KYMCO CK 1 - User Manual

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

Summary

General Information

Engine Serial Number Location

Identifies the location of the engine serial number on the motorcycle.

Technical Specifications

Detailed specifications covering engine, chassis, and performance parameters.

Service Precautions

Important safety and operational precautions for motorcycle maintenance.

Torque Values

Essential torque specifications for engine and frame fasteners.

Special Tools List

Catalog of specialized tools required for specific service procedures.

Lubrication Points

Visual guide to identify lubrication points on the motorcycle.

Cable and Harness Routing

Instructions for correct routing of electrical wires and cables.

Wiring Diagram

Electrical wiring diagram for diagnosing and troubleshooting.

Troubleshooting Guide

Diagnostic charts for common engine and performance issues.

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

This document serves as a comprehensive service manual for the KYMCO CK 1 motorcycle, providing detailed information for its maintenance, repair, and troubleshooting. It is structured to guide technicians through various procedures, ensuring the motorcycle's optimal performance and longevity.

Function Description:

The KYMCO CK 1 is a motorcycle designed for general use, powered by a 125cc O.H.V. (Overhead Valve) gasoline, 4-stroke, single-cylinder engine. It features a 5-speed, foot-operated transmission and a wet multi-disc clutch. The motorcycle utilizes a CDI (Capacitor Discharge Ignition) system for reliable ignition and a paper element air cleaner for efficient air filtration. Braking is managed by a disk brake at the front and a drum brake at the rear, providing balanced stopping power. The suspension system includes a telescopic fork at the front and a linkage system at the rear, both equipped with oil damper springs for a smooth ride. The frame is a rhomboid type, offering structural integrity.

Usage Features:

The manual outlines various aspects related to the motorcycle's operation and maintenance. It begins by detailing the location of the engine and frame serial numbers, crucial for identification and record-keeping. The "General Information" section covers fundamental data, including lubrication points, which are critical for preventing wear and ensuring the smooth operation of moving parts. These points include the speedometer cable, throttle cable, clutch cable, and front brake fluid tube, all of which require regular attention to maintain their functionality and responsiveness.

The manual also provides extensive guidance on cable and harness routing. This is vital for preventing damage to electrical components and control cables, ensuring they are not pinched, twisted, or exposed to excessive heat or sharp edges. Proper routing prevents interference with moving parts, reduces wear, and maintains the integrity of the electrical system. For instance, it specifies how to route the taillight wire connector, CDI unit, wire harness, ignition coil, regulator/rectifier, battery negative and positive cables, starter relay, winker, and fuse box. Adhering to these routing instructions is essential for safety and to avoid electrical malfunctions.

Maintenance Features:

The KYMCO CK 1 service manual places a strong emphasis on meticulous maintenance practices. It includes a "Service Precautions" section that highlights general guidelines for handling components, such as applying designated greases and lubricants to specified points after reassembly. This ensures that all parts operate smoothly and are protected from wear. The manual stresses the importance of checking all parts for proper tightening and operation after reassembly, emphasizing a thorough approach to maintenance.

Safety is a key concern, with instructions to disconnect the battery negative terminal before any electrical work and to avoid damaging the motorcycle's surface when using tools. When working with electrical connectors, the manual advises releasing the lock before disconnection and holding the connector body rather than pulling the wires. It also provides detailed instructions for inspecting connector terminals for bending, protrusion, or looseness, and ensuring that connectors are fully inserted and locked correctly.

For wire harnesses, the manual provides specific instructions to prevent damage and ensure proper function. This includes checking for secure clamping, avoiding squeezing wires against welds or clamps, and ensuring harnesses do not interfere with moving or sliding parts. It also warns against routing harnesses near heat-generating parts and advises protecting them from sharp edges or corners using electrical tape or tubes. The manual also covers the importance of using rubber protecting covers for wire harnesses and repairing any broken sheaths.

The "Torque Values" section provides standard and engine-specific torque specifications for various fasteners, including bolts and nuts of different sizes, as well as critical engine and frame components. This ensures that all parts are tightened to the correct specifications, preventing loosening or damage due to over-tightening.

The "Special Tools" section lists specialized tools required for specific maintenance tasks, such as valve adjusters, valve spring compressor attachments, clutch holders, flywheel pullers, flywheel holders, lock nut socket wrenches, bearing removers, oil seal and bearing installers, steering stem wrenches, and cushion assembly/disassembly tools. The use of these specialized tools ensures that maintenance procedures are performed accurately and efficiently, without causing damage to components.

The manual also includes a comprehensive "Troubleshooting" section, which is invaluable for diagnosing and resolving common issues. It provides flowcharts for various problems, such as "Engine Will Not Start or Is Hard to Start," "Poor Performance (Engine Lacks Power)," "Poor Performance (Especially at Idle and Low Speeds)," "Poor Performance (At High Speed)," and "Poor Charging (Battery Over Discharging or Overcharging)," and "No Spark at Spark Plug." Each flowchart guides the technician through a series of inspection and adjustment steps, leading to probable causes and solutions. This systematic approach helps in quickly identifying the root cause of a problem and applying the correct repair.

For example, the "Engine Will Not Start or Is Hard to Start" flowchart covers checks for fuel delivery, spark plug condition, cylinder compression, and ignition system integrity. The "Poor Performance" flowcharts address issues related to air cleaner clogging, fuel flow restrictions, ignition timing, valve clearance, carburetor clogging, and engine overheating. The "Poor Charging" section guides through checks of the battery, AC generator, regulator/rectifier, and associated wiring. The "No Spark at Spark Plug" section details checks for spark plug condition, ignition coil wires, CDI unit, and related components.

Throughout the manual, symbols are used to indicate specific servicing methods and cautions, such as applying engine oil, applying grease, using special tools, and general cautions or warnings. These symbols enhance clarity and ensure that technicians follow the correct procedures and safety measures. The detailed wiring diagram is also provided, which is essential for diagnosing electrical issues and understanding the motorcycle's electrical system layout.

KYMCO CK 1 Specifications