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Maintenance Manual of

Two-wheeled Motorcycle

(K-LIGHT125)

KS MOTORCYCLES - https://ksmotorcycles.com

Contents

Contents ................................................................................................................................................................. - 1 -

Preface ................................................................................................................................................................... - 4 -

Preparatory information ......................................................................................................................................... - 5 -

General safety ................................................................................................................................................ - 5 -

Maintenance rules .......................................................................................................................................... - 6 -

Motorcycle identification............................................................................................................................. - 10 -

Important notes ............................................................................................................................................ - 11 -

Special tools ................................................................................................................................................. - 11 -

Specification table ........................................................................................................................................ - 18 -

Fault diagnosis ............................................................................................................................................. - 20 -

Inspection / adjustment ................................................................................................................................ - 47 -

Inspection and Maintenance of Electrical System ............................................................................................... - 72 -

I. Battery/Charging System.................................................................................................................................. - 74 -

1.1 Preparatory Information......................................................................................................................... - 74 -

1.2 Fault Diagnosis ...................................................................................................................................... - 75 -

1.3 Battery ................................................................................................................................................... - 76 -

1.4 Charging System .................................................................................................................................... - 77 -

1.5 Disassembly of Voltage and Current Regulator ..................................................................................... - 78 -

1.6 Alternator Charging Coil ....................................................................................................................... - 79 -

1.7 Disassembly of Alternator ..................................................................................................................... - 79 -

II. Ignition System ............................................................................................................................................... - 83 -

2.1 Preparatory Information......................................................................................................................... - 83 -

2.2 Fault Diagnosis ...................................................................................................................................... - 85 -

2.3 Trigger ................................................................................................................................................... - 86 -

2.4 Ignition Coil ........................................................................................................................................... - 86 -

2.5 Spark Plug.............................................................................................................................................. - 88 -

2.6 ECU ....................................................................................................................................................... - 88 -

III. Starter System ................................................................................................................................................ - 90 -

3.1 Preparatory Information......................................................................................................................... - 90 -

3.2 Fault Diagnosis ...................................................................................................................................... - 91 -

3.3 Starter Motor .......................................................................................................................................... - 91 -

3.4 Starter Relay .......................................................................................................................................... - 92 -

IV. Bulbs /Switches/Meters ................................................................................................................................. - 95 -

4.1 Preparatory Information......................................................................................................................... - 95 -

4.2 Fault Diagnosis ...................................................................................................................................... - 96 -

4.3 Replacement of Headlight Bulb............................................................................................................. - 97 -

4.4 Replacement of Front Turn Signal Light Bulb ...................................................................................... - 98 -

4.5 Replacement of Taillight Bulb ............................................................................................................... - 98 -

4.6 Replacement of License Light Bulb ...................................................................................................... - 99 -

4.7 Meters .................................................................................................................................................... - 99 -

4.8 Ignition Switch..................................................................................................................................... - 100 -

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4.9 Electric horn ........................................................................................................................................ - 102 -

4.10 Handlebar Switch............................................................................................................................... - 104 -

Inspection and Maintenance of Chassis ............................................................................................................. - 105 -

V. Brake ............................................................................................................................................................. - 108 -

5.1 Preparatory Information....................................................................................................................... - 108 -

5.2 Fault Diagnosis .................................................................................................................................... - 109 -

5.3 Front Brake Disc .................................................................................................................................. - 109 -

5.4 Rear Brake Disc ................................................................................................................................... - 111 -

5.5 CBS...................................................................................................................................................... - 113 -

VII. Front Wheel/Front Suspension ................................................................................................................... - 134 -

7.1 Preparatory Information....................................................................................................................... - 134 -

7.2 Fault Diagnosis .................................................................................................................................... - 135 -

7.3 Front Wheel ......................................................................................................................................... - 135 -

7.4 Handlebar............................................................................................................................................. - 140 -

7.5 Front Fork ............................................................................................................................................ - 145 -

7.6 Front Shock Absorber .......................................................................................................................... - 151 -

VIII. Rear wheel/rear suspension ...................................................................................................................... - 160 -

8.1 Preparation of Information- ................................................................................................................. - 160 -

8.2 Fault Diagnosis .................................................................................................................................... - 160 -

8.3 Rear wheel ........................................................................................................................................... - 161 -

8.4 Rear shock absorber ............................................................................................................................. - 166 -

8.5 Rear Rocker Arm ................................................................................................................................. - 168 -

8.6 Chain drive .......................................................................................................................................... - 171 -

IX. Fuel Tank/Seat ............................................................................................................................................. - 180 -

9.1 Preparatory information ....................................................................................................................... - 180 -

9.2 Fault Diagnosis .................................................................................................................................... - 180 -

9.3 Seat ...................................................................................................................................................... - 181 -

9.4 Fuel Tank ............................................................................................................................................. - 182 -

X. Disassembly/Installation of Engine .............................................................................................................. - 190 -

10.1 Preparatory information ..................................................................................................................... - 190 -

10.2 Fault Diagnosis .................................................................................................................................. - 190 -

10.3 Disassembly of Engine ...................................................................................................................... - 191 -

10.4 Installation of Engine ......................................................................................................................... - 191 -

Inspection and maintenance of engine ............................................................................................................... - 193 -

XI. Lubrication System...................................................................................................................................... - 195 -

11.1 Preparatory Information ..................................................................................................................... - 195 -

11.2 Fault Diagnosis .................................................................................................................................. - 195 -

11.3 Fuel Pump .......................................................................................................................................... - 196 -

XII. Cylinder head / valve ................................................................................................................................. - 201 -

12.1 Preparatory information ..................................................................................................................... - 201 -

12.2 Fault Diagnosis .................................................................................................................................. - 202 -

12.3 Cylinder Head .................................................................................................................................... - 202 -

12.4 Valve inspection ................................................................................................................................. - 206 -

12.5 Replacement of Valve Guide ............................................................................................................. - 207 -

12.6 Finishing Valve Seat Ring.................................................................................................................. - 208 -

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12.7 Installation of Cylinder Head............................................................................................................. - 209 -

XIII. Cylinder Block and Piston ........................................................................................................................ - 211 -

13.1 Preparatory Information..................................................................................................................... - 211 -

13.2 Fault Diagnosis ............................................................................................................................... - 212 -

3.3 Cylinder Block ..................................................................................................................................... - 213 -

13.4 Piston ................................................................................................................................................. - 214 -

13.5 Installation of Cylinder Block............................................................................................................ - 218 -

XIV. Clutch / kickstarter mechanism .............................................................................................................. - 221 -

14.1 Preparatory Information..................................................................................................................... - 221 -

14.2 Fault Diagnosis .................................................................................................................................. - 221 -

14.3 Clutch................................................................................................................................................. - 222 -

14.4 Kickstarter Mechanism ...................................................................................................................... - 224 -

14.5 Disassembly of primary and auxiliary shafts ..................................................................................... - 225 -

XV. Variable speed gear ..................................................................................................................................... - 229 -

15.1 Preparatory Information..................................................................................................................... - 229 -

15.2 Fault Diagnosis .................................................................................................................................. - 229 -

15.3 Shift mechanism ................................................................................................................................ - 230 -

15.4 Installation ......................................................................................................................................... - 233 -

XVI. Crankcase ................................................................................................................................................. - 235 -

16.1 Preparatory Information..................................................................................................................... - 235 -

16.2 Fault Diagnosis .................................................................................................................................. - 235 -

16.3 Crankcase........................................................................................................................................... - 236 -

16.4 Crankshaft combination ..................................................................................................................... - 239 -

XVII. Exhaust Emission Control System .......................................................................................................... - 246 -

17.1 Guarantee of Exhaust Emission Control System ............................................................................... - 246 -

17.2 Regular Maintenance Notice ............................................................................................................. - 246 -

17.3 Mechanical Function of Exhaust Control System ............................................................................. - 247 -

17.4 Catalyst Conversion System .............................................................................................................. - 247 -

XVIII. Electronic Injection System ................................................................................................................... - 251 -

18.1 Introduction of Electronic Injection System ...................................................................................... - 251 -

18.2 EFI Parts ............................................................................................................................................ - 252 -

18.3 Fault Maintenance and Diagnosis Method ........................................................................................ - 268 -

18.4 Common Troubleshooting Methods .................................................................................................. - 271 -

Circuit Diagram................................................................................................................................................

277

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Preface

This Maintenance Manual is the explanation for the maintenance essentials of

dealers.

Preparatory information includes all matters needing attention for operation in

the Maintenance Manual. Please read this Manual carefully before operation.

Inspection and adjustment is the explanation for the essentials of inspection and

adjustment, as well as the safety of motorcycles and performance maintenance

methods of parts, which should be implemented from the time of regular inspection.

Chapter II and subsequent chapters are the explanations for the decomposition,

combination and inspection of the others of electrical equipment, motorcycle and

engine.

Exploded diagrams and system diagrams, maintenance fault diagnosis and

instructions are provided above all chapters.

Note:

The style or structure of the motorcycle and the photographs, pictures or

instructions on the Manual are subject to change without further notice.

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