K-Pipe 50_01-20130710

1. GENERAL INFORMATION

K-PIPE 50

1

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GENERAL INFORMATION _____________________ _________________________________ _______________________ ______________________ ______________________ ______________________ ________________ _____

ENGINE SERIAL NUMBER -------------------------------------- --------------------------------------------------SPECIFICATIONS ------------------------------------ ---------------------------------------------------------------------------SERVICE PRECAUTIONS -------------------------------------- ------------------------------------------------------TORQUE VALUES -------------------------------------- -----------------------------------------------------------------------SPECIAL TOOLS -------------------------------------- ---------------------------------------------------------------------------LUBRICATION POINTS ------------------------------------- -----------------------------------------------------------CABLE & HARNESS ROUTING --------------------------------------- --------------------------------------WIRING DIAGRAM------------------------------------ -----------------------------------------------------------------------TROUBLESHOOTING-------------------------------------- -----------------------------------------------------------------

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1. GENERAL INFORMATION ENGINE SERIAL NUMBER

Location of Engine Serial Number

Location of Frame Serial Number

K-PIPE 50












K-PIPE 50

SPECIFICATIONS Motorcycle name & Model No. Motorcycle name Overall length (mm) Overall width (mm) Overall height (mm) Wheel base (mm) Engine type Displacement Displacement (cc) Fuel type Front wheel Dry weight (kg) Rear wheel Front wheel Gross weight(kg) Rear wheel Front wheel Tires Rear wheel Ground clearance (mm) Braking distance distance (m) Perform- Braking ance Min. turning radius (mm) Starting system Type Cylinder arrangement arrangement Combustion Combustion chamber chamber type Valve arrangement Bore x stroke (mm) Compression ratio Compression pressure (kg/cm ) Max. output Max. torque Intake Open Close Port (1mm) timing Exhaust Open (1mm) Close Valve clearance Intake (cold) Exhaust Idle speed (rpm) e

in

g

n

E

²

S

L

Lubrication type

K-PIPE 50 LKL6 1950 750 1060 1300 4 49 93# nonleaded gasoline

45 55 100 47 56.5 103.5 2.5-17 41P 3.5-17 54P 180 4 (20km/hr (20k m/hr)) 2.15/1.86 Starting motor & kick starter OHC Single cylinder Semi-spher Semi-s pheree OHC 39×41 9.6:1

F u e l S y st e m E u m ic

tr

c

le

E

n

l

q ip a e t

P o w

T r n

Operating Operating method method Type ra

e D sm ri is y n

1st gear

e

v S

si st G

2nd gear

o

Reduction 3rd gear ratio

e e m a

4th gear

r

5th gear

Front Caster angle Axle Wheel base Front Tire ressure (kg/cm )(2 riders) Rear Left Turning angle Right Front Brake system type Rear M o v in

²

g D e v ic e D

D v

m

15 1.3/7000kw(r/min) 8.5/6000kgm/rpm -5 -5 10 10 14 14 -1 -1 0.06mm 0.06mm 1700±100rpm Forced pressure &

Air cleaner type Sponge Fuel capacity 4liter C Type PD a rb Piston dia. (mm) 18 u re to Venturi dia.(mm) 12equivalent r Throttle type Plunger type S Ig CDI y n Type st i 30 30±2°/3900rpm e ti Ignition timing m o n Spark plug CR7HSA/PZ9HC Spark plug gap 0.6～0.8mm Battery Capacity 12V6AH Clutch Type Wet multi-disc clutch 4-speed transmission Type

e

a

Shock absorber type

ic e in

p g

Frame type

Foot operated Cycle type 3.273 1.706 1.238 0.958 ------27 27 1305 1.75 2.25 45 45 45 45 Disk brake Drum brake

Front

Telescope

Rear

Mono Shock Steel Pipel












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.

K-PIPE 50












 Apply

or add designated greases and lubricants to the specified lubrication points.

 After

reassembly, check all parts for proper tightening and 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.

K-PIPE 50











1. GENERAL INFORMATION the fuse is burned out, find the cause and repair it. Replace it with a new one according to the specified capacity.

K-PIPE 50

 If

 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 protruding or loose.

Confirm Capacity













1. GENERAL INFORMATION 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.

K-PIPE 50

 The

 Before

connecting a terminal, check for damaged terminal cover or loose negative terminal.

 Check

the double connector cover for proper coverage and and installation.

 Insert

the terminal completely.  Check the terminal cover for proper coverage.  Do not make the terminal cover opening face up.

Snapping!












K-PIPE 50

 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.

No Contact !











1. GENERAL INFORMATION  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.

K-PIPE 50

Do not pull too tight!












K-PIPE 50

 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 s teering positions.

 When

a testing device is used, make sure to understand the operating methods thoroughly and operate according to the operating instructions.

 Be

Do you understand the instrument? Is the instrument set correctly?

careful not to drop any parts.

 When

rust is found on a terminal, remove the rust with sand paper or equivalent before connecting.

Remove Rust !











1. GENERAL INFORMATION  Symbols:

The following symbols represent the servicing methods and cautions included in this service manual.

Engine Oil

: Apply engine engine oil to the specified points. (Use designated engine oil for lubrication.)

: Apply grease for lubrication. Grease

Special

: Use special tool.

: Caution

: Warning

K-PIPE 50














K-PIPE 50

TORQUE VALUES STANDARD TORQUE VALUES

Item 5mm bolt, nut 6mm bolt, nut 8mm bolt, nut 10mm bolt, nut 12mm bolt, nut

Torque (kg-m)

Item

Torque (kg-m)

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 Kick plate bolt R/L case bolt Stopper shift bolt Cam gear shift bolt Pin guide bolt Oil pump bolt Clutch nut Rotor oil nut Rotor oil cover bolt Motor bolt Head stud bolt

Quantity

Thread

Torque (kg-m)

2 8 1 1 1 3 1 1 3 3 4

6 6 6 6 8 6 10 10 6 6 7

0.8～1.2 0.8～1.2 0.8～1.2 1.0～1.4 0.8～1.2 0.8～1.2 3.8～4.5 3.8～4.5 0.45 ～0.6 0.8～1.2 0.7～1.1

Remarks












K-PIPE 50

FRAME

Item Steering stem lock nut Steering top cone race Front axle nut Rear axle nut Rear shock absorber upper mount bolt Rear shock absorber lower mount bolt

Rear fork pivot nut Handlebar lock nut Rear driven gear bolt Rear brake panel nut Intake pipe mounting bolt Engine hanger upper nut Engine hanger lower nut

Quantity

Thread

Torque (kg-m)

1 1 1 1 1 1 1 1 4 1 2 1 1

25.4 25.4 14 16 10 10 12 10 8 8 6 1 1

6.0～9.0 0.5～1.3 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 1.8～2.5 1.8～2.5 1.8～2.5

Remarks

SPECIAL TOOLS Tool Name

Tool No.

Ref. Page

Remarks











1. GENERAL INFORMATION LUBRICATION POINTS

Throttle Cable

K-PIPE 50












K-PIPE 50

CABLE & HARNESS ROUTING

Regulater/Rectifier

Wire Harness












Battery Negative Cable Cable

K-PIPE 50













1. GENERAL INFORMATION WIRING DIAGRAM

K-PIPE 50












K-PIPE 50

TROUBLESHOOTING ENGINE WILL NOT START OR IS HARD TO START

Inspection/Adjustment

Symptom

Check if fuel reaches carburetor by loosening drain screw

Fuel reaches carburetor Remove spark plug and install it into spark plug cap to test spark by

Fuel does not reach carburetor

Probable Cause

Empty fuel tank Clogged carburetor fuel inlet tube, vacuum tube or fuel tube Clogged float oil passage Clogged fuel filter Clogged charcoal canister Clogged auto fuel valve strainer Faulty valve passage Faulty fuel pump












K-PIPE 50

POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)


Probable Cause

Symptom

Check ignition timing

Correct

Check carburetor air screw adjustment

Incorrect

Faulty CDI unit Faulty pulser coil












K-PIPE 50

POOR PERFORMANCE (ENGINE LACKS POWER)


Probable Cause

Symptom

Start engine and accelerate lightly for observation Engine speed increases

Engine speed does not increase sufficiently

Check ignition timing using a timing light

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

Correct

Incorrect


Correct

Incorrect

Improper valve clearance adjustment Excessively worn valve seat

Check valve clearance












K-PIPE 50

POOR PERFORMANCE (AT HIGH SPEED)


Symptom

Probable Cause

Check ignition timing

Correct

Check valve clearance

Incorrect















K-PIPE 50

POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging

Inspection/Adjustment Start engine and test

Symptom

Probable Cause












K-PIPE 50

NO SPARK AT SPARK PLUG

Inspection/Adjustment Replace with a new spark plug and inspect again

Symptom

Probable Cause

K-Pipe 50_01-20130710

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