KSR Moto TRIGGER 50 Repair Manual
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KSR Moto TRIGGER 50 Repair Manual

D01
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REPAIR MANUAL
D01 - TRIGGER 50
Vers. 2015_01

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  • Page 1 REPAIR MANUAL D01 - TRIGGER 50 Vers. 2015_01...
  • Page 2 INTRODUCTION It is important that you read this repair manual carefully before the start of work. Only use GENERIC/ KSR spare parts. KSR Motot Motorcycles is a registered brand by KSR Group GmbH. This vehicle can only fulfil the demands placed on it if the service work is made by qualified experts and in accordance with the service schedule.

  • Page 3: Table Of Contents

    INDEX IMPORTANT NOTES REAR BRAKE HOSE REPLACEMENT FRONT BRAKE LEVER ADJUSTMENT LOCATION OF SERIAL NUMBERS REAR BRAKE LEVER ADJUSTMENT VIN (VEHICLE IDENTIFICATION NUMBER) AND FRAME PLATE DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION ANTI TEMPERING LABEL DRIVE CHAIN SLACK ADJUSTMENT ENGINE NUMBER DRIVE CHAIN LUBRICATION DECRYPTING THE VEHICLE IDENTIFICATION NUMBER 7 DRIVE CHAIN WEAR INSPECTION...
  • Page 4 INDEX STARTER REMOVAL STEERING STARTER GEAR REMOVAL EXPLODED VIEW - PART LOCATION / STERRING STATOR REMOVAL HANDLEBAR REPLACEMENT CLUTCH LEVER REPLACEMENT CRANKCASE SEPARATION CRANKSHAFT REMOVAL BRAKE LEVER REPLACEMENT TRANSMISSION DISASSEMBLY INPECTION OF TRANSMISSION AND GEAR SHIFT EXHAUST MECHANISM EXHAUST REPLACEMENT EXPLODED VIEW / PART LOCATION - PRIMARY SHAFT ASSY/ SECONDARY SHAFT ASSY SECONDARY AIR SYSTEM...
  • Page 5 INDEX SWITCHES AND SENSORS IGNITION SWITCH INSPECTION IGNITION SWITCH REPLACEMENT STEERING LOCK ELECTRIC HORN INSPECTION ELECTRIC HORN REPLACEMENT LEFT HANDLE SWITCH RIGHT HANDLE SWITCH LEFT HANDLE SWITCH INSPECTION LEFT HANDLE SWITCH REPLACEMENT RIGHT HANDLE SWITCH INSPECTION RIGHT HANDLE SWITCH REPLACEMENT FRONT BRAKE LIGHT SWITCH INSPECTION / REPLACEMENT REAR BRAKE LIGHT SWITCH INSPECTION...

  • Page 6: Important Notes

    IMPORTANT NOTES WARRANTY The work prescribed in the service schedule must be carried out in an authorized workshop and confirmed in the cus- 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.

  • Page 7: Anti Tempering Label

    LOCATION OF SERIAL NUMBERS VIN (CHASSIS NUMBER) AND FRAME PLATE The vehicle identification number (VIN) (1) is punched into the right side of the steering tube. The frame plate (2) is located on the right side in front of the frame. ANTI TEMPERING LABEL The anti tempering label (3) is fixed on the inner side of the seat bench.
  • Page 8 GENERAL SPECIFICATION ENGINE Version 0 Engine type: Liquid cooled 2 - stroke Cylinder arrangement: Horizontal (+60°) single cylinder Displacement: 49.6 cm³ Compression ratio: 7.0:1 Max. output (kw/rpm): 2.2 kW/ 6500 rpm Max. torque (Nm/rpm): 3.6 Nm/ 5500 rpm Starting system: Electric starter and Kick starter Lubrication system: Fresh oil lubrication ENGINE OIL QUANTITIY Capacity: 1 L...
  • Page 9 GENERAL SPECIFICATION BRAKES Front brake Type: Single Hydraulic disc brake (280 mm)/ Right hand operation Brake fluid: DOT4 Recommended brake fluid: (CASTROL SUPER DISK BRAKE FLUID DOT 4.) Rear brake Type: Hydraulic disc brake (220 mm)/ Right foot operation Brake fluid: DOT4 Recommended brake fluid: (CASTROL SUPER DISK BRAKE FLUID DOT 4.) FRONT SUSPENSION...

  • Page 10: Specific Tightening Torque

    SPECIFIC TIGHTENING TORQUES MODULE PART TORQUE / Nm Starting motor clutch cover bolt Starting motor clutch locknut Rectifier bolt Electrical System Fixing bolt of ignition coil Fixing bolt of flywheel 35-40 Front wheel spindle 55 - 62 Wheel Axles 85 - 98 Rear wheel spindle nut Fixing bolt for fuel tank Fuel tank...

  • Page 11: General Tightening Torque

    GENERAL TIGHTENING TORQUES If no specific torque is given for a bolted assembling use the table below to tighten the screws. If you release a bolted 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.

  • Page 12: Special Tools Special Tools

    SPECIAL TOOLS Special tools are required for some work but mostly professional work shop equipment is enough for service, repair and maintenance of the vehicle. After disassembly, clean the parts that are to be reused and check them for damage and wear.

  • Page 13: Special Tools

    SPECIAL TOOLS Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 12 Fig. 11 Fig. 13 Fig. 14...
  • Page 14 SPECIAL TOOLS 1. Bush-head 2.Shake-handle 3.Ratchet type wrench 4.Connecting-rod Fig. 15 Fig. 16 Fig. 17 Fig. 18 Fig. 19 Fig. 20 Fig. 21a Fig. 21b Fig. 22a Fig. 22b Fig. 23a Fig. 23b...
  • Page 15 SPECIAL TOOLS Fig. 24 Fig. 25 Fig. 26 Fig. 27 Fig. 29 Fig. 28 Fig. 30 Fig. 31 Fig. 32 Fig. 33 Following special tools are not used for 2-stroke engines: -> Fig. 27, Fig. 28, Fig. 29, Fig. 30, Fig. 31, Fig.32, Fig. 33...
  • Page 16 1. PERIODIC MAINTENANCE...

  • Page 17: Periodic Maintenance Chart

    PERIODIC MAINTENANCE CHART Important maintenance work have to be carried out by an authorized workshop. CHECKLIST OF CONSTANT MAINTENANCE The inspection intervals are required, otherwise, no guaran- 1000 km or 4.000 km or 7.000 km or 10.000 km or 13.000 km or tee can be granted.
  • Page 18 IMPORTANT PREPARATION REFERENCES ENGINE Oil/ Oil pump Item Standard Service Limit Oil for replacement 0.4+/- 0.1 L Transmission oil capacitiy Oil for disassemble 0.5+/- 0.1 L Engine oil capacity Engine oil Oil pump Outer diameter of the piston 2.45 mm Cylinder/ Piston Item Standard value [mm]...
  • Page 19 IMPORTANT PREPARATION REFERENCES TRANSMISSION Item Standard value [mm] Allowable limit [mm] Clearance of connecting rod big end in right 0.1 - 0.35 0.55 and left direction Axial clearance of connecting rod big end in Crankshaft 0 - 0.008 0.005 vertical angle Vibration 2.9 - 3 Thickness of wearing plate...
  • Page 20 IMPORTANT PREPARATION REFERENCES STARTER MOTOR Item Standard value Allowable limit Brush length of startup motor 12.5 mm 8.5 mm Liner of startup idler shaft 8.3 mm 7.94 mm Outer diameter of startup idler shaft WHEELS Specification Item Tire pressure (bar) Front wheel of inside 3.00-21 2.25...

  • Page 21: Fuel System Air Cleaner

    FUEL SYSTEM AIR CLEANER Replacement of the air filter element. 1. Remove the seat and the covers on the left side (1). 2. Remove the five mounting bolts (2) and the cover (3) remove the air cleaner element (4). 3. Assembling in reversed order. Check to see if the filter element is polluted or damaged.

  • Page 22: Idle Adjustment

    FUEL SYSTEM IDLE ADJUSTMENT Start and warm up the engine for about 3 minutes, so that the engine will operate in normal running temperature. Adjust the idle adjustment screw (1) and set the idle speed to 1800 U/min. Create a round and stabile engine speed, using the air/ fuel con- trol screw (2).

  • Page 23: Fuel Filters Cleaning

    FUEL SYSTEM/ ENGINE FUEL FILTERS CLEANING The fuel filter must be changed concerning the maintenance chart or when it is blocked. Always check the fuel filter during each work on the fuel system. The fuel filters are placed in the tank. Cleaning: 1.

  • Page 24: Engine Oil Level Sensor Inspection

    ENGINE ENGINE OIL LEVEL SENSOR INSPECTION 1. Remove the front left side cover (4). 2. Remove the oil level sensor (5). 3. Switch on the ignition 4. Remove the oil level sensor, move the floater up and down and check if the indicator light (6) in the dashboard comes on or not.
  • Page 25 ENGINE When you inspect the oil pump you can check several points. 1. Is the oil pump leaking (1)? 2. Does the oil pump work properly? 1. Does the oil pump leak (1)? Check the gaskets on the oil pump shaft. If the gaskets are dam- aged or worn replace the oil pump.

  • Page 26: Oil Pump Adjustment

    ENGINE OIL PUMP ADJUSTMENT WARNING Before you start to adjust the oil pump make sure that the oil cir- cuit is vented correct. If you are start to adjust before the system is vented correct you risk an engine failure during the adjustment. NOTE It doesn’t matter which variant is installed because both need to become adjusted in the same way.

  • Page 27: Transmission Oil Level Inspection

    ENGINE TRANSMISSION OIL LEVEL INSPECTION 1. Switch of the ignition. 2. Place the vehicle on a flat ground. 3. Open the level screw (1). NOTE Oil can flow out. 4. If no oil flow out of the level screw, open the oil cap (2) and fill oil in, till oil flow out of the level screw.

  • Page 28: Sparkplug Images And Analysis

    ENGINE SPARK PLUG IMAGES AND ANALYSIS Colour: 1. Gray/ 2. Light brown Analysis: Engine management ok Colour: 3. Matt black/ 4. Velvety coating Analysis: Fuel/ air mixture wrong. Too much fuel! Solution: Fuel/ air mixture need to adjust. How to adjust see page 21. Colour: 5.

  • Page 29: Adjusting The Clutch Cable Free Play On The Engine Side

    ENGINE/ CLUTCH 2. Check the following items if the compression pressure is too high. • Carbon deposition in combustion chamber or on the top of the piston. TROUBLESHOOTING FAILURE CAUSE TO DO Worn piston ring or cylinder Check the carburettor Cylinder pressure below the allowable Clean or replace the fuel filter limit...

  • Page 30: Clutch Adjustment

    CLUTCH/ WHEELS CLUTCH ADJUSTMENT NOTE When the clutch lever free play is correct and the clutch do not work sufficient check the clutch settings. Before you start to dis- mantle the engine, check the oil level first. You don’t have to re- move the engine from frame while checking the clutch.

  • Page 31: Wheel Bearing And Wheel Axle Damage Inspection

    WHEELS/ BRAKES WHEEL BEARING AND WHEEL AXLE DAMAGE INSPECTION FRONT The wheels rotate with difficulties, sounds strange or have too much free play, the wheel-axle bearings (1) or the gear seats (2) are in failure. To locate the error, the wheel should be removed. BRAKE FLUID LEAK INSPECTION FRONT If the brake fluid level falls below the inspection glass (1) mark, this indicates a leakage in the brake system or worn-out brake...

  • Page 32: Brake Fluid Level Inspection Front

    BRAKES BRAKE OPERATION INSPECTION REAR 1. Operate the foot brake lever (2) until the brake pads lie on the brake disc and check if there is a pressure point. If there is no pressure point check the brake system. 2. While operate the foot brake lever push the vehicle forward and backward (picture (1) on page 31) on the handlebar to check if the brake system is working.

  • Page 33: Front Brake Pads Inspection

    BRAKES FRONT BRAKE PADS INSPECTION Reduced braking efficiency caused by worn brake pads. Change worn brake pads immediately. Always replace the brake pads in pair. 1. Loose the mounting bolts (1) of the braking calliper bracket. 2. If the minimum thickness is less than the indicators (2), damage or cracking is visible change the front brake pads.

  • Page 34: Front Brake Disc Inspection

    BRAKES 3. Remove the circlip (3). 4. Remove the bolt (4). 5. Change the rear brake pads in pair. 6. Reassemble in reverse order. FRONT BRAKE DISC INSPECTION 1. Check the thickness of the front disk at several places on the disk to see if it conforms to measurement.

  • Page 35: Rear Brake Disc Inspection

    BRAKES REAR BRAKE DISC INSPECTION 1. Check the thickness of the rear disk at several places on the disk to see if it conforms to measurement. Allowable limit A: 3 mm If the brake disk thickness is less than the specified value change the brake disk.

  • Page 36: Foot Brake Lever/ Master Brake Cylinder Replacement

    BRAKES FOOT BRAKE LEVER/ MASTER BRAKE CYLINDER REPLACEMENT When the performance of the rear brake is poor it could be possible that the plunger module gaskets are defect. 1. Drain the brake fluid from the hydraulic brake system. 2. Remove the two bolts (1) of the master cylinder cover (2). 3.

  • Page 37: Front Brake Hose Replacement

    BRAKES FRONT BRAKE HOSE REPLACEMENT When the front brake hose is leaking, cracked or worn you had to replace it. Please consider that there is no need to remove the brake calliper when you need to replace the brake hose. WARNING Brake fluid can cause skin irritation on contact.

  • Page 38: Front Brake Lever Adjustment

    BRAKES 3. Remove the master brake cylinder cover. 4. Remove the two plugs (3). 5. Remove the banjo bolt (4) from the master brake cylinder. 6. Replace the brake hose. Take care that the brake hose is installed correct and is connected to all brackets. Use new gaskets when you connect the brake hose.

  • Page 39: Drive Chain

    DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION NOTE The drive chain slack must be checked at the tightest point on the chain. WARNING A drive chain that is too tight can overload the engine and other parts. One that is too loose can skip and damage the swingarm or cause an accident.

  • Page 40: Drive Chain Wear Inspection

    DRIVE CHAIN/ SUSPENSION DRIVE CHAIN WEAR INSPECTION 1. Measure length of 10 chain links. If they cannot meet the specified value, replace the drive chain. Allowable limit A: 127 mm NOTE Stretch the chain by hands and then measure it. The measuring range is from chain link roller to inner side of roller.

  • Page 41: Rear Shock Operation Inspection

    SUPENSION/ STEERING REAR SHOCK OPERATION INSPECTION NOTE At every inspection the rear shock absorbers should be controlled. 1. Compress the rear shock absorber up and down to check for correct function (arrows). 2. Check whether a part of the rear shock absorber is damaged or loosened.

  • Page 42: Steering Bearing Lubrication

    STEERING STEERING BEARING LUBRICATION 1. Place the vehicle on a level surface. 2. Remove the head light, speedometer, handlebar and upper triple tree. 3. Remove the fixation nut (1) and the dust cap (2). 4. Lift the vehicle or lower the front fork. 5.
  • Page 43 ELECTRICAL SYSTEM/ BATTERY BATTERY INSPECTION/ CHARGING The battery (1) is located on the right side of the vehicle. It is recommended to extend the battery whenever it needs servicing. Disconnect the battery poles (2) to extend the battery. 1. This is a conventional battery. You can remove the seal- ing caps to maintain the balancing between the cells.

  • Page 44: Fuses

    ELECTRICAL SYSTEM/ FUSES/ SWITCHES FUSES The main fuses (1) are located next the battery. In the fuse socket strap a replacement fuse (2) is added. NOTE To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1.

  • Page 45: Headlight Aiming Inspection

    ELECTRICAL SYSTEM HEADLIGHT AIMING INSPECTION 1. Place the vehicle at a distance of 5 meters in front of a wall. The vehicle must be placed horizontally. 2. Measure the distance from the ground to the middle of the headlight bulb (X). 3.

  • Page 46: 2. Repair And Diagnostic

    2. REPAIR AND DIAGNOSTICS...

  • Page 47: Chassis Exploded View / Part Location - Frame

    CHASSIS EXPLODED VIEW/ PARTS LOCATION - FRAME PART LIST - FRAME 1. Frame 16. Screw M10x1,25 31. Nut M8 2. Screw M15×12 17. Splint 32. Washer 3. Washer M8 33. Screw M8x50 18. Footrest 4. Rubber pad 19. Spring 34. Rubber pad 5.

  • Page 48: Exploded View / Part Location - Rear Swing Arm

    CHASSIS EXPLODED VIEW / PARTS LOCATION - REAR SWING ARM PART LIST - REAR SWING ARM 1. Mounting shaft REAR SWING ARM 2. Anti dust ring 3. O-Ring 4. Bush 5. Sleeve 6. Chain guid 7. Rear swing arm 8. Nut M14x1.5 9.
  • Page 49 CHASSIS TIGHTENING TORQUE OF FASTENING PARTS ON CHASSIS FASTENING POSITION AND PART NAME TORQUE Front wheel spindle 55-62 Nm Fixing bolt of steering lever 5-9 Nm 85-98 Nm Rear wheel spindle nut Topping nut of the rear shock absorber 37-44 Nm Bottom nut of the rear shock absorber 37-44 Nm Fixing bolt of brake disc rear...
  • Page 50 FUEL SYSTEM/ FUEL TANK EXPLODED VIEW / PART LOCATION - FUEL SYSTEM PART LIST FUEL SYSTEM 1. Screw M8x40 11. Hose clamp 2. Washer M8 12. Fuel hose 3. Sleeve 13. Tank closure 4. Rubber pad 14. Fuel tank cap gasket 5.

  • Page 51: Specification

    FUEL SYSTEM/ FUEL TANK SPECIFICATION FUEL Recommended fuel: Unleaded gasoline only ≥ 95 Oct (SP 95 - SP 98) Do not use any Bio-Ethanol fuel. Fuel tank capacity: 10.0 L ± 0.2 L NOTE Fuel switch shall be set at “OFF” position while removing fuel tank. SPECIAL TOOLS See page 12 - 15 TROUBLESHOOTING...

  • Page 52: Carburettor Exploded View / Part Location - Carburettor

    FUEL SYSTEM/ CARBURETTOR EXPLODED VIEW / PART LOCATION - CARBURETTOR PART LIST - CARBURETTOR 8. Floater 1. Carburettor assy MJ95/ NJ22.5 9. Floater pin 2. Spring 10. Needle valve 3. Idle adjustment screw 11. Float chamber 4. Float chamber gasket 12.

  • Page 53: Carburettor Removal

    FUEL SYSTEM/ CARBURETTOR CARBURETTOR REMOVAL 1. Switch the fuel cock to “OFF” (1). 2. Empty the carburettor by opening the drain screw (2). 3. Loosen the two hose clamps (3). 4. Pull the carburetto backwards to disconnect the carburettor from the membrane (4). 5.

  • Page 54: Carburettor Upper Cover Removal

    FUEL SYSTEM/ CARBURETTOR CARBURETTOR UPPER COVER REMOVAL 1. Loosen the bolts (1) and dismantle the upper cover (2). 2. Take out the spring (3), valve piston (4) and the needle (5). 3. Examine the attrition condition of the parts. 4. If one the parts is worn down, it should be replaced. 5.

  • Page 55: Fuel Tank Removal

    FUEL SYSTEM/ FUEL SUPPLY FUEL TANK REMOVAL 1. Switch of the ignition. 2. Switch the fuel cock (1) to the “OFF” position. 3. Remove the seat bench and the side covers (2). 4. Disconnect the fuel line (3) from the fuel cock. NOTE The fuel line is filled with fuel.

  • Page 56: Fuel Cock

    FUEL SYSTEM/ FUEL SUPPLY FUEL COCK REMOVAL NOTE It´s recommended to drain the fuel from the tank before removal. 1. Switch off the ignition. 2. Switch the fuel cock to the “OFF” position. 3. Disconnect the fuel line from the Carburettor 4.

  • Page 57: Exploded View / Part Location - Cylinder Cylinder Cover

    ENGINE EXPLODED VIEW / PART LOCATION - CYLINDER/ CYLINDER COVER PART LIST - TOP ENGINE 1. Spark plug 8. Outer cylinder head gasket 9. Cylinder 2. Nut 3. Washer 10. Cylinder gasket 4. Temperature sensor 11. Cylinder cover 5. Thermostat 12.

  • Page 58: Exploded View / Part Location - Crank Assembly

    ENGINE EXPLODED VIEW / PART LOCATION - CRANK ASSEMBLY PART LIST - CRANK ASSEMBLY 1. Piston ring 8. Nut 9. Woodruff key 2. Piston pin clip 3. Needle bearing 10. Woodruff key 11. O-Ring 15.5x1.5 4. Piston 5. Piston pin 12.

  • Page 59: Exploded View / Part Location - Crankcase

    ENGINE EXPLODED VIEW / PART LOCATION - CRANKCASE PART LIST - CRANKCASE 1. Nut 19. Seal ring 10. Breather hose 2. Seal ring 11. Nut M6x55 20. Nut M8x12 3. Bearing 6203 12. Simmering 20x35x7 21. Main bearing 4. Needle bearing 22.

  • Page 60: Specification

    ENGINE SPECIFICATION ENGINE TYPE 2 STROKE LIQUID COOLED Unleaded gasoline (SP 95 - SP 98) ≥ 95 Oct Fuel type Do not use any Bio - Ethanol fuel 1 + 60° horizontal - liquid cooled Number of cylinder 40.25×39 Bore and stroke 49.6 ccm Displacement Start system...

  • Page 61: Troubleshooting

    ENGINE TROUBLESHOOTING FAILURE CAUSE TO DO Charge the battery Check the charging of the battery Battery discharged Check if the generator is working correctly Engine does not start when the electric starter button is pushed Check or replace Fuse is blown Check the starter relay Starter relay defective Check the starter motor...

  • Page 62: Engine Overhaul/ Removal

    ENGINE/ DISASSEMBLING ENGINE OVERHAUL/ REMOVAL NOTE It’s not necessary to remove the engine in order to remove the following components: • Cylinder cover • Cylinder • Piston and piston ring • Clutch • Drive gear • Gear shift shaft • Magneto rotor •...

  • Page 63: Cylinder Removal

    ENGINE/ DISASSEMBLING/ TOP END CYLINDER COVER REMOVAL 1. Remove the spark plug (1), the thermo switch (2), the temperature sensor (3) and the four nuts (4). 2. Remove the cylinder head (5) and gaskets (6). NOTE Loosen each nut (4) 1/4 turn, and remove them after all nuts are loosened.

  • Page 64: Oil Pump Removal

    ENGINE/ DISASSEMBLING/ RIGHT CRANKCASE OIL PUMP REMOVAL 1. Remove the two bolts (1) and remove the oil pump (2). WATER PUMP REMOVAL 1. Remove the three bolts (1) and remove the water pump (2). CRANKCASE COVER (RIGHT) REMOVAL NOTE Drain the engine oil before start with the disassembling. 1.

  • Page 65: Clutch Removal

    ENGINE/ DISASSEMBLING/ CLUTCH CLUTCH REMOVAL 1. Remove the four clutch screws (1) with their springs. 2. Remove the clutch pressure plate (2) and the friction plates (3). 3. Rotate the engine and pull out the clutch push rod (4) with the bearing ball (5) and the bolt (6).

  • Page 66: Crankshaft Gear And Main Shaft Gear Removal

    ENGINE/ CRANKCASE CRANKSHAFT GEAR AND MAIN SHAFT GEAR REMOVAL 1. Remove the two nuts (1) and remove the two gears (2). NOTE Watch out not to lose the dowel pins. MEMBRANE REMOVAL 1. Remove the three screws (1) and the secure screw (2). 2.

  • Page 67: Crankcase Cover (Left) Removal

    ENGINE/ DISASSEMBLING/ LEFT CRANKCASE CRANKCASE COVER (LEFT) REMOVAL 1. Remove the socket head cap screws (1) to remove the left crankcase cover. NOTE It´s recommended to loosen the screws crosswise before complete removal. STARTER REMOVAL 1. Remove the two screws (1). 1.

  • Page 68: Crankcase Separation

    ENGINE/ DISASSEMBLING/ CRANKCASE CRANKCASE SEPARATION 1. Rotate the engine 180° and remove the bolt (1) to the right side. 2. Rotate the engine back to the left engine side. 3. Remove the nine bolts (2). NOTE It is recommended to loosen the bolts crosswise before complete removal.

  • Page 69: Transmission Disassembly

    ENGINE/ DISASSEMBLING/ TRANSMISSION TRANSMISSION DISASSEMBLY NOTE After removal of the crank case first check the position of the transmission washer (1). 1. Remove the balancer shaft (2). 2. Turn the shift drum (3) till you can pull out the shift shaft (4). 3.
  • Page 70 ENGINE/ TRANSMISSION NOTE • In Case of a defect of a transmission gear replace always in a pair. • Remove damaged bearings if necessary with a bearing pull- • Use only genuine spare parts. • Before assembling the engine clean the crankcase and all sealing surfaces carefully.

  • Page 71: Exploded View / Part Location - Primary Shaft Assy/ Secondary Shaft Assy

    ENGINE/ TRANSMISSION EXPLODED VIEW / PART LOCATION - PRIMARY SHAFT ASSY/SECONDARY SHAFT ASSY 24 23 PART LIST - PRIMARY SHAFT ASSY/SECONDARY SHAFT ASSY 10. Secondary shaft assy 20. Gearwheel 6th gear 1. Primary shaft assy 11. Secondary shaft 21. Gearwheel 2nd gear 2.

  • Page 72: Exploded View / Part Location - Shift Mechanism

    ENGINE/ TRANSMISSION EXPLODED VIEW / PART LOCATION - SHIFT MECHANISM PART LIST - SHIFT MECHANISM 1. Gear shift shaft assy 11. Spring bracket 21. Shift fork 2. Circlip 12. Spacer 22. Star washer 3. Washer 13. Stop lever 23. Detent 4.

  • Page 73: Exploded View / Part Location - Reduction Gear

    ENGINE/ TRANSMISSION EXPLODED VIEW / PART LOCATION - REDUCTION GEAR PART LIST- REDUCTION GEAR 4. Shift shaft set 8. Shift drum 1. Primary shaft assy 9. Left and right fork shaft 5. Middle fork 2. Secondary shaft assy 6. Middle fork shaft 10.
  • Page 74 ENGINE/ TRANSMISSION TRANSMISSION AND SHIFT MECHANISM INSPECTION ITEM STANDARD VALUE (mm) ALLOWABLE LIMIT (mm) 7.91 Bore diameter of shift fork 7.825 - 7.845 3.95 - 4.05 Shift fork thickness Shift mechanism Shift drum outer diameter 41.8 - 42 41.75 Locked groove width of shift drum 6.05 - 6.15 Check the shift fork shaft (1) with an micrometer.

  • Page 75: Transmission Assembling

    ENGINE/ TRANSMISSION TRANSMISSION ASSEMBLING 1. Install the primary shaft assy (1) and the secondary shaft assy (2). 2. Pull back the preload device (3) and install the shift drum (4). NOTE Watch out to the position of the preload device. 3.

  • Page 76: Crankshaft Inspection

    ENGINE/ CRANKSHAFT NOTE 1. Inspect and clean all parts carefully before assembling. 2. Check all used bearings and replace if necessary. Install the bearing only with the right tool. 3. If you are not proficient, leave the job an specialist. CRANKSHAFT INSPECTION ITEM STANDARD VALUE (mm)
  • Page 77 ENGINE/ CRANKSHAFT 4. Measure the run-out at the bearing pins of the crankshaft. Allowable Limit (A/B): 0.1 mm 5. Check the crankshaft bearings for excessive play. The bear- ings must be replaced if they are noisy or have excessive play. NOTE If the crankshaft, transmission shaft and balance shaft installed in the left crankcase put some surface sealant thin on the plane...

  • Page 78: Top End Parts Inspection

    ENGINE/ TOP END TOP END PARTS INSPECTION NOTE Before reinstall the piston and piston pin measure all dimensions if they are within the limits. STANDARD VALUE ALLOWABLE LIMIT ITEM [mm] [mm] Cylinder inner diameter 40.27 - 40.28 40.3 Cylindrically 0.05 Cylinder Roundness 0.05...
  • Page 79 ENGINE/ TOP END 1. Inspect the flatness of the cylinder. (1. Ruler, 2. Measuring gauge, 3. Cylinder) Allowable limit A: 0,05 mm NOTE Inspect the cylinder head in the same way. 2. Inspect the flatness of the cylinder head. (1. Ruler, 2. Meas- uring gauge, 3.

  • Page 80: Piston Installation

    ENGINE/ TOP END 6. Measure the clearance (X) between piston ring (1) and piston ring groove (2) with an spacer gauge. Allowable limit: Top ring: 0.09 mm Second ring: 0.09 mm 7. Measure the bore diameter (X) of the connecting rod small end inner diameter with an subito.

  • Page 81: Cylinder Installation

    ENGINE/ TOP END CYLINDER INSTALLATION 4. Install the cylinder gasket (1). 5. Add some fresh engine oil on the piston, piston ring and the inner cylinder wall. NOTE A piston ring pincer helps to install the piston in the cylin- der (2).

  • Page 82: Left Crankcase Assembling

    ENGINE/ LEFT CRANKCASE LEFT CRANKCASE ASSEMBLING 1. Install the stator (1) and the pick up (2). Tighten the srews in specific torque. NOTE If there is any signal fault of generator or pick up replace the sta- tor together with the pickup. 2.

  • Page 83: Sprocket Installation

    ENGINE/ LEFT-RIGHT CRANKCASE SPROCKET INSTALLATION 1. Assemble the sprocket in reverse order of removal (see page MEMBRANE INSPECTION 1. Controll the membrane to their thickness. Hold up the mem- brane as shown in the picture (1) and look if light shines throug.

  • Page 84: Clutch Inspection

    ENGINE/ CLUTCH CLUTCH INSPECTION 1. Check if there are burs or broken parts on the center bracket (1) or pressure plate (2) of clutch. If there are, fix and adjust with a file. 2. Check if teeth of pressure plate and center bracket are injured. If they are, replace them.

  • Page 85: Exploded View / Part Location Clutch

    ENGINE/ CLUTCH EXPLODED VIEW / PART LOCATION - CLUTCH PART LIST - CLUTCH 1. Clamp nut 7. Locknut 13. Housing set 2. Adjustment bolt 8. Fixing gasket 14. Dish gasket 9. Wearing plate 3. Bolt and gasket 15. Washer 4. Pressure spring 10.

  • Page 86: Clutch Assembling

    ENGINE/ CLUTCH CLUTCH ASSEMBLING 1. Install housing set (1) and the internal gasket (2). 2. Install the center (3), the secure washer (4) and the nut (5). NOTE Watch out to the position of the secure washer. 3. Tighten the locknut (5) an fix the secure washer (4). TORQUE LIST PART NO.

  • Page 87: Outward Release Lever Adjustment

    ENGINE/ CLUTCH/ RIGHT CRANKCASE 7. Install the springs (10) and the screws (11). 8. Tighten the screws. TORQUE LIST PART. NO. TORQUE 10 - 16 Nm OUTWARD RELEASE LEVER ADJUSTMENT 1. Pull out the release lever (8). The clearance should be about 1mm.

  • Page 88: Actuating Lever Adjustment

    ENGINE/ ACTUATING LEVER ACTUATING LEVER ADJUSTMENT 1. Turn the actuatin lever (1) 180° counter clockwise (arrow). 2. After turning the actuating lever, screw in the bolt (2). TROUBLESHOOTING FAILURE CAUSE TO DO Clutch cable defect, twisted or contaminated Replace or clean it Tight clutch release lever Defect push rod or lifter bearing Replace it...

  • Page 89: Exploded View / Part Location - Oil Pump

    ENGINE/ ASSEMBLING/ OIL PUMP EXPLODED VIEW / PART LOCATION - OIL PUMP PART LIST OIL - PUMP 1. Throttle handle set 6. Circlip 11. Oilpump cover 2. Torsion spring 7. Piston 12. Bolt 3. Camshaft 8. Piston spring 13. Worm gear 9.

  • Page 90: Lubrication Scheme

    ENGINE/ LUBRICATION SYSTEM LUBRICATION SCHEME PART LIST - LUBRICATION SYSTEM NOTE 1. Oil tank 2. Oil pump When the engine oil pump is removed, clean care- 3. Carburettor fully all the components and purge them with high- 4. Crankshaft pressure air. 5.

  • Page 91: Cooling System Scheme

    ENGINE/ COOLING SYSTEM/ WATER PUMP COOLING SYSTEM SCHEME PART LIST - LUBRICATION SYSTEM 1. Water pump 2. Connected to the water tank 3. Flow back to the water tank Water flow direction WATER PUMP INSPECTION 1. Inspect the wear and tear of the impeller set (1). Severe wear and replace it.

  • Page 92: Wheels And Tires

    ENGINE/ WHEELS AND TIRES NOTE Assemble the engine to the frame in reversed order of removal. WARNING Add oil and water before starting the engine. Double check engine oil amount by engine oil niveau screw. EXPLODED VIEW / PART LOCATION - FRONT WHEEL PART LIST - FRONT WHEEL 1.
  • Page 93 WHEELS AND TIRES EXPLODED VIEW / PART LOCATION - REAR WHEEL PART LIST-REAR WHEEL 1. Axle 11. Rim 3.00x17 6. Mounting bolts of chain 2. Press plate wheel 12. Brake disc 3. Left sleeve 7. Chain wheel 55T 13. Mounting bolts of brake 4.

  • Page 94: Wheels (Rims)

    WHEELS AND TIRES WHEELS (RIMS) The wheel rims should be checked for cracks, bends. If any dam- age is found replace the rim. Do not attempt even the smallest repair of the wheel. The wheel should be balanced whenever either the tire or the rim has been changed or replaced. An unbal- anced wheel can result in poor performance, adverse handling characters, and a shortened tire life.

  • Page 95: Wheel Bearing Replacement Rear Wheel

    WHEELS AND TIRES WHEEL BEARING REPLACEMENT REAR WHEEL 1. Place the vehicle on a suitable repair stand. 2. Disconnect the chain (1). 3. Remove the fixing nut (2) and remove the axle (3). 4. Remove the rear wheel (4). 5. Remove the oil seal (5) and the bearing (6). 6.

  • Page 96: Brakes

    BRAKES EXPLODED VIEW / PART LOCATION - FRONT BRAKE WARNING THE BRAKING COMPONENTS MAY NOT BE SPOIL DURING INSTALLATION DISASSEMBLY. RINSE WITH STIPULATED CLEANING AGENT IN ORDER TO AVOID REDUCTION OF BRAKING QUALITY. 11. Brake calliper bolts M 8 x 30 PART LIST - FRONT BRAKE 5.
  • Page 97 BRAKES EXPLODED VIEW / PART LOCATION - REAR BRAKE PART LIST-REAR WHEEL 15. Nut M8x20 1. Brake system 8. Seal 2. Brake fluid reservoir 9. Brake line 16. Brake pads 10. Banjo bolt 3. Brake line 17. Cover master cylinder 4.

  • Page 98: Brake Levers / Front Brake Lever

    BRAKES SPECIAL TOOLS See page 12-15. TROUBLESHOOTING FAILURE CAUSE TO DO Unfavourable brake adjustment Adjust the brake system Brake pads worn Replace the brake pads Brake pads installed improperly Install the brake pads proper Poor brake performance Clean or replace the brake pads Brake pads or brake disc contaminated and clean the brake disc/ drum Air in the front brake hose...

  • Page 99: Brake Fluid

    BRAKES BRAKE FLUID WARNING 1. Never use dirty or unspecified brake fluid or mix different brake fluids because it will damage the brake system. 2. Brake fluid spilled on brake pads or brake disk will reduce the braking effect. Clean the brake pads and brake disk with a high quality brake degreaser.

  • Page 100: Brake Pedal Replacement

    BRAKES BRAKE PEDAL REPLACEMENT 1. Remove the splint (1) and loosen the fixation nut (2) to re- move the screw (3). 2. Remove the splint (4) and loosen the fixation nut (5) to re- move the screw (6). WARNING If you remove the screw (6), the brake pedal can be spring out. NOTE Look to the position of the spring (7) and the screw.

  • Page 101: Exploded View / Part Location - Front Suspension

    SUSPENSION EXPLODED VIEW / PART LOCATION - FRONT SUSPENSION PART LIST - FRONT SUSPENSION 1. Screw M8x35 16. Lower triple tree assy 31. Bracket speedometer drive 17. Screw M5x12 2. Washer M8 cable 3. Upper handlebar clamp 18. Washer M5 32.
  • Page 102 SUSPENSION TORQUE LIST PART NO. TORQUE 5-9 Nm SPECIFICATION ITEM DESCRIPTION VALUE Telescope unit (cartridge) - oil/ spring 110 mm max. travel Fork travel Upper bearing 6205-2RS Lower bearing 30205 DESCRIPTION (VERSION 0) STANDARD NOTE Air chamber length by fork rod (gas filling) 80 mm 95 mm Air chamber length by fork rod (spring)

  • Page 103: Exploded View / Part Location - Adjustable Rear-Suspension

    SUSPENSION EXPLODED VIEW / PART LOCATION - ADJUSTABLE REAR SUSPENSION PART LIST-REAR SUSPENSION 1. Screw M10x1.25x50 4. Adjust nut 2. Nut M10x1.25 5. Lock nut 3. Shock absorber SPECIFICATION ITEM DESCRIPTION VALUE Adjustable, spring loaded telescope units (cartridge) 60 mm max. travel Rear shock absorbers TORQUE LIST PART NO.

  • Page 104: Front Suspension Replacement

    SUSPENSION SPECIAL TOOLS There are no special tools recommended because defect suspension elements may not be dissembled. Always´s replace defect suspension elements. TROUBLESHOOTING FAILURE CAUSE TO DO Insufficient tire pressure Adjust the tire pressure Broken or bent fork leg Replace the affected fork leg Vehicle difficult to steer Control and adjust or replace af- Uneven front shock absorbers...

  • Page 105: Front Suspension Whole Fork Replacement

    SUSPENSION FRONT SUSPENSION WHOLE FORK REPLACEMENT 1. Place an appropriate supporting stand under the vehicle in order to raise the front wheel up. 2. Remove the handlebar (1), head light (2), and upper triple tree (3). 3. Remove the brake calliper and brake line bracket, the indicator brackets, the front wheel, and the front fender.

  • Page 106: Rear Swing Arm Replacement

    SUSPENSION 1. Remove the lower bolt (6) first and upper bolt (7) of the shock absorber. 2. Pull the shock absorber backwards and remove it to the left side (Arrows). 3. Assemble the new shock in reverse order. TORQUE LIST PART NO.
  • Page 107 STEERING EXPLODED VIEW / PART LOCATION - STEERING PART LIST - STEERING 1. Screw M8x35 7. Upper triple tree 13. Seal 2. Washer 8. Nut 14. Lower triple tree assy 9. Upper bearing race 3. Upper handlebar clamp 15. Steering column 4.
  • Page 108 STEERING HANDLEBAR REPLACEMENT In case of any damage of the handlebar you must replace it. 1. Remove the left (1) and right handle switch (2) as described in the manual. 2. Loosen the four screws (3) and remove the handlebar clamp (4).
  • Page 109 STEERING 5. Loosen the screw (8) and slide the left handle switch to the right. 6. Pull off the left grip from the handle bar would be more dif- ficult as the grip is normally glued with grip glue. We suggest to use compressed air (9) and in same way pull the grip to the left.

  • Page 110: Brake Lever Replacement

    STEERING/ EXHAUST BRAKE LEVER REPLACEMENT 1. Loose the secure nut (1) for the brake lever and unscrew the brake lever bolt (2) with a flat-headed screwdriver. 2. Now it is possible to remove the brake lever from the front brake system. 3.
  • Page 111 EXHAUST 3. Remove the screw (7). 4. Pull the exhaust pear frontwards (arrows). 5. To disconnect the exhaust pear remove the three screws (8). If you disconnect the exhaust pear always renew the gasket (9) with a new one. 6. Assembling in reverse order. Silencer 1.
  • Page 112 EXHAUST/ SECONDARY AIR SYSTEM 4. Pull the silencer backwards (Arrow). 5. Assembling in reverse order. SECONDARY AIR SYSTEM INSPECTION 1. Remove the seat, the right side cover and the cover (1). 2. Disconnect the two hoses (2). 3. Remove the three screws (3) and remove the secondary air system (4).
  • Page 113 SECONDARY AIR SYSTEM 5. Controll the membrane (6). 6. If the membrane is broken or work wrong please replace the whole secondary air system. 7. Install the secondary air system in reverse order.
  • Page 114 ELECTRICAL SYSTEM/ GENERAL WIRING DIAGRAM...

  • Page 115: Location - Electrical System

    ELECTRICAL SYSTEM/ GENERAL LOCATION - ELECTRICAL SYSTEM PART LIST- ELECTRICAL SYSTEM 7. Regulator rectifier 1. Winker relay 8. Ignition coil 2. Main fuses 10 Ampere 9. CDI (capacitor discharge ignition) 3. Main switch/ power lock module 10. Starter relay 4. Speedometer 11.

  • Page 116: Location - Lights / Instruments Switches

    ELECTRICAL SYSTEM/ GENERAL LOCATION - LIGHTS / INSTRUMENTS SWITCHES PART LIST - LIGHTS / INSTRUMENTS SWITCHES CERTIFICATION NO. PART NAME CE NO. 1. Head light Head light E4 - 0011534 2. Turn signal front 3. Side reflector Rear light E4 - 0011535 4.

  • Page 117: Specification

    ELECTRICAL SYSTEM/ GENERAL SPECIFICATION ITEM NOMINAL VALUE Spark plug NGK/BR8ES Spark plug gap 0.6-0.7 mm 0.4 Ω±10% Primary coil 8-11 KΩ With spark Resistance value of ignition coil (20°C) plug cover Secondary coil 4.5 - 5.5KΩ Without spark plug cover 100-200 Ω...

  • Page 118: Specification

    ELECTRICAL SYSTEM/ FUSE/ BATTERY FUSE REPLACEMENT If the fuse is burned out, find the cause and repair it. The fuse holder is located beside the battery below the seat. 1. Turn off the main switch and all electrical circuits. 2. Remove the seat. 3.

  • Page 119: Battery Removal

    ELECTRICAL SYSTEM/ CHARGING SYSTEM 6. Inspect the entire electric load. 7. Quick charging is forbidden except in emergency. 8. During quick recharging, the battery must be removed from the motorcycle and recharged. 9. A voltmeter shall be employed to check recharged battery. BATTERY REMOVAL 1.

  • Page 120: Charging System Charging Scheme

    ELECTRICAL SYSTEM/ CHARGING SYSTEM CHARGING SCHEME CHARGING PERFORMANCE TEST 1. Remove the battery cover on the left side. 2. Stop the engine and open the fuse box. 3. Disconnect the wire from the fuse. Connect an ampere meter (A) between the wire and fuse terminal. 4.

  • Page 121: Regulator - Rectifier Inspection

    ELECTRICAL SYSTEM/ IGNITION SYSTEM REGULATOR - RECTIFIER INSPECTION Disconnect the plug from the regulator rectifier. Check continuity between main wiring terminals in the following way. Multimeter White (W) Red (R) Pink (PK) Black (B) Unit: MΩ White (W) 27.04 15.15 25.40 Red (R) Pink (PK)

  • Page 122: Ignition System Ignition System

    ELECTRICAL SYSTEM/ IGNITION SYSTEM IGNITION SYSTEM PREPARATORY DATA Precautions on operation 1. Ignition system inspection: Please perform inspection in the sequence listed in the fault diagnosis table. 2. Ignition system uses electronic-type automatic timing de- vice, which is solidified in the CDI assembly, so it is unnec- essary to adjust the ignition time.

  • Page 123: Specification

    ELECTRICAL SYSTEM/ IGNITION SYSTEM SPECIFICATION Item Standard Value Spark plug NGK/BR8ES Spark plug clearance 0.6-0.7mm Primary coil Black/White-black 0.4 Ω ± 10% 8-11 KΩ White spark plug cap (bl – spark plug cover) Ignition coil impedance value (20°C) Secondary coil 4.5-5.5 KΩ...

  • Page 124: Ignition System Inspection

    ELECTRICAL SYSTEM/ IGNITION SYSTEM IGNITION SYSTEM INSPECTION NOTE When there is no spark from the spark plug, check if compo- nents of wiring are loosened or badly connected and make sure if all the voltage values are normal. There are many brands of multimeters (1) with different interior impedance.

  • Page 125: Trigger Inspection

    ELECTRICAL SYSTEM/ IGNITION SYSTEM TRIGGER INSPECTION Inspect of the trigger can be conducted on the engine. 1. Disconnect the pick up cable from the main wire. 2. Connect the multimeter on the to the pick up cable 3. Positive (+) to blue/white and negative (-) green/white cable 4.

  • Page 126: Starting System

    ELECTRICAL SYSTEM/ STARTING SYSTEM SECONDARY COIL Measure the impedance between lead-wire side of spark plug cap and terminal as shown in picture (2). Standard value: 8-11 KΩ (20°C) Impedance value within the range is good. Impedance value “∞” indicates broken wire inside the coil. STARTING SYSTEM PREPARATORY DATA Precautions on operation.

  • Page 127: Fault Diagnosis

    ELECTRICAL SYSTEM/ STARTING SYSTEM FAULT DIAGNOSIS FAILURE CAUSE TO DO Fuse blown Replace fuse Power shortage in battery Replace battery Bad acts of main switch Check and replace Bad act of startup clutch Check and repair - replace if nessecary Unable to start up Bad act of brake switch Check and replace...

  • Page 128: Starting Relay Voltage Inspection

    ELECTRICAL SYSTEM/ LIGHTNING SYSTEM STARTING RELAY VOLTAGE INSPECTION 1. Disconnect the plug (green/yellow) (1). 2. Turn on the main switch, check the Engine “stop switch” is turned on too. 3. Press the start button and measure the voltage between the ground wire of frame and green/yellow wire of start relay.

  • Page 129: Headlamp Bulb Replacement

    LIGHTNING SYSTEM HEADLAMP BULB REPLACEMENT 1. Remove the two headlight screws (1). 2. Remove the four screws (2) of the front fender (3). 3. Remove the rubber cap (4) from the head light mask (5). 4. Twist the lock plate (6) counterclockwise till you can remove...

  • Page 130: Position Light Bulb Replacement

    LIGHTNING SYSTEM 5. Pull the bulb (7) in and twist it clockwise till you can remove it. 6. Replace the defect bulb and reassemble in reverse order. POSITION LIGHT BULB REPLACEMENT To replace the position light bulb follow the below listed points of 1.

  • Page 131: Rear Winker Replacement

    ELECTRICAL SYSTEM/ LIGHTNING SYSTEM 4. Remove the three screws (2) and replace the whole head- light. 5. Install the new headlight in reverse order. 6. Adjust the height of the low beam. (See page 45) REAR WINKER REPLACEMENT 1. Remove the rear fender cover (1). 2.

  • Page 132: Bulb Winker Replacement

    ELECTRICAL SYSTEM/ LIGHTNING SYSTEM BULB WINKER REPLACEMENT 1. Turn off the ignition switch. 2. Screw off the self-tapping screw (1) on the turn signal lamp. 3. Remove the indicator lens (2). 4. To replace the bulb (3) press the bulb and rotate clockwise until you can pull out the bulb.

  • Page 133: Taillight Replacement

    ELECTRICAL SYSTEM/ LIGHTNING SYSTEM TAILLIGHT REPLACEMENT 1. Remove the rear fender cover. 2. Disconnect the taillight cable (1). 3. Remove the screw (2). 4. Remove the two screws (3). 5. Pull the taillight out of the cover. 6. Reassemble in reverse order. LICENSE PLATE BULB REPLACEMENT 1.

  • Page 134: Speedometer Speedometer Description

    ELECTRICAL SYSTEM/ SPEEDOMETER SPEEDOMETER DESCRIPTION 1. Speedometer 2. Engine coolant tell-tale 3. Engine oil tell-tale 4. Main-beam headlamp tell-tale 5. Dipped-beam headlamp tell-tale 6. Direction tell-tale 7. Neutral tell-tale 8. Odometer SPEEDOMETER REPLACEMENT 1. Remove the headlight before removing the speedometer. 2.

  • Page 135: Electric Horn Inspection

    ELECTRICAL SYSTEM/ INSTRUMENTS ELECTRIC HORN INSPECTION 1. Disconnect the horn wire (1) from the horn (2). 2. The horn is works correct if it sounds when a 12V battery is connected to the plugs. If the horn does not work correct replace it. ELECTRIC HORN REPLACEMENT 1.

  • Page 136: Left Handle Switch Inspection

    ELECTRICAL SYSTEM/ INSTRUMENTS LEFT HANDLE SWITCH INSPECTION 1. Remove the headlight. 2. Disconnect the cables of the left handle switch as shown in the picture (1). 3. Use a continuity tester to measure the switches as shown in the illustrations below. 4.

  • Page 137: Right Handle Switch Replacement

    ELECTRICAL SYSTEM/ SWITCHES AND SENSORS RIGHT HANDLE SWITCH REPLACEMENT 1. Remove the headlight. 2. Disconnect the cables of the right handle switch. 3. Remove the screw (1) of the right handle switch. 4. Pull the right handle switch (2) downwards. 5.

  • Page 138: Rear Brake Light Switch Inspection

    ELECTRICAL SYSTEM/ SWITCHES AND SENSORS REAR BRAKE LIGHT SWITCH INSPECTION 1. Disconnect the two plugs (1) of the brake light switch from the main wire. The two plugs are located on the top of the rear brake master. Check the brake light switch with a continuity tester: Brake pedal pressed: continuity Brake pedal released: no continuity 2.

  • Page 139: Neutral Sensor Inspection

    ELECTRICAL SYSTEM/ SWITCHES AND SENSORS NEUTRAL SENSOR INSPECTION 1. If it is not possible to reach the water residenze plug (1), remove the seat, the side covers, the tank and the oil/water tank. 2. Disconnect the plug coming from the engine. 3.

  • Page 140: Speed Sensor Inspection

    ELECTRICAL SYSTEM/ SWITCHES AND SENSORS SPEED SENSOR INSPECTION 1. The speed sensor plug (picture 1) is located behind the headlight. 2. Remove the headlight and disconnect the plug. 3. Disconnect the plug and use a continuity tester to measure the sensor as described. Switch the multimeter to DC - Voltage 1.
  • Page 141 ELECTRICAL SYSTEM/ SWITCHES AND SENSORS NOTE • Loose cable is a hidden trouble to electrical safety. After clamped check each cable to ensure electrical safety. • It is not allowed to leave any wire clip bending towards bond- ing points. •...

  • Page 142: Fault Diagnosis

    ELECTRICAL SYSTEM/ SWITCHES AND SENSORS FAULT DIAGNOSIS ITEM FAILURE CAUSE TO DO The interior resistance is too low and test it with Replace a designated tester. The cranking speed is too low. Search for error and repair If the voltage measured for High voltage to The tester is disturbed several times is above stand-...

  • Page 143: Left / Right Side Cover Removal

    CHASSIS COVER REPLACEMENT SEAT REMOVAL 1. Turn the key clockwise (arrow) and lift the seat up. 2. To get off the seat, lift (1) the seat and pull it back (2). 3. Install the seat in reverse order LEFT/RIGHT SIDE COVER REMOVAL 1.

  • Page 144: Left / Right Tank Side Cover Removal

    CHASSIS LEFT/RIGHT TANK SIDE COVER REMOVAL 1. Remove the five screws (1). 2. Remove the two screws (2) of the protection mesh. 3. Remove the left/right tank side cover. 4. Install the left/right tank side cover in reverse order. NOTE Only one side (left side) is illustrated.

  • Page 145: Rear Side Cover Removal

    CHASSIS REAR SIDE COVER REMOVAL 1. Follow the steps 1-4 of rear body panel removal. WARNING Before you remove the rear cover you must to uncouple the seat lock from the cable. Lift the seat lock cable (1) afterwards turn it to the right.

  • Page 146: Front Fender Removal

    CHASSIS FRONT FENDER REMOVAL 1. To remove the front fender (1), remove the four screws (2). HEADLIGHT COVER REMOVAL 1. Remove the front fender. 2. Remove the two screws (1). 3. Remove the screw (2) on the left and right side. NOTE Only one side (left side) is illustrated.

  • Page 147: Cover Front Shock Absorber Left Removal

    CHASSIS COVER FRONT SHOCK ABSORBER LEFT REMOVAL 1. Remove the screw (1). NOTE Look to the nut on the rear. 2. Thread of the breaking hose (2). 3. To remove the cover front shock absorber left (3) remove the two screws (4). 4.

  • Page 148: Cover Front Shock Absorber Right Removal

    CHASSIS COVER FRONT SHOCK ABSORBER RIGHT REMOVAL 1. To remove the speedsensor cable (1), remove the screw (2). NOTE Look to the nut on the rear. 2. To remove the cover front shock absorber right (3) remove the two screws (4). 3.

  • Page 149: Mirrow

    MIRROW BACK VIEW MIRROWS At all repairs in the area of the handle bar is advised to remove the back view mirrors. To prevent damage during installation of the back view mirror consider that on the right side is a left-handed thread and vice versa.

  • Page 150: Second Speedometer Second Speedometer

    SECOND SPEEDOMETER SECOND SPEEDOMETER PART LIST SECOND SPEEDOMETER 1. Left button 2. Temperature - Red light 3. Turn signal - Green light 4. High beam - Blue light 5. Display 6. Oil light - Red light 7. Neutral light - Green light 8.

  • Page 151: Removal Of Power Limitation Removal Of Power Limitation

    REMOVAL OF POWER LIMITATION REMOVAL OF POWER LIMITATION WARNING THE REMOVAL OF POWER LIMITATION IS IN THE MOST COUNTRIES NOT LEGAL. IN CAUSE OF DETHROTTLING ALL CLAIMS OF WARRANTY EXPIRE AND ALL DAMAGES OF THE VEHICLE IS IN YOUR OWN RESPONSIBILITY. There are 2 levels of dethrottling.
  • Page 152 KSR Moto is a trademark of Group GmbH Gewerbeparkstrasse 3500 Krems, Austria w w w . k s r - g r o u p . c o m...

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