1. GENERAL INFORMATION
K-PIPE 50
1
1 _____________________ _________________________________ _______________________ ______________________ ______________________ ______________________ ________________ _____
_____________________ _________________________________ _______________________ ______________________ ______________________ ______________________ ________________ _____
_____________________ _________________________________ _______________________ ______________________ ______________________ ______________________ ________________ _____
_____________________ _________________________________ _______________________ ______________________ ______________________ ______________________ ________________ _____
_____________________ _________________________________ _______________________ ______________________ ______________________ ______________________ ________________ _____
GENERAL INFORMATION _____________________ _________________________________ _______________________ ______________________ ______________________ ______________________ ________________ _____
ENGINE SERIAL NUMBER -------------------------------------- --------------------------------------------------SPECIFICATIONS ------------------------------------ ---------------------------------------------------------------------------SERVICE PRECAUTIONS -------------------------------------- ------------------------------------------------------TORQUE VALUES -------------------------------------- -----------------------------------------------------------------------SPECIAL TOOLS -------------------------------------- ---------------------------------------------------------------------------LUBRICATION POINTS ------------------------------------- -----------------------------------------------------------CABLE & HARNESS ROUTING --------------------------------------- --------------------------------------WIRING DIAGRAM------------------------------------ -----------------------------------------------------------------------TROUBLESHOOTING-------------------------------------- -----------------------------------------------------------------
1- 1 1- 2 1- 3 1-11 1-12 1-13 1-14 1-18 1-19
1-0
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1. GENERAL INFORMATION ENGINE SERIAL NUMBER
Location of Engine Serial Number
Location of Frame Serial Number
K-PIPE 50
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
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
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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
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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!
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1. GENERAL INFORMATION
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 !
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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!
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1. GENERAL INFORMATION
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 !
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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
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION LUBRICATION POINTS
Throttle Cable
K-PIPE 50
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1. GENERAL INFORMATION
K-PIPE 50
CABLE & HARNESS ROUTING
Regulater/Rectifier
Wire Harness
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1. GENERAL INFORMATION
Battery Negative Cable Cable
K-PIPE 50
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1. GENERAL INFORMATION WIRING DIAGRAM
K-PIPE 50
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1. GENERAL INFORMATION
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
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1. GENERAL INFORMATION
K-PIPE 50
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Inspection/Adjustment
Probable Cause
Symptom
Check ignition timing
Correct
Check carburetor air screw adjustment
Incorrect
Faulty CDI unit Faulty pulser coil
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1. GENERAL INFORMATION
K-PIPE 50
POOR PERFORMANCE (ENGINE LACKS POWER)
Inspection/Adjustment
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
Faulty CDI unit Faulty pulser coil
Correct
Incorrect
Improper valve clearance adjustment Excessively worn valve seat
Check valve clearance
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1. GENERAL INFORMATION
K-PIPE 50
POOR PERFORMANCE (AT HIGH SPEED)
Inspection/Adjustment
Symptom
Probable Cause
Check ignition timing
Correct
Check valve clearance
Incorrect
Faulty CDI unit Faulty pulser coil
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1. GENERAL INFORMATION
K-PIPE 50
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING) Undercharging
Inspection/Adjustment Start engine and test
Symptom
Probable Cause
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1. GENERAL INFORMATION
K-PIPE 50
NO SPARK AT SPARK PLUG
Inspection/Adjustment Replace with a new spark plug and inspect again
Symptom
Probable Cause