KAYO MOTOR K6-R Service Manual Download Page 51

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Clutch, drive tooth, overrunning clutch, oil pump and shift mechanism

Maintenance instructions

troubleshooting

Disassembly of water pump impelle

Disassembly of right crankcase cover

Disassembly of water pump shaft,

water seal components and oil seal

Disassembly of clutch

Disassembly of drive tooth, overrun

clutch and big starter gear

Disassembly of right oil pump

Disassembly of duplicate gear

Disassembly of start motor

Disassembly of gear shifting

mechanism

Inspection of right crankcase

Inspection of start shaft

Inspection of clutch spring

Inspection of clutch friction plate

Inspection of clutch outer cover

Inspection of drive gear

Inspection of overrun clutch

Inspection of big start gear

Inspection of right body oil pump

Inspection of starter motor and

duplicate gear

Inspection of shifting mechanism

Start shaft assembly

Duplicate tooth assembly

shifting mechanism assembly

right body oil pump assembly

Overrun clutch assembly

Big start gears and overrun clutch

assembly

Drive gear assembly

Clutch assembly

Starter motor assembly

Right crankcase cover assembly

Maintenance instructions

note

：

After the right crankcase cover is removed, disassembly, installation and maintenance of the clutch, oil pump and

gear shifter can be carried out without removing the engine.

Maintenance parameters

Item

Standard mm

Maintenance limits mm

Clutch

Spring free length

32.3

～

33.3

32.3

Friction active plate free thickness

2.95

～

3.05

2.85

Flatness of clutch driven disc

0.1

0.14

Clearance between clutch cover and

friction plate

0.1

～

0.3

0.6

Oil pump Inner and outer rotors radial clearance

0.06

～

0.15

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Summary of Contents for K6-R

Page 1: ...www kayomoto us 1 KAYO MOTO K6 R Service Manual W W W K A Y OMOTO US...

Page 2: ...and update this manual model s structure and spare parts without notice The images in this manual may differ from the actual model This manual contains words like Danger Warning Caution please read th...

Page 3: ...ecific maintenance content 20 Vehicle settings 29 Specific settings and methods 29 Vehicle troubleshooting 31 Possible faults and troubleshooting methods 31 Engine maintenance manual 36 Cylinder head...

Page 4: ...fender 10 Front brake caliper 2 Headlight 11 Front fork 3 Handlebar 12 Fuel tank 4 Vent pipe 13 Carburetor 5 Fuel tank cap 14 Gear shift lever 6 Fuel tank petcock 15 Pedal 7 Air filter 16 Chain 8 Cha...

Page 5: ...ight 25 Rear brake caliper 19 Muffler 26 U shape rocker arm 20 Seat 27 Triangle rocker arm 21 Rear shock 28 Rear brake oil cup 22 Start lever 29 Brake pedal 23 Radiator 30 Muffler pipe 24 Rear brake d...

Page 6: ...www kayomoto us 6 VIN number VIN number Frame plate Engine number 1 2 3...

Page 7: ...apacity 1500ml Oil make SJ 5W 40 Displacement 249 6cc Max power kw r min 19 9000 Max torque N m r min 23 7000 Compression ratio 11 6 1 Transmission type Constant mesh double stage driving 6 speed inte...

Page 8: ...alloy forging CNC hub Front brake Double piston pump hydraulic brake system disc 240mm CNC lever Rear brake Single piston pump hydraulic brake system disc 240mm forging brake pedal Others Air filter t...

Page 9: ...c screw M6 16 6 7 11 6 Front wheel axle nut M16 1 5 H14 1 175 218 7 Pedal bracket bolt M8 20 full thread 2 20 32 8 Gearshift bolt M6 25 1 7 11 9 Engine upper assembly bolt M8 60 3 20 32 10 Engine asse...

Page 10: ...7 11 27 Brake pedal bolt M6 25 full thread 1 7 11 28 Ignition coil bolt M6 20 2 7 11 29 Plastics bolt M6 16 full thread 10 7 11 30 CDI bolt M6 16 full thread 2 7 11 31 Voltage regulator bolt M6 25 fu...

Page 11: ...k switch the tank to the RES position and refuel immediately If fuel is sufficient and the motorcycle is in good condition switch to ON Note when the engine is turned off turn the tank switch to OFF 3...

Page 12: ...not leave brake reservoirs open for extended periods of time Note Always use brake fluid from an unopened container 6 Brake pads Check the caliper brake pad s thickness if the brake pad s thickness is...

Page 13: ...ruing should be performed by a professional 10 Check the chain and its supporting parts Check chain tension If the chain is too loose it can be adjusted by loosening the rear axle and adjusting the ch...

Page 14: ...ing steps The steps to kick start as follows if with kickstart lever 1 Switch the fuel tank to the ON position 2 the left hand pull in clutch handlebar 3 the right hand pull in the brake handle 4 kick...

Page 15: ...throttle for longer times While running the throttle can reach 100 but for no longer than 5 10 seconds 3 7 10h stage Use motorcycles at 75 100 throttle 4 Above 10h Increase the speed to 60 80km h unt...

Page 16: ...ne 5 Add new engine lubricant to the engine 6 Empty the fuel tank if it is not used for a long time the gasoline will deteriorate 7 Lubricate the chain 8 Apply oil to all unpainted metal surfaces to a...

Page 17: ...eelhubs Check the rimrun out Check the spoke tension Check the chain rear sprocket engine sprocket and chain guide Check the chain tension Grease all moving parts e g hand lever chain and check for sm...

Page 18: ...Throttle Turn the throttle handle by hand to checking if it is smooth and snaps back quickly Check whether the throttle cable has a free play of 10 20mm If the free play is too little adjust as follo...

Page 19: ...ns and threads 6 Carburetor Throttle screws and air screws allow idle sp carburetor The steps are as follows Turn the air screw clockwise until it reaches th reverse one and a quarter turns Adjust the...

Page 20: ...rioration or pollution can cause engine wear and damage Oil level check If the motorcycle has just been used wait for a few minutes after the engine has stopped to check Observe the amount of lubricat...

Page 21: ...nd exhaust valve For the inspection adjustment and replacement of this item please refer to the engine maintenance manual for details 10 Exhaust system inspection Exhaust pipe and muffler can guide ga...

Page 22: ...verflow then open the water tank cover complete the disassembly Shaking the motorcycle check the liquid level of the coolant which should be below If the amount of liquid is insufficient adding the re...

Page 23: ...atisfactory position Turn back the retaining nut Rear brake lever Normally the brake lever should have a free travel of 4 5 mm Check the brake lever and make sure the travel is correct Danger please t...

Page 24: ...ke fluid pipe If there is any leakage problem please contact the distributor of KAYO 19 Check brake pump piston and dust cover Regarding the inspection adjustment and replacement of this project pleas...

Page 25: ...the pipe do not start your motorcycle When replacing the pipe please use the matching equipment produced or authorized by KAYO 24 Fuel system inspection Check the oil tank oil tank cover oil tank swi...

Page 26: ...lubrication 27 Rear shock absorber inspection We equipped this model with FASTACE dual adjustable nitrogen airbag rear shock absorbers Check the rear shock absorber to see if the airbag is normal and...

Page 27: ...checking the chain tension in addition to the chain a visual inspection of the chain guide and sprocket is required When the chain is used excessively or the amount of stretching exceeds 2 the chain...

Page 28: ...Battery check Remove the motorcycle seat cushion and use a multimeter to check the voltage and output current of the positive and negative terminals of the battery If the battery is insufficient plea...

Page 29: ...number of front and rear sprocket teeth Rear sprocket 51 teeth Front sprockets 13 teeth Note Please consult the dealer before replacing the sprocket Never change it without permission Warning When rep...

Page 30: ...mpression adjustment screw located on the top Bleed screw located at the top The rebound adjustment screw is located at the bottom Warning Front fork adjustment requires simultaneous adjustment on bot...

Page 31: ...ld fuel and inject new fuel Dirt on spark plug or wet spark plug Clean or dry the spark plug and replace it if necessary Water entered in to engine First drain the engine oil from the crankcase and re...

Page 32: ...of fuel Refuel Engine overheating Lack of coolant Refill the coolant and check the cooling system for leaks Blocked water tank fins Clean the tank fins with a low pressure water stream and replace if...

Page 33: ...ed Change the gear lever Damaged shift drum Replace the shift drum Damaged ratchet Replace ratchet Speed selector position spring is loose or broken Replace speed selector position spring The gears ar...

Page 34: ...to the manual Rear wheel off center Check spokes and adjust spoke tension center if necessary Fork spring is soft or broken Replace front fork spring Wearing of brake discs Inspect the brake disc and...

Page 35: ...r if necessary Brake failure brake discs wearing Replace the brake disc Insufficient brake fluid Replenishing brake fluid Brake fluid deterioration Change the brake fluid Damaged piston Contact KAYO d...

Page 36: ...r head and the oil hole on the rocker shaft The oil passage on the cylinder head must not be allowed to enter and it is required to keep smooth Before installing the cylinder head the cylinder head po...

Page 37: ...ead pad leakage 4 the piston ring gap is too large Excessive noise or abnormal noise 1 Incorrect valve adjustment 2 The valve is stuck or the valve spring is broken 3 Excessive wear on the upper rocke...

Page 38: ...ll disk bolts for tightening the tensioner M6 20 then remove the tensioner bolt tensioner combination tension Device gasket 4 Remove the timing chain from the timing driven sprocket 5 Remove the camsh...

Page 39: ...lve remover to press down the valve spring and remove the valve lock clip then relax the valve remover and remove the valve spring seat valve spring and valve Note 1 In order to prevent permanent defo...

Page 40: ...5 mm Inspection of swing arm and swing arm shaft Check the swing arm and axial clearance If it worn and tear seriously or swing arm roller axial clearance is too large please replace new swing arm Che...

Page 41: ...seat Clean the carbon deposits in the combustion chamber completely then smear a thin layer of red printing oil evenly on the valve seat Put the valve on the valve seat and knock the valve gently wit...

Page 42: ...ing the reamer shall be coated with cutting oil When loading or taking out the reamer it shall be rotated Finally clean cylinder head with cleaning agent and remove metal chips on the cylinder head by...

Page 43: ...Firstly put the inlet and exhaust swing arms into the cylinder head cover and then assemble the inlet and exhaust swing arm shafts through the cylinder head cover and the inlet and exhaust swing arm...

Page 44: ...timing adjustment 1 Remove the large viewing hole cover of front left cover and the NC250 rocker shaft 2 Rotate the NC250 magneto lock nut with a special tool and observe whether the timing calibrati...

Page 45: ...ming mark Cylinder head cover assembly 1 Smear a layer of silicone rubber surface sealant evenly to the cylinder head cover joint surface 2 Install the cover on cylinder head 3 put 2 A88 washers to GB...

Page 46: ...eter 77 77 01 77 018 out of roundness 0 05 0 01 Face flatness 0 03 0 05 Piston Piston ring Piston pin Piston outer diameter 76 96 76 97 76 94 Inner diameter of piston pin hole 16 001 16 006 16 015 Cle...

Page 47: ...much carbon deposits Disassembly of cylinder Remove chain guide plate and cylinder body Clean the remaining gaskets on the cylinder surface with a spatula note If gasket is immersed in gasoline it is...

Page 48: ...and piston pin Remove piston ring note do not damage piston ring Measure the clearance between piston ring and piston ring groove Maintenance limit first ring 0 08mm Second ring 0 08 mm Oil ring 0 08...

Page 49: ...limit 0 1mm Measure outer diameter of piston pin Maintenance limit 15 99 mm Calculate the clearance between piston pin and piston Maintenance limit 0 025 mm Piston ring assembly 1 Clean the piston ri...

Page 50: ...piston pin ring shall be downward 3 If the piston pin ring is sever deformed replace it 4 Do not let the piston pin ring fall into the crankcase Mark face toward engine exhaust side Cylinder body asse...

Page 51: ...tart gear Inspection of right body oil pump Inspection of starter motor and duplicate gear Inspection of shifting mechanism Start shaft assembly Duplicate tooth assembly shifting mechanism assembly ri...

Page 52: ...clutch 1 if there is a clutch failure usually can be adjusted by the clutch hand free travel The bike will move slowly when the clutch is released 1 Large free travel 2 bent clutch plate Clutch opera...

Page 53: ...mponents and oil seal from pump shaft hole Disassembly of clutch 1 Remove the spring and bolts from clutch pay attention to loosen bolts should be divided into two or three times into the way of cross...

Page 54: ...bolt M5 18 from oil pump plate then remove plate combination and rotors combination note There are two washers on carrier gear keep washers rings and pins safe after removing Disassembly of duplicate...

Page 55: ...seal components broken pump shaft sever worn or bend replace them note 1 Apply an appropriate amount of oil in the shaft hole then press the oil seal in place with special tooling keep oil seal mark...

Page 56: ...e limit 2 85mm Check if there is any distortion on the surface of the clutch follower check with the feeler gauge Maintenance limit 0 14mm Check the gap between clutch cover and friction disc Maintena...

Page 57: ...and outside of the oil pump is worn and damaged if the wear and damage is serious it is necessary to replace the assembly parts 2 check if the oil pump bridge gear and oil pump gear combination have...

Page 58: ...nstall the variable arm after assembly the variable arm please check whether the change gear is correct then continue to install the machine Assembly of Right Body Oil Pump 1 first install the oil pum...

Page 59: ...ctive tooth locking nut 150 160N m Installation of clutch 1 Install the clutch cover washer clutch shaft sleeve clutch cover and clutch center sleeve washer to the spindle Note Daub grease evenly on i...

Page 60: ...rs and balancing main and driven Gear Maintenance instructions Removal of the left crankcase cover Removal of the stator of the magneto Removal of the motor rotor Removal of balancing main and slave g...

Page 61: ...then remove the magneto stator combination from the left crankcase cover Removal of the motor rotor Remove the magnet motor rotor locking nut and remove the magnet motor rotor with special tools Note...

Page 62: ...at fasten the cover plate of the left machine oil pump 2 Remove the oil pump cover plate remove the left oil pump rotor assembly oil pump pin should be properly kept to avoid loss Inspection of left c...

Page 63: ...on of the main and driven gear 1 First install the NC250 crankshaft shaft to the balance shaft in the keyway NC250 the balance shaft flat key 4 4 13 to the balance shaft finally install the balance sh...

Page 64: ...f locking nut for magnetic motor rotor 85 90N m Installation of the magneto stator Tighten the magneto stator assembly to the left crankcase cover with 2 GB T818M5 10 and 2 GB T70 1 screws M5GB T818M5...

Page 65: ...rst and the disassembly of other parts about the engine should be carried out before the crankcase is separated Work before crankcase separation Removal of cylinder head Removal of cylinder piston Rem...

Page 66: ...parate the left crankcase from the right crankcase and remove 2pcs of positioning pins Crankshaft balance shaft main and counter shaft disassembly Remove the crankshaft assembly balance shaft fork sha...

Page 67: ...e type of bearing should be replaced 2 Remove the crankshaft bearings of left and right box to check their diameter and end jumps and replace new crankshaft bearings if noise or diameter jumps and end...

Page 68: ...t fork 13 95 mm Measure the thickness of the fork claw Maintenance thresholds 4 7 mm Check for wear or damage to the surface and groove of the transmission hub Inspection the assembly of main and coun...

Page 69: ...he fork marked L is mounted on the left side of the counter shaft 3 The fork marked C is mounted on the main shaft 3 Put the transmission hub into the corresponding hole of the left body then assemble...

Page 70: ...r cover on the double headed bolt and then fastened M5 with 2pcs of GB T6177 1 nuts Fastening torque 7 9 N m Combine the oil filter into the corresponding holes in the left and right boxes then fasten...

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KAYO MOTOR K6-R, Service Manual

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