KAYO MOTOR AU200 Page 102 Maintenance Manual Download

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5.10.1 Troubleshooting

Difficulty gear shifting
1. gear shift fork bent
2, gear shift fork shaft bent

Gear shift abnormal
1. The gear shifting ratchet claws are

worn

2. The gear shift fork is bent or damaged.
3, gear shift fork shaft bending

Crankshaft has noise
1, the connecting rod big end bearing

wear

2, connecting rod bent

Gear shifting gear is noisy
1. Gear shifting gears are worn
2, spline bearing wear

Summary of Contents for AU200

Page 1: ...1 KAYO MOTO AU200 Maintenance Manual...

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

Page 3: ...ter introduces the regular inspection and adjustment of the whole vehicle The fourth chapter introduces the disassembly of the engine peripheral assembly parts The fifth chapter introduces the methods...

Page 4: ...4...

Page 5: ...e outstanding meaning of the engine when repairing it Danger Be alert to high risk Warning Indicates caution against moderate risks Note Indicates concern for mild danger However please note that the...

Page 6: ......

Page 7: ...mediately with plenty of water and go to the hospital for treatment The battery and battery solution should be kept strictly and must be kept in a safe place that children can t get When the battery i...

Page 8: ...The ball bearing can be rotated by the inner ring or the outer ring with the finger to confirm whether the rotation is flexible and smooth If the disassembly method of applying force on the ball is ta...

Page 9: ...gs cylinder blocks intermeshing transmission gears etc Therefore in the initial stage of its use it is necessary to carry out standard running in and the running in can make the moving parts adapt to...

Page 10: ...1 1 4 1 VIN on chasis 2 Vehicle name plate 3 Engine number Model AU200 VIN L6JACMLA5G Engine number F1702K 1 3 2...

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Page 12: ...kg 120kg Tire specifications Front AT23 7 10 Rear AT22 10 10 Minimum ground clearance 175mm Turning circle diameter nearest point minimum turning diameter 3000mm Engine Starting method Electric start...

Page 13: ...e reverse gear Shift mode sequence Hand operation F N R CVT Stepless speed ratio 0 95 2 8 Output type Rear axle output Direction of rotation of Engine output In the forward gear it is clockwise from t...

Page 14: ...ident Oil pump rotor Inner and outer rotor radial clearance 0 12mm clearance between outer rotor and pump body 0 12mm clearance between rotor surface and pump body axial 0 05 0 1 0 2mm Intake system 0...

Page 15: ...n 8 5V 2000r min Rectifier type Full wave rectification Battery capacity 12V 7Ah Voltage between terminals Fullycharged 14 4V No Fully charged Less than 11 8V Ignition device Item Standard Ignition me...

Page 16: ...bulb Headlight 12V 35W Front turnlight 12V 10W Rear light brake light 12V 2 8W Rear turn light 12V 2 5W Position light 12V 3W Valve cylinder head section 05 Engine Cylinder Piston Piston Ring Crank Li...

Page 17: ...ounting screw GB70 85 M8 16 4 22 30 9 Directional mounting bolt GB5783 M10 1 5 30 2 45 59 12 Oil cooler mounting bolt GB5789 M6 25 4 9 12 13 Tow ball fixing plate mounting screw GB70 85 M10 1 5 30 4 4...

Page 18: ...ection 05 Engine 1 6 Lubricating grease sealant location note Kind of grease Steering bearing Light lithium soap grease Throttle cable connection Rocker arm Directional column inner circumference Cush...

Page 19: ...hose cable wiring diagram 1 Headlight connector 2 Left turn signal connector 3 Left hand multi function switch connector 4 Instrument connector 5 right turn signal connector 6 electric door lock swit...

Page 20: ...brake hose 1 Motor line 2 Crankcase exhaust pipe 3 Carburetor 4 Carburetor drain pipe 5 Magnetic motor trigger connector Note The right foot pedal and the right middle guard must be removed before ins...

Page 21: ...assembly check Chapter 2 Body Covers 6 Voltage regulator rectifier 7 charging connector 8 relay 1 Brake light patch cord 2 Left turn signal patch cord 3 Brake light contact wire 4 Right turn signal pa...

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Page 23: ...instrument front cover 2 5 2 4 3 instrument panel 2 5 2 4 4 gear shift head assembly 2 5 2 4 5 shifting decorative cover 2 6 2 5 Disassembly of left middle guard right middle guard left pedal and rig...

Page 24: ...nternal parts of the vehicle are to be removed the relevant cover parts can be removed Refer to this chapter This chapter describes the disassembly and assembly operations of shelves seat cushions and...

Page 25: ...isassembly reverse direction Check if the seat cushion is in place secure etc after installation 2 3 2 Front shelf Disassembly Remove the front shelf mounting screws 1 one left and one right Remove th...

Page 26: ...Installation in reverse order of disassembly 2 4 Disassembly of front panel instrument front cover instrument panel gear shift head assembly and shifting decorative cover 2 4 1front cover Disassembly...

Page 27: ...e front cover of the instrument 2 4 2 remove the 2 screws 3 Remove the instrument panel 4 Assembly In reverse order of reverse disassembly reverse direction 2 4 4 Gear shift head assembly Disassembly...

Page 28: ...rd right middle guard left pedal and right pedal 2 5 1 left middle guard Disassembly Remove the seat cushion 2 3 1 Remove the screw 3 Remove the left decorative panel 4 up Assembly In reverse order of...

Page 29: ...rd 2 5 2 Remove the fastening screw 4 Remove the fixing screws 5 Remove the right foot pedal 6 from the bottom to the top Assembly In reverse order of reverse disassembly reverse direction 2 6 Disasse...

Page 30: ...per 2 Assembly In reverse order of reverse disassembly reverse direction 2 7 Disassembly of fuel tank cover front assembly plate and rear assembly plate 2 7 1 Fuel tank cover Disassembly Remove the mo...

Page 31: ...nnectors after installation to prevent misconnection 2 7 3 Rear assembly board Disassembly Remove the left middle guard 2 5 1 Remove the right middle guard 2 5 2 Remove the left foot pedal 2 5 3 Remov...

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Page 33: ...When the engine is just stopped the temperature of the muffler and the engine is still very high If it comes into contact with the skin it will burn If you must perform maintenance when the engine is...

Page 34: ...ngine maintenance cycle should be shortened accordingly Maintenance item Item odometer km period 1000km 4000km 8000km 12000km note Fuel system access I I I Fuel filter C C C C Carburetor choke Air fil...

Page 35: ...d damage of Brake disc If the working disc thickness of the current brake disc is less than 3mm and the thickness of the working disc of the rear brake disc is less than 3mm it should be replaced in t...

Page 36: ...part and damage of the rocker arm Shock absorber Oil spill and damage function transmissi on Front bridge Transmission lubrication Rear bridge Transmission lubrication Gearbox Oil leakage and oil quan...

Page 37: ...connection status Electrical circuit Looseness and damage at the joint Fuel device Fuel leak Throttle status Throttle handle clearance 2 6mm Lighting device and turn indicator Function Alarmandlockin...

Page 38: ...l position and slowly turn it to the left and right to confirm whether it can be rotated smoothly and flexibly If there is any obstruction in some places check the main cable assembly and the cable ty...

Page 39: ...r worn below the limit of use Inspection of these items is also required before each use of the vehicle Remove the 2 vent screws 1 Remove the oil cup cover 3 Add the brake fluid recommended by Huayang...

Page 40: ...Minimum friction plate thickness 1 mm If it is less than the minimum friction plate thickness please replace it with a new brake friction plate Check the brake lining for damage or cracks If there is...

Page 41: ...s also required before each use of the vehicle Remove the 2 vent screws of the oil cup cover 1 Remove the oil cup cover 3 Add the brake fluid recommended by Huayang until the upper limit line Do not m...

Page 42: ...f the current brake disc thickness is 3 0mm replace the brake disc Rear brake disc limit thickness for use 3 0mm Check the minimum thickness of the brake lining 2 Minimum friction plate thickness 1 mm...

Page 43: ...k and replace bearing rocker buffer sleeve ball pin Front wheel size The vehicle body is placed in a horizontal position and the toe size of the wheel is measured the front of the wheel with respect t...

Page 44: ...ate the operation and ride comfort and cause adverse effects such as eccentric wear of the tire Specified air pressure tire Front tire Rear tire Air pressure 35kPa 0 35kgf cm2 35kPa 0 35kgf cm2 size S...

Page 45: ...the tool to frame the front wheel When the car body does not exert force on the front wheel shake the wheel axially to check for shaking Remove the front wheel when shaking check the wheel hub 3 5 Su...

Page 46: ...ng mechanism2 is flexible and whether the gear position is in the gear If the gear shift is not flexible adjust the length of the shifting mechanism tie rod 3 Loosen the lock nut 4 and adjust the leng...

Page 47: ...e or the movement is still not flexible replace the new throttle cable Speed limit device adjustment The speed limit device is used to limit the opening of the throttle Check the thread limit length o...

Page 48: ...requires power before checking the lighting unit Turn signal inspection Turn the turn signal switch 3 to the left and right respectively to observe whether the front and rear turn signals of the vehi...

Page 49: ...ating parts are cooled before performing maintenance to avoid injury to maintenance personnel Be careful not to damage the frame engine body bolts cables during operation When the engine is disassembl...

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Page 51: ...flames but also high attention to electric sparks In addition due to the danger of explosion after evaporation vaporization of gasoline work should be carried out in a well ventilated area When disas...

Page 52: ...ase the clamp2 Remove the carburetor 3 Remove the fuel tank 4 1 Fuel tank disassembly and safety Loading Remove the 2 mounting screws 4 Release the clamp5 Remove the intake pipe 6 Remove the crankcase...

Page 53: ...front cover front assembly plate rear assembly plate Chapter 2 Body Cover Remove 2 bolts 1 Remove the insulation2 Remove the mounting nut 3 Remove the muffler barrel mounting bolt 4 Remove the exhaust...

Page 54: ...guard left foot pedal right foot pedal Chapter 2 Body Cover Remove the fuel tank 4 1 Fuel System Remove the air filter and carburetor 4 2 Intake System Remove the exhaust pipe assembly 4 3 exhaust sy...

Page 55: ...emove the charging patch cord 4 Remove the crankcase exhaust pipe 5 Remove the motor cable 6 Remove the screw at the relay Remove the carburetor drain pipe 7 Remove the mounting bolts 8 Remove the fix...

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Page 57: ...Check and adjust 5 8 5 4 Fuel System 5 12 5 5 Cylinder head and valve 5 17 5 6 Cylinder and piston 5 30 5 7 Oil pump 5 35 5 8 Right crankcase cover and magneto 5 38 5 9 CVT parts 5 40 5 10 Crankcase...

Page 58: ...or requirements the motorcycle may be damaged 2 When reassembling after disassembly replace gaskets seals and cotter pins 3 When tightening bolts or nuts it should be carried out in the order of diag...

Page 59: ...peed 13N m 6000r min Minimum fuel consumption rate 354g kw h Valve clearance when cooling Intake and exhaust 0 06mm Engine static mass 39kg Idle speed 1700r min Transm ission system clutch Continuousl...

Page 60: ...ate bolt 1 6mm 8 12 Shift drum and dial connecting bolt 1 6mm 8 12 Cylinder head nut 4 8mm 28 30 In addition to the torque values of the important parts listed in the above table the torque range of t...

Page 61: ...ehicle should be repaired according to the specified repair time The meanings of the various codes in the table are as follows C cleaning R Replace A Adjustment L Lubrication I Check and if necessary...

Page 62: ...or damaged Second the lubricant is not clean 1 The engine oil is not replaced according to the maintenance schedule 2 the oil filler thread is damaged Third the lubrication is not normal 1 the oil le...

Page 63: ...ove the spring and filter release the oil in the crankcase and then unscrew the gearbox drain screw 3 to get out the oil in the gearbox 5 2 5 Lubricating oil filter cleaning Clean the filter with a de...

Page 64: ...bes the inspection and adjustment of various parts of the LXCVT200 engine At the same time the technical requirements for adjustment and inspection are introduced For details on the inspection of the...

Page 65: ...he spark plug first screw the spark plug into the hand and tighten it then cover the spark plug cap 5 3 3 Valve clearance Note When adjusting the valve clearance the engine should be in a cold state t...

Page 66: ...ng cannot be adjusted Because CDI capacitor discharge ignition cannot be adjusted If the ignition is not correct check the CDI igniter pulse trigger and magneto and replace the faulty electrical devic...

Page 67: ...e plunger adjustment screw Idle speed 1700 170 r min 5 3 6 Cylinder compression test Warm up the engine then turn off the engine remove the spark plug then install the pressure gauge at the spark plug...

Page 68: ...15 5 4 7 Carburetor installation 5 16 5 4 8 Air conditioning screw adjustment 5 16 Maintenance instructions 1 When using gasoline special care should be taken Always remember to carry out in a well ve...

Page 69: ...6 fuel storage for too long Impurities in the fuel 5 4 2 Carburetor disassembly Turn off the fuel switch and remove the fuel line connection Remove the side covers on both sides Loosen the carburetor...

Page 70: ...g position of the screw Remember the times of turning when removing otherwise it will cause unnecessary trouble when installing the positioning screw Then clean all the channels and surfaces of the ca...

Page 71: ...he float on the float height detector 5 4 6Throttle valve plunger assembly First install the retaining ring in the groove of the oil needle Standard positioning position third ring groove Then insert...

Page 72: ...le handle with the adjustment device on the throttle control line Free stroke of the throttle handle 2 6mm 5 4 8Air conditioning screw adjustment Rotate the locking screw clockwise until it contacts t...

Page 73: ...2 Disassembly of cylinder head cover 5 19 5 5 3 Analysis of Rocker arm support 5 19 5 5 4 Camshaft removal 5 20 5 5 5 Cylinder head removal 5 20 5 5 6 Camshaft inspection 5 21 5 5 7 Rocker arm inspect...

Page 74: ...mm Maximum mm Camshaft Cam lift Intake 31 78 0 06 31 4 exhaus t 31 53 0 06 31 13 Rocker shaft inner diameter 12 000 12 018 12 05 Outer diameter 11 972 11 987 11 93 Valve spring length Outer layer 45...

Page 75: ...much noise 1 Valve adjustment is incorrect 2 The valve is stuck or the valve spring is broken 3 camshaft or rocker arm wear 4 timing chain is too long 5 the timing of the gas is not correct 6 Timing...

Page 76: ...1 Remove the tensioner fastening bolt 2 Remove the tensioner Remove the camshaft 3 Note Do not allow the timing chain to fall into the crankcase 5 5 5 Cylinder head removal Remove the cylinder connect...

Page 77: ...e Note If any rocker arm needs to be maintained or replaced the unevenness of the camshaft protruding part should be checked accordingly Measuring the inner diameter of the rocker arm Maintenance limi...

Page 78: ...original assembly position is reached during assembly 5 5 10 Inspection of valves and valve guides Check if the valves are bent and the burns or valves are abnormally worn Check the movement of the v...

Page 79: ...agent the gasket will be damaged 5 5 11 Cylinder head inspection Check the spark plug hole and valve for cracks check whether the cylinder head is deformed Check the flatness of the cylinder head wit...

Page 80: ...ad are removed with compressed air 5 5 14 Valve seat inspection and grinding First remove the dust on the intake and exhaust valves Apply abrasive to the valve seat Then use the grinding tool of the r...

Page 81: ...surface Maintenance limit 1 5mm If the valve seat is too wide too narrow or has a dent the valve seat should be ground to the correct degree of sealing Valve seat milling cutter Three different angle...

Page 82: ...seat and insert it into the valve to rotate Then take out the valve and see if the contact surface is in good condition Note The situation of contact surface between the valve and the valve seat will...

Page 83: ...clean all abrasives remaining on the cylinder head valve seat and valve guide 5 5 15 Cylinder head assembly Note Before assembling the valve the oil shield should be placed on the valve guide After ap...

Page 84: ...head installation Install new gasket and locating pin Note Do not allow dust and impurities to enter the cylinder Install the cylinder head and insert and support the timing chain to prevent it from...

Page 85: ...cylinder head first tighten the AB bolt nut and then tighten the cylinder connection bolt Injecting lubricant Note Before installing the camshaft fill the oil groove on the cylinder head with clean e...

Page 86: ...lation 5 33 5 6 5 Cylinder installation 5 34 Maintenance instructions The camshaft lubricating oil is injected into the cylinder head through a measuring hole in the engine casing This measuring holes...

Page 87: ...ng groove Top ring 0 015 0 050 0 09 Second ring 0 015 0 045 0 09 Clearance between Cylinder and piston 0 03 0 06 0 10 Piston pin outer diameter 14 994 15 000 14 96 Connect ing rod small end Inner diam...

Page 88: ...d be measured in three positions that is the top middle and bottom of the piston stroke and should be in two directions at right angles to each other Maintenance limit 62 1mm Measure the taper and out...

Page 89: ...and piston ring groove for wear or cracks Measuring piston pin hole inner diameter Maintenance limit 15 04mm Measure the outer diameter at 10 mm above the bottom end of the piston skirt Maintenance li...

Page 90: ...g installation damage When installing the piston ring the marked side is facing up After installation the piston ring should be free to rotate Do not reverse the mounting position of the top ring and...

Page 91: ...ing ring should be staggered from the piston incision Note When assembling after disassembly be sure to use a new piston Pin retaining ring Do not let the piston pin retaining ring fall into the crank...

Page 92: ...n fall into the crankcase Install the timing chain guide plate Install new paper gasket Install the positioning pin Install the cylinder head 5 7 Oil pump Maintenance instructions 5 35 5 7 1 Disassemb...

Page 93: ...0 12 clearance between outer rotor and pump body 0 12 Axial clearance between rotor surface and pump body 0 05 0 1 0 2 5 7 1 Disassembly of the oil pump Remove the oil pipe and spring Remove the magne...

Page 94: ...axial clearance between the rotor surface and the pump body is greater than 0 2 the oil pump should be replaced 5 7 3 Oil pump installation Install the oil pump in the correct position pump mark cont...

Page 95: ...g a magneto rotor Install the magneto motor fastening nut M 14 and washer Install oil pipe and spring 5 8 Right crankcase cover and magneto Maintenance instructions 5 38 5 8 1 Disassembly of the right...

Page 96: ...ning bolt 8 12N m Magneto rotor bolt 35 40N m 5 8 1 Disassembly of the right crankcase cover Remove the 9 M6 bolt Remove the right crankcase cover 5 8 2 Magnetic motor disassembly Remove the oil pipe...

Page 97: ...magneto motor groove Tighten the rotor nut to the specified torque value Torque value 35 40 N m 5 8 4Right crankcase cover installation First install the stator coil Then tighten the 9 M6 bolts accord...

Page 98: ...ver and CVT components eliminates the need to remove the engine from the frame and can be disassembled and tested directly on the vehicle 5 9 1 Disassembly of the left crankcase cover Remove the left...

Page 99: ...isc has a hole diameter greater than 27 06mm and should be replaced The outer diameter of the sliding drive disc sleeve less than 26 94mm then need to replace Clutch friction disc inner diameter great...

Page 100: ...e plate and driven friction plate Fasten M12 nut and washer Torque value 50 60 N m Note When tightening the nut first tighten the nut at the active drive plate 5 9 5 Left crankcase cover installation...

Page 101: ...ve work the crankcase should be separated first the disassembly of other components of the engine should be performed before the crankcase is disengaged Work before crankcase separation Cylinder head...

Page 102: ...nt Gear shift abnormal 1 The gear shifting ratchet claws are worn 2 The gear shift fork is bent or damaged 3 gear shift fork shaft bending Crankshaft has noise 1 the connecting rod big end bearing wea...

Page 103: ...case from the right crankcase Remove the gasket and locating pin Remove the crankshaft and balance shaft Remove the transmission mechanism Remove the shifting mechanism 5 10 3 Crankshaft inspection Pl...

Page 104: ...ring by hand and check its jumping in radial and axial If the engine is noisy and the radial or axial jumping direction is too large it should be replaced Timing sprocket disassemblely installation Di...

Page 105: ...uring the shift fork inner diameter and the thickness of the shift claw Inner diameter maintenance limit 12 05mm Thickness maintenance limit 4 5mm Check if the shift fork shaft is wearing or bending M...

Page 106: ...ssembling the shifting drum and shifting shaft 5 10 6 Crankshaft assembly Lay the left crankcase flat on the workbench Place the timing chain in the position showed in picture Load the balance shaft i...

Page 107: ...positioning pin Install the left crankcase Fasten the bolts at the left crankcase Fasten the box bolt at the right crankcase Coupling bolt torque value 8 12N m Locating Pin Closure bolt Left crankcase...

Page 108: ...normal 2 Restart the engine the engine can ignite but still can t start the engine does not ignite possible reason 1 No fuel in the fuel tank 2 the oil switch is blocked 3 tubing blockage 4 carburetor...

Page 109: ...incorrect the ignition timing is correct 3 Check the valve clearance the valve clearance is incorrect the valve clearance is correct 4 Check cylinder pressure cylinder pressure is too low cylinder pr...

Page 110: ...is not hot 10 During high speed driving the engine emits a knocking sound the engine has no knocking sound 5 11 3 Poor performance at low engine speed and idle speed 1 Check direction 1 Check ignitio...

Page 111: ...eak or intermittent fire jump spark is normal 5 11 4 Poor performance at high engine speed Check direction 1 Check ignition timing and valve clearance incorrect correct 2 Disassemble the carburetor fu...

Page 112: ...he float stuck possible reason 1 Timing chain and timing sprocket are not installed correctly 2 gear wear is serious 5 check the spark plug high speed flashover situation jump fire is not normal jump...

Page 113: ...g rod worn out 3 crank connecting rod head worn out possible reason 1 Crank connection bearing is damaged 2 camshaft bearing worn out possible reason 1 the chain is elongated 2 timing sprocket wheel t...

Page 114: ...is Maintenance information 6 2 6 1 Troubleshooting 6 3 6 2 Front wheel 6 3 6 3 Braking System 6 4 6 4 Front suspension system 6 6 6 5 steering system 6 8 6 6 Rear suspension system 6 12 6 7 Rear drive...

Page 115: ...unout 0 8mm 2 0mm wheel Residual trench 3mm Air pressure 35kPa 0 35kgf cm2 Front brake Brake handle clearance 0mm Tightening torque tool item size torque Steering lock nut GB9457 M10 1 25 33 45N m Fro...

Page 116: ...l bearing 2 Improper installation of the front wheels 3 brake tubing cable clamp Fifth the front suspension is too soft 1 The front shock absorber is weakened 2 the tire pressure is too low Sixth the...

Page 117: ...e removed together Remove the front wheel mounting bracket Installation Installation in reverse order of disassembly Wheel rim mounting nut torque 209N m 278N m Brake disc mounting bolt torque 30N m 3...

Page 118: ...sc Brake disc fixing bolt torque 22N m 30N m Disassembly of front brake hand brake pump Remove the bolt 5 When the front brake hand brake pump 6 is disengaged the front brake hand brake pump does not...

Page 119: ...brake circuit of the brake circuit is installed the brake force must be checked if the front and rear can not be linked control Brake system check whether the joint is connected Check whether the bra...

Page 120: ...the right front lower rocker arm 5 Remove the right front lower rocker ball pin locking bolt 6 Remove the right front lower rocker 7 Pull the steering knuckle out of the drive shaft The car s suspensi...

Page 121: ...of the front constant drive shaft before removing the right front rocker assembly Remove the right front rocker arm combination Check the upper and lower rocker arms Remove the right front upper rock...

Page 122: ...ation in the right front lower rocker welding combination Check the buffer sleeve combination 2 for damage aging and replace with new if necessary installation Press the ball pin into the rocker arm c...

Page 123: ...emove the screw 4 Remove the bolt 5 Remove the front hand brake pump Remove the right hand switch assembly Disassembly of the left hand switch assembly Remove the screw 6 Remove the bolt 7 Remove the...

Page 124: ...rse order of disassembly Directional mounting bolts for aluminum cover M8 35 Torque 30N m 36N m 3 0kgf m 3 6kgf m Note The main cable assembly throttle cable brake oil pipe and cable connecting wire s...

Page 125: ...lamp 5 Remove the split pin 6 Remove the lock nut 7 The steering shaft assembly can be removed by lifting the steering shaft upwards Installation Installation in reverse order of disassembly Note When...

Page 126: ...shock absorber is mounted on the car body and on the flat fork assembly 1 Remove the rear shock absorber 2 examination Check the rear shockremoved and adjust the adjustment cam 3 to the appropriate po...

Page 127: ...brake caliper Remove the rear shock absorber Remove the flat fork assembly and the frame connecting bolts and nuts Remove the rear drive shaft assembly Examination The rear view of the rear drive shaf...

Page 128: ...new ones Check the thickness of the disc brake disc If the thickness of the disc brake is 3mm replace the disc brake disc with a new one Check if the drive shaft is bent or damaged if any replace it w...

Page 129: ...6 17 7 Signal and lighting system Maintenance instructions 7 1 7 1 Fault judgmen 7 2 7 2 Headlight inspection 7 2...

Page 130: ...Light bulb can be changed Front right turn signal White cover yellow light E4 6R 0162294 1 Light bulb can be changed Left headlight JUTELCA5 E4 113R 0125787 E4 7R 0225787 1 Light bulb can be changed R...

Page 131: ...the handlebar switch is damaged Seven the rear right turn signal is not bright 1 the bulb is damaged 2 the connector is not well contacted 3 the handlebar switch is damaged Eight the electric horn is...

Page 132: ...be wiped clean with alcohol or banana water When replacing the headlamp bulb be aware that the two tabs on the bulb are aligned with the two locating holes on the socket Lamp specifications 12V 35W i...

Page 133: ...fore working Disconnect the front turn signal connector 2 Remove the nut 3 1 left and 1 right Remove front turn signal 4 Remove the front cover remove the front turn signal bulb and replace note Alway...

Page 134: ...stallation In reverse order of disassembly 7 4 Ignition switch lock Disassembly Remove the front panel Disconnect the ignition switch lock connector 2 Loosen the nut and remove the ignition switch loc...

Page 135: ...itch Electric starter switch wiring diagram Steering switch 5 wiring diagram Electric horn switch 6 wiring diagram 7 6 Brake light switch Check if the terminals are connected It is normal to turn on a...

Page 136: ...n In reverse order of disassembly 7 8 Meter Start the car body drive slowly and confirm that the instrument display is normal If there is any abnormality in the above check replace the instrument Disa...

Page 137: ...or and the fuel gauge itself Remove the fuel sensor connector 3 Connect the multimeter to the fuel sensor connector terminals Shake the fuel sensor float by hand and measure the resistance of each pos...

Page 138: ...10 Appendix...

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KAYO MOTOR AU200, Maintenance Manual

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