KAYO MOTO S200 Service Manual
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KAYO MOTO S200 Service Manual

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  • Page 1 KAYO MOTO S200 Service Manual www.kayomoto.com...
  • Page 2 Version Code：20230315 Version Name：S200 Service Manual Chinese Version.pdf www.kayomoto.com Zhejiang Kayo Motor Co., Ltd. March 2023...

  • Page 3: Table Of Contents

    S200 four-wheel all terrain Zhejiang Kayo Motor Co., Ltd. vehicle (SSV), and is accompanied by Research and development department detailed graphical materials to guide March 2023 operation.
  • Page 5 Zhejiang Kayo Motor Co., Ltd. The unit conversion table in this book Item Unit conversion 1kgf/cm =98.0665kPa；1kPa=1000Pa Pressure 1mmHg=133.322Pa=0.133322kPa Torque 1kgf·m=9.80665N·m 1mL=1cm =1cc Volume 1L=1000cm Force 1kgf=9.80665N Length 1in=25.4mm Danger/Warning/Caution Please read the following explanations carefully, which emphasizes the special meanings of the words "Danger", "Warning"...

  • Page 7: Maintenance Information

    Zhejiang Kayo Motor Co., Ltd. 1 Maintenance information 1.1 Precautions for operation……………………………………………………………………1-1 1.2 Vehicle identification number………………………………………………………………1-5 1.3 Main parameter table……………………………………………………………………….1-6 1.4 Maintenance parameter table………………………………………………………………1-8 1.5 Tightening torque……………………………………………………………………………1-10 1.6 Lubricants, sealants………………………………………………………………………….1-13 1.7 Wiring diagrams for cables, hoses, and cables……………………………………………..1-14 1.1 Precautions for operation Safety precautions 1.
  • Page 8 1 Maintenance information 8. Since gasoline will expand with the increase of temperature, the fuel tank can only be filled to its specified capacity. The expansion chamber must remain in the tank, especially if the tank is filled with cold gasoline and then moved to a warmer area. !Warning Do not overflow gasoline when filling with gasoline.
  • Page 9 Zhejiang Kayo Motor Co., Ltd.  It was originally a tight fit with the body or the shaft diameter, but if the fit is not tight after disassembly, the bearing should be replaced. 13. Bearings should be coated with engine oil or grease before assembly. Pay attention to the installation direction when assembling single-sided dust-proof bearings.
  • Page 10 1 Maintenance information of work, cool down the engine for 5 to 10 minutes; Avoid rapid acceleration, the throttle should be changed slowly, not suddenly large and small, and do not drag the cargo during the running-in period. Attention： During the running-in period, maintenance should be carried out according to daily maintenance regulations, and any faults found should be promptly eliminated;...
  • Page 11 6. Check the gasoline filter and air filter housing, and clean or replace them if necessary. 1.2 Vehicle identification number ① Frame number ② Vehicle nameplate ③ Engine number Vehicle model S200 Frame number L6JUCMZA~ Engine number 163FML ~ 1- 5...
  • Page 12 1 Maintenance information 1- 6...
  • Page 13 Zhejiang Kayo Motor Co., Ltd. 1.3 Main parameter table Items Parameters Vehicle model S200 Length (mm) 2517 Width (mm) 1487 Height (mm) 1446 Wheelbase (mm) 1900 Engine model CVT200 Total displacement (ml) 196.2 Fuel type 92 and above gasoline Curb weight of the whole vehicle (kg)
  • Page 14 1 Maintenance information Items Parameters Air filter type Sponge filter element filtration type Type Plunger throttle Throttle body Mixture valve diameter 30mm Fuel tank capacity Clutch type Dry automatic clutch Automatic continuously variable transmission Variable speed mode (CVT) One forward gear, one neutral gear, one Gearshift reverse gear Transmission...
  • Page 15 Zhejiang Kayo Motor Co., Ltd. 1.4 Maintenance parameter table Lubrication device Items Standards Usage － Change oil 900ml（without changing the oil filter limit element） Engine oil 1000ml（in the same time change the oil filter Change oil capacity element） － Full capacity 1100ml Only SF 10W/40 engine oil can be used, and do not replace or mix different grades of...
  • Page 16 1 Maintenance information Battery/charging device/trigger coil Items Standards Type Permanent magnet AC generator Output Three phase full wave 120Ω±20Ω Magneto trigger coil resistance Magneto Magneto no-load voltage (engine in cold None state) Maximum output power of magneto 217W（5000r/min） Stabilized voltage 14.5V±0.5V Vp≥1.5V（300r/min）, Trigger coil peak voltage...
  • Page 17 Zhejiang Kayo Motor Co., Ltd. Lights / Meters / Switches Items Standards Fuse Headlamps (high beam) 12V—12W Headlamp (low beam) 12V—6W Lights, light bulbs Daytime running lights 12V-4W Tail lights/brake lights 12V—2W Valve mechanism + cylinder head (see 05-engine part for details) Cylinder + piston + piston ring + crank connecting rod (see 05-engine part for details) Clutch + transmission mechanism (see 05-engine part for details) 1- 11...
  • Page 18 1 Maintenance information 1.5 Tightening torque Attention： Before installing the thread, apply anti-rust grease on the threaded part and joint surface Tightening torques at designated parts - whole vehicle parts Serial Tightening torque Items Fastener code Quantity numbe (N · m) Front disc brake main pump GB6187-86 M8 25-30...
  • Page 19 Zhejiang Kayo Motor Co., Ltd. Front upper and lower rocker GB6187-86 M10*1.25 55-66 arm fixing bolts and nuts Rocker arm ball head fixing GB6187-86 M10*1.25 33~45 slotted nut Steering rod fixing slotted GB6187-86 M10*1.25 33~45 nuts Front and rear shock absorbing fixing bolts and GB6187-86 M10*1.25 55-66...
  • Page 20 1 Maintenance information Ceiling beam fixing bolts GB70-85 M8*16 25-30 1- 14...
  • Page 21 Zhejiang Kayo Motor Co., Ltd. Tightening torque of designated parts - engine parts (see 05-engine part for details) Tightening torque of fasteners at unspecified parts Category Torque N·m Category Torque N·m 5mm bolts and nuts 4.5~6 5mm screws 3.5~5 6mm bolts and nuts 8~12 6mm screws 7~11...

  • Page 22: The Vehicle

    1 Maintenance information 1.7 Wiring diagrams for cables, hoses, and cables 1. Igniter positive and negative plug-in 2. Flasher plug-in 3. Igniter 4. Relay 5. Fuse box 6. Relay plug-in. Attention: The front cover must be dismantled before inspection and maintenance of the above components.
  • Page 23 Zhejiang Kayo Motor Co., Ltd. 7. Rectifier and voltage regulator plug-in 8. Rectifier and voltage regulator plug-in 9. Battery negative plug-in 10. Instrument plug-in 11. Instrument plug-in 12. Battery positive plug-in 13. Instrument speed plug-in 14. Panel switch plug-in 15. Electric door lock plug-in 1.
  • Page 24 1 Maintenance information 1. Generator coil plug-in 2. Pulse coil plug-in 3. Gear display plug-in 4. Heat dissipation system plug-in 5. Grounding wire 1. Rear tail light plug-in 2. Fuel level sensor plug-in 3. Speed sensor plug-in 4. Starting motor wires Attention：Before inspecting and repairing the above components, the right rear fender must be removed.
  • Page 25 Zhejiang Kayo Motor Co., Ltd. 1. Fuel tank cap 2. Oil level sensor Attention：When checking and maintaining the above components, the rear shelf tarpaulin and rear shelf must be removed. For specific disassembly, see the second chapter - Covering parts of the body of the vehicle 1.
  • Page 27 Zhejiang Kayo Motor Co., Ltd. 2 Covering parts of the body of the vehicle 2.1 Maintenance information………………………………………………………2-2 2.2 Installation torque………………………………………………………………2-2 2.3 Disassembly and assembly of front reflectors and ceiling frames 2.3.1 Front left and right reflectors………………………………………………2-3 2.3.2 Ceiling frames and backrest crossbeam……………………………………2-3 2.4 Disassembly and assembly of door inner support panel, door side panel, door frame, inner support and support of hand panel 2.4.1 Left inner support panel……………………………………………………2-4...

  • Page 28: Maintenance Information

    2 Covering parts of the body of the vehicle 2.7.1 Front guard………………………………………………………….……2-17 2.7.2 Rear shelf…………………………………………………………………2-17 2.7.3 Rear taillight frame……….………………………………………………2-18 2.7.4 Instrument cover……………………….…………………………………2-18 2.1 Maintenance information Precautions for operation When replacing the covering parts with regulatory warning labels affixed or riveted on the vehicle, the corresponding labels must be correctly and completely supplemented as they are.

  • Page 29: Front Left And Right Reflectors

    Zhejiang Kayo Motor Co., Ltd. 2.3 Disassembly and assembly frames of front reflectors and ceiling 2.3.1 Front left right reflectors Disassembly Turn reflective sheet counterclockwise (one on each side) Remove the reflective sheet 1 Installation Installation is carried out in reverse order of disassembly 2.3.2 Ceiling...

  • Page 30: Disassembly And Assembly Of Door Inner Support Panel, Door Side Panel, Door

    2 Covering parts of the body of the vehicle Remove the left door frame 3 Installation Installation is carried out in reverse 2.4 Disassembly and assembly of order of disassembly door inner support panel, door side panel, door frame, inner support and support of hand panel 2.4.1 Left inner support panel...

  • Page 31: Right Door Inner Panel

    Zhejiang Kayo Motor Co., Ltd. 2.4.4 Right door inner panel Disassembly Remove the right inner support panel mounting screws 1 (5 pieces in total) Remove the right inner support panel 2 Installation Installation is carried out in reverse order of disassembly 2.4.5 Right door side panel Disassembly Remove the right door inner support...

  • Page 32: Inner Support Of Right Hand Panel

    2 Covering parts of the body of the vehicle Follow the reverse order of disassembly 2.4.7 Inner support of left handrest panel Disassembly Remove the fastening screw 1 from the left handrest Remove the inner support of the left handrest 2 Installation Follow the reverse order of disassembly 2.4.8 Left handrest panel...

  • Page 33: Right Handrest Panel

    Zhejiang Kayo Motor Co., Ltd. is easy to slip off, check whether it is still there before installation) 2.4.10 Right handrest panel Disassembly Remove the right handrest (→ 2.4.9) Remove the fixing screw 1 of the right handrest Remove the right handrest 2 Installation Follow the reverse order of disassembly 2.5 Front cover panel, front...

  • Page 34: Front Body Assembly

    2 Covering parts of the body of the vehicle Installation Follow the reverse order of disassembly Attention Before disassembly, the cables on the front vehicle body and the front left and right headlight connectors should be removed, and after installation, the cables and connectors should be checked to prevent misconnection 2.5.2 Front body assembly...

  • Page 35: Left Fenders

    Zhejiang Kayo Motor Co., Ltd. Disassembly Remove the front cover panel (→ 2.5.1) Remove the front body assembly (→ 2.5.2) Remove the left fender (→ 2.5.3) Remove the fixing screw 1 Remove the fixing screw 2 from the rear left fender (note that when removing this screw, the plastic part needs to be pulled back slightly to remove the fixing screw.

  • Page 36: Right Fenders

    2 Covering parts of the body of the vehicle Disassembly Remove the front cover panel (→ 2.5.1) Remove the front body assembly (→ 2.5.2) Remove the right fender (→ 2.5.5) Remove the fixing screw 1 Remove the fixing screw 2 from the rear left fender (note that when removing this screw, the plastic part needs to be pulled back slightly to remove the fixing screw.

  • Page 37: Left Rear Fender

    Zhejiang Kayo Motor Co., Ltd. Disassembly Remove the front cover panel (→ 2.5.1) Remove the front body assembly (→ 2.5.2) Remove the right fender (→ 2.5.5) Remove the outer cover of the right pedal (→ 2.5.6) Remove the fixing screw 1 Remove the fixing bolt 2 Remove the right rear fender 3 Installation...

  • Page 38: Air Guide

    2 Covering parts of the body of the vehicle 2.6.1 Seat belts and seat cushions (left and right) Disassembly Remove the seat belt fixing screw 1 Remove the seat belt 2 Remove the seat cushion fixing bolt 3 Lift the seat cushion 4 upwards Installation Follow the reverse order of disassembly 2.5.9 Air guide...
  • Page 39 Zhejiang Kayo Motor Co., Ltd. 2.6.3 Right foot pedal Disassembly Remove the seat belt and seat cushion (→ 2.6.1) Remove the fixing screws 1 (19 pieces) Lift up and remove the right foot pedal 2 Installation Follow the reverse order of disassembly (Pay attention to whether the clip nut on the plastic part slides off before installation)
  • Page 40 2 Covering parts of the body of the vehicle Attention After loosening the brake cable fixing nut, it is necessary to pull out the brake cable bolt slightly backwards and pull the handbrake lever to the highest position. 2.6.4Central control components Disassembly Remove the fixing screw 1 Remove the shift handle 2...

  • Page 41: Inner Cover Of Left Foot Pedal

    Zhejiang Kayo Motor Co., Ltd. Installation Follow the reverse order of disassembly 2.6.7 Interior front left fender Disassembly Remove the left foot pedal (→ 2.6.2) Remove the inner shield of the left foot pedal (→ 2.6.5) Remove the fixing screw 1 Remove the interior front left fender 2 Installation Follow the reverse order of disassembly...

  • Page 42: Interior Front Right Fender

    2 Covering parts of the body of the vehicle Installation Follow the reverse order of disassembly 2.6.8 Interior front right fender Disassembly Remove the right foot pedal (→ 2.6.3) Remove the innercover of the right foot pedal (→ 2.6.5) Remove the fixing screw 1 Remove the front right fender 2 of the interior Installation...
  • Page 43 Zhejiang Kayo Motor Co., Ltd. Installation Follow the reverse order of disassembly 2.7 Disassembly and assembly of front guard, rear shelf, rear taillight frame, and instrument cover 2.7.1Front guard Disassembly Remove the front protective fixing bolt Remove the front guard 2 Installation Follow the reverse order of disassembly 2.7.2 Rear shelf...
  • Page 44 2 Covering parts of the body of the vehicle Installation Follow the reverse order of disassembly 2.7.4 Instrument cover Disassembly Front body assembly (→ 2.5.2) Loosen the electric door switch lock plug-in 5 Loosen the panel switch plug-in 6 Loosen the instrument plug-in 7 Loosen the damper cable 8 Remove the damper wire switch 9 Remove the instrument cover...
  • Page 45 Zhejiang Kayo Motor Co., Ltd. 2- 19...
  • Page 47 Zhejiang Kayo Motor Co., Ltd. 3 Regular inspection and adjustment Maintenance information…………………..……………………………………………3-1 3.1 Determination of maintenance cycle…………………………..……………………3-2 3.2 Inspection and maintenance methods….……………………………………………3-3 3.3 Steering column, brake system………………………..…………………………3-5 3.4 Wheels………………………………………………………………………………3-9 3.5 Suspension system……………………….…………………………………………3-11 3.6 Shift mechanism……………………………………………………………………3-12 3.7 Fuel device…………………………………………………………………………3-12 3.8 Throttle inspection…………………………………………………………………3-13 3.9 Instrumentation…………………………….………………………………………3-14 3.10 Lighting device……………………………...……………………………………3-15 Maintenance information...

  • Page 48: Regular Inspection And Adjustment

    3 Regular inspection and adjustment 3.1 Determination of maintenance cycle The maintenance of the engine is a regular and periodic task, and it is very important to maintain the engine at a certain time interval. Standardized maintenance and upkeep can ensure excellent engine performance, reliable operation, and economic durability.

  • Page 49: Inspection And Maintenance Methods

    Zhejiang Kayo Motor Co., Ltd. 3.2 Inspection and maintenance methods Inspection and maintenance items Maintenance period Judgment criteria Daily Semi- Annu Inspection parts Inspection items inspe annua ction inspec inspe tion ction ○ Steering wheel Operational flexibility ○ Steering Damage device Steering system Installation...

  • Page 50: Regular Inspection And Adjustment

    3 Regular inspection and adjustment not be less than 3mm Looseness of wheel nuts and ○ ○ wheel axles Shake of front wheel bearings ○ ○ ○ ○ Shake of rear wheel bearings Suspension arm Shake of the connecting part ○...
  • Page 51 Zhejiang Kayo Motor Co., Ltd. Inspection and maintenance items Maintenance period Dail Semi Annu Inspection parts Inspection items inspe annu inspe Judgment criteria ction ction inspe ction ○ ○ Output shaft Looseness of the connection part Transmissi (transmission ○ on device The shaking of the spline part shaft) Spark...
  • Page 52 3 Regular inspection and adjustment 3.3 Steering wheel, brake system Put the vehicle in a horizontal position, and slowly turn the steering wheel left and right to confirm whether it has the same full left and full right turning ability. If the left and right steering angles are different, check whether the marking lines of the steering device are on the same line (the position...
  • Page 53 Zhejiang Kayo Motor Co., Ltd. oil cup for a long time Oil change (replacement of brake fluid) Brake fluid is replaced once a year Front brake disc, brake pad (brake pad wear) Check the wear of the brake pad If the wear has reached the wear limit, replace the brake pad Attention The brake pads need to be replaced as a...
  • Page 54 3 Regular inspection and adjustment Front and rear brake pump combination 〈 Liquid volume〉 Check the amount of brake fluid. When the brake fluid level decreases to near the lower limit of 1 (LOWER), an alarm will be displayed on the instrument panel.
  • Page 55 Zhejiang Kayo Motor Co., Ltd. Rear brake disc, brake pad (brake pad wear) Check the wear of the brake pad If the wear has reached the wear limit, replace the brake pad Attention The brake pads need to be replaced as a complete set Inspection and replacement of brake discs.

  • Page 56: Wheels

    3 Regular inspection and adjustment 3.4 Wheels Jack up the front wheel with a tool in a horizontal position to ensure that there is no force acting on the wheel. Shake the front wheel left and right to check if the connection of the front wheel is secure.
  • Page 57 Zhejiang Kayo Motor Co., Ltd. Tire pressure tire pressure gauge Use a pressure gauge to check the tire pressure. Attention The inspection of tire pressure should be carried out while the tire is cool. If used in a state where the tire pressure is not appropriate, it will lead to poor operation and riding comfort, and cause adverse effects such as tire bias wear.

  • Page 58: Suspension System

    3 Regular inspection and adjustment shaking. Remove the front wheel and inspect the wheel hub when there is shaking greater than 3mm Wheel nuts and wheel axles Check the looseness of the front wheel axle, rear wheel axle nut 1, and bolt Tighten according to the specified torque when there is looseness Torque:...

  • Page 59: Shift Mechanism

    Zhejiang Kayo Motor Co., Ltd. Adjustment of shock absorber 3.7 Fuel device Use a special tool to adjust the adjusting cam 1 of the shock absorber according to the load. Fuel device Clockwise rotation is adjustable from high The status of the fuel system. to low, and counterclockwise rotation is Remove the rear shelf (→...

  • Page 60: Throttle Inspection

    3 Regular inspection and adjustment When the gap is not within the specified range, adjust the gap. Loosen the throttle cable lock nut 2. Rotate the adjuster to adjust the free travel of the accelerator pedal. After adjustment, tighten the locking nut 2. If the adjustment of the regulator still cannot reach the specified gap or if the action is still not flexible, then replace the throttle cable...

  • Page 61: Lighting Device

    Zhejiang Kayo Motor Co., Ltd. beam lamp are not on, please check whether the line is connected incorrectly. If the wiring is correct, please replace the headlamp in time. Tail light inspection Step on the brake pedal with your foot and observe the tail lights.

  • Page 62: Around The Engine

    3 Regular inspection and adjustment 4 Around the engine 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 removal and installation……………………………………………..4-5 Maintenance information Precautions for operation  During operation and maintenance, please ensure that the vehicle is turned off and left standing for no less than 1 hour.
  • Page 63 Zhejiang Kayo Motor Co., Ltd. contain coolant, engine oil, and fuel to protect the environment. During installation, the coolant and engine oil should be replenished as required. Tightening torque Engine bracket mounting bolts GB5787 M10×1.25×160 55~66N·m 4.1 Fuel system Installation Disassembly Installation is carried out in reverse order of Remove the rear shelf tarpaulin and rear...
  • Page 64 4 Around the engine 5-11...
  • Page 66 Zhejiang Kayo Motor Co., Ltd. Remove the 2 mounting screws 1 Remove the engine exhaust pipe 3 Remove the air filter 2 Installation Installation is carried out in reverse order of disassembly 4.3 Exhaust system Disassembly Remove the fixing bolt 5 Remove the mounting nut 6 Remove the muffler assembly 4 Installation...
  • Page 67 4 Around the engine Engine removal installation Disassembly Remove the rear shelf tarpaulin and rear shelf (→ The second chapter- Vehicle body cover) Remove the fuel tank (→ 4.1 Fuel system) Remove the air filter and carburetor (→ 4.2 Intake system) Remove the exhaust pipe assembly (→...
  • Page 68 Zhejiang Kayo Motor Co., Ltd. Remove the engine fixing bolt - right 3 Remove the engine suspension plate - right 3 bolts 1 Remove the engine suspension plate 2 Remove the air filter fixing bracket mounting bolt 6 Remove the high-pressure package 4 Remove the air filter fixing bracket 5 Pull out the oil pipe 7 Remove the shift cable 8...

  • Page 69: Engine

    Zhejiang Kayo Motor Co., Ltd. 5 Engine 5.1 Overview.........................5-3 5.1.1 Maintenance guidelines....................5-3 5.1.2 Specifications......................5-5 5.1.3 Maintenance specifications..................5-6 5.1.4 Torque value......................5-9 5.1.5 Lubrication and sealing positions................5-10 5.2 Maintenance........................5-11 5.2.1Maintenance information..................5-11 5.2.2 Maintenance specifications..................5-11 5.2.3 Check the level of lubricating oil................5-12 5.2.4 Check the oil pipe....................5-13 5.2.5 Valve clearance......................5-13 5.2.6 Belt...........................5-15 5.2.7 Crankcase lubricating oil..................5-16...
  • Page 70 5 Engine 5.6 Magneto and starting clutch..................5-64 5.6.1 System exploded view..................5-64 5.6.2 Service information....................5-64 5.6.3 Specifications.......................5-65 5.6.4 Right crankcase cover..................5-66 5.6.5 Magneto spindle and trigger.................5-67 5.6.6 Magneto rotor.......................5-68 5.6.7 Starting clutch.......................5-70 5.7 Crankcase and transmission system................5-71 5.7.1 System exploded view...................5-71 5.7.2 Service information....................5-72 5.7.3 Specifications......................5-73 5.7.4 Disassembly and assembly of crankshaft case............5-76...
  • Page 71 Zhejiang Kayo Motor Co., Ltd. 5.1 Overview 5.1.1 Maintenance guidelines...................5-3 5.1.2 Specifications......................5-5 5.1.3 Maintenance specifications..................5-6 5.1.4 Torque value......................5-9 5.1.5 Lubrication and sealing positions................5-10 5.1.1 Maintenance guidelines 1.Please use components, lubricants, or other auxiliary materials produced by Chongqing Longxin Power Co., Ltd. or recognized and recommended by Longxin General Power Co., Ltd.
  • Page 72 5 Engine 5.1.2 Specifications General specifications Items Data Model LX163YML Displacement 196.2ml Cylinder arrangement and In line, inclined forward 15 ° inclination angle (63.5 × 62)mm Cylinder diameter × stroke 17.8ml Combustion chamber 9.5：1 volume (1050±150 )kPa Compression ratio 9.5（1±5%）kW/(7000±500)rpm Cylinder pressure 14.5（1±5%）N·m/(5500±500)rpm Maximum...
  • Page 73 Zhejiang Kayo Motor Co., Ltd. 5.1.3 Maintenance specifications Cylinder head-valve-piston-cylinder block specifications Items Standard value Service limit — Electric starting cylinder pressure 1050±150 kPa — Valve clearance Intake valve (0.06±0.02)mm — Exhaust valve (0.06±0.02)mm — Rocker arm, Rocker Intake/exhaust (12.000～12.018)mm rocker arm shaft inner diameter —...
  • Page 74 5 Engine Lubricating oil - oil pump specifications Items Standard value Service limit Lubricating oil viscosity SJ 10W/40 Engine Capacity 1.1L lubricating oil, Check the oil dipstick crankcase Oil level between marking lines Clearance between inner and outer (0.05～0.15)mm 0.2mm rotors Clearance between the outer rotor Oil pump...
  • Page 75 Zhejiang Kayo Motor Co., Ltd. Starting disc gear specifications Items Standard value Service limit Starting disc gear Outer diameter of shaft (42.575～42.6)mm 42.55mm sleeve Inner diameter of shaft 32.05mm (32.00～32.025)mm sleeve Specifications of crank connecting rod components - crankshaft box kit Items Standard value Service limit...
  • Page 76 5 Engine 5.1.4 Torque value Engine torque value Items Quantity Thread Torque value N · Remarks diameter mm Cylinder head cover fastening 8～12 bolts Valve adjustment bolts and nuts 12～18 Cylinder head fastening nuts 24～32 Cylinder head spark plugs 20～25 Magneto rotor fastening nuts 54～60 Disk gear fastening round nut...
  • Page 77 Zhejiang Kayo Motor Co., Ltd. Engine Material Location Remarks Sealant Silicone flat Magneto rubber wire card sealant 1512 gray flat Assembly position of the left and right box Before cylinder block adhesive cylinder blocks assembly 1271 thread Main shaft bearing pressure plate bolt sealant Engine lubricating oil The entire surface of the inner and outer...
  • Page 78 5 Engine 5.2 Maintainance 5.2.1Maintenance information..................5-11 5.2.2 Maintenance specifications..................5-11 5.2.3 Check the level of lubricating oil................5-12 5.2.4 Check the oil pipe....................5-13 5.2.5 Valve clearance.......................5-13 5.2.6 Belt..........................5-15 5.2.7 Crankcase lubricating oil..................5-16 5.2.8 Transmission lubricating oil..................5-18 5.2.9 Spark Plug.......................5-19 5.2.1 Maintenance information Overview ·Before all operations, please place the entire vehicle on a horizontal plane.

  • Page 79: Check The Level Of Lubricating Oil

    Zhejiang Kayo Motor Co., Ltd. Every year Lubric ating filter screen *Repairs should be carried out by Longxin dealers, unless the owner has the required tools and a certain mechanical knowledge foundation to conduct self maintenance, they should also refer to this manual. *Repairs should be carried out by Longxin dealers, unless the owner has the required tools and a certain mechanical knowledge foundation to conduct self maintenance, they should also refer to this manual.

  • Page 80: Check The Oil Pipe

    5 Engine 5.2.4 Check the oil pipe If the oil pipe is not properly maintained, the high pressure inside the oil pipe may cause lubricating oil leakage A or oil pipe rupture. Visually inspect the oil pipes for signs of damage. Squeeze the oil pipe, and the oil pipe should not be hard or brittle, nor should it be soft or swollen.

  • Page 81: Valve Clearance

    5 Engine 5.2.5 Valve clearance Attention The valve clearance can only be checked ·Confirm that the large circular hole A of when the engine has cooled to room the driven wheel for cylinder head timing temperature. is above the engine cylinder head surface, Check valve clearance and the two small holes B are flush with the cylinder head plane...
  • Page 82 Zhejiang Kayo Motor Co., Ltd. ·Measure the valve clearance using a feeler gauge B, and measure the clearance between the end of the valve stem and the adjusting screw A. ·Valve clearance (when cold) Exhaust valve: (0.04-0.08) mm Intake valve: (0.04-0.08) mm ★...

  • Page 84: Belt

    5 Engine 5.2.6 Belt Check for belt wear Warning Attention Any improper operation or clutch stalling or When replacing the belt, check the active slipping may cause severe wear or damage pulley components and the driven pulley to the transmission and wheels due to belt components.

  • Page 85: Crankcase Lubricating Oil

    Zhejiang Kayo Motor Co., Ltd. 5.2.7 Crankcase lubricating oil Replace lubricating oil ·After preheating the engine, keep it in a horizontal position on both the front, rear, left, and right sides. ·Remove the oil drain plug A and drain the lubricating oil.
  • Page 86 5 Engine Clean the lubricating oil filter screen ·Drain the lubricating oil. ·Remove the lubricating oil filter cover A and the pressure spring. ·Clean the lubricating oil filter screen with a high ignition point solvent to remove particles sticking to the lubricating oil filter screen. Warning Do not use gasoline or low ignition point solvents to clean the lubricating oil filter.

  • Page 87: Transmission Lubricating Oil

    Zhejiang Kayo Motor Co., Ltd. 5.2.8 Transmission lubricating oil ·Replace with a new gasket Check the transmission oil level ·After the oil is completely drained, ·Park the vehicle so that it is level in front, assemble the drain bolt and flat washer. back, left, and right.

  • Page 88: Spark Plug

    5 Engine ·Fill the transmission box with high-quality oil. Transmission oil type: Viscosity: SJ 10W/40 Capacity: 0.4L 5.2.9 Spark Plug Clean/inspect spark plugs Clean the spark plug, preferably in a sandblasting device, and then clean the abrasive particles. It can also be cleaned with a wire brush or other suitable tools.
  • Page 89 Zhejiang Kayo Motor Co., Ltd. 5.3 Lubrication system 5.3.1 System explosion view...................5-20 5.3.2 Maintenance information................5-20 5.3.3 Specifications....................5-21 5.3.4 Lubrication system diagram................5-22 5.3.5 Lubricating oil and filter................5-23 5.3.6 Oil pump......................5-25 5.3.1 System explosion view 5.3.2 Service information Overview  This chapter covers the disassembly and inspection of oil pump components. ...

  • Page 90: Specifications

    5 Engine 5.3.3 Specifications Items Standard value Service limit Lubricant viscosity SJ 10W/40 Engine Capacity 1.1L lubricating oil Check with dipstick Crankcase The oil level between the marking lines Clearance between inner and (0.05～0.15)mm 0.2mm outer rotors Clearance between the outer Oil pump rotor and the lubricating oil (0.12～0.21)mm...

  • Page 91: Lubrication System Diagram

    Zhejiang Kayo Motor Co., Ltd. 5.3.4 Lubrication system diagram cylinder cover cam oil pool valve bolt in valve bolt ex cylinder rocker arm head passage Right cover diversion chamber crankshaft pipe oil chamber mesopore middle hole of oil joint Ф5 flat tube of oil cooler bent 6 middle hole of pipe joint Ф5 times...

  • Page 92: Lubricating Oil And Filter

    5 Engine 5.3.5 Lubricating oil and filter ★If the oil level is too low, oil can be added Warning through filling hole. Running a vehicle under inappropriate lubricating oil of the same type and conditions, harsh conditions, composition. contaminated engine lubricating oil can Attention accelerate wear and tear, and may also lead to engine shutdown, accidents, and injuries.
  • Page 93 Zhejiang Kayo Motor Co., Ltd. Remove the lubricating oil filter screen ·Drain the lubricating oil. ·Disassemble： Lubricating oil filter cover A and O-ring B Pressure spring C Lubricating oil filter screen D Assembly of lubricating oil filter screen ·Assembly and disassembly are exactly the opposite.

  • Page 94: Oil Pump

    5 Engine 5.3.6 Oil pump Remove the oil pump ·Disassemble： Magneto rotor flat washer A, nut B Chain wheel cover bolt C Oil pump driving gear flat washer D, round nut E ·Disassemble： Magneto rotor Starting clutch round nut A, flat washer B Starting clutch combination Flat washer Oil pump driven nut A...
  • Page 95 Zhejiang Kayo Motor Co., Ltd. ·Disassemble： Oil pump cover bolt A Oil pump B Disassemble： Balance shaft driving gear A Balance shaft driven gear B Square key C Balance shaft driven gear washer D Assemble the oil pump ·Apply lubricating oil to the following parts: Oil pump transmission shaft Inner rotor A and outer rotor B...
  • Page 96 5 Engine ·Check if the oil pump transmission shaft rotates freely. ·Assemble the oil pump assembly so that the arrow mark A is aligned with the small hole ·Tighten the lubricating oil pump assembly bolts. Tightening torque of lubricating oil pump bolts: (8～12)N·m ·Assembly:...
  • Page 97 Zhejiang Kayo Motor Co., Ltd. ·Clearance between outer rotor and oil pump body Standard: (0.12-0.21) mm. Service limit：0.26mm Check the oil pump ·Remove the oil pump. ·Use a feeler gauge to check the gap A ·Visually inspect the oil pump driven between the outer rotor end face and the wheel, inner and outer rotors, and oil lubricating oil pump body.

  • Page 98: System Explosion View

    5 Engine 5.4 Cylinder head and valves 5.4.1System explosion view.....................5-29 5.4.2Service information....................5-30 5.4.3Specifications......................5-31 5.4.4 Cylinder head cover....................5-32 5.4.5 Tensioner.........................5-33 5.4.6 Valve rocker arm and shaft..................5-35 5.4.7 Camshaft........................5-38 5.4.8 Timing chain......................5-40 5.4.9 Cylinder head......................5-41 5.4.10 Valve........................5-45 5.4.1 System explosion view 5- 20...
  • Page 99 Zhejiang Kayo Motor Co., Ltd. 5.4.2 Service information Overview  This chapter covers the maintenance and inspection of cylinder heads, valves, camshafts, and rocker arms.  When repairing the camshaft, rocker arm, and tensioner adjustment screw, there is no need to remove the engine from the frame; When repairing cylinder heads and valves, the engine must be removed from the frame.

  • Page 100: 3Specifications

    5 Engine 5.4.3 Specifications Items Standard value Service limit Clearance between valve Valve rocker arm rocker arm and (0.013～0.046)mm 0.05mm valve rocker arm shaft ～ Exhaust (31.47 31.59)mm 31.41mm Cam height of camshaft Inlet (31.72～31.84)mm 31.66mm Available Cylinder pressure Cylinder head range:(900～1200)kpa Flatness 0.03mm...

  • Page 101: Cylinder Head Cover

    Zhejiang Kayo Motor Co., Ltd. 5.4.4 Cylinder head cover Remoe cylinder head cover ·Disassemble： Fuel tank (refer to the fuel system chapter) ·Remove pipe clamp A and vent pipe B. ·Remove cylinder head cover assembly bolts C and cylinder head cover Assemble the cylinder head cover ·Replace the cylinder head cover gasket A with a new one.

  • Page 102: Tensioner

    5 Engine ·Press the push rod A and use a suitable 5.4.5 Tensioner screwdriver to rotate clockwise until the Remove the tensioner push rod is in place. Attention Attention This is not an automatic return tensioner. Do not rotate the push rod counterclockwise When the push rod is pushed out to before assembling the tensioner, as it may compensate for the slack in the timing...
  • Page 103 Zhejiang Kayo Motor Co., Ltd. ·Replace the tensioner gasket with a new one. Fix the push rod in place with a suitable push rod support plate A, and then assemble the tensioner on the cylinder block. ·Tightening torque tensioner assembly bolt A: (8～12)N·m ·Remove support plate B.

  • Page 104: Valve Rocker Arm And Shaft

    5 Engine 5.4.6 Valve rocker arm and shaft Remove valve rocker arm ·Disassemble： Rocker arm support seat (refer to the camshaft chapter) Baffle bolt A, baffle B Rocker arm shaft C Valve rocker arm assembly Assemble valve rocker arm ·Apply lubricating oil to the following parts: Valve rocker arm shaft Valve rocker arm assembly hole...
  • Page 105 Zhejiang Kayo Motor Co., Ltd. Intake rocker arm shaft (with oil passage ring groove), installed into the bracket without word end Rotate the rocker arm shaft so that the notched end of the rocker arm shaft faces inward. Align the notch and threaded hole of the rocker arm shaft with the plane of the pressure plate facing upwards...
  • Page 106 5 Engine Check the valve rocker arm and valve rocker arm shaft ·Check area A on the rocker arm where it rubs against the cam. ★ If the rocker arm is scratched, discolored, otherwise damaged, replace it, and check the camshaft tip at the same time.

  • Page 107: Camshaft

    Zhejiang Kayo Motor Co., Ltd. 5.4.7 Camshaft Remove the camshaft ·The piston turns to the top dead center. ·Disassembly: Cylinder head cover Tensioner Rocker arm support seat assembly nut A Rocker arm support seat B ·Remove camshaft A. ·Support the timing chain with a suitable tool.
  • Page 108 5 Engine ·Assemble the rocker arm support seat ·Due to the very small manufacturing with the EX mark D facing the exhaust tolerance of bearings, the wear of side. bearings must be based on hand feeling ·Apply lubricating oil to the threads of rather than measurement.

  • Page 109: Timing Chain

    Zhejiang Kayo Motor Co., Ltd. ·Quickly rotate the bearing by hand to ·Visually inspect the rubber on the check its condition. guide plate and tensioning plate. ★ If there is abnormal noise, unsmooth ★ If the rubber is damaged, cut or peeled rotation, or any violent stop in the off, replace...
  • Page 110 5 Engine 5.4.9 Cylinder head Measure cylinder pressure Attention Use a fully charged battery. ·Warm up the engine then stop. ·Remove the spark plug. ·Connect cylinder pressure gauge A and adapter B firmly into the spark plug hole. Tool - cylinder pressure gauge 20kg/cm2 Adapter M12×1.25 ·Start the engine and fully open the throttle until the cylinder pressure gauge reading no...
  • Page 111 Zhejiang Kayo Motor Co., Ltd. If the cylinder pressure gauge reading is not within the available range, please refer to the following table: Problem Diagnosis Remedial measures Piston carbon deposits, cylinder head, Cylinder combustion chamber may be due to If necessary, remove carbon damage to the oil shield and/or deposits and replace damaged pressure...
  • Page 112 5 Engine Remove cylinder head ·Disassemble： Carburetor (refer to the fuel system chapter) Exhaust pipe Spark plug cap Cylinder head cover Cylinder head nut A and flat washer B Assemble the cylinder head ·Replace with a new cylinder head gasket. ·Assembly: Positioning pin A, new cylinder head gasket B Cylinder head, camshaft...

  • Page 113: Cylinder Head

    Zhejiang Kayo Motor Co., Ltd. Check the deformation of the cylinder head ·Check the deformation of the cylinder head ·Clean the cylinder head; ·Place a straight edge on the lower surface of the cylinder head; ·Measure the gap between the straight edge B and several positions on the lower plane of the cylinder head using a feeler gauge A.

  • Page 114: Valve

    5 Engine 5.4.10 Valve Intake valve: (0.04-0.08) mm Check valve clearance ★If the valve clearance is not correct, Attention please adjust the valve clearance. The valve clearance can only be checked when the engine has cooled to room temperature. ·Disassemble： Cylinder head cover Right decorative cover bolt A Right decorative cover B...
  • Page 115 Zhejiang Kayo Motor Co., Ltd. seat. Adjust valve clearance · Assemble the spring with the sparse ·Loosen the locking nut and rotate the coil facing upwards and the dense coil adjusting screw until the gap is correct; facing downwards. ·Secure the adjusting screw B with fixture A and tighten the locking nut C;...
  • Page 116 5 Engine Valve spring outer race C Valve outer spring height: 43.65 Valve spring inner seat ring H Valve inner and outer springs D Valve spring upper seat E Locking clip F, sealing ring end G Measure the clearance between the valve and valve guide ·Measure the outer diameter of each valve stem and the inner diameter of each...
  • Page 117 Zhejiang Kayo Motor Co., Ltd. 5.5 Belt transmission system 5.5.1 System explosion view....................5-48 5.5.2 Service information....................5-48 5.5.3 Specifications......................5-49 5.5.4 Left crankcase cover....................5-50 5.5.5 Belt...........................5-52 5.5.6 Active pulley components..................5-54 5.5.7 Driven pulley components..................5-57 5.5.1 System explosion view 5.5.2 Service information Overview ...

  • Page 118: Specifications

    5 Engine 5.5.3 Specifications Items Standard value Service limit Belt Belt width 19mm (19.5～20.0)mm Bore diameter of drive plate assembly hole (27～27.05)mm 27.1mm Active pulley Outer diameter of bushing (26.98～26.959)mm 26.91mm components Outer diameter of roller (20.9～21.1)mm 20.8mm Driven sliding plate assembly hole diameter (34～34.025)mm 34.06mm Driven fixed shaft diameter...

  • Page 119: Left Crankcase Cover

    Zhejiang Kayo Motor Co., Ltd. ·Use a suitable tool to remove bearing C 5.5.4 Left crankcase cover Remove left crankcase cover ·Disassemble： 10×M6 bolts Left crankcase cover Assemble left crankcase cover ·Replace with a new left crankcase cover gasket. ·Assembly: Positioning pin A New sealing gasket B Left crankcase cover...
  • Page 120 5 Engine filled with water. If there is water, Assemble left crankcase cover please remove the drain bolt A and bearing tighten the bolt after draining the ·Use a pressure head to press the shaft water into the assembly hole. Tightening torque: (8-12) N ·...

  • Page 121: Belt

    Zhejiang Kayo Motor Co., Ltd. 5.5.5 Belt Remove the belt ·Remove the active pulley components. ·Remove the clutch outer plate. Attention Before disassembly, observe the orientation of information A (such as the manufacturer's name) engraved on the belt so that the belt can be reassembled on the pulley and rotate in the same direction as the original assembly.
  • Page 122 5 Engine components. Check for belt wear Warning Any improper operation or clutch stalling or slipping may cause severe wear or damage to the transmission and wheels due to belt jamming. This may cause the operator to lose control and lead to accidents, resulting in injury or death.

  • Page 123: Active Pulley Components

    Zhejiang Kayo Motor Co., Ltd. 5.5.6 Active pulley components Remove the active pulley components ·Remove the left crankcase cover. ·Install the stop fixture A and remove the drive pulley nut B and bushing C. ·Remove the sliding drive disc D. Tools - stop rotation tooling.
  • Page 124 5 Engine degreasing detergent, and then dry the Check active pulley drive disc cone, crankshaft, and belt components with a clean cloth. ★ If the surface A of the driving pulley is damaged, the sliding drive plate and/or drive plate should be replaced. ★...
  • Page 125 Zhejiang Kayo Motor Co., Ltd. Warning These cleaning agents are usually highly flammable and harmful if breathed for a long time. Be sure to pay attention to the manufacturer's warning. · When assembling sliding drive plate A, press the sliding drive plate tightly to move the belt outward to the lowest position, then install bushing B, and apply a small amount of lubricating oil...

  • Page 126: Driven Pulley Components

    5 Engine 5.5.7 Driven pulley components device. Remove driven pulley components ·Disassemble： Left crankcase cover Active pulley components ·Install the stop rotation fixture A, remove the driven pulley assembly nut Tools - Stop rotation tooling. ·Remove bushing C and clutch outer plate D.
  • Page 127 Zhejiang Kayo Motor Co., Ltd. ·Clamp the clutch spring compression device A onto a vice. ·Using a 39 mm hex nut B wrench, remove the clutch driven plate nut. Tool - Clutch spring compression device. ·Release the clutch spring compression device and remove the driven pulley component assembly.
  • Page 128 5 Engine ·Wipe off the grease. ·Remove the pin shaft and locating pin · Remove the driven sliding plate C from the driven fixed plate B. ·Disassemble： Oil seal A ·Remove needle bearing A. ·Remove the circlip B and outer bearing Tool - Circlip pliers with inner snap.
  • Page 129 Zhejiang Kayo Motor Co., Ltd. ★If the driven sliding disc is damaged circlip B. or worn, please replace it. Tool - Circlip pliers with inner snap. ·Driven sliding plate assembly hole ·Apply lubricating grease around the aperture A driven fixed shaft hole C. Standard：(34～34.025)mm Service limit：34.06mm ★...
  • Page 130 5 Engine ·Align plane B of clutch drive plate A Attention with plane D of driven fixed plate C. Fill the bearing cavity with heat-resistant Attention 230 ℃ lubricating grease. Be sure to use a clutch spring ·Press a new needle bearing into the compressor to avoid damage to the driven fixed plate.
  • Page 131 Zhejiang Kayo Motor Co., Ltd. ·Fit the hole A of the driven pulley · Assemble the fixed disc F and fit a component onto the pin of the clutch new circlip in the groove of the drive spring compressor B. disc pin shaft.
  • Page 132 5 Engine Check the clutch ·Check if the clutch shoes are damaged. ★ If there is any damage, please replace it. ·Measure the thickness A of the clutch lining. ★ If the lining thickness is worn beyond the service limit, please replace the clutch shoe. ·Clutch lining thickness Standard：(1.8～2.2)mm Service limit：1.0mm...

  • Page 133: System Explosion View

    Zhejiang Kayo Motor Co., Ltd. 5.6 Magneto and starting clutch 5.6.1 System explosion view....................5-64 5.6.2 Service information....................5-64 5.6.3 Specifications......................5-65 5.6.4 Right crankcase cover....................5-66 5.6.5 Magneto spindle and trigger..................5-67 5.6.6 Magneto rotor......................5-68 5.6.7 Starting clutch......................5-70 5.6.1 System explosion view 5.6.2 Service information Overview ...

  • Page 134: Specifications

    5 Engine 5.6.3 Specifications Items Standard value Service limit Outer diameter of shaft 42.55mm (42.575～42.6)mm Starting disc gear sleeve Inner diameter of shaft (32.00～32.025)mm 32.05mm sleeve Tools 5- 66...

  • Page 135: Right Crankcase Cover

    Zhejiang Kayo Motor Co., Ltd. 5.6.4 Right crankcase cover Disassemble/assemble Attention： ·When disassembling right crankcase cover, place a clean oil pan at the bottom of the engine to prevent lubricating oil from flowing out. After assembly, recommended lubricating oil to the specified amount. Place the entire vehicle on a level surface and keep it level.

  • Page 136: Magneto Spindle And Trigger

    5 Engine Remove locating pin A and paper pad B. Remove all sealing gasket materials from the joint surface of the right crankcase and box cover. The assembly sequence is opposite to the disassembly sequence. Torque: Right crankcase cover bolt: (8-12) N · m Attention：...

  • Page 137: Magneto Rotor

    Zhejiang Kayo Motor Co., Ltd. 6.6.6 Magneto rotor Disassemble Remove the right crankcase cover. Use magneto retainer A to fix magneto rotor B, and remove nut C and flat washer Attention: Install the fixing block of the magneto rotor retainer to prevent the rotor from rotating. Remove the rotor nut and washer.
  • Page 138 5 Engine Assemble Attention： ·Be careful not to damage the half round keyway and crankshaft. Assemble the double gear and double gear shaft. Apply engine lubricating oil until the disc teeth come into contact with the crankshaft area and assemble the disc gear Control torque: (54~60) N ·...

  • Page 139: Starting Clutch

    Zhejiang Kayo Motor Co., Ltd. 5.6.7 Start clutch Start clutch operation check Remove the rotor. Check the operability of the starting clutch by rotating the disc teeth [1]. Check if the disc teeth rotate smoothly clockwise and ensure that there is no counterclockwise rotation.
  • Page 140 5 Engine 5.7 Crankcase and transmission system 5.7.1System explosion view....................5-71 5.7.2Service information....................5-72 5.7.3Specifications......................5-73 5.7.4 Disassembly and assembly of crankshaft case............5-76 5.7.5 Remove the reverse intermediate shaft components..........5-81 5.7.6 Assembly of reverse intermediate shaft components..........5-82 5.7.7 Disassemble the spindle...................5-82 5.7.8 Assemble the spindle....................5-83 5.7.9 Secondary shaft......................5-83 5.7.10 Reverse transmission shaft components..............5-84 5.7.11 Check the runout of the shift fork shaft..............5-84...
  • Page 141 Zhejiang Kayo Motor Co., Ltd. 5.7.2 Service information Overview  This chapter includes the disassembly and inspection of the crankshaft case and the 5- 93...
  • Page 142 5 Engine transmission system.  When disassembling, the disassembled parts should be marked and placed properly to ensure correct positioning during reassembly.  Before inspection, all dismantled components should be cleaned with cleaning agent and blown dry with compressed air. 5.7.3 Specifications Items Standard value...
  • Page 143 Zhejiang Kayo Motor Co., Ltd. Tools Internal circlip pliers External circlip pliers Oil seal and bearing remover, adapter A: Bearing drive tool set 5- 93...
  • Page 144 5 Engine Bearing drive,32 Bearing drive adapter,42 Oil seal and bearing remover Flywheel rotor retainer 5- 92...

  • Page 145: Disassembly And Assembly Of Crankshaft Case

    Zhejiang Kayo Motor Co., Ltd. 5.7.4 Disassembly and assembly of crankshaft case  Disassemble Boxing bolt 9 × M6 Remove the right body to separate the left and right bodies  Disassemble Sealing gasket A, locating pin B Crank connecting rod component C, balance shaft D Transmission mechanism E Shift mechanism F ...
  • Page 146 5 Engine 6202 (82.8～82.9)mm 6204 (82.9～83）mm 6203 (34.5～34.6）mm Install pressure plate A and bolt B Install the reverse intermediate shaft A Install the reverse transmission shaft component B The gear shifting drum sector tooth end faces upwards A and faces the opposite side of the transmission tooth.
  • Page 147 Zhejiang Kayo Motor Co., Ltd. Place the timing chain in the left box chain cavity, completely avoiding the crankshaft hole The splined end of the crankshaft faces the box and is assembled to the crankshaft hole. Press crankshaft A firmly to make the assembly in place, pull the chain to confirm that it is not stuck, and hang the chain on the clamp at the same time...
  • Page 148 5 Engine 5801_RNA4905 (8.7～8.8)mm Install the circlip A with internal calipers 6205RS Install locating pin A and sealing gasket B The spline end of the secondary shaft passes through the bearing hole of the secondary shaft, and the left and right hands respectively take one side of the secondary shaft A and the box body B, align the crankshaft C and the balance shaft, and close the box until it fits...
  • Page 149 Zhejiang Kayo Motor Co., Ltd. Install the auxiliary shaft oil seal B using tooling A, with the bushing with the hole section facing downwards, and install the auxiliary shaft. Using the oil seal guide sleeve, guide the secondary shaft oil seal into contact with the hole Use a nylon hammer to strike the oil seal until tooling A is combined with the box body...

  • Page 150: Remove The Reverse Intermediate Shaft Components

    5 Engine 5.7.5 Remove the reverse intermediate shaft components  Disassemble: Press out bushing A Flat washer B Forward driven wheel C Bushing D Shift ratchet Special tool - puller Elastic washer A Spline washer B Needle bearing C Reverse driven wheel D Special tool - external expanding circlip pliers Flat washer A Inspect the gears, journals, and sleeve bearings for...

  • Page 151: Assembly Of Reverse Intermediate Shaft Components

    Zhejiang Kayo Motor Co., Ltd. 5.7.6 Assembly of reverse intermediate shaft components Assemble the reverse intermediate shaft components as shown in the figure 1. Reverse intermediate shaft components 7. Elastic washer (GB/T 894.1_d=22) 2. Bushing (φ15×φ20×12) 8. Spline washer（ φ 22 ×φ 35 × 3) 3.

  • Page 152: Assemble The Spindle

    5 Engine  Disassemble: Elastic retaining ring A. Use a suitable puller to remove rolling bearing B. Inspect the gears and journals for wear or damage. If necessary, please replace it. Special tool: external caliper bearing puller. 5.7.8 Assemble the spindle Assemble: Spindle bearing [A] Special tool - bearing press fixture B.

  • Page 153: Reverse Transmission Shaft Components

    Zhejiang Kayo Motor Co., Ltd. 5.7.10 Reverse transmission shaft components Disassemble/assemble： Reverse transmission wheel A Reverse transmission shaft B Inspect the gears and journals for wear or damage. If necessary, please replace it. Special tools: Hydraulic press - fitting fixture 5.7.11 Check the runout of the shift fork shaft ·...

  • Page 154: Check The Variable Speed Drum

    5 Engine  Visually inspect the condition of the shift shaft [A], clamp [B], and spring [C] ★ If the shift shaft is excessively bent or damaged, a new shift shaft should be replaced. ★ If the snap ring or spring is damaged or excessively worn, it should be replaced with a new snap ring or spring ...

  • Page 155: Check The Bearing

    Zhejiang Kayo Motor Co., Ltd. Attention please Without the aforementioned tools. Heating the casing to a maximum temperature of about 93 ℃ can achieve satisfactory results, and tapping the bearing may allow for removal Attention please Do not use a unipolar heat source to heat the casing. This will cause the box to twist.
  • Page 156 5 Engine replace it. 5.8 Crank connecting rod components 5.8.1System explosion view..................5-87 5.8.2Service information....................5-88 5.8.3Specifications......................5-88 5.8.4 Cylinder block disassembly..................5-88 5.8.5 Piston disassembly....................5-88 5.8.6 Cylinder block wear inspection................5-89 5.8.7 Piston wear inspection..................5-90 5.8.8 Clearance inspection between piston and cylinder block........5-90 5.8.9 Wear inspection for piston ring and piston ring groove........5-90 5.8.10 Piston ring end clearance inspection..............5-91 5.8.11 Wear inspection of piston, piston pin, and connecting rod hole......5-91 5.8.12 Inspection of crank and connecting rod components..........5-92...

  • Page 157: 2Service Information

    Zhejiang Kayo Motor Co., Ltd. 5.8.2 Service information Overview  This chapter includes the disassembly and inspection of crank components, pistons, cylinder bodies, and starting motors.  There is no need to remove the engine from the frame, and it can be directly disassembled and tested on the entire vehicle.
  • Page 158 5 Engine Remove the cylinder block. Place a clean cloth under the piston and remove the piston pin wire retainer [A] different Attention please direction Do not reuse the piston pin wire retainer. s, please During disassembly, it may weaken and deform take them, and they may fall off and scratch the measure...

  • Page 159: Piston Wear Inspection

    Zhejiang Kayo Motor Co., Ltd. 20mm C Cylinder body diameter standard: (63.5- 63.51) mm Service limit:63.57 mm 5.8.7 Piston wear inspection · Measure the outer diameter of the piston [A] from the bottom of the piston up 12mm [B], perpendicular to the direction of the piston pin hole ★...

  • Page 160: Wear Inspection Of Piston, Piston Pin, And Connecting Rod Hole

    5 Engine Side clearance of piston ring groove Standard: The first ring groove (0.03-0.07) mm. Second ring groove (0.02-0.06) mm. Service limit: The first ring groove of 0.10mm. The second ring groove is 0.09mm. 5.8.10 Piston ring end clearance inspection ...
  • Page 161 Zhejiang Kayo Motor Co., Ltd. Service limit:15.04mm. ★If the diameter of the piston pin hole exceeds the usage limit. Replace the piston.  Measure the diameter B of the piston pin. Standard:(14.994～15)mm. Service limit:14.96mm. ★If the diameter of the piston pin is less than the usage limit at any time, replace the piston pin ·Measure the inner diameter A of the small end of the connecting rod.

  • Page 162: Piston Assembly

    5 Engine connecting rod. ★ If the measurement exceeds the standard. Replace the crankshaft and connecting rod components with new ones. Free oscillation of the small end of the connecting rod [B] Standard: (0.8-1.0) mm  Measure the clearance C on the large end side of the connecting rod ★...
  • Page 163 Zhejiang Kayo Motor Co., Ltd.  Apply lubricating oil to the oil ring machine and lining ring. Assemble the oil ring liner ring A in the bottom of the piston ring groove, so that both ends B butt joint.  Assemble the oil ring scraper ring.

  • Page 164: Cylinder Block Assembly

    5 Engine  Install a new piston pin wire retainer on one side of the piston, so that the opening A of the wire retainer does not coincide with the notch B of the piston pin hole  When assembling the piston pin retainer ring, only compress it enough to fit the piston pin steel wire retainer ring, do not compress too much...
  • Page 165 Zhejiang Kayo Motor Co., Ltd. Chain tensioning plate D Starter motor assembly Starter motor assembly B Bolt A Control torque: (8-12) N · m.

  • Page 167: Vehicle Chassis

    6 Vehicle chassis 6 Vehicle chassis Maintenance information………………………………………………………… 6-2 6.1 Fault diagnosis………………………………………………………………...6-3 6.2 Front wheel…………………………………………………………………..6-3 6.3 Braking system………………………………………………………………..6-4 6.4 Front suspension system……………………………………………………..6-7 6.5 Steering system………………………………………………………………..6-9 6.6 Rear suspension system……………………………………………………….6-11 6.7 Rear transmission shaft assembly……………………………………………..6-12 6- 3...

  • Page 168: Maintenance Information

    Zhejiang Kayo Motor Co., Ltd. Maintenance information Attention •When conducting maintenance work on the front wheel and suspension system, the frame must be firmly supported before operation •The maintenance and inspection of lighting, instruments, and switches should be carried out according to the corresponding chapters •Do not exert excessive force on the wheels.

  • Page 169: Front Wheel

    6 Vehicle chassis Open end ratchet wrench s8 Pneumatic wrench s12 Open end wrench s10-s12 Pneumatic wrench s14 Open end ratchet wrench s14 Socket wrench m12 Open end wrench s17-s19 Socket wrench m14 Open end ratchet wrench s22 Socket wrench m20 Open end ratchet wrench s24 Socket wrench m24 Cross screwdriver...

  • Page 170: Braking System

    Zhejiang Kayo Motor Co., Ltd. Inspection of wheel rims Observe if there are cracks in the brake Check if wheel rim1 is damaged, deformed, caliper and if there is oil leakage at each or scratched, and replace it if there are any fastening point, replace it if there is any abnormalities.
  • Page 171 6 Vehicle chassis ensured When the brake system assembly is Removal of brake pads Loosen one fastening bolt installed, the braking force must be checked. Rotate brake caliper 1 Remove the brake pads 2 Check Measure the thickness of brake pad friction layer 2.
  • Page 172 Zhejiang Kayo Motor Co., Ltd. vehicle body Disassembly of the brake main pump connector Installation Remove the oil cup bolt 1 Installation is carried out in reverse order of Remove bolt 2 disassembly Pull out the cotter pin 3 Attention：The direction of the oil pipe on Pull out the pin shaft 4 the vehicle body must be ensured to be Unplug the foot brake switch plug-in 5...

  • Page 173: Front Suspension System

    6 Vehicle chassis 6.4 Front suspension system Installation Installation is carried out in reverse order of Removal of the right front suspension assembly disassembly Attention： When repairing the suspension system, the The removal, installation and inspection left and right suspension systems cannot be methods of the left front suspension removed simultaneously, otherwise the...
  • Page 174 Zhejiang Kayo Motor Co., Ltd. occur, replace the ball pin with a new one. front rocker arm assembly Remove the right front shock absorber Remove the bolt and nut 1 fastening the Installation right front upper rocker arm installed on the Use a special tool to press the ball pin into frame the rocker arm assembly...

  • Page 175: Steering System

    6 Vehicle chassis Installation Installation is carried out in reverse order of disassembly Attention：When installing the steering wheel assembly into the steering shaft opening, align the steering shaft marking line 6.5 Steering system Disassembly and assembly of steering wheel Remove the steering wheel trim cover 1 in an upward direction Remove the fixing bolt 2 Remove steering wheel 3...
  • Page 176 Zhejiang Kayo Motor Co., Ltd. Disassembly and assembly of steering system Disassembly and assembly of steering system Remove the front cover plate Remove the front body assembly Front protection Remove the steering wheel assembly Remove bolt 2 Remove the steering lever 1 Remove the steering rod nut 3 Remove the fixing bolt 4 Remove steering gear 5...

  • Page 177: Rear Suspension System

    6 Vehicle chassis 6.6 Rear suspension system Disassembly and assembly of the left rear suspension assembly When repairing the suspension system, the vehicle body should be suspended first and the suspension system should be removed, otherwise the vehicle body will fall down due to lack of support Park the vehicle on a level surface and use a jack to firmly support the rear of the vehicle...
  • Page 178 Zhejiang Kayo Motor Co., Ltd. 6.7 Disassembly and assembly of rear drive assembly Disassembly When repairing the suspension system, the vehicle body should be suspended first and the suspension system should be removed, otherwise the vehicle body will fall down due to lack of support Park the vehicle on a level surface and use a jack to firmly support the rear of the vehicle...

  • Page 179: Signal And Lighting Systems

    6 Vehicle chassis Quant Quant Name Name Rear drive assembly Rear disc brake disc Rear axle half shaft left assembly Rear hub assembly Outer hexagonal Rear axle half shaft opposite side bolt Rear drive assembly right assembly GB5785 Rear Sheep Horn Hexagon flange self- Assembly locking nut GB6187-86...
  • Page 180 7 Signal and lighting system Maintenance instructions When conducting inspection operations, the entire vehicle can be powered on; When carrying out disassembly and installation operations, the entire vehicle should be powered off first and both hands should be kept dry. Specifications of each component Quant Name...
  • Page 181 Zhejiang Kayo Motor Co., Ltd. 1). Bulb damage 2). Poor contact of connectors 2). Poor contact of connectors 3). Brake sensing damage 3). Damaged dashboard switch 7. The electric horn does not sound or 5. Front right low beam lamp does not is too light work 1).
  • Page 182 7 Signal and lighting system Replace daytime lights Disassembly Remove fixing bolt 1 of low beam lamp Disassembly Removing high beam headlights Remove low beam lamp 2 Remove the fixing bolt 4 Disconnect the low beam lamp plug-in 3 Remove daytime running lights 5 Disconnect the daytime running light plug-in 6 Installation...
  • Page 183 Zhejiang Kayo Motor Co., Ltd. Check Check the continuity between the terminals of the switch lock connector according to the table below. The continuity between ● and ● is considered normal. Ignition switch wiring diagram blue-white，green，black，red，yellow- red，green Installation Follow the reverse order of disassembly 7.5 Panel switch Remove the front cover plate Remove the front body assembly...
  • Page 184 7 Signal and lighting system Check When connecting a fully charged 12V battery, confirm that the electric horn sounds. If there are any abnormalities in the above inspection, replace the electric horn Installation Follow the reverse order of disassembly 7.8 Meter Start the vehicle body, drive slowly, and confirm that the instrument display is normal.
  • Page 185 Zhejiang Kayo Motor Co., Ltd. Shake the fuel sensor float by hand and measure the resistance value at each position of the float. If there are any abnormalities in the above inspection, replace the fuel sensor Installation Place the fuel sensor into the mounting hole of the fuel tank and ensure it is properly assembled without any oil leakage.
  • Page 186 7 Signal and lighting system Appendix 7- 8...

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