KAYO MOTO S200 Service Manual Download

Page: 1 / 186

S200

Service Manual

www.kayomoto.com

KAYO MOTO

Summary of Contents for S200

Page 1: ...3 S200 Service Manual www kayomoto com KAYO MOTO...

Page 2: ...4 Version Code 20230315 Version Name S200 Service Manual Chinese Version pdf www kayomoto com Zhejiang Kayo Motor Co Ltd March 2023...

Page 3: ...hapter introduces the regular inspection and adjustment of the whole vehicle The fourth chapter introduces the dismantling of the assembly parts around the engine The fifth chapter introduces the disa...

Page 4: ...4...

Page 5: ...ould be paid to their prominent meanings when repairing the engine Danger means to be vigilant to high danger Warning means to be vigilant to moderate danger Caution means to pay attention to minor da...

Page 6: ......

Page 7: ...contact with the skin and eyes If clothes or skin accidentally come into contact with battery solution please wash it with plenty of water immediately and go to the hospital for treatment Batteries an...

Page 8: ...n disassembling necessary places should be inspected and relevant data should be measured so that it can be restored to the state before disassembly during assembly 8 Fasteners such as bolts nuts and...

Page 9: ...eal lip before assembly 18 When installing rubber hose parts insert the rubber hose to the root of the joint If there is a pipe clip install the pipe clip in the dent of the pipe Replace the rubber ho...

Page 10: ...and do not allow water to enter any part of the engine or air intake 3 Drain the gasoline in the fuel tank 4 Replace the engine oil 5 Block the holes on the exhaust system with a clean cloth 6 Apply...

Page 11: ...signal lights adjust or replace if necessary 2 Check the tire pressure and inflate to the recommended pressure if necessary 3 Tighten all fasteners It is recommended to tighten the calibrated fastene...

Page 12: ...1 Maintenance information 1 6 1 3 2...

Page 13: ...pecificatio ns Front wheel AT22 7 0 10 Rear wheel AT22 10 10 Minimum ground clearance 230mm Turning circle radius minimum turning radius at the closest point 4800mm Engine Starting method Electric sta...

Page 14: ...gear one reverse gear Transmission mode sequence Manual operation D N R CVT continuously variable ratio 0 703 2 413 Output type Rear axle output Engine output rotation direction When in forward gear i...

Page 15: ...e engine damage and accidents Oil pump rotor Radial clearance between inner and outer rotors 0 12mm Radial clearance between outer rotor and pump body 0 12mm Axial clearance between rotor surface and...

Page 16: ...peak voltage Vp 1 5V 300r min Vp 5V 1500r min Rectifier type Full wave rectification Battery Capacity 12V14AH Voltage between terminals Fully charged 14 4V Insufficient charge Less than 11 8V Items S...

Page 17: ...details Cylinder piston piston ring crank connecting rod see 05 engine part for details Clutch transmission mechanism see 05 engine part for details Items Standards Fuse 15A Lights light bulbs Headlam...

Page 18: ...B70 3 M6 16 10 9 grade 12 14 17 7 Rear wheel hub and disc brake disc fixing bolts M8 Step bolts included in disc brake rotors 8 25 30 8 Fixing screw for steering wheel GB70 85 M6 16 6 10 12 9 Fixing s...

Page 19: ...shaft 2 72 89 30 Lower suction pipe fixing bolts and nuts GB6187 86 M6 2 10 12 31 Handbrake fixing bolts and nuts GB6187 86 M8 2 25 30 32 Fuel tank fixing bolts GB5789 M8 25 4 25 30 33 Cross pan head...

Page 20: ...1 Maintenance information 1 14 45 Ceiling beam fixing bolts GB70 85 M8 16 8 25 30...

Page 21: ...Steering bearing Lightweight lithium soap based lubricating grease Throttle cable connection Rocker arm movable parts Inner peripheral surface of directional column Movable parts of seat cushion lock...

Page 22: ...nd 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 For details se...

Page 23: ...ug in 14 Panel switch plug in 15 Electric door lock plug in 1 Horn plug in 2 Foot brake switch plug in 3 Brake oil pipe Attention The plastic parts of the front body assembly must be removed before in...

Page 24: ...m 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...

Page 25: ...or 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 th...

Page 26: ......

Page 27: ...front body assembly left and right fenders left and right pedal outer guards rear fender and air guide 2 5 1 Front cover panel 2 7 2 5 2 Front body assembly 2 8 2 5 3 Left fenders 2 9 2 5 4 Left peda...

Page 28: ...disassembly and assembly sequence of vehicle body covers When repairing internal components of the vehicle that require disassembly of relevant covers it can be referred to in this chapter This chapte...

Page 29: ...tallation is carried out in reverse order of disassembly 2 3 2 Ceiling frames and backrest crossbeam Disassembly Remove the top shelf fixing bolt 1 total 12 Remove the upper suction pipe fixing bolt 3...

Page 30: ...ly 2 4 2 Left door side panel Disassembly Remove the left door inner support panel 2 4 1 Remove the left door side panel mounting screws 1 5 in total Remove the left door side panel 2 Installation Ins...

Page 31: ...e right door side panel mounting screws 1 5 pieces in total Remove the right door side panel 2 Installation Installation is carried out in reverse order of disassembly 2 4 6 Right door frame Disassemb...

Page 32: ...isassembly 2 4 8 Left handrest panel Disassembly Remove the inner support of the left handrest 2 4 7 Remove the fastening screw 1 of the left handrest Remove the left handrest 2 Installation Follow th...

Page 33: ...isassembly 2 5 Front cover panel front body assembly left and right fenders left and right pedal outer guards rear fender and air guide 2 5 1 Front cover panel Disassembly Remove the front instrument...

Page 34: ...cable plugin 6 Remove the left and right low beam cable plug in 7 Remove the left and right daytime running light cable plug in 8 Remove the flasher plug in 9 Remove the igniter plug in 10 Remove the...

Page 35: ...outer guard 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 fend...

Page 36: ...6 Right pedal outer guard 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...

Page 37: ...screw 1 Remove the fixing bolt 2 Remove the left rear fender 3 Installation Follow the reverse order of disassembly 2 5 8 Right rear fender Disassembly Remove the front cover panel 2 5 1 Remove the fr...

Page 38: ...y of safety belts seat cushions inner guards of left and right foot pedals left and right foot pedals central control components and interior front bumper components 2 6 1 Seat belts and seat cushions...

Page 39: ...the reverse order of disassembly Pay attention to whether the clip nut on the plastic part slips off before installation 2 6 3 Right foot pedal Disassembly Remove the seat belt and seat cushion 2 6 1...

Page 40: ...e fixing screw 4 Remove the brake cable fixing nut 5 Pull the handbrake lever to the highest position Lift up and remove central control component 6 Installation Follow the reverse order of disassembl...

Page 41: ...r cover of right foot pedal Disassembly Remove the seat belt and seat cushion 2 6 1 Remove the right foot pedal 2 6 3 Remove the fixing screw 1 Remove the inner shield 2 of the right pedal Installatio...

Page 42: ...xing screw 1 Remove the front right fender 2 of the interior Installation Follow the reverse order of disassembly 2 6 9 Interior front fender Disassembly Remove the front left fender of the interior 2...

Page 43: ...cover 2 7 1Front guard Disassembly Remove the front protective fixing bolt 1 Remove the front guard 2 Installation Follow the reverse order of disassembly 2 7 2 Rear shelf Disassembly Remove the rear...

Page 44: ...emove the rear taillight frame 4 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...

Page 45: ...Zhejiang Kayo Motor Co Ltd 2 19 5 6 7 8 9 10 0...

Page 46: ......

Page 47: ...ed or a place with poor ventilation When the engine just stops the temperature of the muffler and the engine is still very high If it touches the skin it will cause burns If it is necessary to carry o...

Page 48: ...der severe conditions the maintenance cycle of the engine should be correspondingly shortened Maintenance item Items Odometer km Cycle 1000km 4000km 8000km 12000km Notes Fuel system passage I I I Fuel...

Page 49: ...ng and brake discs Front and rear brake fluid volume The brake fluid should be above the lower limit Wear and damage of brake discs When the thickness of the working disc of the front brake disc is le...

Page 50: ...heel bearings Buffer device Suspension arm Shake of the connecting part and damage to the rocker arm Shock absorber Oil leakage and damage Function Transmissi on device Front Axle Transmission lubrica...

Page 51: ...edal 2 6mm Lighting device and direction indicator Function Alarm and lock device Function Instrument Function Exhaust pipe and muffler Whether the installation is loose or damaged The function of the...

Page 52: ...the red arrow If they are confirmed to be on the same line check the splines of the steering wheel and adjust the steering wheel Turn the steering wheel left and right If you feel that some positions...

Page 53: ...inimum thickness of the friction pad is 1 mm If it is less than the minimum thickness of the friction pad please replace the new brake pad Check if there is any damage or crack on the brake friction p...

Page 54: ...brake pad If there is damage or wear below the limit of use please replace it It is also necessary to inspect these items before each use of the vehicle Take off the oil cup cover 2 Replenish the brak...

Page 55: ...the current brake disc thickness is 3 0mm replace the brake disc Rear brake disc service limit thickness 3 0mm Check the minimum thickness of brake friction plate 2 Minimum friction plate thickness 1...

Page 56: ...replace bearings rocker arm buffer sleeves ball pins Front wheel size Place the vehicle body in a horizontal position and measure the toe in dimensions of the wheels The front wheel is relative to the...

Page 57: ...o poor operation and riding comfort and cause adverse effects such as tire bias wear Designated air pressure tire Front wheel Rear wheel Air pressure 35kPa 0 35kgf cm2 35kPa 0 35kgf cm2 Tire size See...

Page 58: ...of the wheel hub Use a tool to lift the front wheels and when there is no force on the front wheels shake the wheels axially to check if there is any shaking Remove the front wheel and inspect the wh...

Page 59: ...mechanism 2 is flexible and if the gear is shifting in If it is difficult to shift adjust the length of the shift mechanism lever 3 Loosen the lock nut 4 and adjust the length of the shift mechanism...

Page 60: ...still cannot reach the specified gap or if the action is still not flexible then replace the throttle cable with a new one If the height of the throttle pedal decreases or is too high adjust the limit...

Page 61: ...pection Step on the brake pedal with your foot and observe the tail lights If the tail lights do not light up please check if the wiring is connected incorrectly If the wiring is correct please replac...

Page 62: ...e please ensure that the vehicle is turned off and left standing for no less than 1 hour Confirm that the heating components have cooled before proceeding with maintenance to avoid injury to maintenan...

Page 63: ...but also high attention should be paid to electric sparks In addition due to the risk of explosion after gasoline evaporation vaporization operations should be carried out in a well ventilated area W...

Page 64: ...4 Around the engine 5 11 2 6 4 3 5 8 7...

Page 65: ......

Page 66: ...emove 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 ass...

Page 67: ...t pipe assembly 4 3 Exhaust system Loosen the heat dissipation system plug in 1 Remove the oil cooling pipe 2 Remove the oil cooler fixing bolt 3 Remove the oil cooler 4 Remove the suction pipe fixing...

Page 68: ...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 Remove the star...

Page 69: ...system 5 20 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...

Page 70: ...nents 5 84 5 7 11 Check the runout of the shift fork shaft 5 84 5 7 12 Check the shift fork 5 84 5 7 13 Check the variable speed drum 5 85 5 7 14 Disassemble and assemble the bearing 5 85 5 7 15 Check...

Page 71: ...with non metric specifications Bolts nuts and screws of metric specifications cannot be interchanged with fasteners of imperial specifications 3 When reassembling after disassembly please replace with...

Page 72: ...ission system Clutch Gearbox Forward gear ratio Reverse gear ratio CVT gear ratio Shift mode Dry clutch Infinitely variable speed Forward gear i 43 14 40 17 7 227 Reverse gear i 49 14 49 15 40 17 26 9...

Page 73: ...59 mm 31 41mm Valves valve guides Valve stem diameter Intake 5 45 5 465 mm Exhaust 5 43 5 445 mm Valve guide inner diameter Intake exhaust 5 475 5 485 mm Valve stem to valve guide clearance Intake 0 0...

Page 74: ...lubricating oil pump body 0 05 0 11 mm 0 16mm Belt main and driven pulley component specifications Items Standard value Service limit Belts Belt width 19 5 20 0 mm 19mm Active pulley components Drivin...

Page 75: ...k connecting rod components Runout 0 03mm 0 1mm Connecting rod small end diameter 17 013 17 025 mm 17 06 mm Connecting rod large end clearance crank width 0 15 0 4 mm 0 6 mm Bearing axial direction 0...

Page 76: ...eys 1 12 54 60 Crankcase oil drain bolts 1 12 32 40 Transmission box oil drain bolts 1 8 20 25 Transmission box refueling bolts 1 10 24 32 Shifting and shifting bolts 1 14 25 35 Lubricating oil filter...

Page 77: ...nd rod end of the valve stem The entire surface of the timing chain The rolling surface of the camshaft The inner surface of the cylinder borePiston outer surface piston pin hole and piston ring groov...

Page 78: ...ce the entire vehicle on a horizontal plane Tool Valve adjustment screw fixing tool 5 2 2Maintenance specifications Please check according to the maintenance interval in the maintenance table of the I...

Page 79: ...ut according to the specified cycle above When driving in particularly humid or dusty areas maintenance work should be carried out more frequently When driving in the rain or at full speed the mainten...

Page 80: ...ating 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 If any w...

Page 81: ...until the T marking line A on the magneto rotor aligns with the notch B on the right crankcase cover as shown in the figure it is the top dead center of cylinder compression Attention Unable to rotate...

Page 82: ...clearance is not correct please adjust the valve clearance Adjusting valve clearance Loosen the locking nut and rotate the adjusting screw until the gap is correct Secure the adjusting screw A with f...

Page 83: ......

Page 84: ...nance schedule Remove the left crankcase cover As shown in the figure use a pair of suitable straight edge holders to measure the width A of the belt at several positions If the measured value is less...

Page 85: ...vironment with a quality grade of SJ or above Viscosity SJ 10W 40 Capacity 1 1L disassembling crankshaft case Attention Please use the specified lubricating oil and do not add other chemical additives...

Page 86: ...t solvents may be flammable and or explosive which can cause serious burns Clean the lubricating oil filter screen in a well ventilated area and ensure that there are no sparks or flames near the work...

Page 87: ...sary replenish it by opening the inspection bolts Use the same type and brand of oil as the transmission box Replace with a new flat washer and tighten the inspection bolt Check the tightening torque...

Page 88: ...les It can also be cleaned with a wire brush or other suitable tools If the spark plug electrode is corroded or damaged or the insulation material is broken please replace the spark plug Use standard...

Page 89: ...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 When disassembling the disasse...

Page 90: ...SJ 10W 40 Capacity 1 1L The oil level Check with dipstick between the marking lines Oil pump Clearance between inner and outer rotors 0 05 0 15 mm 0 2mm Clearance between the outer rotor and the lubri...

Page 91: ...oil filter screen oil pump mesopore oil cooler section cylinder cover cylinder head Right cover diversion chamber oil chamber cam oil pool rocker arm valve bolt in valve bolt ex middle hole of oil jo...

Page 92: ...off the engine and then wait for one minute until the lubricating oil settles Accelerating the engine before the lubricating oil reaches each level will cause the engine to stop running If the oil le...

Page 93: ...C Lubricating oil filter screen D Assembly of lubricating oil filter screen Assembly and disassembly are exactly the opposite Note that a new O ring needs to be replaced Tightening torque of lubricati...

Page 94: ...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 Di...

Page 95: ...ply lubricating oil to the following parts Oil pump transmission shaft Inner rotor A and outer rotor B Assembly Inner rotor Outer rotor Check if the positioning pin is properly assembled Align the loc...

Page 96: ...ven gear B Attention Align the concave points of the main and driven teeth of the balance shaft A B B B A Other reverse assembly Oil pump driving wheel oil pump chain oil pump driving wheel oil pump d...

Page 97: ...er and outer rotors Standard 0 05 0 15 mm Service limit 0 2mm Use a feeler gauge to check the gap A between the outer rotor and the oil pump body If the measured value exceeds the service limit please...

Page 98: ...ew 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...

Page 99: ...sure correct positioning during reassembly Before inspection all dismantled components should be cleaned with cleaning agent and blown dry with compressed air The camshaft lubricating oil is injected...

Page 100: ...7 31 59 mm 31 41mm Inlet 31 72 31 84 mm 31 66mm Cylinder head Cylinder pressure Available range 900 1200 kpa Flatness 0 03mm 0 05mm Valve clearance Exhaust valve 0 04 0 08 mm Intake valve 0 04 0 08 mm...

Page 101: ...efer to the fuel system chapter Remove pipe clamp A and vent pipe B Remove the cylinder head cover assembly bolts C and cylinder head cover D Assemble the cylinder head cover Replace the cylinder head...

Page 102: ...e bolts are loosened the tensioner must be disassembled and reset according to the instructions for assembling the tensioner Do not rotate the crankshaft when removing the tensioner as it may disrupt...

Page 103: ...support plate A and then assemble the tensioner on the cylinder block Tightening torque of tensioner assembly bolt A 8 12 N m Remove support plate B Replace with a new sealing ring Apply lubricating...

Page 104: ...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 Assemble the following parts as show...

Page 105: ...stalled 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 pl...

Page 106: ...he end of valve adjustment bolt B contacts the valve If there is mushroom shaped or other damage to the end of the valve adjustment bolt or the bolt cannot rotate smoothly please replace it and check...

Page 107: ...rt seat B Remove camshaft A Support the timing chain with a suitable tool Assemble camshafts Apply lubricating oil to all cam components Assemble locating pin A Engage the timing chain and timing driv...

Page 108: ...ved components Check the cam wear Remove the camshaft Measure the height A of the cam with a micrometer If the measured value exceeds the cam wear limit replace the camshaft Cam height Standard Exhaus...

Page 109: ...Chain guide plate C Remove timing chain D from the timing driven wheel Assemble the timing chain Reverse assembly Hang the timing chain on the timing driven wheel Assembly Chain guide plate Chain ten...

Page 110: ...er 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...

Page 111: ...amaged parts Incorrect thickness of cylinder head gasket Replace with a standard specification sealing gasket Cylinder pressure below available range There is gas leakage around the cylinder head Repl...

Page 112: ...w cylinder head gasket Assembly Positioning pin A new cylinder head gasket B Cylinder head camshaft Tighten the cylinder head bolts Tightening requirements The exposed height of the bolt is 190 5 192...

Page 113: ...ease replace it If the deformation of the cylinder head is lower than the limit of use grind the lower plane with fine sandpaper Check the width of each valve seat surface of the cylinder head The wid...

Page 114: ...ch on the bolt of the magneto rotor and rotate the crankshaft clockwise until the T mark A on the magneto rotor aligns with the notch B on the right crankcase cover as shown in the figure at the end o...

Page 115: ...e valve Remove the cylinder head Mark the valve position so that it can be assembled back to its original position Remove the valve using valve spring compression device A and adapter B Tool valve spr...

Page 116: ...he corresponding inner diameter of the valve guide to obtain the clearance between them If the gap exceeds the service limit replace the cylinder head Valve and valve guide clearance Standard Exhaust...

Page 117: ...5 5 2 Service information Overview This chapter includes the disassembly and inspection of the left crankcase cover and CVT components There is no need to remove the engine from the frame and it can b...

Page 118: ...6 98 26 959 mm 26 91mm Outer diameter of roller 20 9 21 1 mm 20 8mm Driven pulley components Driven sliding plate assembly hole diameter 34 34 025 mm 34 06mm Driven fixed shaft diameter 33 97 33 99 mm...

Page 119: ...B Left crankcase cover Tighten the left crankcase cover bolts Tightening torque of the left crankcase cover assembly bolt 8 12 N m Assemble the intake and exhaust pipes Fit the protruding part A of th...

Page 120: ...s removed it needs to be replaced with a new one When checking whether there is clearance and whether the rotation is flexible turn the bearing A back and forth If gaps roughness or adhesion are found...

Page 121: ...belt can be reassembled on the pulley and rotate in the same direction as the original assembly Remove driven pulley component B and belt C Assembly belt Attention Ensure that the engraved information...

Page 122: ...ce schedule Remove the left crankcase cover As shown in the figure use a pair of suitable straight edge holders to measure the width A of the belt at several positions If the measured value exceeds th...

Page 123: ...nents 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 Disassemble Bushing A Drive...

Page 124: ...rvice limit 27 10mm If the bushing is damaged or worn please replace it Outer diameter A of bushing Standard 26 98 26 959 mm Service limit 26 91mm If the roller is damaged or worn please replace it Ro...

Page 125: ...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 t...

Page 126: ...shing C and clutch outer plate D Disassemble Driven pulley component A Disassemble the driven pulley component assembly Attention Be sure to use a clutch spring compressor to avoid damage to the compr...

Page 127: ...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 asse...

Page 128: ...te C from the driven fixed plate B Disassemble Oil seal A Remove needle bearing A Remove the circlip B and outer bearing C Tool Circlip pliers with inner snap Check the driven pulley components If sur...

Page 129: ...mit 33 95mm If the pressure spring is damaged or worn please replace it Free length A of pressure spring Standard 88 90 mm Service limit 86mm If the spring coil is twisted please replace it Assembly o...

Page 130: ...oil seal B into the driven sliding plate with the oil seal end face flush with the shaft end face C Assemble the driven sliding plate onto the driven fixed plate Apply lubricating grease to the pin sh...

Page 131: ...ch driven plate nut to the specified torque Tool clutch spring compressor Release the clutch spring compressor and remove the driven pulley component assembly Disassemble the clutch assembly Remove th...

Page 132: ...amage please replace it Measure the inner diameter A of the clutch outer plate If the wear of the clutch outer disc exceeds the service limit please replace it Inner diameter of clutch outer plate Sta...

Page 133: ...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 This chapter covers the maintenance of the stator and rotor...

Page 134: ...Engine 5 66 5 6 3 Specifications Items Standard value Service limit Starting disc gear Outer diameter of shaft sleeve 42 575 42 6 mm 42 55mm Inner diameter of shaft sleeve 32 00 32 025 mm 32 05mm Tool...

Page 135: ...ace and keep it level Remove the following components Right side cover of the entire vehicle Magneto trigger plug Remove the right decorative cover bolt A remove the right decorative cover B take out...

Page 136: ...e Replace the right crankcase cover paper pad with a new one Check the lubricating oil level Ensure that there are no lubricating oil leaks 6 6 5 Magneto spindle and trigger Disassemble assemble Remov...

Page 137: ...ll the fixing block of the magneto rotor retainer to prevent the rotor from rotating Remove the rotor nut and washer Use Tool E to remove rotor B Remove round nut F and flat washer G Remove the starti...

Page 138: ...he crankshaft cone and the inner hole of the rotor Assemble the rotor paying attention to aligning the half round key on the crankshaft with the keyway on the rotor Apply clean engine lubricating oil...

Page 139: ...eformation If necessary please replace it Disc teeth Starting clutch Ensure that all components meet the specifications of the magneto and starting clutch Replace the component if it exceeds the repai...

Page 140: ...sembly 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...

Page 141: ...Zhejiang Kayo Motor Co Ltd 5 93 5 7 2 Service information Overview This chapter includes the disassembly and inspection of the crankshaft case and the...

Page 142: ...ice limit Crank connecting rod components Runout 0 03mm 0 1mm Connecting rod small end diameter 17 013 17 025 mm 17 06 mm Connecting rod large end clearance crank width 0 15 0 4 mm 0 6 mm Bearing axia...

Page 143: ...Zhejiang Kayo Motor Co Ltd 5 93 Tools Internal circlip pliers External circlip pliers Oil seal and bearing remover adapter A Bearing drive tool set...

Page 144: ...5 Engine 5 92 Bearing drive 32 Bearing drive adapter 42 Oil seal and bearing remover Flywheel rotor retainer...

Page 145: ...sket A locating pin B Crank connecting rod component C balance shaft D Transmission mechanism E Shift mechanism F Assemble Bearing A faces towards the short end of spindle B The retaining ring C plane...

Page 146: ...posite side of the transmission tooth The shift fork B is assembled into the middle ring groove of the transmission shaft C One shift fork shaft is inserted into the end and dipped in oil passing thro...

Page 147: ...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 Assemble one end of the short shaft diameter of balance shaft A to the ba...

Page 148: ...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 a...

Page 149: ...e 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 Install gear display conta...

Page 150: ...rd 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 Insp...

Page 151: ...her 15 25 1 4 Bushing 15 17 10 5 Forward driven wheel 6 Bushing gear tooth combination sleeve 7 Elastic washer GB T 894 1_d 22 8 Spline washer 22 35 3 9 Reverse driven wheel 10 Needle roller bearing R...

Page 152: ...er 5 7 8 Assemble the spindle Assemble Spindle bearing A Special tool bearing press fixture B Assemble a new circlip C Tools Outer Ring Calipers Assemble Spindle bearing pressure plate B Use non perma...

Page 153: ...ase replace it Special tools Hydraulic press fitting fixture 5 7 11 Check the runout of the shift fork shaft Measure the runout of the shift fork shaft If the measurement exceeds the usage limit Repla...

Page 154: ...shaft is bent replace it with a new one 5 7 13 Check the variable speed drum Check whether the variable speed drum and journal are worn or damaged If necessary please replace it Assemble Steel ball A...

Page 155: ...ttention please Do not remove the bearings for inspection Remove them may damage them Check the ball bearing Due to the close tolerance of ball bearings wear must be judged by sensation rather than me...

Page 156: ...on 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 cle...

Page 157: ...ston Cylinder inner diameter 63 5 63 51 mm 63 57mm Outer diameter of piston 63 47 63 48 mm 63 4mm Side clearance of piston ring First ring 0 03 0 07 mm 0 1mm Second ring 0 02 0 06 mm 0 09mm Piston pin...

Page 158: ...on Carefully open one ring of piston ring with your thumb then push the other side of piston ring up A and take down one ring of piston ring Use your thumb to remove the second ring and scraper ring i...

Page 159: ...learance inspection between piston and cylinder block Subtracting the piston diameter from the cylinder diameter to obtain the piston cylinder gap Piston cylinder clearance Standard 0 02 0 04 mm If th...

Page 160: ...e cylinder where there is less wear on the cylinder Measure the clearance between the two ends of the ring with a thickness gauge B piston ring end clearance Standard The first ring 0 15 0 35 mm The s...

Page 161: ...sage limit replace the crankshaft components 5 8 12 Inspection of crank and connecting rod components Disassemble the crankshaft connecting rod components refer to the crankshaft case Measure the smal...

Page 162: ...4 60 5 mm Assemble the crankshaft connecting rod components refer to the crankshaft case Wear inspection for main bearing of crank connecting rod parts Rotate the crankshaft connecting rod component b...

Page 163: ...insert the rail into the bottom piston ring groove Or press the rail into the bottom piston ring Apply lubricating oil on piston ring Do not mix the first and second rings assemble the first ring A wi...

Page 164: ...ng oil to the inner diameter of the cylinder and the piston skirt The position of piston ring opening must be as shown in the figure The first ring A The second Ring B Oil ring scraper ring upper C Oi...

Page 165: ...95 Zhejiang Kayo Motor Co Ltd 5 Chain tensioning plate D Starter motor assembly Starter motor assembly B Bolt A Control torque 8 12 N m B A...

Page 166: ......

Page 167: ...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...

Page 168: ...imit Rims Axial runout 0 8mm 2 0mm Radial runout 0 8mm 2 0mm Tires Residual groove 3mm Pressure 35kPa 0 35kgf cm2 Front brakes Brake handle clearance 0mm Tightening torque Name Specifications Torque S...

Page 169: ...4 Frame deformation 5 Tire wear and eccentric wear 6 Wheel bearing shaking 3 Front wheel runout 1 Wheel deformation 2 Poor wheel bearings 3 Poor tires 4 Improper wheel balance 5 Poor fastening around...

Page 170: ...gether Remove the front wheel mounting bracket Installation Installation is carried out in reverse order of disassembly Rim shaft mounting nut torque 72N m 89N m Brake disc installation bolt torque 14...

Page 171: ...c 3 and front wheel mount 4 together from the vehicle Remove the brake disc 3 Check Front brake disc thickness If it is less than 3 0mm replace it with a new brake disc Installation Install the brake...

Page 172: ...pipe on the vehicle body must be ensured to be smooth according to the cable and wire routing diagram in the first chapter When the brake system assembly is installed the brake force must be checked...

Page 173: ...ight front upper rocker arm ball pin Remove the right front upper rocker arm 5 Remove the split pin and lock nut 9 from the steering rod ball pin Remove the bolt and nut 4 installed on the frame of th...

Page 174: ...has deteriorated grease model No 2 lithium based grease GB7324 87 and whether the dust boot on the ball pin is cracked or aged If the above problems occur replace the ball pin with a new one Remove t...

Page 175: ...late Remove the front body assembly Remove bolt 4 Remove the steering seat bolt 5 Loosen bolt 6 Remove the steering wheel assembly 7 Attention For the specific disassembly of the plastic part refer to...

Page 176: ...e steering lever 1 Remove the steering rod nut 3 Remove the fixing bolt 4 Remove steering gear 5 Installation Installation is carried out in reverse order of disassembly Throttle pedal Disassembly Rem...

Page 177: ...brake caliper Remove the bolt 1 of the left rear shock absorber Remove the rear shock absorber 2 Remove the rear upper rocker arm fixing bolt 4 Remove the fixing bolt 6 Remove the rear upper rocker ar...

Page 178: ...a jack to firmly support the rear of the vehicle Remove the rear fender Remove the rear wheel Remove the brake caliper Remove the left and right rear shock absorbers Remove the left and right rear upp...

Page 179: ...t with a new one Check the thickness of the disc brake disc If the disc brake thickness is 3mm a new disc brake disc should be replaced Check if the rear transmission shaft is bent or damaged and if s...

Page 180: ...ece Left front low beam headlight SJ WZ8 H 12V 6W 2 pieces Osram lamp beads with built in constant current drive 1 Replace the entire piece Right front low beam headlight SJ WZ8 H 12V 6W 2 pieces Osra...

Page 181: ...dlamp inspection Turn the lighting switch to the lighting position and check if the headlights are on Lighted Normal Unlighted Main cable disconnection or short circuit Fuse broken Switch damage Lamp...

Page 182: ...the reverse order of disassembly Replace the low beam lamp Disassembly Remove fixing bolt 1 of low beam lamp Remove low beam lamp 2 Disconnect the low beam lamp plug in 3 Installation Follow the rever...

Page 183: ...ding to the table below The continuity between and is considered normal Ignition switch wiring diagram Installation Follow the reverse order of disassembly 7 5 Panel switch Remove the front cover plat...

Page 184: ...hen 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...

Page 185: ...e fuel sensor and fuel gauge themselves Connect a multimeter between the terminals of the fuel sensor connector Shake the fuel sensor float by hand and measure the resistance value at each position of...

Page 186: ...7 Signal and lighting system 7 8 Appendix S200 series electrical schematic diagram...

Search results

Summary of Contents for S200

Reviews:

Related manuals for S200

Brands by name

Popular brands

KAYO MOTO S200, Service Manual

Search results

Summary of Contents for S200

Reviews:

Related manuals for S200

Brands by name

Popular brands