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KAYO MOTOR A180, Service Manual

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KAYO MOTOR A180 Service Manual Download Page 53

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Rear brake disc, brake pad <brake pad wear> 

Check the wear of the brake pads If the wear  

has reached the wear limit, replace the brake 
pads. 

 

Note: The brake pads should be replaced as a 
complete set 

 

Inspection and replacement of brake discs 

Check whether the sliding surface of brake disc 1 
is worn or damaged. If the current brake disc 
thickness ≤3.0mm, replace the brake disc 

 

Use limit thickness of rear brake disc: 3.0mm 

 

 

 

 

 

 

 

 

Check the minimum thickness of the brake 
friction lining 2. The minimum friction lining 
thickness ≥ 1 mm. If it is less than the minimum 
friction lining thickness, please replace with a 
new brake friction lining; check whether the 
brake friction lining is damaged or cracked. If 
there is damage or cracks, please Replace with 
new brake pads. 

 

 

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Summary of Contents for A180

Page 1: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto com KAYO MOTO A180 SERVICE MANUAL ManualSERVICE MANUALSERVICE MANUAL www kayomoto com...

Page 2: ......

Page 3: ...ular inspection and adjustment 3 Engine peripheral parts 4 Engine 5 Vehicle chassis 6 Signal and lighting system 7 Electrical schematic diagram Appendix The first chapter mainly introduces general ope...

Page 4: ...s manual are subject to change due to vehicle improvements and other reasons without further notice The actual state of the vehicle shall prevail during maintenance ZHEJIANG KAYO MOTOR CO LTD R D depa...

Page 5: ...kPa Torque 1kgf m 9 80665N m Volume 1mL 1cm 3 1cc 1L 1000cm 3 Moment of force 1kgf 9 80665N Length 1in 25 4mm Danger Warning Caution Please read the following explanation carefully which emphasize the...

Page 6: ...ned in this SERVICE MANUAL cannot cover all potential risks during the use and maintenance of the engine Therefore in addition to the danger and warning regulations maintenance personnel must also hav...

Page 7: ...sulfuric acid is a strong corrosive agent which may cause burns and blindness when it touches the skin and eyes If your clothes or skin are accidentally stained with battery solution please rinse the...

Page 8: ...TV before maintenance 4 Gaskets O rings piston pin retaining rings split pins etc must be replaced with new ones after disassembly 5 The elastic collar will be deformed if the opening is too large dur...

Page 9: ...rings that feel stuck in rotation should be cleaned and those that still feel stuck after cleaning should be replaced and those that cannot be cleaned should be replaced directly If the bearing is ori...

Page 10: ...he groove Engine running in The engine has many parts for relative movement such as pistons piston rings cylinder blocks intermeshing transmission gears Therefore in the initial stage of using it is n...

Page 11: ...ance according to the specification and promptly remove any fault After the running in is over the whole machine can be maintained before entering the normal driving stage 1 2 Vehicle identification n...

Page 12: ...ZHEJIANG KAYO MOTOR CO LTD 4 4 1 2 3...

Page 13: ...re size Front AT23 7 10 Rear AT22 10 10 Ground Clearance 160mm Turning radius minimum turning radius of the closest point 2400mm Engine Starting method Electric start Hand pull start Engine type Singl...

Page 14: ...quence Manual F N R Output type Rear axle output Rotation direction of engine output In the forward gear viewed from the rear of the vehicle the front is clockwise Steering device Maximum steering ang...

Page 15: ...e accidents Oil pump rotor Radial clearance of inner and outer rotor 0 12mm Radial clearance between outer rotor and pump body 0 12mm Axial clearance between rotor surface and pump body 0 05 0 1 0 2mm...

Page 16: ...tion coil primary 300 450V Pulse generator 20kV 30kV Coil resistance of starting relay 3 5 Item Standard Magneto Type Permanent magnet alternator Output Three phase full wave Magneto trigger coil resi...

Page 17: ...A Light bulb Headlamp 12V 35W Tail light brake light 12V 2 8W Valve train cylinder head see 05 Engine section for details Cylinder Piston Piston Ring Crank Connecting Rod see 05 Engine section for det...

Page 18: ...mounting screw GB70 85 M8 16 4 22 30 12 Mounting bolt of direction handlebar pressure block GB5783 M10 1 5 30 2 45 59 13 Oil cooler mounting bolt GB5789 M6 25 4 9 12 14 Trailer ball fixing plate moun...

Page 19: ...ools see 05 Engine section for details Engine special tools see 05 Engine section for details 1 6 Lubricants and sealants Coating place Note Grease Steering bearing Lightweight lithium soap grease Thr...

Page 20: ...ate GB T5671 Engine operating materials and installation accessories see 05 Engine section for details Engine operating materials include lubricating oil oil grease butter and coolant etc Installation...

Page 21: ...ble wiring diagram 1 Gear display connector 2 Gear indication connector 3 Headlamp connector 4 Spare neutral display connector 5 Electric door lock switch connector 6 Left handle multi function switch...

Page 22: ...ZHEJIANG KAYO MOTOR CO LTD Note The front panel must be removed before inspecting and repairing the above components For detailed disassembly please refer to Chapter 2 Body Covering Parts...

Page 23: ...1 Maintenance information 6 8 7 8 Brake sensor one for left and right 9 Throttle cable 10 Brake oil pipe 8 9 10 2 3 4 1 5...

Page 24: ...ain pipe 4 Starter motor line 5 Engine exhaust pipe 6 gear display connector 7 Magneto trigger connector 8 Stabilized rectifier connector Note The front and rear jerseys must be removed before checkin...

Page 25: ...1 Maintenance information 8 Relay 9 Battery negative wire 10 Starting motor wire 11 Battery positive wire 12 Voltage stabilizer rectifier 8 9 10 11 12...

Page 26: ...ZHEJIANG KAYO MOTOR CO LTD 1 Taillight connection cord 2 Taillight 1 2...

Page 27: ...sembly 2 4 1 Front cover of the hood 2 3 2 4 2 Front gear display lampshade 2 4 2 4 3 Gear display meter 2 4 2 4 4 Shift lever assembly 2 4 2 5 Disassembly and assembly of left and right pedal tubes a...

Page 28: ...he relevant covers need to be disassembled for the maintenance of the internal parts of the finished vehicle refer to this chapter This chapter describes the disassembly and assembly operations of she...

Page 29: ...d pull the seat cushion backward 1 Remove the seat cushion Assembly Follow the reverse order and direction of disassembly After installation check whether the seat cushion is in place and firm etc 2 4...

Page 30: ...front panel fixing bolt 1 and remove the head cover in the direction of the arrow Note the buckle on the head cover is easy to break and proceed with caution Assembly Follow the reverse order and dir...

Page 31: ...ent front cover 2 Note before removing the front lampshade remove the head cover and pull out the main lock insert Assembly Follow the reverse order and direction of disassembly 2 4 3 Gear display met...

Page 32: ...erse order and direction of disassembly 2 4 4 Shift lever assembly Disassembly Remove the foot stop lever mounting bolt 6 Remove the foot stop lever 5 Assembly Follow the reverse order and direction o...

Page 33: ...move fastening screws 1 2 3 4 5 Note 2 and 4 are on the corresponding right side Remove the left foot pedal tube Remove the left foot tube The removal method of the right pedal tube is the same as tha...

Page 34: ...2 5 2 Left and right iron pedals Remove the left iron pedal Remove the pedal fixing bolt 1 and the iron pedal 2 Disassembly method of right iron pedal and left iron pedal 1 2...

Page 35: ...te in the direction of the arrow Note The buckle on the hood is easy to break and operate with caution Assembly Follow the reverse order and direction of disassembly 2 6 2 Front vehicle cover Disassem...

Page 36: ...remove the cables on the front assembly board and check the cables and connectors after installation to prevent wrong connection 2 6 3 Rear vehicle cover Disassembly Remove the fixing bolts 1 2 3 and...

Page 37: ...les of the tail lamp and rear turn signal lamp and when disassembling the battery turn off the ignition switch disassemble the positive pole of the battery first and install the negative pole of the b...

Page 38: ...as carbon monoxide CO please do not run the engine for a long time in a closed place or a poorly ventilated place When the engine just stopped the temperature of muffler and engine was still very high...

Page 39: ...3 3 Note Don t let the rotating parts such as the drive system catch your hands and clothes Note The vehicle must be placed on a flat and stable ground...

Page 40: ...use conditions Under severe conditions the maintenance period of the engine should be shortened accordingly Maintenance item Item Odometer km cycle 1000km 4000km 8000km 12000km Remark Fuel system acce...

Page 41: ...3 3 I Inspect Note When driving in a dusty place it should be cleaned frequently...

Page 42: ...ke disc is less than 3mm and the working disc thickness of the rear brake disc is less than 3mm it should be replaced in time Brake pad Wear and damage of brake pads The minimum brake pad friction pad...

Page 43: ...3 on Gearbox Oil spill and oil volume Loosen the oil filler bolt and the oil quantity should reach the orifice...

Page 44: ...Ignition period Accumulator Terminal connection status Electric circuit Looseness and damage of the connection Fuel device Fuel leak Throttle status Throttle lever clearance 2 6mm Lighting device and...

Page 45: ...ce of the steering column locking nut or disassemble the steering column for maintenance Place the car in a horizontal position and slowly turn the direction handle to the left and right to confirm wh...

Page 46: ...TD to the inability to control the direction of the handle Clearance of the front brake handle Operate the front brake handle to check the braking effect and the movement of the handle Check the play...

Page 47: ...ck the wear of the brake disc and brake pad If it is damaged or worn below the service limit replace it It is also necessary to check these items before using the vehicle every time Remove two exhaust...

Page 48: ...ZHEJIANG KAYO MOTOR CO LTD and right and then remove the oil cup cover after the brake pump assembly is in a horizontal state 1 Exhaust screw 2 Lower limit line 3 Oil cup cover 4 Observation hole...

Page 49: ...face of brake disc 1is worn or damaged If the current brake disc thickness 3 0mm replace the brake disc Use limit thickness of front brake disc 3 0mm Check the mini thickness of brake lining 2 The min...

Page 50: ...level at a safe position check the oil circuit and connection points for damage if any please replace it in time check the main pump caliper for damage if any please replace it in time Note Do not ope...

Page 51: ...rake pad If it is damaged or worn below the service limit replace it It is also necessary to check these items before using the vehicle every time Remove the two exhaust screws 1 of the oil cup cover...

Page 52: ...e oil circuit and connection points are damaged and if there is any damage please replace it in time check whether the main pump caliper is damaged and if there is any damage please replace it in time...

Page 53: ...rake disc 1 is worn or damaged If the current brake disc thickness 3 0mm replace the brake disc Use limit thickness of rear brake disc 3 0mm Check the minimum thickness of the brake friction lining 2...

Page 54: ...ZHEJIANG KAYO MOTOR CO LTD Oil change brake fluid replacement Brake fluid is replaced once a year...

Page 55: ...ighten the rocker arm axle rim bolts and nuts If there is still shaking check and replace bearing rocker arm buffer sleeve and ball pin Front wheel size Place the body in a horizontal position and mea...

Page 56: ...ZHEJIANG KAYO MOTOR CO LTD the steering rod 1 Note After adjusting the toe size drive the vehicle slowly and make sure that the handlebars can correctly restrict the direction of the vehicle body...

Page 57: ...ld If the tire is used under an improper tire pressure it will worsen the operation and riding comfort and cause adverse effects such as tire eccentric wear Designated air pressure tire Front Rear Air...

Page 58: ...KAYO MOTOR CO LTD Tire pattern Check the tire pattern once the pattern height is less than 3mm replace with a new tire Note When the tire pattern is less than 3mm it must be replaced immediately More...

Page 59: ...que Torque Front axle nut 126N mm 218N mm 12 6kgf mm 22kgf mm Rear axle nut 199N mm 311N mm 20kgf mm 31kgf mm Shaking of the wheel hub Raise the front wheel with a tool When the body does not exert an...

Page 60: ...ion and compress the car body up and down several times according to the position shown in the figure If there is shaking or abnormal noise check the shock absorber for oil leakage and whether the fas...

Page 61: ...wo way adjustable 3 6 Gear shifting mechanism and fuel device Shift mechanism Change gears check whether gear shifting mechanism 2 is flexible and whether the gears are in gear If gear shifting is not...

Page 62: ...fuel pipe with a new one when it is aged or damaged Check whether the vent pipe of fuel tank or adsorption pipe of fuel evaporation system is cracked or bent and replace it with a new one if it is da...

Page 63: ...lexible replace the accelerator cable with a new one Adjustment of speed limiting device The speed limiter is used to limit the opening of the throttle valve Check the thread limit length of speed lim...

Page 64: ...ck whether the wiring is loose or fall off If the wiring is normal replace the horn in time 3 8 Gear display meter Check the display meter When the vehicle system is powered on for the first time or a...

Page 65: ...please check whether the line connector is loose or falling off If the wiring is normal replace the anti fog lamp in time In the second gear observe whether the front headlights are on If not please c...

Page 66: ...than 1 hour Confirm that the heating components are cooled before performing maintenance to avoid injury to maintenance personnel Be careful not to damage the frame engine body bolts cables etc durin...

Page 67: ...ZHEJIANG KAYO MOTOR CO LTD Tightening torque Engine bracket mounting bolt GB5787 M10 1 25 160 45 59N m...

Page 68: ...erated in a well ventilated place When disassembling the fuel tank if there is still fuel in the fuel tank the oil pipe should be blocked to prevent fuel leakage and then the fuel tank should be disas...

Page 69: ...ZHEJIANG KAYO MOTOR CO LTD Remove the seat cushion and rear assembly board Chapter 2 Body Cover Remove the mounting bolts 5 1 each on the left and right Remove the carburetor 6...

Page 70: ...4 Remove the fuel tank 4 1 Removal and installation of the fuel tank Loosen the clamp 1 Remove the air filter 2 Assembly Installation shall be carried out in the reverse order of disassembly 1 2...

Page 71: ...mble Remove the seat cushion front cover of gear indicator front assembly plate and rear assembly plate Chapter 2 Body Covers Remove two screws 3 Remove muffler fixing bolt 3 Assembly Installation sha...

Page 72: ...llation of engine Disassemble Remove the seat cushion the front cover of the gear display meter the left foot pedal the right foot pedal and the rear body assembly Chapter 2 Body Covers Remove the fue...

Page 73: ...ZHEJIANG KAYO MOTOR CO LTD Remove bolt 4 Remove bolt 5 Remove the chain 6 Assembly Installation shall be carried out in reverse order of disassembly 6...

Page 74: ...ntent Index 1 1 1 8 Preparation of information fault diagnosis 1 2 1 2 10 Maintenance information 2 3 1 3 6 Lubrication system 3 4 1 4 14 Cylinder head valve 4 5 1 5 8 Cylinder piston 5 6 1 6 14 V bel...

Page 75: ...ZHEJIANG KAYO MOTOR CO LTD 8 1 8 9 Generator starting clutch 8 9 1 9 5 Crankshaft axle box 9...

Page 76: ...tructions are not followed equipment damage or personal injury is very likely Engine oil Limited use of SF MA 15W 40 or equivalent engine oil otherwise we will not be responsible for the warranty liab...

Page 77: ...1 Preparation of information fault diagnosis...

Page 78: ...pre ading into the air General safety matters carbon monoxide If it is necessary to run the engine in some operation matters please work in a well ventilated place and do Exhaust gas contains toxic ca...

Page 79: ...y from it Engine and exhaust system parts will generate high temperature after the engine runs which will last for a long time When handling these parts wear insulating gloves or wait for them to cool...

Page 80: ...1 Preparation of information fault diagnosis...

Page 81: ...s will deteriorate due to aging and are easily damaged by solvents and oils These parts should be checked before reassembly and replaced if necessary To loosen the parts with multiple joints they shou...

Page 82: ...ain bolt 1 12 3 5 4 5 Engine drain bolt 1 30 1 3 1 7 Crank oil drain bolt 1 8 0 8 1 2 Crank oil filler bolt 1 10 1 0 1 4 Oil pump screw 3 3 0 1 0 3 Engine left side cover bolt 7 6 1 0 1 5 With rubber...

Page 83: ...ing torque Type Tightening torque 5mm bolt and nut 0 45 0 60kgf m 3mm screw 0 05 0 08 kgf m 6mm bolt and nut 0 8 1 20kgf m 4mm screw 0 10 0 15 kgf m 8mm bolt and nut 1 80 2 50kgf m 5mm screw 0 35 0 50...

Page 84: ...fuel tank evaporation system is blocked Fault diagnosis The engine cannot be started or is difficult to start Possible causes of failure Loosen the drain screw to check if there is gasoline inside th...

Page 85: ...ve the spark plug and check No stain or discoloration and check Serious stain and discoloration Check if the engine is overheated No overheating Overheating Speed up No knock phenomenon Knock phenomen...

Page 86: ...s not flash Check the ignition time Correct Incorrect Check the status of automatic oil cup Good Bad Check whether the carburetor nozzle is blocked Non blocking Block 1 Bad ignition time C D I group o...

Page 87: ...en the engine is idling Unsatisfactory start poor climbing performance 1 The drive belt is worn and broken 2 The swash plate of the sliding drive plate is damaged 3 The drive disc spring is damaged 4...

Page 88: ...0 7mm Mark F of idle ignition angle Before top dead center 13 1700 rpm Full ignition angle Before top dead center28 5000 rpm Idle speed 1700 100 rpm Cylinder compression pressure 10 1 kg cm2 Valve cle...

Page 89: ...r replacement I I 9 Gearoilreplacement I Changeevery1000kilometers 10 Ignitiontiming I I 11 Carburetorthrottleactuation I I 12 Enginescrewtorque I I 13 CVT transmission belt I R 14 CVT transmission ro...

Page 90: ...requent high speed driving and more mileage the maintenance frequency must be increased 4 Expected maintenance a Ignition system there are obvious continuous ignition failures engine stalls afterburni...

Page 91: ...kcase to drain the oil After the oil leaks completely the bolts and washers can be cleaned to install the bolts If the washers are damaged they need to be replaced Torque 3 5 4 5 kgf m Replenish engin...

Page 92: ...evel Clean the oil filter To leak the oil from the engine remove the oil filter cover spring and filter from the lower right side of the engine If the filter is attached you can clean the filter with...

Page 93: ...and drain the gear oil into the measuring cup Check whether there is enough oil Replace Remove the oil injection bolt first and then remove the oil drain bolt to drain the oil After the gear oil is d...

Page 94: ...l quantity When decomposed 400 c c When replacing 350 c c Please make the main adjustment from the lower end of the wire Loosen the fixing nut and turn the adjusting nut to adjust Tighten the fixing n...

Page 95: ...he mark on the crankcase and the top dead center mark on the cam sprocket and also level the top of the cylinder head The other half of the cam sprocket is a single circle The hole faces upwards the p...

Page 96: ...ustment Note NOTE The machine with the starting embryo reducing val ve mechanism should not move in the reverse direc tion of the time slot to prevent the pressure reducin g valve from operating and t...

Page 97: ...le speed adjustment NOTE The idle speed can be checked and adjusted only after all other parts of the engine that need to be adjusted have been adjusted To check and adjust the idle speed correctly th...

Page 98: ...ngine speed needle 2 Adjust the idle speed screw the engine speed is 1700 100rpm 3 The sampling pipe of the exhaust gas instrument is connected to the test hole at the front end of the exhaust pipe an...

Page 99: ...ooling fan cover or remove the cooling fan cover Check ignition timing with timing lamp Start the engine and adjust the engine speed to 1700rpm If the mark is aligned with the F point the ignition tim...

Page 100: ...he spark plug cover Clean the dirt around the spark plug hole Remove the spark plug Measure the electrode gap of the spark plug Spark plug electrode gap 0 6 0 7 mm Adjust the side electrode carefully...

Page 101: ...too low check the following items The valve clearance is incorrect The valve is leaking Cylinder head leaks pistons piston rings and cylinders are worn out If the compression pressure is too high it m...

Page 102: ...regular checklist maintenance and replacement period replace with new products Width limit 20 8mm or more Clutch plate Start the vehicle and gradually increase the throttle opening to check the moveme...

Page 103: ...evice name Valve spring remover installer name Valve spring removal installation compressor name Valve clearance adjustment wrench name Valve lash adjuster name Oil seal knock in fixture name Oil seal...

Page 104: ...3 Lubrication system name Internally drawn bearing extractor name Out drawing bearing extractor name Clutch spring compressor...

Page 105: ...2 Maintenance information Catalog of Specialized Tools name Clutch fixed nut wrench name Universal fixator name Alternator flywheel remover...

Page 106: ...3 Lubrication system...

Page 107: ...3 Lubrication system Rocker arm Forced lubrication Camshaft Splash lubrication connecting rod Forced lubrication Crankshaft Inner oil passage Oil filter screen Oil pump...

Page 108: ...3 Lubrication system...

Page 109: ...0 12 Outer rotor body clearance 0 12 Clearance between rotor end face and body 0 05 0 10 0 20 Unit mm Torque value Oil drain bolt 3 5 4 5 kgf m Oil filter cover 1 3 1 7 kgf m Gear oil drain bolt 0 8...

Page 110: ...l change Note Place an oil pan under the engine and remove the oil leakage bolt to drain the oil Confirm that the aluminum washer of the drain bolt should be replaced with a new one if it is damaged L...

Page 111: ...oil oil viscosity SF MA 15W 40 into the engine oil hole Install the oil dipstick and start the engine to idle for a few minutes Turn off the engine and wait for 3 5 minutes to check the oil level aga...

Page 112: ...or refer to Chapter 8 Remove the one way clutch and start gear fixed nut X1 Confirm that the pump shaft can rotate freely Remove the oil pump cover bolt x2 and then remove the oil pump drive gear fixi...

Page 113: ...3 Lubrication system Engine right side cover Start gear Start clutch group Oil pump outer cover Oil pump drive gear Oil pump Oil pump shaft Outer rotor Inner rotor Oil pump cover Right crankcase cover...

Page 114: ...tall the drive gear and fixing clip Note Oil pump installation Install the oil pump bolt X2 Install the oil pump chain and lock the oil pump cover bolt X2 Check whether the oil pump can rotate smoothl...

Page 115: ...Lubrication system Install the starting gear and alternator set See Chapter 8 bolt X2...

Page 116: ...suring cup and check whether the gear box oil meets the standard value If the amount of oil is too low add gear oil Gear oil viscosity standard oil volume 400 c c general replacement 350 c c Gear oil...

Page 117: ...m the gear oil injection hole replenish it install the gear oil injection hole bolts and tighten Torque value 1 0 1 4 kgf m After changing the gear oil Start the engine for a test ride for 2 to 3 minu...

Page 118: ...d valve Mechanism diagram Precautions Fault diagnosis Camshaft disassembly Valve guide rod replacement Inspection and correction of valve seat Cylinder head assembly Cylinder head installation Camshaf...

Page 119: ...9 966 9 984 9 910 Valve Outer diameter of steam valve stem Intake 4 975 4 990 4 900 Exhaust 4 950 4 975 4 900 Guide bush 5 000 5 012 5 030 Clearance between valve stem and guide sleeve Intake 0 010 0...

Page 120: ...valve Valve adjusting fixing nut 0 7 1 1 kgf m Threaded part and seat surface coated with engine oil Spark plug 1 0 1 4 kgf m Tool Special tools Valve wire reamer 5 0mm Valve guide driver 5 0mm Valve...

Page 121: ...n pressure is too low 1 Valve Poorly adjusted valve clearance Burned or bent valve Inaccurate valve timing Valve spring damage Valve carbon deposit Poor air tightness of the valve seat Poor spark plug...

Page 122: ...ing Camshaft wear or damage The cam chain is worn or loose The cam chain tensioner is worn or damaged Camshaft chain gear wear Wear of rocker arm or rocker shaft The exhaust pipe emits white smoke Wor...

Page 123: ...the O ring Use a flat screwdriver to rotate in a clockwise direction tighten the screws in the cam bar adjuster and loosen the adjuster Rotate the flywheel clockwise with a T shaped wrench to align t...

Page 124: ...arings are loose or worn If so replace the entire set of camshafts Camshaft holder decomposition Use 5mm bolts to screw in the cam rocker arm shaft and pull out the cam rocker arm shaft Remove the cam...

Page 125: ...r arm Available limit 10 1mm above exchange Measure the outer diameter of the valve rocker arm shaft and the movable part of the valve rocker arm Available limit exchange above 9 910 Calculate the cle...

Page 126: ...x4 Remove the camshaft Remove the 2 bolts on the left side of the cylinder head Remove the cylinder head gasket and 2 positioning pins Remove the chain guide Remove all the debris from the gasket on...

Page 127: ...ide oil seal Remove the carbon deposits in the combustion chamber Remove the debris and foreign matter from the gasket surface of the cylinder head Note Do not damage the cylinder and the cylinder joi...

Page 128: ...4 Cylinder head valve Do not damage the joint surface of the cylinder head...

Page 129: ...for bending burnt damage or abnormal wear Check the movement of each valve stem in the pipe measure and record the outer diameter of the valve stem Available limit Air intake 4 90mm Exhaust 4 90mm Val...

Page 130: ...ance value between the valve stem and the catheter Available limit Intake 0 08mm Exhaust 0 10mm After replacement use a reamer to trim the fit If the fitting clearance is still exceeded after replacin...

Page 131: ...uide reamer 5 mm After the cylinder head has cooled to room temperature ream the new duct with a reamer Cutting oil is required when trimming with a reamer When inserting or moving the reamer After th...

Page 132: ...ng tool to drive the valve valve to grind each other Remove the valve and check whether the valve contact surface is tight Do not allow emery to enter the valve stem and conduit After running in wash...

Page 133: ...seat The worn seat surface must be trimmed with a special valve seat surface dresser Use a 45 seat surface dresser to grind any rough or irregular surfaces of the seat Use a 32 cutter to remove 1 4 o...

Page 134: ...not rotate so that a clear mark is produced on the valve surface the entire circumference must be evenly contacted If the contact surface on the valve valve is too high grind the valve seat with a 32...

Page 135: ...a 45 cutter to the specified width If the contact surface on the valve valve is too low grind the inner valve seat with a 60 cutter Grind the seat surface with a 45 cutter to the specified width Widt...

Page 136: ...and cylinder valve Cylinder head combination Lubricate the valve stem with engine oil and then insert the valve into the catheter Install a new valve stem oil seal Install the valve spring and spring...

Page 137: ...ber hammer to make the valve plug and the valve stem fit well In order to prevent the spring from losing its elasticity do not over compress the spring and use the most suitable length to install the...

Page 138: ...head Camshaft installation Combined camshaft fixing seat Assemble the exhaust valve rocker arm on the side marked EX on the camshaft mount Install the intake valve rocker arm and rocker arm shaft The...

Page 139: ...eft side of the cylinder head Torque value 1 8 2 2 kgf m Lock the spark plug Torque value 1 0 1 2 kgf m Apply engine oil to the threads of the cylinder head bolts and tighten them 2 3 times diagonally...

Page 140: ...unterclockwise with a thin flat blade screwdriver to make it pop out and tighten the chain guide plate install new O ring coated oil into the tensioner adjustment hole and lock the tensioner adjustmen...

Page 141: ...Mechanism diagram Precautions Fault diagnosis Piston removal inspection Piston ring installation Piston installation...

Page 142: ...Piston outer diameter 62 450 62 500 62 410 Piston outer diameter measurement position Approximately 9mm at the bottom of the skirt Piston and cylinder clearance 0 050 0 100 0 200 Piston tip bore inne...

Page 143: ...ear Too much carbon deposits on the piston head Piston tip hole and piston tip wear Cylinder disassembly Remove the cylinder head refer to Chapter 6 Remove 2 bolts and take out the cam chain automatic...

Page 144: ...5 Cylinder piston Remove the cylinder gasket and fixed pin The residue of the gasket attached to the joint surface of the cylinder head and the crankcase is scraped out clean...

Page 145: ...the cylinder and measure and record the value of the cylinder inner diameter in the X and Y axis directions respectively Usable limit 62 650mm Calculate the roundness the difference between the X dire...

Page 146: ...atness of the cylinder Usable limit correction or replacement above 0 05mm Piston disassembly Use a clean cloth to plug the crankcase opening and cam chain hole to prevent the piston pin buckle and ot...

Page 147: ...gap of the piston ring groove Usable limit Top ring replace above 0 09mm Second ring replace above 0 09mm NOTE The piston ring is easy to break please be careful when removing it NOTE Use the top of...

Page 148: ...e limit 14 96 mm Measure the inner diameter of the small end of the connecting rod Usable limit 15 06 mm Measure the inner diameter of the piston pin hole Usable limit 15 04 mm Calculate the clearance...

Page 149: ...ter of the piston Usable limit 62 410mm Compare this measurement with the usable limit and calculate the piston and cylinder clearance NOTE The measurement position is 9mm from the bottom of the pisto...

Page 150: ...the marks on the piston ring must be upward when installed After the installation is complete it must be confirmed that all piston rings can rotate freely and there Piston ring installation Clean the...

Page 151: ...Top ring Second ring Side rail Spacer Side rail Oil wiper 20mm or more Top groove Second groove Scraping oil groove...

Page 152: ...the debris or foreign objects fall into the crankcase Install 2 positioning pins and new gaskets Coat the inside of the cylinder piston and piston ring with new engine oil Carefully insert the cylind...

Page 153: ...tall the cam chain guide cylinder head gasket and positioning pin Install the cylinder head refer to Chapter 4 Install the cam chain automatic adjuster bolt x2 NOTE Do not use force to sleeve the cyli...

Page 154: ...6 V belt drive system Mechanism diagram Maintenance instruction Fault diagnosis Left crankcase cover Drive belt Sliding drive plate Clutch drive pulley...

Page 155: ...0 135 40 Thickness of clutch pad 2 500 1 500 Length of drive pulley spring 130 00 125 00 Outer diameter of drive pulley set 33 965 33 985 33 940 Inner diameter of sliding drive pulley 34 000 34 025 34...

Page 156: ...he left engine cover bolt x9 Inspection The inside of the left side cover is dirty and blown out with an air gun Whether the left side cover and bearing hole are worn or damaged replace them with new...

Page 157: ...6 V belt drive system...

Page 158: ...the clutch cover and remove the nut and clutch cover Squeeze the drive belt into the groove of the drive pulley as shown in the figure to loosen it and then take out the belt and clutch at the same t...

Page 159: ...replace it if necessary Measure the width of the drive belt as shown in the figure If it exceeds the maintenance limit replace the drive belt Usable limit 20 8 mm NOTE Please use original parts for re...

Page 160: ...the belt Install the clutch cover Fix the clutch jacket with a universal fixing clip and tighten the nut to the specified torque value Torque value 5 0 6 0 kgf m NOTE After the drive belt pulley is pu...

Page 161: ...a universal clamp and remove the fixing nut of the drive plate Remove the drive disk Remove the drive belt from the belt pulley Remove the sliding drive plate assembly and drive plate hub from the cra...

Page 162: ...Remove the hammer roller from the sliding drive plate Sliding drive plate Hammer roller...

Page 163: ...easure the outer diameter of each roller and replace it with a new one if it exceeds the specified limit of use Usable limit 19 45 mm Check whether the drive shaft hub is worn or damaged and replace i...

Page 164: ...inclined plate The two end faces of the heavy hammer roller are different In order to prolong the life of the roller and prevent abnormal wear please assemble the closed end face on the sliding drive...

Page 165: ...rive plate and press down the upper and lower ends of the drive belt to separate the belt from the drive plate hub NOTE There should be no grease on the belt surface remove unnecessary grease with oil...

Page 166: ...rsal clamp Tighten the nut to the specified torque Torque value 5 0 6 0 kgf m Install the left crankcase cover NOTE Make sure that there is no grease on both sides of the belt pulley and remove unnece...

Page 167: ...drive plate assembly on the crankshaft Driver installation Put the drive belt on the sliding drive plate and press down the upper and lower ends of the drive belt so NOTE There should be no grease on...

Page 168: ...orque Torque value 5 0 6 0 kgf m Install the left crankcase cover NOTE Pressing down the upper and lower ends of the drive belt can prevent the belt from being damaged and ensure that the drive plate...

Page 169: ...e and use a special nut wrench to remove the fixing nut Loosen the clutch spring compressor and remove the clutch and spring from the drive belt pulley Remove the oil seal sleeve from the drive belt d...

Page 170: ...cover Measure the inner diameter of the friction surface of the clutch jacket If the maintenance limit is exceeded replace the clutch jacket Available limit 135 40 mm O ring Guide pin Guide pin rolle...

Page 171: ...limit 125 mm Drive belt pulley Check the following Whether the two disk surfaces are damaged or excessively worn Whether the guide pin groove is damaged or deformed Replace damaged or excessively wor...

Page 172: ...ing for damage or excessive clearance and replace it if necessary Rotate the inner side of the outer bearing with your fingers to check whether the bearing can rotate smoothly and silently whether the...

Page 173: ...ry replace it Spread a little butter on the fixed tip Spread a little butter on the fixed pin but there should be no butter on the clutch block If there is butter on the clutch block replace it Instal...

Page 174: ...Use pliers to snap the spring into the groove spring Clutch block...

Page 175: ...g into position and its sealed end should face outward Apply the specified grease and install the G 3 grease on the ring clamp to fix the bearing 6 V belt drive system NOTE The drive pulley is equippe...

Page 176: ...stall a new oil seal if necessary NOTE When installing the bearing pay attention that the sealed end should face outward Use the hydraulic press to install needle bearings and use the hydraulic press...

Page 177: ...Use the specified grease to lubricate the inside of the sliding plate Install the sliding drive plate on the drive belt plate Install the guide pin and the guide pin roller Install the oil seal sleeve...

Page 178: ...ly until the fixed nut can be installed Clamp the clutch spring compressor on the vice and screw the nut to the specified torque with a special nut wrench Remove the spring compressor Torque value 5 0...

Page 179: ...hanism reverse gear mechanism decomposition Bearing replacement Final reduction mechanism reverse gear combination Drive shaft Intermediate shaft Output shaft Wire clip Gearshift lever group Lower end...

Page 180: ...ration Specification Use gear oil four stroke lubricating oil Gear oil volume 400 c c 350 c c when replacing Torque value Gear box cover 2 0 2 4 kgf m Gearbox drain bolt 1 0 1 4 kgf m Tool Special too...

Page 181: ...sm reverse gear mechanism Fault diagnosis ATV can t move after the engine starts Damaged transmission gear set Transmission gear set burned out Broken drive belt Gear oil leaking Oil level is too high...

Page 182: ...Remove the gasket and positioning pin Remove the drive shaft intermediate shaft output shaft shift gear set shift shaft shift drum and fork Final reduction mechanism reverse gear mechanism inspection...

Page 183: ...he outer ring of the bearing is tightly combined with the gear box and the cover If the bearing rotates unevenly has abnormal noise or is loose in combination with the gear box or the cover it should...

Page 184: ...t the gearbox bearings or the bearings on the cover the following special tools are required Internally drawn bearing extractor Install the new bearing into the gearbox or cover Special tools Press in...

Page 185: ...of the drive shaft is still connected to the shaft when the drive shaft is pressed out the bearing needs to be pulled out with an externally drawn bearing extractor and shaft protector Special tools U...

Page 186: ...reverse gear mechanism Install the new final shaft bearing on the gear box cover Special tools Press into the bearing with a C shaped press or bearing knock in jig Grease the lips of the new final sh...

Page 187: ...drive shaft wheel output shaft and gear shaft with butter install gear box cover and bolts 10 pieces and lock them Torque value 2 0 2 4 kgf m Install the clutch sliding drive belt pulley Install the...

Page 188: ...ing clutch Mechanism diagram Precautions Flywheel disassembly Disassembly of generator coil set Starting clutch inspection Starting clutch installation Right crankcase cover installation Generator coi...

Page 189: ...nd Inspection Specification unit mm Torque value Flywheel nut Bolt 8mm Oil filter cover Starting clutch fixing bolt Starting clutch hexagon socket bolt Special tools Item Available limit Inner diamete...

Page 190: ...8 Alternator Starting clutch Flywheel puller Universal fixator...

Page 191: ...nator Starting clutch Alternator disassembly Flywheel removal Drain the engine oil and remove the cooling fan cover bolt X4 Remove the cooling fan bolt X4 pulser flywheel fan fan cover coil wire fixin...

Page 192: ...8 Alternator Starting clutch Use the universal fixing clip to fix the flywheel Remove the 10 mm nut on the flywheel Special tools Universal fixator cooling fan Universal fixing clip...

Page 193: ...d pulse generator connector Remove the six bolts of the pulsator generator coil and wire fixing piece and take out the alternator coil assembly NOTE Before installing the flywheel extractor insert the...

Page 194: ...al Remove the right crankcase cover bolt X9 Remove the positioning pin and gasket Clean the gasket debris and foreign matter on the joint surface of the cover and the crankcase NOTE The joint surface...

Page 195: ...ti falling fixing bolts and gaskets Special tools Anti dropping fixed nut sleeve Universal fixator Remove the starting driven gear Remove the starting clutch starting idler and shaft Starting clutch i...

Page 196: ...Fix the starting clutch and rotate the starting driven gear Lifting driven gear must be rotatable clockwise but not counterclockwise...

Page 197: ...iameter below 22 1 mm Check whether the starting idler gear and shaft are worn or damaged Measure the inner diameter of starting idler gear Usable limit Inner diameter below 10 05 mm Measure the outer...

Page 198: ...the clutch and clutch cover Remove the clutch roller plunger and spring from the one way clutch Check each roller and plunger for wear and damage Install the roller plunger and spring Clutch cover Rol...

Page 199: ...1 4 kgf m Starting clutch installation Install the idler shaft and idler Install the starting clutch Install the starting driven gear on the starting clutch Use a universal holder to fix the starting...

Page 200: ...Special tools Anti dropping fixed nut sleeve Universal fixator Torque value 9 0 10 0 kgf m Apply engine oil to the threads of the fixed nut...

Page 201: ...the crankshaft with the key groove in the flywheel and install the flywheel Fix the flywheel with the universal fixing clip to fix the crankshaft and then tighten the nut Torque value 5 0 6 0 kgf m b...

Page 202: ...8 Alternator Starting clutch Install the cooling fan boltX4 Remove the cooling fan cover bolt X4 Replenish engine oil according to the specified quantity cooling fan...

Page 203: ...nce Shaft Generator starting clutch Mechanism diagram 9 1 Crankshaft inspection 9 3 Precautions in operation 9 2 Balance shaft inspection 9 4 Fault diagnosis 9 2 Crankshaft balance shaft installation...

Page 204: ...Generator starting clutch chapter 8 If crankshaft bearings or timing chains need to be replaced the whole set of crankshafts needs to be replaced Specification Unit mm Item Standard value Available li...

Page 205: ...tractor Out drawing bearing extractor Bearing press in fixture Oil seal press in fixture Fault diagnosis Engine noise is too loud The bearing clearance is too large Excessive clearance of crankshaft t...

Page 206: ...ight crankcase from the right side of the crankcase Remove 5 balance shaft cover bolts from the left crankcase and remove and pull Force rod fixing bolts 3 Turn the left crankcase down and disassemble...

Page 207: ...nce Shaft NOTE Never pry the joint surface of the crankcase to separate it otherwise it will damage the joint surface and cause oil leakage Before pressing the left right crankcase the cam chain must...

Page 208: ...on the crankcase joint surface with the shim scraper Remove the balance cover oil seal Remove the chain tension rod and lock the fixing bolt X3 NOTE The left right side bearing of the crankshaft is pr...

Page 209: ...aft Balance Shaft Tension rod fixing bolt X3 Balance Shaft Scrape surface debris Oil seal The upper surface of the oil seal is required to be level with the surface of the balance shaft cover and not...

Page 210: ...ss gauge Usable limit replace new products above 0 55 mm Measure the radial clearance of the big end of the connecting rod in the vertical direction of the crankshaft Usable limit 0 05 mm Place the cr...

Page 211: ...the cam bar into the right crankcase chain hole and spread the chain NOTE Do not damage the cam chain when installing the crankshaft When installing the balance shaft driving gear ensure that the bal...

Page 212: ...rankshaft Balance Shaft Install 2 locating pins and new right crankcase gasket Install the right crankcase and tighten the crankcase bolts 2 bolts Torque value 1 5 2 0 kgf m Right crankcase gasket Pos...

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