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KAYO MOTOR AU200 Maintenance Manual
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KAYO MOTOR AU200 Maintenance Manual

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KAYO MOTO
AU200
Maintenance Manual
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Summary of Contents for KAYO MOTOR AU200

  • Page 1 KAYO MOTO AU200 Maintenance Manual...
  • Page 2 W W W . K A Y O MOTO.COM Version code：20180915 Version name：AU200 Maintenance manual English version.pdf WWW.KAYOMOTO.COM...

  • Page 3: Table Of Contents

    Description This manual specificially descripted the maintenance adjustment procedures Kayo Moto for the AU200 four-wheels vehicle (ATV), Research and Development Department disassembly and assembly methods, 2018 - 08 inspection and maintenance points, troubleshooting methods and maintenance technical data, and detail graphic data.
  • Page 5 浙江华洋赛车股份有限公司 Unit conversion table Item Unit conversion 1kgf/cm =98.0665kPa；1kPa=1000Pa Pressure 1mmHg=133.322Pa=0.133322kPa Torque 1kgf· m=9.80665N· m 1mL=1cm 3 =1cc Volume 1L=1000cm 3 Force 1kgf=9.80665N Length 1in=25.4mm Warning Please read the following explanation carefully, which emphasizes the specific meaning of the words “danger”, “warning” and “attention”, and pay special attention to the outstanding meaning of the engine when repairing it.

  • Page 7: Maintenance Information

    浙江华洋赛车股份有限公司 1 Maintenance information 1.1Notes for Operation……………………………………………………………………………1-1 1.2 Vehicle identification number…………………………………………………………………1-3 1.3 Main parameter list……………………………………………………………………………1-4 1.4 Maintenance parameter list……………………………………………………………………1-6 1.5 Tightening torque………………………………………………………………………………1-8 1.6 Lubricant, sealant………………………………………………………………………………1-10 1.7 Cable, hose, cable wiring diagram……………………………………………………………1-11 1.1 Work precautions Safety Precautions 1. Work clothes (such as overalls), hats, and safety boots that are suitable for the work must be worn. If necessary, wear protective glasses such as dust-proof glasses, dust masks, gloves, etc.
  • Page 8 1 维修信息 4. The gasket, O-ring, piston pin retaining ring, split pin, etc. must be replaced with new ones after disassembly. 5. If the opening of the circlip is too large when disassembling, it will be deformed and will fall off easily after reassembly.
  • Page 9 浙江华洋赛车股份有限公司 When assembling, be careful not to curl the oil seal lip and prevent the burr from scratching the oil seal lip. Apply grease to the oil seal lip before assembling. 18. When installing the hose parts, insert the hose into the joint root. There is a pipe clamp to install the pipe clamp in the recessed mark of the pipe.
  • Page 10 1 维修信息 1 VIN on chasis 2 Vehicle name plate 3 Engine number Model AU200 L6JACMLA5G ~ Engine number F1702K ~ 1- 4...
  • Page 12 1 维修信息 1.3 Main parameter list Item Parameter Model AU200 Length（mm） 1786 Width（mm） Height（mm） 1050 Wheelbase（mm） 1120 Engine model LC162FMC-2 Total displacement（ml） Fuel type No.92 and above gasoline Vehicle Dry weight (kg) Number of Passenger 1 person（driver） 1 person ＋ 60kg = 120kg...
  • Page 13 浙江华洋赛车股份有限公司 Item Parameter Air filter type Sponge filter Model Plunger throttle Throttle body Mixing valve diameter 30mm Fuel tank volume Clutch type Dry automatic clutch （CVT） Variable speed mode One forward gear, one neutral gear, one Gear shift position reverse gear Transmission Shift mode / sequence Hand operation/F—N—R...
  • Page 14 1 维修信息 1.4 Maintenance parameter list Lubricating device Item Standard limited － Change oil 800ml（No oil filter replaced） Engine Change oil 900ml（ oil filter replaced） capacity － Full capacity 1000ml Only use SAE 15W/40-SE，Do not substitute or mix different grades of engine oil, which will Recommended engine oil cause damage to the engine and cause an accident.
  • Page 15 浙江华洋赛车股份有限公司 Battery / charging device / trigger coil Item Standard model Permanent magnet alternator output Three-phase full wave Magneto-trigger coil resistance Magneto no-load voltage (engine is in cold Magneto state) Magneto maximum output power 180w Stable voltage 14.5 ± 0.5V ≥1V，200r/min；≥8.5V，2000r/min Trigger coil Max voltage Rectifier type...
  • Page 16 1 维修信息 Light / instrument / switch Item Standard fuse Headlight 12V—35W Front turnlight 12V—10W Light, bulb Rear light / brake light 12V—2.8W Rear turn light 12V—2.5W Position light 12V—3W Valve + cylinder head ( section 05 - Engine) Cylinder + Piston + Piston Ring + Crank Link (section 05 - Engine ) Clutch + transmission（...
  • Page 17 浙江华洋赛车股份有限公司 1.5 Fastener tightening torque Note: Put some rust-proof grease to the threaded part and the joint before installing the thread Tightening torque at the specified part - the entire vehicle part Tightening torque Item Fastener code quantity （N· m） Suspension lower rocker bolt GB5789 M10×1.25×80 45~59...
  • Page 18 1 维修信息 Tightening torque at the specified location - engine section ( section 05-Engine ) tightening torque at the unspecified location kind kind Torque N· m Torque N· m 5mm Bolts and nuts 5mm Screw 4.5~6 3.5~5 6mm Bolts and nuts 6mm Screw 8~12 7~11...
  • Page 19 浙江华洋赛车股份有限公司 Engine operating materials include lubricating oil (oil), grease (butter) and coolant; installation accessories include flat sealant, thread locker, etc. 1.7 Cable, hose, cable wiring diagram 1. Headlight connector 2. Left turn signal connector 3. Left hand multi-function switch connector 4. Instrument connector 5, right turn signal connector 6, electric door lock switch connector Note: The front panel must be removed before inspection of the above components.
  • Page 20 1 维修信息 7, brake sensor (left one and right one) 8, throttle line 9, brake hose 1. Motor line 2. Crankcase exhaust pipe 3. Carburetor 4. Carburetor drain pipe 5. Magnetic motor trigger connector Note: The right foot pedal and the right middle guard must be removed before inspection and maintenance of the above components.
  • Page 21 浙江华洋赛车股份有限公司 For specific disassembly,check Chapter 2 Body Covers. 6、Voltage regulator rectifier 7, charging connector 8, relay 1、Brake light patch cord 2. Left turn signal patch cord 3. Brake light contact wire 4. Right turn signal patch cord 1- 13...
  • Page 23 浙江华洋赛车股份有限公司 2 Vehicle Body Covers 2.1 Maintenance information………………………………………………………2-2 2.2 Mounting torque………………………………………………………………2-2 2.3Disassembly of seat cushion and front/ rear shelves 2.3.1 cushion……………………………………………………………………2-3 2.3.2 front shelf…………………………………………………………………2-3 2.3.3 rear shelf……………………………………………………………………2-4 2.4 Disassembly of front panel, instrument front cover, instrument panel, gear shift head assembly and shifting decorative cover 2.4.1 front panel…………………………………………………………………2-4 2.4.2 instrument front cover………………………………………………………2-5 2.4.3 instrument panel……………………………………………………………2-5...

  • Page 24: Maintenance Information

    2 车体覆盖件 2.1 Maintenance information Precautions When the cover on the vehicle is pasted or riveted, the warning cover shall be correctly and completely filled with the corresponding mark when it is replaced. This chapter describes the disassembly and assembly sequence of the body cover. When the internal parts of the vehicle are to be removed, the relevant cover parts can be removed.

  • Page 25: Front Shelf

    浙江华洋赛车股份有限公司 Disassembly of seat cushion and front/ rear shelves 2.3.1 Cushion Disassembly Open the seat cushion hook upwards Lift the back of the seat cushion and pull the seat cushion back Remove the seat cushion Assembly In reverse order of reverse disassembly, reverse direction Check if the seat cushion is in place, secure, etc.

  • Page 26: Rear Shelf

    2 车体覆盖件 2.3.3 Rear shelf Disassembly Remove the rear shelf mounting screws Remove the mounting bolt 2 Remove the mounting bolt 3 Remove the rear shelf 4 Assembly Installation in reverse order of disassembly 2.4 Disassembly of front panel, instrument front cover, instrument panel, gear shift head assembly and shifting decorative cover...

  • Page 27: Instrument

    浙江华洋赛车股份有限公司 2.4.2 Instrument front cover Disassembly remove the 2 screws 1 Remove the front cover of the instrument 2 Assembly In reverse order of reverse disassembly, reverse direction 2.4.3 Instrument panel Disassembly Remove the front cover of the instrument (→ 2.4.2) remove the 2 screws 3 Remove the instrument panel 4 Assembly...

  • Page 28: Shifting Decorative Cover

    2 车体覆盖件 2.4.5 Shift decorative cover Disassembly Remove the gear shifter combination (→ 2.4.4) Remove 2 mounting screws 1 Remove the shift cover 2 Assembly In reverse order of reverse disassembly, reverse direction 2.5 Disassembly of left middle guard, right middle guard, left pedal and right pedal 2.5.1 left middle guard Disassembly...
  • Page 29 浙江华洋赛车股份有限公司 Assembly 2.5.3 Left foot pedal In reverse order of reverse disassembly, reverse direction Disassembly Remove the left middle guard (→ 2.5.1) Remove the fastening screw 1 Remove the fixing screws 2 Remove the left foot pedal 3 from the bottom to the top Assembly In reverse order of reverse disassembly,...

  • Page 30: 2Bumper

    2 车体覆盖件 2.6.1 bumper Disassembly Remove the front shelf (→ 2.3.2) Remove the mounting bolts 1 (two on each side) Remove the bumper 2 Assembly In reverse order of reverse disassembly, reverse direction 2.7 Disassembly of fuel tank cover, front assembly plate and rear assembly plate 2.7.1 Fuel tank cover Disassembly...
  • Page 31 浙江华洋赛车股份有限公司 2.7.2 Front assembly board Disassembly Remove the front cover of the instrument (→ 2.4.2) Remove the front panel (→ 2.4.1) Remove the left middle guard (→ 2.5.1) Remove the right middle guard (→ 2.5.2) Remove the left foot pedal (→ 2.5.3) Remove the right foot pedal (→...
  • Page 33 浙江华洋赛车股份有限公司 3 Regular inspection and adjustment Inspection………………………………………………………………………………...3-1 3.1 Determination of maintenance period…………………………………………………3-2 3.2 Inspection and repair method…………………………………………………………3-3 3.3 Direction column, brake system………………………………………………………3-5 3.4 Wheel…………………………………………………………………………………3-9 3.5 Suspension system……………………………………………………………………3-12 3.6 Shifting mechanism, fuel device……………………………………………………...3-13 3.7 Throttle check…………………………………………………………………………3-14 3.8 Meter…………………………………………………………………………………3-15 3.9 Lighting device………………………………………………………………………3-15 Maintenance information Precautions Note...

  • Page 34: Adjustment

    3 定期检查与调整 3.1 Determination of maintenance period Engine maintenance is a regular periodic work. It is very important to maint ain the engine at regular intervals. Standard maintenance can ensure excellent engine performance, reliable operation, and economical and durable. The following is the LXCVT200 engine.
  • Page 35 浙江华洋赛车股份有限公司 3.2 Inspection Inspection and repair project period daily Half year Check parts Check item Benchmark year ○ steering wheel Operational flexibility ○ damage steering Steering system device steering system ○ installation status ○ Sloshing of the pin ○ ○ Pedal stroke Brake pedal ○...
  • Page 36 3 定期检查与调整 wheel bearing Suspension Shaking of the connecting part and ○ ○ Buffer damage of the rocker device ○ ○ Shock absorber Oil spill and damage ○ function ○ ○ Front bridge Transmission, lubrication Rear bridge Transmission, transmissi ○ ○...
  • Page 37 浙江华洋赛车股份有限公司 Inspection and repair project period dail Half year Benchmark Check parts Check item year ○ ○ Loose connection Output shaft transmissi (transmission ○ Splashing of the spline shaft) clearance ： Spark plug ○ Status of the spark plug 0.6mm~0.7mm Ignition device ○...

  • Page 38: Direction Column, Brake System

    3 定期检查与调整 handle. 3.3 Direction column, brake system Place the car in a horizontal position, and grasp the direction to check the presence or absence of shaking in the direction shown. If you feel shaking, check if the steering column is shaking or other shaking and perform the corresponding maintenance.
  • Page 39 浙江华洋赛车股份有限公司 Front brake pump combination <liquid quantity> Check the amount of brake fluid Check the brake fluid volume through the observation hole 4. When the brake fluid volume decreases to the vicinity of the lower limit line 2 (LOWER), the vehicle will not be able to continue to use at this time, and it is necessary to check the brake pump, the brake pipe and the leakage at each joint.
  • Page 40 3 定期检查与调整 Front brake disc, brake pad <wearing of brake pads> Check the wear of the brake pads If the wear has reached the wear limit, replace the brake pads Note Brake pads need replaced completely Brake disc inspection and replacement Check the sliding surface of the brake disc 1 for wear and damage.
  • Page 41 浙江华洋赛车股份有限公司 Rear brake pump combination <liquid volume> Check the amount of brake fluid Check the brake fluid volume through the observation hole 4. When the brake fluid volume decreases to the vicinity of the lower limit line 2 (LOWER), the vehicle will not be able to continue to use at this time, and it is necessary to check the brake pump, the brake pipe and the leakage at each joint.
  • Page 42 3 定期检查与调整 Rear brake disc, brake pad <wearing of brake pads> Check the wear of the brake pads If the wear has reached the wear limit, replace the brake pads note Brake pads need to be replaced completely Brake disc inspection and replacement Check the sliding surface of the brake disc 1 for wear and damage.

  • Page 43: Wheel

    浙江华洋赛车股份有限公司 3.4 wheel Lift the front wheel with the tool in the horizontal position, make sure that the car body has no force on the wheel, shake the front wheel from side to side, check whether the front wheel connection is firm, check for shaking.
  • Page 44 3 定期检查与调整 Tire pressure Check the tire pressure using a barometer Note The tire pressure is checked while the tire is cool. If it is used in a state where the tire air pressure is not suitable, it will deteriorate the operation and ride comfort, and cause adverse effects such as eccentric wear of the tire.

  • Page 45: Suspension System

    浙江华洋赛车股份有限公司 Wheel nut and wheel axle Check the front axle, rear axle nut 1 and the looseness of the latch Fasten at specified torque when loose Torque: Front axle nut: 126N·mm～218N·mm (12.6kgf·mm to 22kgf·mm) Rear axle nut: 199N·mm~311N·mm (20kgf·mm to 31kgf·mm) Shaking of wheel hub Use the tool to frame the front wheel.

  • Page 46: Shifting Mechanism, Fuel Device

    3 定期检查与调整 Shock absorber adjustment Adjusting the adjustment cam 1 of the shock absorber according to the load with a special tool Clockwise rotation is from high to low, counterclockwise rotation is adjustable from low to high bidirectional 3.6 Shifting mechanism, fuel device Shifting mechanism Replace the gear position, check whether the shifting mechanism2 is flexible, and whether...

  • Page 47: Throttle Check

    浙江华洋赛车股份有限公司 3.7 Throttle check Check the free stroke of the throttle button 1 Clearance: 2 ~ 6 mm Adjust the clearance when the clearance is not within the specified range Remove the sheath 3 Release the throttle cable lock nut 2 Turn the adjuster to adjust the free travel of the throttle button After adjustment, tighten the lock nut 2 to...

  • Page 48: Meter

    3 定期检查与调整 3.8 Meter Check meter When the vehicle system is powered on for the first time (or after the instrument is replaced for the first time), when the engine is not working, the speed should be in the zero position, start the engine, pay attention to whether the speed value indicates change, if it does not change, it should be repaired in time.

  • Page 49: Engine Periphery

    4 发动机周边 4 Engine periphery Maintenance information……………………………………………………………4-1 4.1 Fuel System……………………………………………………………………4-2 4.2 Intake system……………………………………………………………………4-2 4.3 Exhaust system…………………………………………………………………4-3 4.4 Engine disassembly and installation……………………………………………4-5 Maintenance information precautions  When repairing the operation, please ensure that the vehicle is turned off and left still for less than 1 hour, and confirm that the heating parts are cooled before performing maintenance to avoid injury to maintenance personnel.
  • Page 51 浙江华洋赛车股份有限公司 4.1 Fuel System Disassembly Remove the seat cushion, fuel tank cover, instrument front cover, front assembly plate ( → Chapter 2 Body Cover) Remove the mounting bolt 1 Release the oil level sensor connector 3 Remove the oil pipeline 4 (connected to the carburetor) Remove the fuel tank 2 Note...
  • Page 52 4 发动机周边 4.2 Intake system Disassembly Remove the seat cushion and rear assembly panel ( → Chapter 2 Body Cover) Remove the mounting bolts 1 (one for each of the left and right) Release the clamp2 Remove the carburetor 3 Remove the fuel tank (→4.1 Fuel tank disassembly and safety) Loading)
  • Page 53 浙江华洋赛车股份有限公司 4.3 Exhaust system Disassembly Remove the seat cushion, fuel tank cover, instrument front cover, front assembly plate, rear assembly plate (→ Chapter 2 Body Cover) Remove 2 bolts 1 Remove the insulation2 Remove the mounting nut 3 Remove the muffler barrel mounting bolt 4 Remove the exhaust pipe assembly 5 installation...
  • Page 54 4 发动机周边 4.4Engine disassembly and installation Disassembly Remove the seat cushion, fuel tank cover, instrument front cover, left middle guard, right middle guard, left foot pedal, right foot pedal (→ Chapter 2 Body Cover) Remove the fuel tank ( → 4.1 Fuel System) Remove the air filter and carburetor (→...
  • Page 55 浙江华洋赛车股份有限公司 Remove the spark plug cap 1 Remove the throttle tube connector 2 Remove the magneto motor trigger patch cord 3 Remove the charging patch cord 4 Remove the crankcase exhaust pipe 5 Remove the motor cable 6 (Remove the screw at the relay) Remove the carburetor drain pipe 7 Remove the mounting bolts 8...

  • Page 57: Engine

    浙江华洋赛车股份有限公司 5 Engine 5.1 Overview…………………………………………………………………………………5-2 5.2 Lubrication system………………………………………………………………………5-6 5.3 Check and adjust…………………………………………………………………………5-8 5.4 Fuel System……………………………………………………………………………5-12 5.5 Cylinder head and valve………………………………………………………………5-17 5.6 Cylinder and piston……………………………………………………………………5-30 5.7 Oil pump………………………………………………………………………………5-35 5.8 Right crankcase cover and magneto……………………………………………………5-38 5.9 CVT parts…………………………………………………………………………….5-40 5.10 Crankcase, crankshaft, variable speed drive…………………………………………..5-43 5.11 Fault judgment………………………………………………………………………..5-50 5- 1...
  • Page 58 5 发动机 5.1 Overrview Maintenance precautions……………………………………………………………………………5-2 5.1.1 Main performance technical parameters………………………………………………5-3 5.1.2 Mark torque data……………………………………………………………………5-4 5.1.3 Maintenance schedule…………………………………………………………………5-5 Maintenance precautions 1、Parts, lubricants or other auxiliary materials produced or approved by Chongqing Longxin Group shall be used. If the materials used do not meet the “Loncin” specifications or requirements, the motorcycle may be damaged;...
  • Page 59 浙江华洋赛车股份有限公司 5.1.1 Main performance technical parameters item data model LC162FMK–2 type Ignition Cylinder arrangement Vertical Cylinder diameter × 62× 58.4 stroke Working volume Basin type combustion chamber，17.8ml Compression ratio 9.7:1 Maximum power and 9kw/8000r/min Engine corresponding speed 13N•m/6000r/min Maximum torque and corresponding speed 354g/kw•h Minimum...
  • Page 60 5 发动机 5.1.2 Mark torque data Thread Torque N•m Item quantity diameter Cylinder head cap fastening bolt 10~14 Cylinder head fastening nut 23~30 Magneto motor rotor fixing bolt 45~53 16mm 40~50 Primary active tooth lock nut 36mm 10~20 Oil filter cover nut 8~12 Shift drum positioning plate bolt Shift drum and dial connecting...
  • Page 61 浙江华洋赛车股份有限公司 5.1.3 Maintenance schedule item Mileage（km） times Maintenance item period 1000 4000 8000 12000 note Fuel system ☆ access ☆ Fuel filter ☆ Carburetor choke Air filter element Note① Spark plug ☆ Valve clearance Engine oil year Lubricating filter year ☆...
  • Page 62 5 发动机 5.2 Lubrication system Maintenance instructions……………………………………………………………………5-6 5.2.1 Troubleshooting………………………………………………………………………5-6 5.2.2 Engine lubrication system……………………………………………………………5-6 5.2.3 Lubricating oil inspection……………………………………………………………5-7 5.2.4 Lubricating oil replacement……………………………………………………………5-7 5.2.5 Lubricating oil filter cleaning…………………………………………………………5-7 5.2.6 Lubricating oil filter cleaning…………………………………………………………5-7 Maintenance instructions This section describes the engine lubrication system and the cleaning, inspection, and replacement of various parts of the system.
  • Page 63 浙江华洋赛车股份有限公司 then stopped. Then, keep the body 5.2.3 Lubricating oil inspection flat and check the oil level of the oil dipstick. At this time, the oil level Park the motorcycle on a flat surface and check the must reach the lower line and check amount of oil with a dipstick 1.
  • Page 64 5 发动机 Upper line Lower line 5.3 Inspection and adjustment Maintenance instructions……………………………………………………………………5-8 5.3.1 skills requirement………………………………………………………………………5-8 5.3.2 Spark plug……………………………………………………………………………5-9 5.3.3 Valve clearance………………………………………………………………………5-9 5.3.4 Ignition timing………………………………………………………………………5-10 5.3.5 Carburetor idle speed…………………………………………………………………5-11 5.3.6 Cylinder compression test………………………………………………………………5-11 Maintenance instructions This section describes the inspection and adjustment of various parts of the LXCVT200 engine.

  • Page 65: Spark Plug

    浙江华洋赛车股份有限公司 （3800± 200r/min） Idle speed 1700 ± 170r/min Cylinder compression force 1450 ± 145kPa 5.3.2 Spark plug Remove the viewport cover and top viewport cover Use a socket wrench to remove the spark plug Rotate magneto flywheel counterclockwise to align the “T” and visually inspect the spark plug insulator for damage.

  • Page 66: Ignition Timing

    5 发动机 Indicator mark T mark Use a gauge to insert the adjustment screw and If the “F” mark on the magneto rotor is check the clearance between the valve stem aligned with the indication mark on the left Valve clearance: intake valve: 0.06mm front cover, the timing is correct.

  • Page 67: Carburetor Idle Speed

    浙江华洋赛车股份有限公司 5.3.5 Carburetor idle speed Note: After adjusting other items of the engine to the specified range, check and adjust the idle speed of the carburetor. When adjusting, the engine should be in a hot state, support the main bracket, and rotate the plunger adjustment screw Idle speed：1700 ±...
  • Page 68 5 发动机 started until the pressure gauge stops rising. The maximum reading usually arrives after 4 to 6 starts. Cylinder compression force：1450 ± 145kPa 5.4 Fuel System Maintenance instructions……………………………………………………………………5-12 5.4.1 trouble clearing………………………………………………………………………5-12 5.4.2 Carburetor disassembly………………………………………………………………5-13 5.4.3 Throttle plunger………………………………………………………………………5-13 5.4.4 Float, float needle, nozzle……………………………………………………………5-14 5.4.5 Float height adjustment………………………………………………………………5-15 5.4.6 Throttle plunger assembly……………………………………………………………5-15 5.4.7 Carburetor installation…………………………………………………………………5-16...

  • Page 69: Carburetor Disassembly

    浙江华洋赛车股份有限公司 the engine can ignite, but can not start 1. There is no fuel in the fuel tank. Loosen the hook screw with the air filter. 2. No fuel enters the carburetor Then remove the carburetor cover and pull the 3, too much fuel into the cylinder throttle plunger out.

  • Page 70: Float, Float Needle, Nozzle

    5 发动机 Remove the connecting screw and float cover of the float chamber cover. Then pull the float arm pin out. Remove the float and float needle . Check the contact surface of the float needle for wear and damage. Replace the new float needle when necessary.

  • Page 71: Float Height Adjustment

    浙江华洋赛车股份有限公司 First measure the height of the float with an altimeter Float height：15 ± 1 mm Float When you need to adjust the height of the float, slowly change the angle of the float arm until the tip of the float arm just touches the float needle.

  • Page 72: Carburetor Installation

    5 发动机 5.4.7 Carburetor installation Install the throttle valve plunger into the carburetor body. Note: The groove of the throttle valve plunger should be aligned with the locking screw on the carburetor body. Then tighten the end cap of the top of the carburetor After installing the carburetor, adjust the free stroke of the throttle handle with the...
  • Page 73 浙江华洋赛车股份有限公司 Start the engine to warm up to the operating temperature Adjust the throttle locking screw to achieve idle speed 1700 ± 170r/min Constantly manipulate the throttle hand Check if the engine can accelerate or decelerate steadily Then adjust the positioning screw until the maximum speed is reached;...
  • Page 74 5 发动机 Maintenance instructions The camshaft lubricant is injected into the cylinder head via a control orifice on the engine casing. This control orifice must not be blocked. When assembling, apply molybdenum disulfide lubricant on the cam bearing as the basic lubrication.

  • Page 75: Troubleshooting

    浙江华洋赛车股份有限公司 5.5.1 Troubleshooting Low cylinder pressure 1、Valve Valve clearance adjustment is incorrect Valve seal is not strict Remove the connecting bolts that secure the The timing of the valve is wrong. cylinder head 1 Valve spring break Remove the cylinder head cover 2 2, cylinder head The spark plug is not tightly connected to the cylinder head...
  • Page 76 5 发动机 5.5.4 Camshaft removal Remove the tensioner sealing bolt 1 Remove the tensioner fastening bolt 2 Remove the tensioner Remove the camshaft 3 Note: Do not allow the timing chain to fall into the crankcase 5.5.5 Cylinder head removal Remove the cylinder connection bolt 4 Remove the cylinder head 5 5- 20...

  • Page 77: Camshaft Inspection

    浙江华洋赛车股份有限公司 5.5.6 Camshaft inspection Check the lift distance of each cam Use a micrometer to measure the length of the convex portion of the cam to check for wear. Maintenance limit Intake: 31.4mm Exhaust:31.13mm 5.5.7 Rocker arm inspection Check the rocker for wear, damage or oil hole blockage Note: If any rocker arm needs to be maintained or replaced, the unevenness of...

  • Page 78: Decomposition Of Cylinder Head

    5 发动机 5.5.9 Decomposition of cylinder head Press the valve spring with a valve remover Remove the valve lock clip Then relax the valve remover Remove valve spring seat, valve spring and valve Note: In order to prevent permanent deformation of the valve spring, the valve spring cannot be compressed excessively, only the valve lock clip can be removed.

  • Page 79: Cylinder Head Inspection

    浙江华洋赛车股份有限公司 Note: Before measuring the inner diameter of the valve guide, the carbon deposit in the conduit should be completely removed. If the valve guide needs to be replaced, the valve seat should be reground. Completely remove the carbon deposits in the combustion chamber Remove the residue on the cylinder head plane with a spatula.

  • Page 80: Valve Seat Inspection And Grinding

    5 发动机 On the cylinder head, press the new valve guide and the “O” ring. Then reaming the newly installed valve guide Note: When reaming, apply cutting oil to the reamer. Rotate when loading or unloading the reamer. Finally, the cylinder head is cleaned with a cleaning agent and all the metal chips accumulated on the cylinder head are removed with compressed air.
  • Page 81 浙江华洋赛车股份有限公司 Valve duct reamer Measuring the width of the valve seat contact surface Maintenance limit：1.5mm If the valve seat is too wide, too narrow or has a dent, the valve seat should be ground to the correct degree of sealing. Contact width Valve seat milling cutter Three different angles of milling cutter...
  • Page 82 5 发动机 Flat trimming knife Valve correction knife Internal trimming knife Milling the upper ring of the valve seat with a 32° milling cutter Width of old valve seat Finish the valve seat's work surface with a 45° milling cutter to the correct width. Milling the bottom ring of the valve seat Working face width standard value：1.0mm with a 60°...

  • Page 83: Cylinder Head Assembly

    浙江华洋赛车股份有限公司 Contact surface too low Width of old valve seat If the valve contact surface is too low, use a 60 ° milling cutter to raise the contact surface. Finally, the 45° milling cutter is used for machining and abolishing, and the valve seat contact surface is machined to the pre-set width.

  • Page 84: Cylinder Head Installation

    5 发动机 clip into the valve spring seat. Note: To prevent permanent deformation of the valve spring, do not over compress the spring , only need to fit the valve lock clip. Then tap the end of the valve with a plastic hammer to make the lock clip firmly into the ring groove.

  • Page 85: Cylinder Head Cover Installation

    浙江华洋赛车股份有限公司 brake the magneto rotor in a clockwise direction so that the “T” mark is aligned with the indicator. At the same time,ensure that the 2×Φ3 hole connection line is parallel to the head cover joint surface, and the Φ6 hole is perpendicular to the head cover joint surface.
  • Page 86 5 发动机 Disc bolt Cylinder head cover 5.6 Cylinder and piston Maintenance instructions…………………………………………………………………5-30 5.6.1 Troubleshooting………………………………………………………………………5-31 5.6.2 Cylinder disassembly…………………………………………………………………5-31 5.6.3 Piston disassembly……………………………………………………………………5-31 5.6.4 Piston installation……………………………………………………………………5-33 5.6.5 Cylinder installation…………………………………………………………………5-34 Maintenance instructions The camshaft lubricating oil is injected into the cylinder head through a measuring hole in the engine casing.
  • Page 87 浙江华洋赛车股份有限公司 crankcase.. Specifications item standard（mm） Maintenance limit（mm） Cylinder inner diameter 62~62.01 62.1 — Taper 0.10 cylinder — Out of roundness 0.10 — Top distortion 0.10 Piston diameter 61.965~61.975 61.78 Piston pin hole inner diameter 15.002~15.008 15.04 Piston pin and piston pin hole 0.002~0.014 0.02 clearance...
  • Page 88 5 发动机 Remove the cylinder head (→5.5.5) Remove the positioning pin and paper pad Remove the cylinder Note: When removing the cylinder, the timing chain must never fall into the crankcase. Scrap the paper gasket remainings on the cylinder surface with a scraper. Middle Bottom Note: If the paper gasket is immersed in gasoline,...
  • Page 89 浙江华洋赛车股份有限公司 Insert each piston ring into the cylinder and measure the end gap Maintenance limit: First ring / second ring：0.5mm Check the piston and piston ring groove for wear or cracks. Measuring piston pin hole inner diameter Maintenance limit: 15.04mm Measure the outer diameter at 10 mm above the bottom end of the piston skirt...
  • Page 90 5 发动机 piston pin Maintenance limit: 14.96mm Calculate the gap between the piston and the piston Maintenance limit: 0.02mm 5.6.4 Piston installation Piston ring installation Thoroughly clean the piston ring groove Assemble the piston ring Note: Pistons and piston rings should be protected during installation.
  • Page 91 浙江华洋赛车股份有限公司 Piston installation Top Ring Second Ring Install the piston, piston pin and new piston retaining Oil Ring ring. 20mm or bigger Note: When installing the piston, the side marked with the “IN” mark should be aligned with the intake valve. The end gap of the piston pin retaining ring should be staggered from the piston incision Clip Spring...
  • Page 92 5 发动机 Apply a layer of oil to the cylinder and piston ring Install cylinder Note: When installing, avoid destroying the piston Can't let the timing chain fall into the crankcase. Install the timing chain guide plate Install new paper gasket Install the positioning pin Install the cylinder head Piston pin retaining ring...
  • Page 93 浙江华洋赛车股份有限公司 Maintenance instructions The installation and maintenance work after removing the right crankcase cover can also be operated without removing the engine; Do not allow dust or impurities to enter the engine when the oil pump is removed; It is not allowed to repair the oil pump. If a certain size reaches the maintenance limit, the entire oil pump should be replaced.
  • Page 94 5 发动机 External Rotor 5.7.2 Oil pump inspection If the radial clearance between the outer rotor and the pump body is greater than 0.12, Pump the oil pump should be replaced. body External Rotor If the radial clearance between the inner rotor and the outer rotor is greater than 0.12, the oil pump should be replaced.
  • Page 95 浙江华洋赛车股份有限公司 Install the oil pump sprocket cover fastening bolt 2×M6 Install one-way device Install the one-way fastening nut M 22 and washer Installing a magneto rotor Install the magneto motor fastening nut M 14 and washer Install oil pipe and spring 5.8 Right crankcase cover and magneto Maintenance instructions…………………………………………………………………5-38 5.8.1 Disassembly of the right crankcase cover……………………………………………5-38...
  • Page 96 5 发动机 Maintenance instructions For the disassembly and installation of the magneto motor described in this section, simply remove the right crankcase cover, no need to remove engine. Torque value Right crankcase cover fastening bolt: 8~12N·m Magneto rotor bolt：35~40N· m 5.8.1 Disassembly of the right crankcase cover Remove the 9×M6 bolt...
  • Page 97 浙江华洋赛车股份有限公司 Note: The semi-circular button on the crankcase is aligned with the magneto motor groove Tighten the rotor nut to the specified torque value Torque value：35~40 N· m 5.8.4Right crankcase cover installation First install the stator coil Stator coil Then tighten the 9×M6 bolts according to the specified torque.
  • Page 98 5 发动机 Maintenance instructions…………………………………………………………………5-40 5.9.1 Disassembly of the left crankcase cover……………………………………………5-40 5.9.2 Disassembly of CVT parts……………………………………………………………5-40 5.9.3Inspect of CVT parts…………………………………………………………………5-41 5.9.4 Install of CVT parts…………………………………………………………………5-42 5.9.5 Left crankcase cover installation……………………………………………………5-42 Maintenance instructions The removal and detection of the left crankcase cover and CVT components eliminates the need to remove the engine from the frame and can be disassembled and tested directly on the vehicle.
  • Page 99 浙江华洋赛车股份有限公司 Take out the belt Take out drive and driven parts Belt Active disc bushing 5.9.3 Inspect of CVT parts Belt width less than 17mm should be replaced The sliding drive disc has a hole diameter greater than 27.06mm and should be replaced.
  • Page 100 5 发动机 Clutch friction material thickness less than 2mm, then need to replace. Clutch 5.9.4 Install of CVT parts Clutch Install the drive pulley unit Install the belt into the clutch Install the clutch Active pulley components Install active drive plate and driven friction plate Fasten M12 nut and washer Torque value：50~60 N·...
  • Page 101 浙江华洋赛车股份有限公司 5.10 Crankcase, crankshaft, variable speed drive Maintenance instructions…………………………………………………………………5-43 5.10.1 Troubleshooting……………………………………………………………………5-44 5.10.2 Decomposition of the crankcase……………………………………………………5-45 5.10.3 Crankshaft inspection………………………………………………………………5-45 5.10.4 Decomposition of transmission components………………………………………5-47 5.10.5 Assembly of transmission parts……………………………………………………5-48 5.10.6 Assembly of crankshaft components………………………………………………5-48 Maintenance instructions This section describes the disassembly and assembly of the transmission components and the crankshaft.
  • Page 102 5 发动机 5.10.1 Troubleshooting Difficulty gear shifting Crankshaft has noise 1. gear shift fork bent 1, the connecting rod big end bearing 2, gear shift fork shaft bent wear 2, connecting rod bent Gear shift abnormal 1. The gear shifting ratchet claws are Gear shifting gear is noisy worn 1.
  • Page 103 浙江华洋赛车股份有限公司 5.10.2Decomposition of the crankcase Place the engine on the workbench Remove the right crankcase box bolt 8×M6 Remove the left crankcase box bolt M6 Turn the engine over so that the right crankcase is above Remove the right crankcase and separate the left crankcase from the right crankcase Remove the gasket and locating pin Remove the crankshaft and balance shaft...
  • Page 104 5 发动机 Measuring radial clearance of two points in the X and Y directions of the large connecting rod Maintenance limit: 0.05mm Measuring the big head gap of the connecting rod with the feeler gauge Maintenance limit: 0.8mm Turn the crankshaft bearing by hand and check its jumping in radial and axial.
  • Page 105 浙江华洋赛车股份有限公司 5.10.4 Decomposition of transmission components Pull out the fork shaft and take out the fork Take out the shift drum and shift shaft Take out the reverse intermediate shaft and reverse drive shaft assembly Shift Reverse Revers Speed Shaft transmission middle shift...
  • Page 106 5 发动机 5.10.5 Assembly of transmission parts Reverse Install the components in the correct middle Variable speed drum position, as shown in the picture: Axle Reverse Shift shaft Transmission Axle Note: Before assembly, each part should be coated with engine oil. Check if the shift gear can rotate freely and without jamming.
  • Page 107 浙江华洋赛车股份有限公司 Fit the positioning pin Install the left crankcase Fasten the bolts at the left crankcase Fasten the box bolt at the right crankcase Coupling bolt torque value: 8~12N·m Locating Pin Closure bolt Left crankcase Closure bolt 5- 51...
  • Page 108 5 发动机 5.11 Fault judgment 5.11.1 Engine can't start or start difficult…………………………………………………5-50 5.11.2 Engine power is Insufficient……………………………………………………5-51 5.11.3 Poor performance at low engine speed or idle speed………………………………5-52 5.11.4 Engine performance is poor at high speeds…………………………………………5-53 5.11.5 The engine has abnormal noise……………………………………………………5-54 possible reason 5.11.1 Engine can't start or start hard...
  • Page 109 浙江华洋赛车股份有限公司 1. Throttle opening is too large carburetor is not blocked 2. The carburetor plunger fine adjustment screw is improperly adjusted. 3, the intake pipe leaks 4, the ignition timing is not correct 5, remove the spark plug → spark plug wet → spark plug drying 6.
  • Page 110 5 发动机 3, valve seat wear 4, cylinder and piston ring wear 1、Check direction 5, cylinder gasket damage 6, the timing of the valve is not correct 1. Check ignition timing and valve clearance → incorrect → 7, the spark plug is not assembled in place correct possible reason 1, the fuel is not clean...
  • Page 111 浙江华洋赛车股份有限公司 2. Excessive carbon deposit in the combustion chamber 3. The fuel used does not meet the specifications. 4, the ignition timing is too much ahead 2. Disassemble the carburetor fuel pipe → the fuel flow is restricted → the fuel can flow freely possible reason 1, CDI failure...
  • Page 112 5 发动机 5.11.5The engine has abnormal noise possible reason 1. Magneto motor failure Check direction 2, CDI failure 3, sensor failure 1. The valve makes an 4, improper valve clearance abnormal sound 1. The fuel in the fuel tank has been used up. 2, the fuel tank lock cover air hole is blocked 3, the fuel tank to the carburetor oil circuit is blocked 2, piston and cylinder stroke...
  • Page 113 浙江华洋赛车股份有限公司 short circuit 4, improper adjustment of the chain regulator possible reason 1. The machining accuracy of the gear is not good possible reason 1, the valve clearance is too large 2, valve worn out possible reason 1, piston and cylinder worn out 2, piston pin and small end connecting rod worn out 3, crank connecting rod head worn out possible reason...

  • Page 114: Vehicle Chassis

    6 车辆底盘 6 Vehicle chassis Maintenance information………………………………………………………… 6-2 6.1 Troubleshooting…………………………………………………………………6-3 6.2 Front wheel……………………………………………………………………6-3 6.3 Braking System…………………………………………………………………6-4 6.4 Front suspension system………………………………………………………6-6 6.5 steering system…………………………………………………………………6-8 6.6 Rear suspension system………………………………………………………6-12 6.7 Rear drive shaft assembly……………………………………………………6-12 6- 2...
  • Page 115 浙江华洋赛车股份有限公司 Maintenance information Attention • When carrying out maintenance work on the front wheel and suspension system, the frame must be securely supported before it can be used. • Inspection, inspection and inspection of lights, instruments and switches are carried out according to the corresponding chapters.

  • Page 116: Troubleshooting

    6 车辆底盘 Open ratchet wrench s24 Socket wrench m24 Phillips screwdriver Needle-nose pliers Flat mouth screwdriver External circlip pliers hammer 6.1 Troubleshooting Steering is too heavy 1, poor wheel bearing 2. Improper installation of the front 1. The upper bolt of the direction wheels column is too tight 3, brake tubing, cable clamp...
  • Page 117 浙江华洋赛车股份有限公司 6.3 Brake system Front brake caliper disassembly Remove the front wheel Remove the 2 bolts mounted on the steering knuckle 6 Remove the brake caliper 7 examination Observe the brake caliper for cracks, oil Wheel inspection Check if the rim 1 has damage, deformation, and scratches.
  • Page 118 6 车辆底盘 vehicle body when the brake pump assembly is not replaced. Installation Installation in reverse order of disassembly Note: Do not use the brake hose to suspend the brake pump Fearing that the front brake hand brake pump is dumped will cause air to enter the hydraulic system, so keep it in the direction Brake pad removal Loosen a fastening bolt...

  • Page 119: Front Suspension System

    浙江华洋赛车股份有限公司 6.4 Front suspension system Disassembly of the right front suspension combination Note: When repairing the suspension system, the left and right suspension systems cannot be removed at the same time, otherwise the car body will fall down without support. Brake tee joint disassembly Remove the bolt 1 Will brake the tee joint 2 separate the car...
  • Page 120 6 车辆底盘 Remove the bolts on the front and rear lower suspension rocker arms of the right front shock absorber. Remove the front shock absorber 7 Remove the bolts on the frame and the nuts that fasten the bolts on the right front upper rocker arm 1 Remove the right front upper rocker ball pin and install the split pin and nut on the right...
  • Page 121 浙江华洋赛车股份有限公司 Disassembly and assembly of the right front rocker arm Remove the right front shock absorber Remove the bolts on the frame and the nuts that fasten the bolts on the right front upper rocker arm 1 Remove the bolts that attach the right front lower rocker arm to the frame and the nuts that tighten the bolts.
  • Page 122 6 车辆底盘 Installation Installation is in reverse order of disassembly. Remove the right front lower rocker welding combination Remove the lower ball combination 1 Check if the lower pin combination 1 can be flexibly rotated in all directions and the clearance in the upper ball pin, if it is not flexible or the clearance is too large;...
  • Page 123 浙江华洋赛车股份有限公司 Release connector Remove the left handle switch multi-function plug 8 Installation The left and right hand switch assemblies are reversed in reverse order 6.5 steering system Direction Dash cover removal Remove the instrument cover 1 , instrument panel 2 , Installation Installation in reverse order of disassembly Handle removal...
  • Page 124 6 车辆底盘 Throttle cable Disassembly Remove the screw 4 Remove the right hand Remove the throttle cable connector 5 Unscrew the throttle seat connector 6 Remove the throttle cable Installation Installation in reverse order of disassembly Directional removal of the tube Remove the meter cover Remove the left and right handles Separate the hydraulic brake handbrake...
  • Page 125 浙江华洋赛车股份有限公司 Remove the fixing bolts 3 Remove the clamp plate 4 Remove the clamp 5 Remove the split pin 6 Remove the lock nut 7 The steering shaft assembly can be removed by lifting the steering shaft upwards Installation Installation in reverse order of disassembly Note: When installing the split pin, replace the new split pin;...

  • Page 126: Rear Suspension System

    6 车辆底盘 Remove the bolts on which the rear shock absorber is mounted on the car body and on the flat fork assembly 1 Remove the rear shock absorber 2 examination Check the rear shockremoved and adjust the adjustment cam 3 to the appropriate position installation Installation in reverse order of disassembly 6.7 Rear drive shaft assembly...
  • Page 127 浙江华洋赛车股份有限公司 Remove the drive chain 4 Remove the rear brake caliper Remove the rear shock absorber Remove the flat fork assembly and the frame connecting bolts and nuts Remove the rear drive shaft assembly Examination The rear view of the rear drive shaft assembly of the vehicle is as follows 6- 15...
  • Page 128 6 车辆底盘 quanti quanti item item Rear hub Flat fork guide sleeve Big nut Rear sprocket seat Rear disc brake disc Screw（M8×20） transmission shaft Chain wheel Fastening bolt Plastic supporter （M12×30×1.25） screw Back bridge Steel bushing ball Flat fork assembly Inspection after disassembly of rear drive shaft ...

  • Page 129: Signal And Lighting System

    浙江华洋赛车股份有限公司 7 Signal and lighting system Maintenance instructions……………………………………………………………7-1 7.1 Fault judgmen…………………………………………………………………7-2 7.2 Headlight inspection……………………………………………………………7-2 6- 17...
  • Page 130 7 信号及照明系统 7.3 change the bulb…………………………………………………………………7-3 7.4 Ignition switch lock……………………………………………………………7-5 7.5 Hand switch……………………………………………………………………7-6 7.6 Brake light switch………………………………………………………………7-6 7.7 Electric horn……………………………………………………………………7-7 7.8 Meter……………………………………………………………………………7-7 7.9 Fuel sensor……………………………………………………………………7-8 Maintenance instructions When the inspection work is carried out, the whole vehicle can be energized; when disassembling and installing the work, the whole vehicle should be powered off first, and the hands should be dry.
  • Page 131 浙江华洋赛车股份有限公司 Second, the right headlights are not Six, the rear left turn signal is not bright bright 1, the bulb is damaged 1, the bulb is damaged 2, the connector is not well contacted 2, the connector is not well contacted 3, the handlebar switch is damaged 3, the handlebar switch is damaged Third, the front left turn signal is not...
  • Page 132 7 信号及照明系统 cool before working Remove the front assembly plate 1 Unpacking the headlight combination 2 Disconnect the headlamp connector 3 Remove the rear cover and headlight connector and remove the headlamp bulb and replace it. note Always wear clean gloves when replacing the lamp.
  • Page 133 浙江华洋赛车股份有限公司 damaged, only the entire taillight can be replaced. Disassemble the rear taillight socket Remove 2 nuts Take down and replace the taillights installation In reverse order of disassembly Front turn signal bulb note When the light is turned on, the temperature is very high.
  • Page 134 7 信号及照明系统 The rear turn signal is a one-piece structure. If the turn signal is damaged, only the entire rear turn signal 5 combination can be replaced. Disassemble the rear taillight socket Remove 2 nuts Take down and replace the taillights installation In reverse order of disassembly 7.4 Ignition switch lock...
  • Page 135 浙江华洋赛车股份有限公司 7.5 Hand switch Remove the front panel Disconnect the connection of the left hand switch connector 1 Check whether the terminals of each steering switch connector are turned on according to the following tables. The pattern is normal. Lighting switch 2 wiring diagram Black Brown White Blue...
  • Page 136 7 信号及照明系统 7.7 Electric horn Disassembly Remove the front assembly board Remove the electric horn connector Remove the nut Remove the electric horn 1 Examination When the fully charged 12V battery is connected, confirm that the electric horn is ringing. If there is any abnormality in the above inspection, replace the electric horn.
  • Page 137 浙江华洋赛车股份有限公司 7.9 Fuel sensor Disassembly Remove the fuel sensor fastening screws 1 and remove the fuel sensor from the fuel tank 2 Disconnect the fuel sensor connector an examination Connect fuel sensor connector Ignition switch is set to ON Shake the float of the fuel sensor by hand to confirm the position of the float, and the scale on the fuel gauge is consistent.
  • Page 138 附 录 Appendix...