KAYO MOTOR JACKAL 200 Service Manual
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KAYO MOTOR JACKAL 200 Service Manual

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ZHEJIANG KAYO MOTOR CO., LTD.
Model A200
JACKAL 200
Service Manual
WWW.RIDEKAYO.COM

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Summary of Contents for KAYO MOTOR JACKAL 200

  • Page 1 ZHEJIANG KAYO MOTOR CO., LTD. Model A200 JACKAL 200 Service Manual WWW.RIDEKAYO.COM...
  • Page 2 ZHEJIANG KAYO MOTOR CO., LTD. Introduction This manual contains detailed information for Kayo A200 (ATV), maintenance, adjustments, disassembly, installation, inspection points and specifications. Please read the manual carefully and follow the instructions closely when performing inspections and repairs, this will increase the reliability, performance and overall lifespan of the vehicle .
  • Page 3 ZHEJIANG KAYO MOTOR CO., LTD. Content Chapter 1; Maintenance information Chapter 2: Plastics and Body parts Chapter 3: Regular Maintenance and adjustment Chapter 4: Outer parts of engine Chapter 5: Engine internals Appendix: Electrical schematic diagram ZHEJIANG KAYO MOTOR CO., LTD.

  • Page 4: Conversion Table

    ZHEJIANG KAYO MOTOR CO., LTD. Conversion table Unit conversion Item 1kgf/cm =98.0665kPa；1kPa=1000Pa pressure 1PSI=0.0689kgf/cm 1mmHg=133.322Pa=0.133322kPa 1kgf·m=9.80665N·m Torque 1mL=1cm =1cc volume 1L=1000cm Moment 1kgf=9.80665N 1in=25.4mm Length Danger/warning/attention Take the the following warnings seriously, it’s important for regular maintenance, especially important during engine maintenance.
  • Page 5 ZHEJIANG KAYO MOTOR CO., LTD. 1.1 Safety precautions Safety first 1. Wearing work clothes (coveralls), hat and safety boots suitable for the operation. In some conditions safety glasses, dust masks, gloves and other safety protective supplies are needed to protect you from injury.
  • Page 6 ZHEJIANG KAYO MOTOR CO., LTD. 6. After disassembly and inspection, clean parts and blow the cleaning agents away with compressed air before measuring. Grease the moving surfaces before assembly. 7. During disassembly, check all the necessary specifications and measure according to directions in this manual.
  • Page 7 ZHEJIANG KAYO MOTOR CO., LTD. parts rinse and dilute with water immediately. 17. When installing oil seals manufacturer’s mark and sizes face outward.  Check the oil seal before using.  Grease the oil seal lip before assembly. 18. When installing rubber hose parts, insert the rubber pipe into the fitting . If there is a hose-clamp, install the hose-clamp in the hose indentation.

  • Page 8: Vin Number

    ZHEJIANG KAYO MOTOR CO., LTD. quick acceleration. Note:  During break-in period, do everyday maintaining, and eliminate hidden trouble in time.  Break-in period ended, make a maintenance for the vehicle, then putted into formal use. 1.2 VIN Number A200...
  • Page 9 ZHEJIANG KAYO MOTOR CO., LTD. 1.3 Specifications, Model information Item Brand KAYO Type A200 Name 200cc Utility ATV Company ZHEJIANG KAYO MOTOR CO., LTD. ● Dimensions, Vehicle Specifications Dimension（L*W*H）（mm） 1700*1050*1080 1080 Handlebar height（mm） Handlebar width（mm） Rear height（mm） 1010 Ground clearance of seat（mm）...
  • Page 10 ZHEJIANG KAYO MOTOR CO., LTD. Turning radius（mm） 2500 Turning angle（degree） 38°±2° Net weight（Kg） Curb weight （ battery+fuel） （Kg） 164.8 Max. Speed Km/h 70（limited speed） Item Start type Electric Engine type Single cylinder, four stroke, air cooling Distribution SOHC/by chain Cylinder diameter × mileage...
  • Page 11 ZHEJIANG KAYO MOTOR CO., LTD. Clutch type Manual Gear change 1+5 by foot Step on rear direction to add gear and front Gear range to reduce. Shift type R~N~1-2-3-4-5 Reduction Forward gear Reverse gear R ratio 1-2-3-4-5 Primary Gear hub of clutch/primary gear...
  • Page 12 ZHEJIANG KAYO MOTOR CO., LTD. （see original Recommended engine oil ·four-strokes motorcycles SAE-15W-40 ） For replacements, it must be within following scope: · API classification： SG or upper grade engine ·SAE specification：refer to left table Radial clearance of inner and 0.07 mm～0.15mm...
  • Page 13 ZHEJIANG KAYO MOTOR CO., LTD. Front brake（one disc thickness 3.5mm with two） Brake handle 5~10mm stroke Braking force 400N*m Rear brake disc thickness 3.5mm Brake handle 10~20mm stroke Braking force 500 N*m ●Ignition device Item Standard Ignition method CDI electric ignition...
  • Page 14 ZHEJIANG KAYO MOTOR CO., LTD. Item Standard Relay insert fuse Light Headlight 12V*55W*2 Taillight/brake light Gear indicator ●Valve mechanism + cylinder cover（see engine section） ●Cylinder + piston + piston ring + crank connecting link（see engine section） 1.4 Tightening moment of fastener Note: When installing threads, please manually attach 2~3 turns of thread first.
  • Page 15 ZHEJIANG KAYO MOTOR CO., LTD. rocker arm Rear rocker arm M10*1.25 10.9 class 58~71 bolt Fork axle M16*1.25 10.9 class 50~60 18~25 （with Brake Rear disc 8.8 class blue thread sealants） Front disc 10.9 class 15~20 Disc pump 10.9 class...
  • Page 16 ZHEJIANG KAYO MOTOR CO., LTD. body parts, Oil tank switch 18~25 plastic Pedal 8~12 Reinforced pedal 7~11 Plastic screw ST4.2 ● Tightening moment at specified position - engine（see engine section） ● Engine service tool（see engine section） ● Engine special tool（see engine section ）...

  • Page 17: Cable And Hose Routing

    ZHEJIANG KAYO MOTOR CO., LTD. Note: please coat inside of handlebar grip with grip glue before installing. Engine operating materials and installation accessories (see engine section) Engine operating materials include lubricating oil (engine oil), Grease and may require thread sealant or thread lock.
  • Page 18 ZHEJIANG KAYO MOTOR CO., LTD. Neutral gear connector (analog models) Reverse gear indicator (analog models) For clutch switch combination switch connector Voltage regulator Electric lock/ Key headlight Headlights switch WWW.RIDEKAYO.COM...
  • Page 19 ZHEJIANG KAYO MOTOR CO., LTD. Regulator/rectifier Tail light Igntition coil Brake light switch connector Rear light connector Ignition Battery negative Start motor cable Relay connector Battery positive WWW.RIDEKAYO.COM...

  • Page 20: Maintenance Cautions

    ZHEJIANG KAYO MOTOR CO., LTD. 2 Plastic body 2.1 Maintenance warnings 2.2 Installation torques 2.3 Seat, front guard, hood, rear body, left and right guard, plastics foot guards, dismounting left and right footpegs 2.1 Maintenance cautions Operation cautions 1. When replacing plastics parts, please install new warning labels, stickers and riveted tags to the new plastics.
  • Page 21 ZHEJIANG KAYO MOTOR CO., LTD. Installation:In reverse order of disassembly. Locate tabs into slots and push to lock into place then install bolts 1 and 2 (note: replace hood plastic if any of the tabs broke during disassembly) 3. Remove the screws from the throttle 2.3.2 Handlebar...

  • Page 22: Front Bumper

    ZHEJIANG KAYO MOTOR CO., LTD. Installation In reverse order from disassembly, follow steps 5. Through 1. *after install, make sure to double check electrical connections, wire, cable and hose routing) 2.3.3 Seat Disassembly Locate the seat latch under the seat...
  • Page 23 ZHEJIANG KAYO MOTOR CO., LTD. 1. The mounting bolts in order. Then remove the front bumper Mounting bolts Installation 1. position the front bumper lining up mounting holes install the mounting bolts loosely. Then adjust bumper into position and tighten bolts.
  • Page 24 ZHEJIANG KAYO MOTOR CO., LTD. 安装 Installation Install the plastic body in reverse order from disassembly. *check all electrical connectors, cable, and hose routing after installation. WWW.RIDEKAYO.COM...
  • Page 25 ZHEJIANG KAYO MOTOR CO., LTD. 2.3.7 Rear body Disassembly 1. Remove the mounting bolts1/2，3/4,5/6, 7/8(and corresponding bolts on opposite side） Take the rear body off. Installation Install in reverse order from disassembly. （Note: replace locking nuts and rubber washers as needed.)
  • Page 26 ZHEJIANG KAYO MOTOR CO., LTD. 2.3.7 Middle guard Disassembly 1. Remove the mounting bolt 1、2、3、4， 2. Remove the middle guard Installation Install in reverse order from disassembly WWW.RIDEKAYO.COM...

  • Page 27: Front Body

    ZHEJIANG KAYO MOTOR CO., LTD. （Note: replace mounting bolts, nuts and rubber washers if damaged or worn) 2.3.8 Front body Disassembly （Note: remove the handlebar, hood, and middle guard) 1. Remove the front body mounting bolts1/2, 3/4, 5. 2. Remove the key switch, headlight connector, then remove the front body...
  • Page 28 ZHEJIANG KAYO MOTOR CO., LTD. Installation 1. Install in reverse order from disassembly. replace mounting bolts, nuts and rubber washers as needed when worn.) *check all electrical connectors, cable, and hose routing after installation 2.3.9 Foot peg guards Disassembly 1. Remove mounting bolts 1、2、3，...
  • Page 29 ZHEJIANG KAYO MOTOR CO., LTD. Disassembly floorboard/ foot peg 1. Remove the mounting bolts 1, 2, 3, 4, 5. 2. Remove peg bracket and foot peg. Left foot peg front bracket 1. Remove front bracket 2. Remove plastic 3. Remove screws 1, 2, 3, 4，...
  • Page 30 ZHEJIANG KAYO MOTOR CO., LTD. Left foot peg rear bracket 1. Remove front bracket 2. Remove plastic 3. Remove the left foot peg. 4. Remove mounting nut 1， 5. Remove the rear bracket. WWW.RIDEKAYO.COM...

  • Page 31: Maintenance Information

    ZHEJIANG KAYO MOTOR CO., LTD. Installation Install in reverse order from disassembly. （Note: replace mounting bolts, nuts and rubber washers in time, once they worn.) Regular maintenance and adjustment 3.1 Maintenance information 3.6 Suspension system 3.2 Maintenance period 3.7 Gear box and fuel system 3.3 Inspection ways...
  • Page 32 ZHEJIANG KAYO MOTOR CO., LTD. Engine maintenance is a regular periodic work,due at certain time intervals for engine maintenance, keeping up on standard maintenance will increase the lifespan and reliability of the components , the following is the A150 engine maintenance period table.
  • Page 33 ZHEJIANG KAYO MOTOR CO., LTD. Above the brake fluid ○ ○ Brake fluid lower limit Replace the disc in time, Hydraulic when front or rear brake brake and working disc’s thickness brake disc Tear and damage of brake disc is less than 3mm.
  • Page 34 ZHEJIANG KAYO MOTOR CO., LTD. Function of muffler ○ Frame Joints and welds ○ Other state of grease in frame ○ Exception can be identified in Make sure relevant parts are normal. ○ operation. 3.4 Steering column and brake system Keep vehicle in steady place and hold handlebar firmly as it shown in the picture to check if it’s shaking.
  • Page 35 ZHEJIANG KAYO MOTOR CO., LTD. If it’s caused by steering column, tighten the bottom lock nut on steering column, or you can also disassemble the steering column to check bearing and clamps. Keep vehicle in steady place and turn the handlebars slowly making sure movement is smooth.
  • Page 36 ZHEJIANG KAYO MOTOR CO., LTD. Brake fluid sight glass Note: ● When adding brake fluid, do not mix with dust or water, always add fluid from a new sealed container. ● Brake fluid can damage plastic, painted, and rubber surfaces. Wipe clean...
  • Page 37 ZHEJIANG KAYO MOTOR CO., LTD. 3.5 Wheel With the atv on a jack of atv lift. Lift the front wheels off the ground. Push and pull the wheel in and out as shown in the diagram. If there is movement, check torques on hub, steering shafts, spindles.

  • Page 38: Suspension System

    ZHEJIANG KAYO MOTOR CO., LTD. Tire pressure Check the tire pressure with a tire pressure gauge. (pressure range: 4~6PSI) Note: Check the tire pressures while the tire is cool . If tire pressure is out of specification please adjust to within range specified. Riding with tires out of specified range will affect vehicle handling and may cause premature wear and or damage to tire tread.
  • Page 39 ZHEJIANG KAYO MOTOR CO., LTD. 3.7 Gear shifter and fuel system Changing gears, with the shift lever should be smooth and gear changes should have a positive firm feeling. Gearshift lever Fuel device Remove the plastic parts first. Check fuel vacuum and vent lines for aging, dry rot cracks and damage. Replace if any damages are found.

  • Page 40: Throttle Check

    ZHEJIANG KAYO MOTOR CO., LTD. 3.8 Throttle check Check the free stroke of the thumb throttle lever. Press the accelerator several times as shown in the diagram, check the free-play of the thumb throttle. Check for any sticking or slow return of the lever. Thumb throttle should be easy and smooth to push and should snap back quickly when released.
  • Page 41 ZHEJIANG KAYO MOTOR CO., LTD. Pull back rubber sleeves 1. Loosen lock nut 3 and barrell adjuster 2, then adjust throttle free-play to within specification. Speed limiting device adjustment Speed limit device is used to restrict throttle opening. Inspect the thread length limit of speed limit screw.

  • Page 42: Engine Systems

    ZHEJIANG KAYO MOTOR CO., LTD. Engine systems 4.1 Maintenance information 4.3 Air intake system 4.2 Fuel system 4.4 Exhaust system 4.5 Disassembly and installation of engine 4.1 Maintenance information Precautions ● Before performing maintenance, please make sure that the engine is not running, battery is disconnected and that the heated parts have cooled, to avoid injury.
  • Page 43 ZHEJIANG KAYO MOTOR CO., LTD. Fuel tank removal Remove the plastic body parts, remove fuel lines from tank and fuel valve, then remove tank mounting bolts and tank. *Fuel tank pictures may differ from tanks on U.S. models Fuel line Mounting bolts 3 4.3 Air filter system...

  • Page 44: Exhaust System

    ZHEJIANG KAYO MOTOR CO., LTD. clamp Installation Installation shall be in the reverse order of removal. Make hose clamp is in the groove and any vacuum lines are hooked up correctly 4.4 Exhaust system Disassembly Disassemble the clamp between muffler and exhaust head pipe, then remove the muffler mounting bolt to remove muffler.
  • Page 45 ZHEJIANG KAYO MOTOR CO., LTD. Assembly Installation shall be in the reverse order of removal. *do not reuse exhaust head pipe gasket always replace, replace muffler gasket and any hardeware for exhaust if damaged or deformed. 4.5 Disassembly and installation of engine Disassembly 1.
  • Page 46 ZHEJIANG KAYO MOTOR CO., LTD. Remove the 3 engine mounting bolts. 3. Remove the engine from the right side of vehicle. Installation Installation shall be in the reverse order of removal 5. Engine 5.1 Maintenance information Cylinder and valve WWW.RIDEKAYO.COM...

  • Page 47: Maintenance Precautions

    ZHEJIANG KAYO MOTOR CO., LTD. Precautions Cylinder head check troubleshooting Measure the valve-face width Disassemble Assemble cylinder head Swing arm check Assemble cylinder head cap Disassembly of cylinder head Assemble cam shaft Valve and spring check Install cylinder head Install cylinder head cap...
  • Page 48 ZHEJIANG KAYO MOTOR CO., LTD. Radial clearance in swing arm and swing arm shaft 0.016～0.045 0.08 Item Standard mm Limited mm φ4.96 φ4.972～φ4.987 Valve bar diameter Air intake φ4.96～φ4.975 φ4.94 Valve Air intake φ5～φ5.012 φ5.035 Valve guide pipe inner Air intake diameter φ5～φ5.012...

  • Page 49: Troubleshooting

    ZHEJIANG KAYO MOTOR CO., LTD. bar and guide pipe Air intake 0.25～0.052 0.08 Valve seal width ---- Cylinder head Flatness 0.04 0.05 The working width of valve seat ---- Troubleshooting Cylinder low pressure Black smoke 1、 valve 1、 Valve guider pipe worn ----------wrong valve clearance 2、...
  • Page 50 ZHEJIANG KAYO MOTOR CO., LTD. WWW.RIDEKAYO.COM...
  • Page 51 ZHEJIANG KAYO MOTOR CO., LTD. Disassemble cylinder head cap 1. Remove four M6×20 fastening bolts from the cylinder head. 2. Remove air chamber covers of air intake. 3. Remove two M6×60 bolts, two M6×35 bolts, four M6×30 bolts and two A88 air intake pipe gasket, then install it on M6×60 bolt.

  • Page 52: Disassemble Cylinder Head

    ZHEJIANG KAYO MOTOR CO., LTD. Disassemble cylinder head 1 remove seal sleeves and cam shaft board 2.Remove (GB/T16674) ”M6×16” bolt and (ZS500) 6.5×1.5×18 locating plate gasket. WWW.RIDEKAYO.COM...
  • Page 53 ZHEJIANG KAYO MOTOR CO., LTD. 3.remove 2 bolts from tensioner, then tensioner bolts, assembly and gaskets 4.remove timing chain 5.remove cam shaft assembly. 6.remove bolts which connect cylinder head and body WWW.RIDEKAYO.COM...
  • Page 54 ZHEJIANG KAYO MOTOR CO., LTD. 7.remove four nuts (ZS500A) and nuts (M10×1.25), then gaskets (10.5×2×20)； 8.remove cylinder head Separate cylinder head cap WWW.RIDEKAYO.COM...
  • Page 55 ZHEJIANG KAYO MOTOR CO., LTD. 1.Remove 2 blots from cap and locating plate of swing shaft. 2.Remove air intake and exhaust swing arm shaft and swing arms. Separate cylinder head Pressure the spring with valve tool to remove valve lock clap. Then release tool to remove spring, spring seat and valve.
  • Page 56 ZHEJIANG KAYO MOTOR CO., LTD. properly. Valve and spring check Check if there is bend, burn or abnormal damage of valve. Measure diameter of valve bar. Maintenance limited: Intake：φ4.96mm exhaust：φ4.94mm Maintenance limited for contact width：1.5mm note： Replace valve if the valve face is not smooth for bad seal.
  • Page 57 ZHEJIANG KAYO MOTOR CO., LTD. Measure free length of valve spring:48.35mm Service limited value (intake and exhaust)spring:47.5 mm Swing arm and shaft check Replace in following condition: swing arm worn, damaged or the axial clearance is large. If the swing arm shaft is worn seriously, replace.

  • Page 58: Cylinder Head Check

    ZHEJIANG KAYO MOTOR CO., LTD. Cam shaft parts check 1. If the cam shaft surface is worn, damage or the two end aren’t smooth, replace the parts； 2.Check if the pressure reducing raiser has cranks or fractures, if the raiser and element shaft is loose, if it happens, replace it.
  • Page 59 ZHEJIANG KAYO MOTOR CO., LTD. Service limited value： intake：φ5.035 mm exhaust：φ5.035 mm note：Clean the pipe before measuring Adjust valve seat once replace guide pipe, and inject all valve in pipe to observe it’s movement, measure the clearance between valve lever and guide pipe at last.

  • Page 60: Cylinder Head Assembly

    ZHEJIANG KAYO MOTOR CO., LTD. Measure valve seat contact width Service limited value：1.5 mm If the valve seat is too wide or narrow, adjust it. When adjust valve, use electric gun with rubber pipe, then add valve lever on rubber pipe, smear...
  • Page 61 ZHEJIANG KAYO MOTOR CO., LTD. valve dismounting tool, then install valve lock clip in valve spring seat. Note： Don’t pressure spring too much in case it deformed. 4. Check if the lock clip in right position. 5. Test sealing of cylinder head assembly.
  • Page 62 ZHEJIANG KAYO MOTOR CO., LTD. cap holes. 2. Finish install, turn swing arm to see if it smoothly. 3. Tighten-ting torque of swing arm fixing plate bolt： 16～20N·m。 Cylinder head installing 1. Replace new cylinder head gasket, then locating pin.
  • Page 63 ZHEJIANG KAYO MOTOR CO., LTD. cam shaft driven sprocket, check if the engine is timing position, if not adjust it. .engine timing adjust: （1） Remove hole cover of left front cover and fixing plate bolts. （2） Turn magneto locking nut with special tools, check if the scale line .fixing plate bolt of...
  • Page 64 ZHEJIANG KAYO MOTOR CO., LTD. 1. Smear plane sealant on contact surface of cylinder head cap. 2. Install prepared cylinder head cap on cylinder head 3.put two”A8” intake pipe ring on ”GB/T1667-M6×60” bolts, then set into oil pipe hole of cylinder head cap.
  • Page 65 ZHEJIANG KAYO MOTOR CO., LTD. Cylinder head and piston precautions piston disassembly troubleshooting piston and piston ring check Cylinder disassembly piston ring assembly Valve check piston assembly Cylinder assembly Precautions  Before installing cylinder, make sure the engine left oil hole which next to AB bolts working.

  • Page 66: Troubleshooting

    ZHEJIANG KAYO MOTOR CO., LTD. φ16.001～φ16.006 φ16.015 Hole inner diameter of piston pin Clearance between piston pin and 0.001～0.012 0.025 the hole piston Piston ring closed Top ring 0.2～0.35 Piston ring interval /second Piston pin Oil ring 0.2～0.7 Clearance between Top ring 0.03～0.07...

  • Page 67: Cylinder Disassembly

    ZHEJIANG KAYO MOTOR CO., LTD. Cylinder disassembly Remove chain guide plate to take the cylinder. Clean up remained washer on cylinder Note : It’s easy to separate washers if put them into petrol. Take care of cylinder surface. WWW.RIDEKAYO.COM...
  • Page 68 ZHEJIANG KAYO MOTOR CO., LTD. Cylinder body check Check if the cylinder worn or damaged. Measure cylinder inner diameter: top, middle and bottom position of piston stroke. Service limited value：φ77.018mm WWW.RIDEKAYO.COM...

  • Page 69: Piston Disassembly

    ZHEJIANG KAYO MOTOR CO., LTD. Piston disassembly Remove piston pin ring by pointed-noise pliers, then piston pin and piston. Note: Take care don’t drop piston pin ring into crankcase. Piston and piston ring check Remove piston ring Note: keep piston ring well.
  • Page 70 ZHEJIANG KAYO MOTOR CO., LTD. Check if piston ring worn or cranked, and groove worn. Put piston ring into cylinder to measure end play. Service limited value: First ring: 0.5mm Second ring: 0.5mm Oil ring: 1.4 mm Measure the inner diameter of piston pin hole.
  • Page 71 Measure part diameter which is 7mm height from piston skirt. ZHEJIANG KAYO MOTOR CO., LTD. Service limited value： φ76.94 mm Compute the distance between cylinder and piston. Service limited value：0.1mm Measure piston pin diameter. Service limited value：15.99 mm Compute the distance between piston pin and piston.
  • Page 72 Piston assembly ZHEJIANG KAYO MOTOR CO., LTD. Put piston, piston pin and new piston ring together. Note: 1. When install piston, the side marked with“ ”faces to engine exhaust pipe. 2. The piston ring end gap opening faces down. 3. If the piston ring severe deformed, replace.
  • Page 73 ZHEJIANG KAYO MOTOR CO., LTD. Clutch, driving gear, overrun clutch, oil pump and gearshift Precautions Water pump impeller check Troubleshooting Right crankcase check Water pump cover disassembly Clutch check Right crankcase cover disassemlby Driving gear check Clutch disassemlby Overshoot and start gear check...
  • Page 74 ZHEJIANG KAYO MOTOR CO., LTD. clutch Spring free length 32.3～33.3 32.3 driving disc free thickness 2.95～3.05 2.85 Driven disc flatness 0.14 Clearance of outer cover and 0.1～0.3 friction disc Oil pump Radial clearance of outer and 0.06～0.15 ---- inner rotors...
  • Page 75 ZHEJIANG KAYO MOTOR CO., LTD. 3. clutch plate curved Clutch trouble operating Handlebar over pressure 1. burr on clutch outer cover groove 1. clutch cables stick, damage or untidy Shifting difficulties 2. lifting mechanism damaged. 1. stopper plate curved or worn 2.
  • Page 76 ZHEJIANG KAYO MOTOR CO., LTD. Water pump impeller disassembly Remove drain bolts from pump cover, then drain the water, remover cover and impeller last. Right crankcase disassemblly 1. Drain oil first (remove oil screens from both sides and oil screen assembly from body, until the oil drain out completely) 2.
  • Page 77 ZHEJIANG KAYO MOTOR CO., LTD. 1. Remove pressuring spring and bolts; 2. Pressure plate, pull rod and friction disc; 3. remove locking nuts and washers. 4. remove central bush, outer cover, axle cover and washers; 5. remove clutch push lever.
  • Page 78 ZHEJIANG KAYO MOTOR CO., LTD. Right body pump disassembly 1. Remove oil pump intermediate gear and oil pump assembly rings; 2. Remove intermediate gear washer, intermediate gear and oil pump assembly; 3. Remove 3 ”GB/T16674-M5×18” bolts from right oil pump cover, then remove oil pump plate assembly and outer and inner rotors of oil pump.
  • Page 79 ZHEJIANG KAYO MOTOR CO., LTD. Starting motor disassembly Remove starting motor tighten bolts, then starting motor. Gearshift disassembly 1. Remove five-star plate bolts (GB/T70.1 M6×35) and five-star plate. 2. Remove gearshift arm parts. 3. Remove tighten bolts, washers and locating plate assembly.
  • Page 80 ZHEJIANG KAYO MOTOR CO., LTD. crankcase cover, if it worn, replace. Note: 1. The oil seal end face has the ”TCV” mark. 2. The side with mark faces out. 2. Check if the oil seal of starting shaft, if it worn, replace.
  • Page 81 ZHEJIANG KAYO MOTOR CO., LTD. pump shaft groove. Starting shaft check check gears condition (if only electric start, ignore) Clutch spring check Measure free length of clutch spring Service limited value：32.3mm Clutch friction disc check If the friction disc got worn or faded,...
  • Page 82 ZHEJIANG KAYO MOTOR CO., LTD. heck the driven disc surface with clearance gauge ：0.14 mm Service limited value Plate of right body oil pump Check the clearance of clutch outer cover and friction disc. Service limited value：0.6 mm Outer inner...
  • Page 83 ZHEJIANG KAYO MOTOR CO., LTD. Driving gear check Check if the driving gear worn or damaged severely, if so replace. Overshoot clutch check Remove the rand from clutch end face to check if the wedge block worn or damaged. Starting gear check Check the wear or damage condition of starting motor.
  • Page 84 ZHEJIANG KAYO MOTOR CO., LTD. 1. Check if the outer and inner rotors worn or damage, if the condition is severely, replace the oil pump rotors assembly. Check if the gap bridge gear and gear assembly broken, if so replace them.
  • Page 85 ZHEJIANG KAYO MOTOR CO., LTD. Starting shaft assembly Install starting shaft to shaft holes of right body. If only electric start, ignore this step. Duplicate gear assembly 1. Install duplicate gear on duplicate gear shaft. 2. Put duplicate gear washer on end face of duplicate gear.
  • Page 86 ZHEJIANG KAYO MOTOR CO., LTD. Right body oil pump assembly 1. Put the oil pump pin into hole of oil pump shaft. 2. Install rotors assembly on right body hole, and fix the oil pump cover plate on oil pump rotors with 3 “GB/T16674-M5×18”...
  • Page 87 ZHEJIANG KAYO MOTOR CO., LTD. Starting gear and overshoot clutch installation 1. Install the starting gear washer on right crank. 2. Install staring gear and overshoot clutch on right crank. Note: Smear lubricating grease on inner hole of starting gear before installing.
  • Page 88 ZHEJIANG KAYO MOTOR CO., LTD. the inner side of clutch shaft sleeve. 2. First, install clutch central cover and locking nuts on main shaft, and smear 3-4 threads glue to tight it on main shaft. Note: Locking nut tight torque：80～...
  • Page 89 ZHEJIANG KAYO MOTOR CO., LTD. torque: 11～13N·m 2. install the water pump impeller on water pump shaft, tighten torque: 2～ 4N·m. install upper cover gasket of water pump first, then install cover, tight with three ”GB/T16674-M6×35” bolts and one “...
  • Page 90 ZHEJIANG KAYO MOTOR CO., LTD. Magneto, balance driving gear and driven gear Precautions Balance driving gear and driven gear disassembly and check Left crankcase disassembly Balance driving gear and driven gear assembly Magneto stator and rotor disassembly Magneto stator and rotor assembly...
  • Page 91 ZHEJIANG KAYO MOTOR CO., LTD. magneto stator disassembly remove two ”GB/T818-M5×10 （color-zinc）ML35-HIPER” fastening bolts. 2. remove two”GB/T70.1-M5×30” fastening bolts from stator coil, then remove stator assemlby. magneto rotor disassembly remove rotor locking nut, then remove rotor with special tools. WWW.RIDEKAYO.COM...
  • Page 92 ZHEJIANG KAYO MOTOR CO., LTD. note： 1. use special tool to remove magneto rotor, do not knock it. 2. if the rotor gets dropped or knocked, replace it. Balance driving gear and driven gear disassembly 1. remove timing chain and chain tensing plate, then remove nuts and washer.
  • Page 93 ZHEJIANG KAYO MOTOR CO., LTD. left crankcase cover check check the oil seal condition of left crankcase cover, if it damaged, replace. magneto stator and rotor check 1. check if rotor magnetic tile worn or cranked, if so replace. 2. if the rotor worn or damaged, replace.
  • Page 94 ZHEJIANG KAYO MOTOR CO., LTD. note： 1.when install oil pump rotor, the marked sides should in same direction. 2.tighten torque of left body oil pump cover bolt：7～9N·m； 3.check if the oil pump shaft is smoothly after installation. balance driving gear and driven gear...
  • Page 95 ZHEJIANG KAYO MOTOR CO., LTD. tighten torque:：80～90N·m。 Magneto rotor installation install magneto rotor on left crank, then smear glue on magneto nut for “IB175-FC” 3-4 threads, install it on left crank. Note： locking nut tighten torque: 85-90N·m。 magneto stator installation tight the stators on left crankcase with two "GB/T818 M5×10”...
  • Page 96 ZHEJIANG KAYO MOTOR CO., LTD. crankcase, crankshaft, variable transmission and balance shaft precautions pedal starting device disassembly Troubleshooting starter shaft transmission gear check crankcase disassembly starter shaft check crankshaft disassembly starter shaft assembly crankshaft check install starter shaft gearbox disassembly...
  • Page 97 ZHEJIANG KAYO MOTOR CO., LTD. value mm φ14.016～φ14.043 φ14.045 ／left fork inner diameter right fork inner diameter fork (counter shaft) φ12.016～φ12.043 φ12.045 inner diameter (main shaft) fork claw thickness 4.8～4.9 φ11.973～φ12 φ11.95 shaft outer diameter (main fork shaft) fork shaft φ13.973～φ14...
  • Page 98 ZHEJIANG KAYO MOTOR CO., LTD. 3. crankshaft bearing worn transmission skip 1.gearshift gear claw worn gearshift gear noise 2.fork bend or worn 1.gearshift gear worn 3.fork shaft bend 2.spline shaft worn crankcase disassembly up left crankcase. 1.put “GB/T16674-M6 ×65” eight 2.remove...
  • Page 99 ZHEJIANG KAYO MOTOR CO., LTD. assembly. note： when remove main shaft and counter shaft assembly make sure all the parts are removed. crankshaft check put crankshaft on V type iron. measure crankshaft radial clearance by dial indicator. the radial clearance value should be half of TIR.
  • Page 100 ZHEJIANG KAYO MOTOR CO., LTD. service limited value： 0.02 mm Measure the big end of the connecting rod with a thick gauge. service limited value： 0.7 mm left and right crankcase bearings check if the bearing doesn’t work smoothly, replace it.
  • Page 101 ZHEJIANG KAYO MOTOR CO., LTD. gearshift fork/fork shaft/variable speed drum check check if the condition of fork, measure inner diameter. φ12.45 main shaft service limited value： φ counter shaft service limited value： 14.45 mm the condition of main shaft and...
  • Page 102 ZHEJIANG KAYO MOTOR CO., LTD. Measure fork claw thickness Service limited value：4.7 mm Check the transmission drum surface and grove to see it is damaged or worn. Main vice shaft check Check all gears and clamps condition, if there is damaged, deformed or fall off.
  • Page 103 ZHEJIANG KAYO MOTOR CO., LTD. filter screen, if it not clean, wash with oil. 2. Check if any of two parts worn, if there is, replace it. WWW.RIDEKAYO.COM...
  • Page 104 ZHEJIANG KAYO MOTOR CO., LTD. Transmission / crankshaft / balance shaft assembly 1.install crankshaft and balance shaft into the specific holes of left body. .install main shaft and counter shaft into specific left body holes, then install fork to right position.
  • Page 105 ZHEJIANG KAYO MOTOR CO., LTD. 1. Apply a layer of sealant evenly on the right crankcase, attach the locating pin to the corresponding hole in the left crankcase, and then join the right box to the left box. install five”GB/T16674-M6×45” and eight “GB/T16674-M6×65”...

  • Page 106: Electrical Schematic Diagram

    ZHEJIANG KAYO MOTOR CO., LTD. Electrical schematic diagram WWW.RIDEKAYO.COM...

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A200

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