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1. is important procedure in the valve maintenance Remove the cylinder head cover 20 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Turn the cooling fan clockwise until the mark of the timing drive sprocket on the camshaft is at top dead center and the T symbol or other mark of the magneto flywheel aligns with the crankcase mark e The crankshaft should co rotate otherwise the exhaust port may not be adjusted When adjusting loosen the lock nuts adjust the bolts with a valve adjusting wrench if turning clockwise the valve clearance decreases and if turning counterclockwise the valve clearance increases Then put a feeler gauge with specific size between valve and rocker to check for correct clearance Take out the feeler gauge tighten the lock nuts and then inspect the valve clearance again e Sometimes when tightening the lock nuts it will change the clearance So it must be rechecked for the proper clearance Valve clearance 0 06 0 07 mm CAMSHAFT The camshaft is a main driving unit of the valve train There are the air inlet cam the exhaust cam and the cam journal on the shaft It controls the in ake 4cd exhaust valve to open and close at the correct time The camshaft wear will affect engine performance and cause excessive noise CAMSHAFT REMOVAL Loosen valve cover bolts and rem Vve cover Remove the cam chain screw and remove the O
2. Mount the final gear on the final gear shaft Install the new dowel and gasket 62 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Install the transmission case cover and bolt Mount the driven pulley the clutch set Mount the drive pulley the transmission belt and the left crankcase cover Fill the transmission case with oil 63 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 4 ELECTRIC SYSTEM CHARGING SYSTEM INSPECTION ELECTRIC LEAKAGE TESTING Turn the main switch to the OFF position Disconnect the negative ground wire from the battery Connect the positive end of the ammeter with the negative end of the battery Connect the negative end of the ammeter with the ground wire Test the electric leakage In general it demands the number less than 1 it is unusual inspect if there is short circuit of the main switch and the main wiring CHARGING STATUS INSPECTION Install the fully charged battery Connect the voltmeter between the binding posts of the battery Remove the fuse and connect the ammeter with two ends of ing use Connect the tachometer with the engine it s not needed wren there is rpm indicator on the vehicle Start the engine and accelerate slowly measure the charginy voltage and current d 19 5 15 5 Charging current A IR 5 Charging voltage V Measuring condition 5000 r min If the voltage is not in the range of the abo e lt cified val
3. TIRE PRESSURE WEAR Check the tire pressure every time the vehicle is ridden The tire pressure is very important for the stability of the ride Tire pressure Front 175 kpa Rear 200 kpa BRAKE PERFORMANCE 1 Always check that there is plenty of brake fluic ur the vrake fluid reservoir Check that the front rear brake pads are quod condition Check the brake rotor for abnormal wear AIR CLEANER Clean the air cleaner quarterly lt ore often in dusty conditions If the air cleaner is clogged tii dust performance will be severely decreased even engin damages can occur Check and clean in the following manner PAPER FILTER MAINTENANCE 1 Remove the air cleaner from its housing 2 the filter on an object knocking dust from filter 3 Replace the element if it is wrinkled or torn KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 FOAM FILTER MAINTENANCE 1 Remove the foam filter from steel cage 2 Wash in non flammable cleaning solvent 3 Submerge in oil and squeeze to remove excess oil 4 Install the element back into the air box NUTS AND BOLTS IN THE CHASIS Inspect first week and every month thereafter Always pay attention to the nuts and bolts Some loosening a er use is a normal situation and should be checked regularly TIGHTENING TORQUE TABLE Conventional marked bolt 8 8 marked bolt KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 ON pos
4. KINROAD KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the KINROAD 150 The KINROAD 150 fits the needs of a wide variety of KINROAD users above 16 years old Those who will be servicing this KINROAD should carefully review this manual before performing any repair or service All information illustrations photographs and specifications contained in the manual are based on the latest product information available at the time of publication Due to imprevemem or other changes there may be some discrepancies in this manual Therefore if newest inforir tsn is requested in the future please contact the local distributor Distributor reverse the right to make production changes at tims without notice and without incurring any obligation to make same or similar changes to vehicles previously built or sold KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 CONTENTS 1 GENERAL INFORMATION ann ao nun 4 2 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES nnn 7 A A id 13 4 ELECTRIC SYSTEM sn zen ee 64 A N 74 6 WIRING DIAGRAM 2 nn ER 81 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 1 GENERAL INFORMATION MODEL IDENTIFICATION FRAME NUMBER
5. 2 Cam chain tensioner 3 chain tensioner lifter 4 Gasket 5 Cam chain tensioner pivot 6 Cam chain guide 7 Bolt 8 Screw pan 9 1 O ring 0 O ring The operational principle of the tensioner is as shown in the piuture As for the adjustment of the cam chain tensioner turning clockwise is tightening and turning counterclockwise is loosening 24 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 VALVE AND VALVE SPRING VALVE AND VALVE SPRING REMOVAL Remove the cylinder head First remove the valve cotter with the valve compressor and then remove in turn the upper spring race valve spring lower spring race and valve stem oil seal Remove the valve from the other side e The removed parts should be placed properly in order It s better to place the intake valve parts and exhaust valve parts separately VALVE AND VALVE SPRING INSPECTION Inspect to see if the valve is bent or burned Inspect if the action is smooth between the valve and the valve guide Measure the outer diameter of the valve stem Service limit 4 9mm Measure the free length of the inner and outer va vo spring Valve Inlet valve Exhaust vave Inner spring 31 2mm 34 271 Outer spring 34 1 mm 184 Mm VALVE AND VALVE SPRING INSPECT ON Mount the spring retainer valve guide o seal Itis recommended to repla s 52 valve guide oil seal with a new one After apply
6. 57 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Observe the oil level It is correct when the oil level is parallel with the observing hole When the oil level is too low add until the oil flows from the level screw e Supply the same kind of oil according to the prescribed brand and specification Mount the transmission case oil level bolt and the washer e Inspect if the bolt oil seal is damaged TRANSMISSION CASE OIL REPLACEMENT Remove the transmission case oil level bolt Remove the oil drain bolt to drain the oil Mount the drain bolt and its oil seal and fasten Supply the oil with the prescribed specification and oil level Mount the level bolt After replacing the oil inspect for any oil leakage TRANSMISSION CASE TRANSMISSION CASE REMOVAL Remove the driven belt pulley Drain out the oil in the transmission case Remove the drive sprocket Remove the bolt and remove the transmission case cover Remove the gasket and the dowe vin Remove the final gear ine final gear shaft and remove the sub shaft sub shaft gear 58 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 TRANSMISSION CASE GEAR INSPECTION Inspect if the sub shaft sub shaft gear is damage or worn Inspect if the final gear the final gear shaft is damaged or worn BEARING ON THE TRANSMISSION CASE COVER REPLAC MENT e When removing or installing the bearing on the transmissinr case cover you must use the special too
7. abrasion of the bore exceeds the limitation it should be replaces PISTON RING SET Before setting up apply oil on every piston ring and then enlarge uiston rings AT the same time cover them on the piston and move forwards gradually until piston rinds fai nto the ring groove PISTON RING INSTALLATION Remove the gasket attached to the crankcase Mount piston onto the small end of the connecting rcc e The top of the piston with IN mark shoulc br rr ounted towards the direction of the inlet port If the mark is EX it should be mounteu towards the direction of the exhaust port Mounting piston pin and piston pin clip e Apply oil on the piston pin to lubricar it e Cover a piece of cloth on the cran case port to avoid the piston pin clip from dropping into the crankcase KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 CRANK CONNECTING ROD SET The connecting rod is the component that link piston and crank The picture shows the structure and assembly relations of the crank connecting rod component CRANKCASE AND CRANKSHAFT RENUVAL Take the following procedures wien ramoving the crankcase and crankshaft Remove the engine Remove the cylinder cover Remove the cylinder Remove the piston Remove the drive plate and the driven plate Remove the AC generator Remove the starting motor Remove the oil pump Then remove the cam chain tensioner bolt Remove the cam chain tensioner KINR
8. clearance KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Turn the cam chain tensioner adjusting bolt counter clockwise and release the lock Apply oil on the new O ring Mount and tighten the cam chain tensioner cover bolt e The o ring must be mounted properly in the groove Replace the valve cover gasket and mount the cover e The valve cover gasket must be mounted properly in the groove Tighten the valve cover positioning bolt ROCKER ARM AND ROCKSHAFT ROCKER ARM AND ROCKSHAFT REMOVAL Remove the camshaft holder Take out the rockshaft by removing the bolt Remove the rocker arm ROCKER ARM AND ROCKSHAFT INSPEC tiON Inspect if there is any abrasion or damage 25 tne rocker arm and rockshaft or if the oil hole clogged o lf there is abrasion on the surface of the rocker arm the camshaft should also be inspected Measure the inner diameter o ihe iocker arm Service limit 10 10 mr Measure the outer diariste of the rockshaft Service limit 9 91 m ROCKER ARM AND ROCKSHAFT INSTALLATION Read the EX mark on the camshaft holder then mount the exhaust port rocker arm and the rockshaft After that mount the inlet port rocker arm and rockshaft Apply some oil on the rockshaft before mounting it on 23 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 CAM CHAIN TENSIONER The chain tensioner must be in good working order for proper chain tension 1 Cam chain
9. install the starter motor Tighten holding bolts REDUCTION MECHANISM The picture shows the structure of the reduction mechanism 1 Starter reduction gear 11 Clamp 2 Starter reduction gear shaft 12 Bolt 3 Starting clutch gear comp 13 Nut 4 Starting clutch outer comp 14 Washer 5 Flange starting clutch 15 Dowel pin 6 Starting clutch roller spring 16 Key woodruff 7 Spring holder 17 Roller 8 Starter motor 18 Needle bearing 43 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 9 Starter motor lead wire 19 O ring 10 Clamp 20 Screw 21 Bolt REDUCTION GEAR INSPECTION Remove the starting clutch Remove the reduction gear to inspect its wearing degree Measure the inner diameter of the reduction gear lt should be replaced when the diameter is more than 10 05 mm Measure the outer diameter of the reduction gear shaft It should be replaced when the diameter is less than 9 94mm ENGAGING MECHANISM STARTING CLUTCH REMOVAL Remove the right crankcase cover Remove the left crankcase cover Hold the drive face with the universal set wrench Remove the starting clutch fixing nut e Notice that the thread of the fin nui should be left handed rotation Remove the starting clutch the whole cot STARTING CLUTCH Inspect if the movement vetween the clutch and the driving gear is normal The driving gear should smoothly turn clockwise and should not move countercloc
10. oil seal collar Remove the excessive grease No grease on the movable face of the driven plate Assemble with the clutch and install on the left crankcase KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 TRANSMISSION BELT TRANSMISSION BELT INSPECTION Remove the left crankcase cover Inspect if the transmission belt is chapped or worn Measure the width of the belt Service limit 19 0mm Replace the belt if its width is less than the above limitation When replacing you must use the OEM part for correct fit See the drive pulley removal and installation procedure for the repizcement KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 REAR TRANSMISSION MECHANISM INSPECTION AND SERVICING The structure of the rear transmission mechanism is shown in the following picture COVER TRANSMISSION GASKET TRANSMISSION COVER BEARING RADIAL BALL BEARING RADIAL BALL BEARING RADIAL BALL BOLT SPECIAL WASHER OIL SEAL 9 GEAR FINAL 10 CIRCLIP EXTERNAL 11 SHAFT FINAL 12 SHAFT COMP COUNTER 13 NUT 14 WASHER 15 SHAFT DRIVE N DO oO A WD TRANSMISSION CASE cil REPLACEMENT TRANSMISSION CASE OIL INSPECTION When inspecting the oil level of the transmission case use flat ground and keep the body level Inspect if there is oil leakage around the transmission case After the engine stops remove the transmission case oil level bolt
11. ring Tighten the cam chain tensioner adjusting bolt clockwise 21 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Turn the flywheel counterclockwise to make the T mark on the flywheel align with the mark on the crankcase When the hole on the cam chain timing drive chain wheel is up it is the top dead center position Remove the cylinder head positioning bolt Remove the camshaft holder bolt cap washer Remove the camshaft holder and dowel pin Remove the cam chain wheel from the cam chain and remove the camshaft CAMSHAFT INSPECTION Inspect if the camshaft bearings for play If they ars ten replace the whole set Inspect cam surface for damage Measure the height of the cam Inlet cam 25 96 mm Exhaust cam 25 815 mm CAMSHAFT INSTALLATION t Rotate the flywheel to aligr ne T mark on the flywheel with the camshaft mark The round hole on the cam chain wheel shoulc vc up The left and right sit parallel with the cylinder head the lobes of the camshaft are down Ins ne camshaft on the cylinder head Mount the cam chain on the cam chain wheel Install the dowel pins Mount the camshaft holder washer and nut on the cylinder head Tighten the cylinder head bolt and nut 1 While installing first apply some oil on the thread part of the camshaft holder bolt 2 The camshaft nuts should be tightened diagonally in a 3 step process 3 After installing adjust the valve
12. several minutes in the idle position to make sure is no oil leakage Stop the engine and inspect if the oil level is proper ROTARY OIL PUMP The oil pump is the critical component of the lubrication systera so it should be maintained periodically and should be replaced as a unit when damaged seriously OIL PUMP REMOVAL Remove the flywheel of the magneto Remove the stator coil trigger winding Remove the right crankcase cover noke and remove the right crankcase cover Remove the gasket dowel xas Remove the starting reduction gear starting clutch Remove the oil pump partition plate positioning bolts and remove the oil pump partition plate 31 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Remove the oil pump driving gear nut and remove the driving gear chain Remove the oil pump positioning bolts and remove the oil pump assembly Remove the screws and disassemble the oil pump OIL PUMP INSPECTION Inspect the clearance between the oil pump body and ins outer rotator Service limit 0 12 mm Inspect the clearance between the inner row and the outer rotor Service limit 0 12 mm Inspect the clearance turaen the rotor plane and the oil pump Service limit 0 20 mm e If the inspection result exceeds the above stated service limit the whole set should be 32 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 20
13. the spring needle valve Do not damage the vacuum membrane Inspect if the needle valve is worn or not Inspect if there is damage on the vacuum membrane Inspect if the plunger is damaged 35 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 FLOAT CHAMBER INSPECTION Inspect the float for any damage and fuel in the float Inspect the float valve and float valve seat for wear If there is wear it should be replaced Clear every fuel line and air line on the carburetor body with compressed air FLOAT CHAMBER INSTALLATION Install the main fuel injection nozzle and fuel injection needle seat Install the air adjusting screw and choke adjusting screw and turn them according to the noted number of turns while removing Assemble the float valve the float and the float pin Tighten the float pin positioning screw FUEL CHAMBER INSTALLATION Measure the fuel level Fuel level 18 5 mm Inspect the float for any damage and inspect the float valve ic excess wear Confirm the up and down movement of the float is norma CARBURETOR INSTALLATION Reverse the removal procedure for installation After installing make sure all carburetor linkage and cables are in correct position Made sure the carburetor is in idle position AIR CUT VALVE ACV The air cut valve can avoid some bnermity when the throttle closes too quickly for example the mixed gases are t
14. very important for the valve to seal properly VALVE SEAT WIDTH MEASUREMENT Clean the carbon accumulation in the combustion chamber Measure the width of the valve seat with a vernier caliper Standard 1 0mm Service limit 1 8mm 27 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 If the valve seat still cannot contact evenly with the valve after trimming the valve should be revised or replaced VALVE AND VALVE SEAT LAPPING After finishing the valve and valve seat should be lapped in order to make them seal properly Spread a thin layer of silicon carbide on the working bevel of the valve and use a valve suction cup tool Then repeatedly rotate the valve suction cup to lap the valve and valve seat evenly until they match tightly Before lapping clean the valve valve seat and valve guide e When lapping do not use too much force e During lapping do not drop any silicon carbide into the place between the valve lever and the valve guide After lapping the valve and valve seat the air impermean litv 1 their joint surface should be inspected Method one same as the method of valve seat position inspection Method two evenly draw several lines on tia working surface of the valve with a pencil Put the valve into th vaive seat if the lines are all broken after turning 1 8 1 4 ring then it shows the air impermea
15. 05 OIL PUMP ASSEMBLY Assemble the inner and outer rotors of the oil pump and mount the oil pump shaft When assembling align the unfilled corner of the oil pump shaft with the corner of the inner rotor and then assemble Mount the dowel pin After aligning the oil pump plate with the dowel pin install it Tighten the oil pump plate screws After assembling gently turn the oil pump shaft and make sure the oil pump can turn smoothly OIL PUMP INSTALLATION Install the oil pump on the crankcase Before installing fill the oil pump wit lt When installing the arrow of the oil pump must be upwards Tighten the oil pump positioning bolts Align the oil pump driving gear with the oil pump shaft unfilled corner then assemble the driving gear chain 33 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Install the partition board and tighten bolts Install the starting reduction gear starting clutch Assemble the gasket dowel pins Assemble the right crankcase cover positioning bolt Assemble the trigger winding and the stator coil Tighten the right crankcase cover positioning bolt e The bolt should be gradually diagonally tightened in twe a three steps After finishing the installation inspect for any oil leak2ge CARBURETOR IDLING ADJUSTMENT AIR ADJUSTING SCREW ADJUSTMENT Step one Turn on the air adjusting screw tien turn ou
16. C 2005 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Tire pressure wear Brake performance Tightness of screws Air cleaner C C Carburetor C Spark plug C A Drive chain CAL Brake fluid Replacement of gearbox oil i R Chassis O Fuel switch fuel tank C Battery Engine oil R Valve clearance of engine A A adjust C clean I inspect clean or replace if necessary L lubricate R replace MAINTENANCE AND TUNE PROCEDURE This section describes ic servicing procedures for each item in the SEAM DIRT CARBONVERIFY Periodic Maintenance Intervals 10 025 0 03 SPARK PLUG Clear up the carbon around the spark plug to prevent it from dripping into the cylinder when removing the spark plug Remove the spark plug 1 In general it should be carried on after the engine is cold KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 2 If the spark plug is too tight to remove spray rust inhibiter on the spark plug washer and the thread part Rotate the spark plug after soaking Clear up the filth and carbon accumulation on the spark plug with a steel brush or a blade Inspect the spark plug gap in general it should be about 0 6 0 8 mm When the carbon accumulation and wear of the spark plug are too serious replace the spark plug Replace a spark plug of the same specification
17. E port Bl Y m e Remove rear wheel and hub assembly by sliding off war n splines of axle Ca Remove the chain Loosen nuts on bearing carrier and remove bolts Remove axle and bearing carriers as a unit REAR SWING ARM mn 8 Note Swing arm axle and motor can be removed as a unit if needed p 4 2 Pe Remove Rear Shock lt nn Hi ET Remove rear brake caliper and set aside ft 5 h Do not remove brake hose 205 e Unplug brake light wiring from the electrica e Remove throttle cable e Remove bolts from swing arm pivot e Check Buffer Rubber Bushing or waar If wear is present on bushing it should be replaced 74 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 FRONT amp REAR SHOCKS The Front and Rear Shocks are oil dampened units They are non re buildable e If any oil seepage is noticed the shock should be replaced A ADJUSTMENT OF FRONT SHOCK 9 e There are 5 positions for you to choose on front shock X The default position would be set by the manufacture f fe CNR 18 cp in the middle the third position amp gt ay e Please use round nut wrench as you adjust the c AN position the tension of shock spring would increase x as you turn screw left and decrease as you turn screw s right FRONT WHEEL REPLACEMENT a e Do not disassemble the castle nuts when vou replace the l front wheels e e Itis only necessary to tighten the nuts so tna
18. Install the left crankcase cover and lock tightly Install the starting pedal 40 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 ELECTRICAL STARTING MECHANISM STARTER MOTOR REMOVAL Before removal first shut off the main switch and disconnect the battery connecting wire Then press the starting button At this time the starter motor should not run This must be done for insuring safety Remove the starter motor lead wire clamp Remove the starter motor holding bolt and remove the starter motor Roll up the rubber water resistance cover and remove the starter motor joint Remove the motor case bolt the carbon brush seat and the motor case etc ARMATURE INSPECTION Inspect the armature surface for uneven wear or damage or burn When where are metal fines avtached to the gap of the armature surface use a cleanina to remove them Please do not use sencpaper to grind and do not wash it in any solvent wnich can dissolve or damage its insulation Measure the conducting condition of the armature coil according to the picture It should be conductive Measure the conducting condition between the armature coil and the armature according to the right picture It should be non conductive If not it should be replaced 41 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 CARBON BRUSH INSPECTION Inspect the insulating condition between the connecting wire terminal and the start
19. NSTALLATION Apply some grease evenly in the movable drive plate ut tne centrifugal rollers into the movable drive plate Install the ramp plate Put the drive plate hub into mc plate 50 VERSION 1 DEC 2005 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Install the movable drive plate on the crankshaft Enlarge the driven plate belt groove and mount on the driven belt Mount the other end of the driven belt on the drive plate hub Assemble the drive plate the drive plate washer and nut Hold the drive plate with a multiuse holder to traks it unmovable At the same time fasten the nut on the shaft e Do not allow any grease or oil on tis s ace of the movable drive plate and the driven belt CLUTCH CLUTCH REMOVAL Remove the left crankcas coer Remove the drive plate he driven belt Hold the clutch friction plate with a multiuse holder and remove the nut Remove the clutch friction plate 51 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 CLUTCH INSPECTION Inspect if there is any abrasion or damage on the clutch friction plate Measure the inner diameter of the clutch friction plate Service limit 125 5mm Inspect if there is any abrasion or damage of the clutch centrifugal weight friction piece Measure the thickness of the clutch centrifugal weight friction piece Service limit 1 5mm CLUTCH DISASSEMBLING If it is needed to repl
20. OAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Use special tools to remove the starting driven gear Remove the crankcase positioning bolts Separate the right crankcase and the left crankcase The joint face cannot be damaged Remove the gasket and the dowel pins Remove the crankshaft from the crankcase Take out the cam chain Clean up the gasket on the crankcase joint face Fay attention not to damage the joint face Remove the oil seal from ins 2 amp crankcase KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Remove the oil seal from the right crankcase CRANKSHAFT AND CRANKCASE INSPECTION Replace the whole set of the crankshaft if serious wear is found while inspecting Measure the axial clearance of the big end of the connecting rod When measuring make one side of the connecting rod big end close to the crank and insert the feeler gauge between the other side and the crank and get the correct end play Service limit 0 55 mm Measure the radial X Y clearance of the big end of the con rua Service limit 0 05 num Measure the main shaft jump of the crankshaft If the crank jump is too much it will cause the engine s5 e abnormally and shorten the life of the engine So it must be examined carefully when inspecting Service limit 2 90 0 10mm B 105 Examine if there is any looseness or unusual sound when the crank jo
21. The frame number or VIN is stamped under the seat on the frame cross member and stuck behind the seat ENGINE NUMBER The engine number is located on the lowe iront left side of the engine cases KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 FUEL AND OIL RECOMMENDATIONS Be sure to use the specified fuel and oil FUEL Gasoline should SAE 904 or higher Unleaded gasoline is recommended ENGINE OIL SAE10W 30 engine oil of high quality should be used BREAK IN PROCEDURE For the first 2 hours of riding do not exceed 2 3 throttle Vary engine speed for the first 5 hours Never hold engine at full throttle for long periods of time SPECIFICATIONS DIMENSIONS Overall Length Overall Width Overall Height Wheelbase Ground Clearance ENGINE Type Engine Capacity Displacement Bore x Stroke Compression Ratio Max Power Max Torque Fuel Type Lubricate Oil Ignition Starting Spark Plug Transmission Carburetor Lubrication DOUBLE uN Cu E SEAT 2159mm 2075n 1400mm 125 dre 1470mm 00min 1499mm 11430mm 170mim 132 nm Foise air cooled single cylinder 4 Stroke 15Ncc 119 5 57 4 57 8mm 9 2 1 7 4kw 7500rpm 9 5N m 5500rpm SAE 90 or above unleaded SAE 10W 30 C D I Electric C7HSA NGK Automatic C V T MIKUNI BS24J Force amp Splash KINROAD 150 SERVICE MANUAL CAPACITIES Maximum Load Fuel Tank Engine Oil Starting 400lbs 7 0L 850ml lt 5s VERSION 1 DE
22. ace the centrifugal weight set you must disassemble the clutch e When the friction piece is worn it should be replaced with the centrifugal weight set Remove the clutch friction plate Remove the whole set of clutch driven slats Compress the driven pulley spring wii ine clutch spring compressor and at the same time remove the nut on the shaft Disassemble the clutch with the amen pulley Remove the circlip and rn the connecting piece Remove the clutch cent u2 weight set and the spring 52 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 CLUTCH INSTALLATION Mount the clutch damper rubber on the drive plate pin Mount the new clutch weight set and spring on the drive plate Install the connecting piece the circlip and the bottom plate Reverse the removal procedure for installation e When assembling the clutch and the driven plate you must use a clutch spring compressor otherwise it will damage this spring No grease on the driven pulley DRIVEN BELT PULLEY DRIVEN BELT PULLY REMOVAL After removing the clutch friction piace remove the guide pin the roller and the movable driver n ete Remove the oil seal on the movable driven plate 53 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 DRIVEN BELT PULLEY INSPECTION Measure the free length of the driven belt pulley spring Service limit 163 7mm Inspect if there is any abrasion or damage on the driven
23. ative pole of ne battery Charge the battery for the charging time marked on the battery e Donotuse fast charging unless it is emergent e smoking or open fire near the battery when cha ing e Atthe beginning or the end of charging turn off the Crarger first to avoid the connecting part arcing Measure the voltage 30 minutes after chary ig is finished and it should reach the specified value otherwise it needs recharging Charging current Normal 0 7A Fast 3 0A Charging time Normal 5 10 hours Fast 30 minutes Charging result Open circuit voltage gt 12 8V PRIMARY COIL 65 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 GENERATOR REMOVAL Remove the cooling fan cover bolt and screw Remove the cooling fan cover Remove the cooling fan bolt and remove the cooling fan Hold the flywheel with a universal holding wrench at the same time remove the flywheel nut key Remove the generator wire connector Remove the generator wire naaar Remove the generator cc 2t Remove the generator w r ubber bushing from the right crankcase Remove the coil set Donot damage the coil when removing GENERATOR INSTALLATION 67 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Reverse the removal procedure for installation REGUALTE RECTIFIER MAIN WIRING SUB ELECTRIC CIRCUIT CONDON INSPECTION Remove the 4 c
24. bility is good Method three mount the valva o wie cylinder head and fill the inlet and exhaust vent with non flam nanie solvent and preserve for 5 minutes If there is no leaking the valve is seated correctly 29 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 LUBRICATION SYSTEM INSPECTION AND SERVICING GENERAL INTRODUCTION The picture shows the functional diagram of the lubrication system After the lubrication oil crosses the filter screen it is pumped by the rotator oil pump some of it goes into the big end of the connecting rod and splashes on the cylinder wall and the small end of the connecting rod the other goes through some oil passages such as the shaft neck of the camshaft and splashes on the cam rockshaft and cam chain The lubrication oil that falls back into the oil groove can be re circulated FRackarshaft OIL SYSTEM INSPEC is AND REPLACEMENT OIL REPLACEMENT Tighten the dipstick Remove the oil filter screen cap and the screen to let the oil flow out 30 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Step on the kick starter for several times to drain all the remaining oil Inspect if there is any damage of the screen and O ring If so it should be replaced Install the oil filter screen and the screen cover and tighten them Supply the specified oil to the specified level Oil level Disassembling Replacing 0 90 L 0 75 L Start the engine and run
25. d the lower position is the smal ast diameter At the same cross section measure the difference of diameter between two points mutur y osrpendicular which is the circularity of the cylinder In order to make he measuring point perpendicular with the bore axis of the cylinder and to ensure the precision of the measurement the bar of the gauge can be slightly swung in the direction of the gauge bar and take the smallest reading number as the result In the situation without a dial gauge a feeler gauge can be used to make relativity measurement Put a new piston into the cylinder and use the feeler gauge to measure the gap between the piston skirt and the cylinder wall and then figure out the abrasion loss of the cylinder If the circularity of the cylinder exceeds the limit a cylinder reboring machine should be used to re bore the 13 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 cylinder and to enlarge its diameter by 0 50mm or 1 00mm then fit the piston and piston ring whose sizes are also enlarged If the wear is too severe and cannot be reworked a new cylinder should be installed Cylinder bore 57 4mm Cylindricity 0 05mm Circularity 0 05mm CRANK CONNECTING ROD MECHANISM PISTON SET PISTON PIN INSPECTION AND SERVICING Insert the piston pin horizontally into the pinhole of piston and inevsct he clearance between piston and piston pin Service limit 0 02 mm If th
26. e free play is too much the worn condition of piston and the pinhole of piston must be inspected respectively Measuring the external diameter of piston pin Service limit 14 96 mm If the result is less than service limit it sho Ge replaced After replacement the clearance betwee piston pin and the pinhole of piston must comply with the requirement Measure the inner diameter of piston pin Service limit 15 04 nm If the result is more than ssrvice limit it should be replaced After replacement the tic ence between the pinhole of piston and piston pin must be sure to comply with the requirement PISTON RINGS INSPECTION AND SERVICING Inspect if there is a flaw serious wear or serious conglutination on the piston ring If there is it should be replace If the piston ring s lateral clearance and notch clearance are too large or too small malfunction may be caused So it must be measured Measure the clearance of piston ring in the piston ring groove This clearance is the piston ring s lateral KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 clearance First ring 0 09 mm Second ring 0 09 mm CONNECTING ROD END INSPECTION Put the piston ring and bearing into the connecting rod end inspect the degree of tightness of the piston pin in connecting rod end Measure the inner diameter of the connecting rod end Service limit 15 06 mm When the
27. elay Connect the C end and the D end ine starting relay with the battery and the and B end with the multimeter e The battery voltage shcuia s at 12 volts At this time the multimete 3 w uld indicate conductive condition otherwise the starting relay is not good 46 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 BELT DRIVEN CVT MECHANISM INSPECTION AND SERVICING GENERAL INTRODUCTION The belt driven CVT mechanism is made up of two belt pulleys the drive belt pulley and the driven belt pulley whose diameter can be changed and a notched driven belt The driving belt pulley is mounted on the engine crankshaft and the driven belt pulley connects with the rear driven mechanism Diwan pale Movable driven plue Movable drive plata Dre plate Its basic operational principle is to realize automatic CVT une diameter changes the transmission ratio changes of the driving a driven belt pulley When the diameter of the driving belt puiley changes form small to big proportionally the diameter of the driven selt pulley changes from big to small because the perimeter of the ove belt is constant AT this time the speed increases On the contrary t speed decreases 47 ram n A Clutch weight E o Drive Driven pulley Rato of transmission Rabo of transmission i Srnall KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 The
28. er motor case and it should be non conductive Inspect the conducting condition between the connecting wire terminal and the carbon brush and it should be conductive Measure the length of the carbon brush Replace it if it exceeds service limit Measure the insulating condition of the carbon brush bracket and it should be non conductive If not it should be replaced Inspect the needle bearing in the carbon brusn base It should be able to move smoothly with no play Inspect the dust seal for wear and damage If so it should be replaced STARTER MOTOR INSTA ATION Apply some oil on the seal Install the carbon brush the carbon brush base Apply a little oil on the moving part of the armature ends Put the carbon brush into the bracket and then install the carbon brush base Do not damage the contact area of the carbon brush and the armature e While installing do not damage the lip of the dust sea 42 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Assemble the new O ring on the carbon brush base Install armature into starter motor case making sure not to damage the carbon brushes Tighten motor case bolts O Make sure the starter motor case is free of metal particles because it is magnetic Before installing the starter motor on the vehicle after assembling it first connect the lead wires and inspect if the motor runs normally Apply oil on the O ring and
29. h warme AE f IET nee DRIVE CHAIN ADJUSTMENT 1 GN DIS ME 2 UTER u T daa A wert te HE B d riu vee Y s m WE es EEZ 80 Fa agr A KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 RATDER CLASSIC WIRING DIAGRAM
30. ification is 0 025 0 030 b Before installing spark plug thread lightly with graphite grease if possible to ensure easy removal next time the spark plug needs inspection c It is advisable to replace the spark plug at least once a year to insure easy starting and good engine performance FRONT WHEEL ALIGNMENT VERSION 1 DEC 2005 SEAM DIET CAABON VERIFY i 50 50 03 Wail T HEAT HIT WASHER VERIFY SEAM cAi The front wheels should be toed in from 1 8 to 1 4 To c isck elignment measure distance from to B to the centerline CL of the tires with the wheels foinied straight ahead For the proper toe in dimension A should be 1 8 1 4 greater than dimension amp Loosen the lock nuts on both sides of Front Tie Rods Ta Dimension B smaller screw the rod left If B needs to be longer screw the rod right Tight 1 ine am nut tightly against the rod end Recheck the distance and repeat the above steps until the rensions are the same as data in paragraph 1 Al LOCK NUT FR WHEEL TIE ROD T RIGHT ROTATE LEFT ROTATE LEFT ROTATE RIGHT ROTATE FR WHEEL TIE ROD 79 KINROAD 150 SERVICE MANUAL CHAIN ADJUSTMENT VERSION 1 DEC 2005 After the first two hours of operation check the chain adjustment and readjust if it has more than 1 2 flex 1 Loosen Nut 1 2 Adjust Nut 2 3 Tighten Nut 1 Verify if the chain is loose Repeat the above mentioned steps until it is good enoug
31. ing oil on the valve mount it into the valve guide Mount the inner and outer valve springs Mount the valve locke wih a spring compressor e When mounting the twisting direction of the inner and outer springs must be opposite and cannot be the same Tap at the valve gently two or three times with a rubber hammer to make the valve and the valve lock match well Do not damage the valve 25 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 VALVE GUIDE Carbon accumulation of the valve guide will make the valve move rough causing the valve not to open or close properly Valve guide abrasion is one of the reasons that cause the exhaust pipe fuming white smoke CLEAN CARBON ACCUMULATION OF THE VALVE GUIDE Remove the valve and valve springs Clean the carbon accumulation with a valve guide reamer VALVE GUIDE INNER DIAMETER MEASUREMENT Service limit 5 03 mm Calculate the clearance between the valve stem and the ve ve guide The inner diameter of the guide subtracts the outer diameter of the valve stem Valve Inlet valve exhaust valve Service limit 0 08mm 2 10mm 26 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 After tapping the valve guide you need to trim it with a reamer Clean the cylinder head and eliminate the scraps generated while reaming VALVE SEAT The relative position between the valve seat and the working surface of the valve is
32. ing plate and remove the return spring Remove the whole set of starting lever Remove the starting idle shaft Disassemble the starting spindle Disassemble the starting idle shaft Inspect if there is any z esion or damage of the starting spindle Inspect if there is any abrasion or damage of the starting idle shaft Inspect if there is any abrasion or damage of the starting spindle bushing and starting idle shaft hole 39 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM INSTALLATION Assemble the starting idle shaft set Before assembling apply a little grease on the bore of the idle shaft Assemble the starting spindle the return spring and the Return spring spring holder pin A little grease should be applied on the part of the starting spindle Align the idler shaft holding pin with the groove of ins crankcase then put it in e Before installing apply a little grease on the grave cf the rotary retaining spring on the idler shaf e The rotary retaining spring should be z gnec with the specific groove of the crankcase to ir stall Align the scribing mark of the start spindle with the punching mark of the idle shaft and then aszemt a the starting spindle Hook on the two ends of the return spring Install the return spring stoping plate Install the crankcase dowel pin gasket Install the driven belt the driving plate
33. ition The normal operating position for the fuel valve lever is the ON position In this position fuel will flow to the carburetor RES position If the fuel lever in the fuel tank becomes too low for the engine to operate with the fuel valve lever in the ON position turn the lever to the RES position to use the reserve fuel supply and refuel as soon as possible OFF position The closing position for the fuel valve lever is the OFF position en When the vehicle is not in use always make sure the petcock is in the G nosition FINAL GEAR OlL Inspect monthly and change quarterly 1 To check the oil level remove the level screw on the ie rear engine case 2 To drain oil remove the drain plug e ine ear bottom of the engine case It is recommended to warm tiis for 10 minutes or more before draining final gear oil NOTE Mobil 85w 90 gear oil is r c nmended in the final drive case However in extreme cold weather conditions you may experience the vehicle to be hard to start It is then advised to use lighter viscosity oil such as 75 wt or equivalent motorcycle transmission fluid Gear Oil Capacity 0 2L 85w 90 11 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 ENGINE OIL Inspect every time before riding Replace monthly 1 Remove the drain plug from the left side bottom of the engine Drain into oil pan for disposal 2 Remove the
34. kwise 44 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Inspect if there is any abrasion or damage on the contact surface between the driving gear and the needle bearing lt should be replaced if the surface is damaged Measure the inner diameter of the driving gear It should be replaced when the diameter is more than 32 06mm Inspect the condition of the needle bearing It should be replaced if there is any damage Inspect if there is any abrasion or damage on the contact surface between the outer clutch component and the roller Inspect if there is any injury on the roller Inspect if there is any distortion of the spring If the damage is serious it should be replaced Measure the inner diameter of the flange clutch It shou be replaced when the diameter is more than 27 94mm STARTING CLUTCH INSTALLATION Install the spring the roller and the top en the body of the clutch Align the dowel pin on the flange clut v th the hole on the clutch body then install Apply some thread lock on the uter clutch component bolt and tighten Apply some oil on the nez and the driving gear and then put the outer clutch comus ent on Align the groove of the woodruff key on the crank and install the starting clutch Apply some oil on the reduction gear and the reduction gear shaft then install Hold the drive face with the universal wrench At the same time fasten the cl
35. l shown in the picture Press the driven belt pulley shaft out of the transmss o cover Remove the oil seal and drive cut the bearing Remove the final gear shaft bearing 59 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Remove the sub shaft bearing Drive in the new final gear shaft and bearing When driving in the final gear shaft bearing keep the bearing parallel The same is required when installing the sub shaft bearing and the driven pulley shaft bearing Drive in the new sub shaft bearing Drive in the driven pulley shaft bearing BEARING ON THE LEF IRANCASE BODY REPLACEMENT When removing stalling the bearing on the left crankcase body you must use the special tool Inspect if the bearing and oil seal on the left crankcase for wear or damage If it is damaged it must be replaced Remove the oil seal Drive out the final gear shaft bearing 60 KINROAD 150 SERVICE MANUAL Remove the sub shaft bearing Remove the driven belt pulley shaft bearing Drive in the new driven belt pulley shaft bearing Drive in the new sub shaft bearing Drive in the new final shaft bearing 61 VERSION 1 DEC 2005 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Install the driven belt pulley shaft on the transmission case cover Drive in the transmission case cover oil seal Mount the sub shaft sub shaft gear and the final gear shaft in she left crankcase
36. large cap on the left bottom of the engine and remove the screen 3 Wash the screen with cleaning solvent and refit making sive th O ring is still in good conditions 4 Refill the engine with SAE10W 30SF engine and cr 5 ininutes 5 Check oil level on the filler cap stick to assure pr pe ievel 6 The cap needs to be screwed in to check CHASSIS 1 Grease chassis bushings and with grease quarterly to assure smooth operation and extended life of the bushings and the components 2 If used in extreme wet ana muddy conditions or dusty conditions it is recommended to service more often KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 3 ENIGNE CYLINDER CYLINDER REMOVAL The removal can be done on the vehicle body Remove cylinder head Remove cylinder Remove cylinder gasket bolts Erase cylinder gasket A CAUTION 1 Do not damage the bond area of the cylinder 2 Do not drop sundries such as cylinder gasket ateiial into the crankcase CYLINDER INNER WALL WEAR INSPECTION Use a bore diameter dial gauge to measure the degree ct wear The measuring point is divided into three sectional planes in the axial direction upper middle lower measure every plane eacn time on the mutually perpendicular directuns X Y The least measured dimensior the cylinder bore the data measured the most upper position is the largest dia mster an
37. oo thin The structure of the air cut valve is shown in the picture spring 37 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 AIR CUT VALVE REMOVAL Remove the air inlet manifold of the air cut valve Remove the bolt and remove the vacuum membrane cover the spring and the vacuum membrane AIR CUT VALVE INSTALLATION Assemble the vacuum membrane on the carburetor bolt Assemble the spring the vacuum member cover and the lock bolt e The bottom side of the vacuum membrane should be aligned with the carburetor and the topside should be aligned with the vacuum membrane AIR CHECK VALVE The air check valve starts working under 50km h impel the second air inlet to burn and reduce CO displacement AIR CHECK VALVE INSTALLATION Reverse the procedure for removal e When installing make sur every connecting pipes are connected properly and they cannot be squeezed be or clogged TRANSMISSION COMPONENTS SPECTION AND SERVICING STARTING MECHANISM INSPECTION AND SERVICING The starting mechanism en be divided into two types kick starting and electric starting SPIRAL SPLINE TRANSFERRING STYLE STARTING MECHANISM REMOVAL Remove the left crankcase cover Remove the crankcase gasket dowel pins Remove the movable driving plate the whole set Remove the starting spindle washer 38 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Remove the return spring stopp
38. ore connector of the 1 gulte rectifier Measure the conducting status beiveer the main wiring terminals according to the previous wiring diagram Connecting type Normal condition Battery the red wire Vania body Battery voltage value Connecting wire the ec wire Vehicle body Conductive 68 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Clean the carbon around the spark plug to prevent it from dropping into the cylinder when removing the spark plug Remove the spark plug e When installing connect the black yellow wire of the primary ignition coil with the black yellow connector of CDI and the green wire with the green connector of CDI Clean the filth and carbon accumulation on the spark plug with a steel brush or a blade Inspect the spark plug gap In general it should be about 0 6 0 7mm When the carbon accumulation and wear of the spark plug are too much the spark plug Replace with the spark plug of the same specification 73 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 5 CHASSIS REAR AXLE REMOVAL e Disassemble RR Wheel O e Remove the Cotter Pins on Axle Nut RR Wheel Remove the Axle Nut RR Wheel MT Pd Block up rear end of machine
39. plate Measure the outer diameter of the driven plate pulley hub Service limit 33 94mm Inspect if there is any abrasion or damage of the movable drven plate Measure the inner diameter of the movable driven plate Service limit 34 06mm Inspect if the groove of the guide pin is worn DRIVEN PLATE BEARING REPLACEMENT e Ifthe driven plate needle bearing the ball bearing are loose damaged or have some unusual sound they should be replaced Remove the needle bearma the driven plate The removed bez cannot be reused 54 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Remove the circlip from the driven plate Drive the ball bearing out e The removed bearing cannot be reused Apply some grease on the new ball bearing Drive the ball bearing into the driven plate with its front face upwards Assemble the circlip Apply grease evenly on the inner wall of the driven plate Use the prescribed grease rn Drive the new needle bearing into with its mark upwards Use the special tool Apply grease around the bearing NAM AZ DRIVE BELT PULLEY INSTALLATION Remove the grease on the driven plate Assemble the oil seal Apply a little grease on the O ring Assemble the movable driven plate intc the driven plate After applying some grease an ine roller and the guide pin assemble them into the driven alate hole Install the
40. r ine wheel turns l 1 freely on the axle with minimum end play lease tighten the 4 AN vw ILE Mol hol nuts after replacing the wheels AE 2 x y wm 5097249 i M apy FRONT HUBS Check seals for rips tears and replace if any exist Sani e Remove bearings wiin a punch from the opposite side e Inspect bearings for ease of movement If dirt or mud has 0 e is gotten to them wash them in cleaning solvent and spin with te d d E l i Burirs your finger Never spin them with compressed air v Apply an ample amount of grease to the bearing and i i reinstall with a bearing tool making sure they go in straight If the bearing is not straight damage to the hub can occur Samal Install seals into hub It is recommended to apply a small 75 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 amount of grease to the lip of the seal If the retention spring is in bad shape replace the seal with a new one SEAT Remove all the Nuts and Bolts underneath the seat rail O Remove the seat STEERING SHAFT 42 e Remove Nuts Steering Block and grease inside A Steering Block periodically yos AN e Loosen Steering Shaft and Clamp Nut Steering Wear dese I Box i Remove Steering Shaft 217 Pariin en A Per STEERING GEAR BOX AND BALL HE AC STEERING af Tr GEAR BOX dii Remove four bolts on LH amp RH Clamp Nut Steering Gear s q Box Gross Pa
41. sccticaty a e Remove and check Ball Heac Dusi Cover Steering Gear e Box for wear Check Steering Cover c toth sides of Steering Gear Box and Grease the Ball osc 2 1 Steering Gear with Grease after cleaning the dust a It is recommended to eplace the Ball Joint if it is loose or 4 not smooth d n UM 1 n THROTTLE amp BRAKE PEDAL A eN e Remove Throttle Throttle Pedal and Axle Nut Check for la a signs of wear Replace if wear is present Fill with grease order to make the Brake Pedal swing more Crees Poricdically flexible before installation 76 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 A ARMS Grease the nipples of Upper amp Lower A Arm FR Wheel periodically e Remove Bolt of Upper 8 Lower A Arm FR Wheel e Check the Nylon Bushing of Upper amp Lower A Arm FR Wheel for wear Replace them immediately if wear is present STEERING KNUCKLE SUPPORT e Remove Rubber Dust Cover of ti ruckle Support e Check the grease of Ball Join Clean it if dirty and fill with grease Replace the Steering knuck e support if the Ball Joint is loose or steering isn t flexible A 77 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 TIE ROD Tie rods should be checked for ease of movement in their full rotation Remove protective boot and apply grease Check tie rod ends periodically for tightness a
42. structure of the driving belt pulley is shown in the picture The picture shows the working theory of the driving belt pulley When rof ng 2 2 rises Movable drive plate The picture shows the structure the riven belt pulley The clutch showed in the picture is the automatic dry centrifugal weight clutch 48 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 DRIVE BELT PULLEY DRIVE BELT PULLEY REMOVAL Remove the left crankcase air pipe lock bolt Remove the kick starter and remove the left crankcase fixing bolt Remove the left crankcase cover Hold the drive plate with a universal wrench and then remove the nuts and gasket on the drive plate shaft Remove the drive plate Remove the driven belt from the drive plate Remove the gasket and the dowel pin Remove the movable drive plate the whole set Remove the ramp plate Remove the centrifugal rollers 49 KINROAD 150 SERVICE MANUAL DRIVE BELT PULLEY INSPECTION Inspect if there is any abrasion or damage of the centrifugal roller Measure the outer diameter of the centrifugal roller Service limit 17 0mm Mea sure the inner diameter of the movable drive plate Service limit 24 06mm Inspect if there is any abrasion or damage of the drive plate hub Measure the outer diameter of the drive plate hubs movable surface Service limit 23 94mm DRIVE BELT PULLEY I
43. t by the prescribed number of turns Turn out numbers g turns 3 1 8 3 4 Step two Adjust the throttle adjusinmg crew to the prescribed idle rpm Step three Adjust the air adjustir screw slightly to find the highest position of the rpm Add throttle quic and gently the rpm is from low to high and return throttle immediately then observe for 16 ic 5 minutes to find the idle remains the same 34 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 VACUUM CHAMBER The picture shows the structure of the vacuum chamber of the CV carburetor RE i Ele I Yom ee m 2 cum plunger valve pressure y ES SS E chamber ar xi AAA VACUUM CHAMBER REMOVAL Remove the body cover Remove the automatic choke lead wir 2 Loosen the fuel drain bolt and drain the fuel in the float cha nte Remove the fuel line and the vacuum pipe Loosen the throttle cable adjusting nut and positioning n t the throttle cable Loosen the carburetor air inlet vent clip and the inle man fold clip remove the carburetor Remove the vacuum cover bolt and remove ine vacuum cover Notice Move slowly to prevent the spring am ejecting Take out the spring the membrane and the plunger Press down the holding ciamp of the needle valve top and turn left to take out the clamp Take out
44. t their i adjusting nuts e Always use a new cotter pin after removal REVERSE ADJUSTMENT ADJUSTING HUT WH REVERSE GABLE 1 Press down the reverse lever to the FW position so M T E N EEE that the units can move forward Pull back the lever to X BW so that the units can move backward A AM 2 Adjusting Nut 1 on the top of the reverse cable car am Y i adjust the mesh status inside the reverse gear box In tne Ha AA 5 A forward position there should be about 1 4 inch play i i ine cable for the correct adjustment SERVICE AIR CLEANER l 1 s ler Service every 100 hours i mm El Note Service more often under ausiy conditions gt emn 1 Remove cleaner cover 2 Remove air cleaner 2 3 TO SERVICE PRE CLEANER 1 Clean foam filter with no flammable cleaner If filter is paper tap filter on an object knocking dust from filter or replace with new filter 2 Dry filter after cleaning then dip it into engine oil specified by the manufacturer and wring excess oil out of filter 78 KINROAD 150 SERVICE MANUAL SPARK PLUG a Remove the spark plug and inspect it each time you change the oil Use a spark plug wrench The electrodes should be kept clean and free of carbon The presence of carbon or excess oil will greatly deter proper engine performance If possible check the spark plug gap area between electrodes using a wire feeler gauge This spec
45. ue please inspect the voltage regulator BATTERY The battery is an important component of the electric system This battery used on the vehicle is a maintenance free battery For ior period of storage the battery will discharge by itself so it should be charged every 3 month After 2 3 years of regular usage the capacity of the battery will descend so it will need charging Replace type of battery when replacing BATTERY REMOVAL e Shut down the main switch to make sure no electric current goes through the vehicle Disconnect the negative battery lead wire first Disconnect the positive battery second The disconnecting order cannot be reversed When disconnecting the positive cable do not touch the body of the vehicle with the removal tool otherwise short circuit will occur and ignite gas to damage the battery 64 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Connect the positive cable first and then connect the negative cable BATTERY OPEN CIRCUIT VOLTAGE INSPECTION Disconnect the cable on the battery terminals e Disconnect the negative pole first and then the positive pole Measure the voltage between the two poles of the battery Full charging 13 1V Under charging 12 3V BATTERY CHARGING Lift the battery out of the vehicle Connect the positive pole of the charger with the positive pole of the aitary Connect the negative pole of the charger with the neg
46. urnal bearing turns If there is the whole set should be replaced Inspect if the joint face of the crankcase is smooth and clean and notice if it will affect the sealing performance between the left ana vigiit crankcase while reassembling After the above inspection uz oilstone to furnish the crankcase if it has some surface damage Replace cover if damage is too severe The right and left crankcase axle hole must be concentric so generally they must be replaced at the same time KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 VALVE MECHANISM INSPECTION AND SERVICING The picture shows the common valve train of a four stroke engine This is a kind of overhead valve its intake port exhaust port camshaft are all located in the cylinder head the valve bottoms up over the combustion chamber GENERAL INTRODUCTION The four stroke engine completes its four stroke with one pision stroke Intake stroke Compression stroke Expansion stroke Exhaust stroke VALVE CLEARANCE ADJUSTMENT Valve clearance is an important technica carameter Make sure that the valve can close ghuy under any conditions especially when the engine is overheated there must be certain clearan 2 xset when the valve is in the cold condition This clearance is called valve clearance When the engine s unning the valve clearance should be neither too big nor too small So the valve clearance
47. utch nut Notice that the thread of the nut should be left handed rotation 45 KINROAD 150 SERVICE MANUAL VERSION 1 DEC 2005 Install the right crankcase cover Install the left crankcase cover Take the reduction mechanism and the engaging mechanism as a whole unit then this unit is called the starter CONTROLING MECHANISM STARTER RELAY INSPECTION Turn the main switch to the position and press down the starting motor buten and listen if there is a click sound If there is it is normal if there isn t follow the below procedures Inspect if the brake switch is conductive At this time turn the main switch an ana ald the brake lever The battery voltage should be at 12 volts Measure the voltage between the inlet line the green yellow line starting relay and the ground wire of the body The voltmeter reading should be close to the magnituce ot voltage between the two ends of the battery If not the brake switch its wire or the wire ic not good Inspect if the start button is conductive At this time remuve the starting relay inlet line the green yellow line Connect the yellow red line with the ground wire and press the start button It should be conductive between the yellow red line and the ground w lt earerwise the start button its wire or the wire connector is not good Inspect if the working condition of the starting relay At this time remove the starting r

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