Kinroad 150 Manuale utente
KINROAD 150 SERVICE MANUAL VERSION 1, DEC., 2005
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KINROAD
KINROAD 150 SERVICE MANUAL VERSION 1, DEC., 2005
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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 usersabove 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 improvement or other changes, there
may be some discrepancies in this manual. Therefore, if newest information is requested in the future,
please contact the local distributor.
Distributor reverse the right to make production changes at any time, 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
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CONTENTS
1. GENERAL INFORMATION -------------------------------------------------------------------------------------------------4
2. PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES -----------------------------------------------------7
3. ENGINE --------------------------------------------------------------------------------------------------------------------------13
4. ELECTRIC SYSTEM ---------------------------------------------------------------------------------------------------------64
5. CHASIS --------------------------------------------------------------------------------------------------------------------------74
6. WIRING DIAGRAM -----------------------------------------------------------------------------------------------------------81
KINROAD 150 SERVICE MANUAL VERSION 1, DEC., 2005
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1. GENERAL INFORMATION
MODEL IDENTIFICATION
FRAME NUMBER
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 lower front left side of the engine cases.
KINROAD 150 SERVICE MANUAL VERSION 1, DEC., 2005
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FUEL AND OIL RECOMMENDATIONS
Be sure to use the specified fuel and oil.
FUEL
Gasoline should SAE 90# 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 DOUBLESEAT/SINGLESEAT
Overall Length 2159mm/2075mm
Overall Width 1400mm/1235mm
Overall Height 1470mm/1400mm
Wheelbase 1499mm/1450mm
Ground Clearance 170mm/130mm
ENGINE
Type Forced air-cooled, single cylinder, 4-Stroke
Engine Capacity 150cc
Displacement 149.5cc
Bore x Stroke 57.4mm x 57.8mm
Compression Ratio 9.2:1
Max Power 7.4kw/7500rpm
Max Torque 9.5N.m/5500rpm
Fuel Type SAE 90# or above (unleaded)
Lubricate Oil SAE 10W/30
Ignition C.D.I.
Starting Electric
Spark Plug C7HSA (NGK)
Transmission AutomaticC.V.T.
Carburetor MIKUNI, BS24J
Lubrication Force & Splash
KINROAD 150 SERVICE MANUAL VERSION 1, DEC., 2005
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CAPACITIES
Maximum Load 400lbs
Fuel Tank 7.0L
Engine Oil 850ml
Starting <5s
Climbing 25ｏ
Battery 12V 8Ah
Head Light 12V 21W
Tail Light 12V 21W/5W
Fuse 10A
Brake Track <7 m@20mph
Top Speed 30mph
CHASSIS
Front/rear Brake Hydraulic disc, left foot control
Front Tire 21x7-10
Rear Tire 22 x 11 –10
Front Suspension Independent Dual A-Arm
Rear Suspension Swing Arm/Double Damped Shock
TIRE PRESSURE
Front 175kpa
Rear 200kpa
WEIGHT
Net Weight 170kg/105kg
** The specifications are subject to change without notice.
KINROAD 150 SERVICE MANUAL VERSION 1, DEC., 2005
PERIODICAL CHECK AND SERVICES
The maintenance intervals in the following table are based upon average riding conditions.
Riding in unusually dusty areas requires more frequent servicing.
Timeofservice
Items Initial service
(First week) Monthly Quarterly Yearly
Tire pressure/wear I I
Brake performance I I
Tightness of screws I I
Air cleaner C C I
Carburetor I A C
Spark plug C, A
Drive chain I I C, A, L
Brake fluid I
Replacement of gearbox oil I R
Chassis C, I L
Fuel switch/fuel tank C
Battery I I
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-UP PROCEDURE
This section describes the servicing procedures for each item in the
Periodic Maintenance Intervals.
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
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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.
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.
BRAKE PERFORMANCE
1. Always check that there is plenty of brake fluid in the brake fluid
reservoir.
2. Check that the front/rear brake pads are in good condition
3. Check the brake rotor for abnormal wear.
AIR CLEANER
Clean the air cleaner quarterly or more often in dusty conditions.
If the air cleaner is clogged with dust, performance will be severely
decreased; even engine damages can occur. Check and clean in the
following manner.
PAPER FILTER MAINTENANCE
1. Remove the air cleaner from its housing.
2. Tap the filter on an object knocking dust from filter.
3. Replace the element if it is wrinkled or torn.
Tire pressure
Front 175 kpa
Rear 200 kpa
KINROAD 150 SERVICE MANUAL VERSION 1, DEC., 2005
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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 after use is a normal situation and should be
checked regularly.
TIGHTENING TORQUE TABLE
Conventional marked bolt 8.8 marked bolt
Bolt
Diameter
(mm) N·m Kg·m lb-ft N·m Kg·m lb-ft
4 1-2 0.1-0.2 0.7-1.5 1.5-3 0.15-0.3 1.0-2.0
5 1-4 0.2-0.4 1.5-3.0 3-6 0.3-0.6 2.0-4.5
6 4-7 0.4-0.7 3.0-5.0 8-12 0.8-1.2 6.0-8.5
8 10-16 1.0-1.6 7.0-11.5 18-28 1.8-2.8 13.0-20.0
10 22-35 2.2-3.5 16.0-25.5 40-60 4.0-6.0 29.0-43.5
12 35-55 3.5-5.5 25.5-40.0 70-100 7.0-10.0 50.5-72.5
14 50-80 5.0-8.0 36.5-58.0 110-160 11.0-16.0 79.5-115.5
16 80-130 8.0-13.0 58.0-94.0 170-250 17.0-25.0 123.0-181.0
18 130-190 13.0-19.0 94.0-137.5 200-280 20.0-28.0 144.5-202.5
FUEL SWITCH (PETCOCK)
1. Periodically clean the petcock externally with grease remover and water.
2. Check for any leaks or seeping fuel.
3. Replace the petcock if there are any leaks found.
This vehicle has a manually operated fuel valve. There are three positions.
“ RES ” “ OFF “ “ ON “
1.Before and during cleaning, inspect the element for tears. Atorn element must be replaced.
2.Make sure the element is seated properly and no foreign material can pass by it
KINROAD 150 SERVICE MANUAL VERSION 1, DEC., 2005
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“ON” position
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.
When the vehicle is not in use, always make sure the petcock is in the "OFF" position
FINAL GEAR OIL
Inspect monthly and change quarterly.
1. To check the oil level, remove the level screw on the left rear engine
case.
2. To drain oil, remove the drain plug at the rear bottom of the engine
case. It is recommended to warm the engine for 10 minutes or more
before draining final gear oil.
NOTE:
Mobil 85w/90 gear oil is recommended 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
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