................... 1-16
SPECIAL TOOLS .................................1-11
Location of Engine Serial Number
Location of Frame Serial Number
1-0

1. GENERAL INFORMATION
CK 1
SPECIFICATIONS
Motorcycle name & Model No.
CK 1
Chassis name & Model No.
LKH3
Overall length (mm)
2030
Overall width (mm)
1050
Overall height (mm)
750
Wheel base (mm)
1330
Engine type
O.H.V
Displacement (cc)
125
Fuel type
93# nonleaded gasoline
Dry weight (kg)
Front
59
Rear
64
Total
123
Gross weight (kg)
Front
64
Rear
70
Total
134
Tires
Front
80/100-17
Rear
110/80-17
Ground clearance (mm)
195
Perform
-
ance
Braking distance (m)
7 (30km/h)
Min. turning radius (m)
2.16/1.92
Starting system
Starting motor
Type
Gasoline, 4-stroke
Cylinder arrangement
Single cylinder
Combustion chamber type
Semi-sphere
Valve arrangement
SOHC-2V
Bore x stroke (mm)
54 x 54.5
Compression ratio
9.5
Compression pressure
(kg/cm²−rpm)
12±2
Max. output (kw/rpm)
7.6/8000
Engine
Max. torque (N.M/rpm)
9.8/6000
Port
timing
Intake
(7.68mm)
Open
-2°
Close
22°
Exhaust
(7.38mm)
Open
32°
Close
3°
Valve clearance
(Cold engine)
Intake
0.06mm
Exhaust
0.06mm
Idle speed (rpm)
1700
Lubrication System
Lubrication type
Forced pressure &
wet sump
Oil pump type
Inner/outer rotor
Oil filter type
Wire gauze filter
Oil capacity
0.9 liter
Cooling Type
Air cooling
Fuel System
Air cleaner type
Paper element
Fuel capacity
12.5liter
Carburetor
Type
VM
Piston dia. (mm)
φ23
Venturi dia.(mm)
φ25 equivalent
Throttle type
Butterfly type
Electrical Equipment
Ignition System
Type
CDI
Ignition timing

Breaker type

Spark plug CR8E
Spark plug gap
0.8mm
Battery
Capacity
12V7AH
Power Drive
System
Clutch
Type
Wet multi-disc clutch
Transmission
Gear
Type
5-speed transmission
Operating method
Foot operated
Type
International type
Reduction
ratio
1st gear
4.056
2nd gear
2.533
Moving Device
Front
Caster angle
26°
Axle
Wheel base (mm)
1330
Tire pressure
(kg/cm
²
)(2 riders)
Front
1.75/2.0
Rear
1.75/2.25
Turning angle
Left
45°
Right
45
°
Brake system
type
Front
Disk brake
Rear
Drum brake
Damping Device
Suspension
Front
Telescopic fork
Rear
Linkage
Shock absorber
Front
Oil damper spring
Rear
Oil damper spring
Frame type
Rhomboid frame
1-1

1. GENERAL INFORMATION
CK 1
SERVICE PRECAUTIONS
Make sure to install new gaskets, O-rings,
circlips, cotter pins, etc. when
reassembling.
When tightening bolts or nuts, begin with
larger-diameter to smaller ones at several
times, and tighten to the specified torque
diagonally.
Use genuine parts and lubricants.
When servicing the motorcycle, be sure to
use special tools for removal and
installation.
After disassembly, clean removed parts.
Lubricate sliding surfaces with engine oil
before reassembly.
1-2

1. GENERAL INFORMATION
CK 1
Apply or add designated greases and
lubricants to the specified lubrication
points.
After reassembly, check all parts for proper
tightening and operation.
When two persons work together, pay
attention to the mutual working safety.
Disconnect the battery negative (-) terminal
before operation.
When using a spanner or other tools, make
sure not to damage the motorcycle surface.
After operation, check all connecting points,
fasteners, and lines for proper connection
and installation.
When connecting the battery, the positive
(+) terminal must be connected first.
After connection, apply grease to the
battery terminals.
Terminal caps shall be installed securely.
1-3

1. GENERAL INFORMATION
CK 1
If the fuse is burned out, find the cause and
repair it. Replace it with a new one
according to the specified capacity.
After operation, terminal caps shall be
installed securely.
When taking out the connector, the lock on
the connector shall be released before
operation.
Hold the connector body when connecting
or disconnecting it.
Do not pull the connector wire.
Check if any connector terminal is bending,
protruding or loose.
Confirm
Capacity
1-4

1. GENERAL INFORMATION
CK 1
The connector shall be inserted
completely.
If the double connector has a lock, lock
it at the correct position.
Check if there is any loose wire.
Before connecting a terminal, check for
damaged terminal cover or loose
negative terminal.
Check the double connector cover for
proper coverage and installation.
Insert the terminal completely.
Check the terminal cover for proper
coverage.
Do not make the terminal cover opening
face up.
Secure wire harnesses to the frame with
their respective wire bands at the
designated locations.
Tighten the bands so that only the insulated
surfaces contact the wire harnesses.
Snapping!
1-5

1. GENERAL INFORMATION
CK 1
After clamping, check each wire to make
sure it is secure.
Do not squeeze wires against the weld or
its clamp.
After clamping, check each harness to
make sure that it is not interfering with any
moving or sliding parts.
When fixing the wire harnesses, do not
make it contact the parts which will
generate high heat.
Route wire harnesses to avoid sharp edges
or corners. Avoid the projected ends of
bolts and screws.
Route wire harnesses passing through the
side of bolts and screws. Avoid the
projected ends of bolts and screws.
No Contact !
1-6

1. GENERAL INFORMATION
CK 1
Route harnesses so they are neither
pulled tight nor have excessive slack.
Protect wires and harnesses with electrical
tape or tube if they contact a sharp edge or
corner.
When rubber protecting cover is used to
protect the wire harnesses, it shall be
installed securely.
Do not break the sheath of wire.
If a wire or harness is with a broken sheath,
repair by wrapping it with protective tape
or replace it.
When installing other parts, do not press or
squeeze the wires.
Do not pull
too tight!
Do not press or
squeeze the wire.
1-7

1. GENERAL INFORMATION
CK 1
After routing, check that the wire harnesses
are not twisted or kinked.
Wire harnesses routed along with handlebar
should not be pulled tight, have excessive
slack or interfere with adjacent or
surrounding parts in all steering positions.
When a testing device is used, make sure to
understand the operating methods
thoroughly and operate according to the
operating instructions.
Be careful not to drop any parts.
When rust is found on a terminal, remove
the rust with sand paper or equivalent
before connecting.
Do not bend or twist control cables.
Damaged control cables will not operate
smoothly and may stick or bind.
Do you understand
the instrument? Is
the instrument set
correctly?
Remove Rust !
1-8

1. GENERAL INFORMATION
CK 1
Symbols:
The following symbols represent the
servicing methods and cautions included in
this service manual.
: Apply engine oil to the
specified points. (Use
designated engine oil for
lubrication.)
: Apply grease for lubrication.
: Use special tool.
: Caution
: Warning
Special
＊
Engine Oil
Grease
1-9

1. GENERAL INFORMATION
CK 1
TORQUE VALUES
STANDARD TORQUE VALUES
Item
Torque (kg-m)
Item
Torque (kg-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.45～0.6
0.8～1.2
1.8～2.0
3.0～4.0
5.0～6.0
5mm screw
6mm nut, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.35～0.5
0.7～1.1
1.0～1.4
2.0～3.0
3.5～4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Exhaust muffler joint lock nut
Valve adjusting lock nut
Oil bolt
Cylinder bolt
A.C. generator flywheel bolt
Cylinder head cover bolt
Oil pump bolt
Oil filter lock nut
Rocker arm lock bolt
Cylinder head lock bolt
Cylinder bolt
Crankcase assembly bolt
Crankshaft damper bolt
Right crankcase cover bolt
Left crankcase cover bolt
A.C. generator coil lock bolt
Starter gear set plate bolt
Carburetor lock bolt
2
2
1
2
2
1
2
1
4
2
1
3
1
2
10
1
8
4
4
1
2
8
8
30
6
5
12
6
14
6
6
16
8
8x79
6x22
6
6x25
6
6
5
6
6
2.8～3.2
2.8～3.2
1.5～3.0
0.8～1.2
1.4～1.8
2.0～3.0
0.8～1.2
4.0～5.2
0.8～1.2
0.7～1.1
1.5～3.0
1.5～2.0
1.5～2.0
0.8～1.2
0.8～1.5
0.8～1.2
0.8～1.2
0.8～1.2
0.4～0.7
1.0～1.6
0.8～1.2
Double end bolt
Double end bolt
Double end bolt
FRAME
Item Q‘ty Thread dia.(mm) Torque (kg-m) Remarks
Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper mount bolt
Rear shock absorber lower mount bolt
Rear fork pivot nut
Handlebar lock bolt
Rear driven gear bolt
Rear brake panel bolt
1
1
1
2
2
1
4
4
1
22
14
16
10
10
12
6
8
8
6.0～9.0
5.5～7.0
6.0～8.0
3.0～4.0
3.0～4.0
5.5～7.0
6.0～9.0
1.8～2.0
1.8～2.5
1-10

1. GENERAL INFORMATION
CK 1
SPECIAL TOOLS
Tool Name Tool No. Remarks Ref. Page
Valve adjuster
E036
Valve spring compressor attachment
E040
Clutch holder
E013
Flywheel puller
E005
Flywheel holder
E021
Lock nut socket wrench
E010
Bearing remover
E037
Oil seal & Bearing install
E014
Steering stem wrench
F007
Cushion assemble & Disassemble
F004
1-11

1. GENERAL INFORMATION
CK 1
LUBRICATION POINTS
Throttle Cable
Speedometer Cable
Clutch Cable
Front Brake Fluid Tube
1-12

1. GENERAL INFORMATION
CK 1
CABLE & HARNESS ROUTING
Taillight Wire
Connector
Wire
Harness
CDI Unit
Ignition Coil
1-13

1. GENERAL INFORMATION
CK 1
Starter Relay
Throttle Cable
Positive Cable
Battery Negative Cable
Ignition Coil Wire
Clutch Cable
Winker
Regulator/Rectifier
Fuse Box
1-14

1. GENERAL INFORMATION
CK 1
WIRING DIAGRAM
1-15

1. GENERAL INFORMATION
CK 1
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Empty fuel tank
Clogged fuel line between fuel
tank and carburetor
Clogged float valve
Clogged fuel filter
Clogged fuel tank cap breather
hole
Clogged auto fuel valve strainer
Clogged fuel valve passage
Clogged carburetor air balance
tube
Faulty spark plug
Fouled spark plug
Faulty CDI unit
Faulty pulser coil
Faulty exciter coil
Faulty ignition switch
Broken or shorted ignition coil
wire
Faulty or slipping clutch
Valve clearance too small
Valve stuck open
Worn cylinder and piston rings
Leaking cylinder head gasket
Faulty choke control system
Leaking intake manifold
Incorrect ignition timing
Incorrectly adjusted air screw
Flooded carburetor
Throttle valve excessively open
Clogged air cleaner
Check if fuel reaches
carburetor by loosening
drain screw
Remove spark plug and
install it into spark plug
cap to test spark by
making it contact the
engine
Inspection/Adjustment
Probable Cause
Spark jumps
Normal
compression
Engine does not
fire
Weak or no spark
Low or no
compression
Engine fires but
does not start
Test cylinder compression
Start engine by
follow-ing normal
starting procedure
Remove spark plug and
inspect again
Symptom
Fuel reaches
carburetor
Fuel does not
reach carburetor
Wet spark plug
Dry spark plug
1-16

1. GENERAL INFORMATION
CK 1
POOR PERFORMANCE (ENGINE LACKS POWER)
Clogged air cleaner
Poor fuel flow (Restricted)
Clogged fuel tank cap breather hole
Clogged exhaust muffler
Carburetor fuel level too low
Clogged carburetor high speed fuel
passage
Faulty CDI unit
Faulty pulser coil
Improper valve clearance
adjustment
Excessively worn valve seat
(protruded valve stem)
Improper valve and seat contact
Worn cylinder and piston rings
Leaking cylinder head gasket
Improper valve timing
Clean and unclog
Fouled spark plug
Incorrect heat range plug
Oil level too high
Oil level too low
Oil not changed
Clogged oil line
Faulty oil pump
Worn cylinder and piston rings
Mixture too lean
Poor quality fuel
Excessive carbon buildup in
combustion chamber
Ignition timing too advanced
Excessive carbon build-up in
combustion chamber
Poor quality fuel
Clutch slipping
Mixture too lean
Start engine and accelerate
lightly for observation
Inspection/Adjustment
Symptom
Probable Cause
Engine speed
increases
Correct
Engine speed does not
increase sufficiently
Incorrect
Check ignition timing
using a timing light
Test cylinder compression
Check carburetor for
clogging
Rapidly accelerate or run
at high speed
Remove spark plug and
inspect
Check for engine overheating
Check valve clearance
Correct
Incorrect
Normal
compression Low compression
Check crankcase for oil
level and condition
Check cylinder head for oil
lubrication
Engine overheats
Engine does not
overheats
Plug not fouled or
discolored
Plug fouled or
discolored
Correct and not
contaminated
Incorrect or
contaminated
Valve train lubricated
properly
Valve train not
lubricated properly
Engine does not knock
Engine knocks
Not clogged
Clogged
1-17

1. GENERAL INFORMATION
CK 1
Ignition timing too advanced
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Faulty CDI unit
Faulty pulser coil
Mixture too lean (turn screw in)
Mixture too rich (turn screw
out)
Faulty intake manifold gasket
Carburetor not securely
tightened
Damaged insulator rubber
Broken vacuum tube
Faulty or fouled spark plug
Faulty CDI unit
Faulty A.C. generator
Faulty ignition coil
Faulty ignition switch
Faulty A.C. generator
Damaged vacuum tube
Clogged air vent hole
Remove spark plug and
install it into spark plug
cap to test spark by
making it contact the
engine
Inspection/Adjustment
Symptom
Probable Cause
Check ignition timing
Check A.C. generator
Check carburetor
gasket for air leaks
Check carburetor air
screw adjustment
Correct
Incorrect
Correctly adjusted
No air leak
Air leaks
Good spark
Weak or inter-
mittent spark
Good
Faulty
Incorrectly adjusted
1-18

1. GENERAL INFORMATION
CK 1
POOR PERFORMANCE (AT HIGH SPEED)
Faulty CDI unit
Faulty pulser coil
Improperly adjusted valve clearance
Worn valve seat
Empty fuel tank
Clogged fuel filter
Clogged fuel tank cap breather
hole
Clean and unclog
Cam timing gear aligning marks
not aligned
Faulty spring
Inspection/Adjustment
Symptom
Probable Cause
Check ignition timing
Check carburetor for
clogged jets
Check fuel filter for
fuel supply
Correct
Incorrect
Check valve spring
tension
Check valve clearance
Fuel flows freely
Fuel flow restricted
Correct
Incorrect
Not clogged
Clogged
Correct
Incorrect
Not weakened
Weak spring
Check valve timing
1-19