KAYO MOTOR TS90 Service Manual Download | Manualshive

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ZHEJIANG KAYO MOTOR CO., LTD.

2.   Check whether the air filter sponge is damaged.
3.   Check whether the fire net is damaged
4.   Check whether the air filter block is degummed with the sponge surface
If   the   air   filter   is   damaged,   replace   the   corresponding   parts;   if   no   parts   are   damaged,   perform
maintenance as follows:
1.   Clean the air filter hose with water and let it air dry.
2.   Clean the dust attached to the air filter sponge and soak the surface with air filter oil. If the dust

on the sponge is difficult to resolve, you can also replace a new air filter sponge.

3. Clean the fire net with gasoline and let it air dry naturally.

4.

Clean the air filter block with water and let it air dry.

REMOVING OR INSTALLING THE EXHAUST PIPE

Removing steps as below:
1.   Remove the cover.
2.   Remove the muffler tube
3.   Remove   the   fixing   nut   at   the   connection   of   the

engine exhaust pipe

4.   Remove the exhaust pipe
5.   Remove the gasket.
Installing Steps:
The   installment   should   be   carried   out   in   the   reverse
order of removal.

NOTE:

install the exhaust pipe with a new gasket.

REMOVING OR INSTALLING THE MUFFLER TUBE

The  exhaust  pipe  and  the  muffler  tube  can  guide  the  gas
emission and reduce the noise.
f   the   exhaust   pipe   is   rusty   or   ruptured   or   damaged   by
impact,  please  replace  it  with  a  new  one  immediately.  If
the   noise   is   too   high   or   the   engine   performance   is
degraded, replace the muffler tube.
For   the   cleaning   of   the   exhaust   system,  please  consult
with KAYO dealers before operating.
If   you   need   to   replace   the   muffler   tube,   please   follow
the steps below

Unscrew the mounting bolts of the muffler tube

Loosen the buckle at the connection between the
muffler tube and the exhaust pipe

Pull out the muffler tube backwards

Replace the muffler tube and install the fasteners

Installing Steps:
The installment should be carried out in the reverse
order of removal.

REMOVING OR INSTALLING THE FUEL TANK
Removing steps as below:
1.   Remove the seat cushion.
2.   Unscrew the rear fixing screw of the fuel tank
3.   Unscrew the fuel tank front installation screws.

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Summary of Contents for TS90

Page 1: ...ZHEJIANG KAYO MOTOR CO LTD KAYO MOTO TS90 SERVICE MANUAL www kayomoto com ...

Page 2: ...ZHEJIANG KAYO MOTOR CO LTD ...

Page 3: ...ut incurring any obligation The vehicle pictured in this owner s manual may not match your actual vehicle PREFACE Congratulations on your purchase of the 2021 TS90 Dirt Bike and we believe that this choice won t let you down This manual will give you an understanding of the better use of our product it has specialized the maintenance and adjustment procedures disassembly and assembly points inspec...

Page 4: ... different law s requirement we ve adjusted model accordingly the model image in this manual maybe not match your actual vehicle In addition if there is any question concerning this manual please visit our website www kayomoto com and consult our customer service The contents of this manual are subject to change without prior notice due to vehicle improvement The actual state of the motorcycle sha...

Page 5: ...R OF THE REAR WHEEL AND THE REAR FENDER IN SUSPENSION 22 MEASURE DISTANCE BETWEEN CENTER OF REAR WHEEL AND REAR FENDER UNDER NO LOAD 22 MEASURE DISTANCE BETWEEN REAR WHEEL CENTER AND REAR FENDER IN DRIVING CONDITION 23 ADJUSTING THE SPRING PRELOAD OF REAR SHOCK ABSORBER 23 CHECK FOR THE SETTING OF FRONT SHOCK ABSORBER 23 ADJUSTING THE HANDLEBAR 24 VEHICLE MAINTENANCE 24 PLACEMENT 24 REMOVING OR IN...

Page 6: ...K AND REFUEL THE REAR BRAKE DISK LIQUID LEVEL 33 CHECK THE REAR BRAKE PADS 34 TIRE INSPECTION AND MAINTENANCE 35 REMOVING OR INSTALLING THE FRONT WHEEL 35 REMOVING OR INSTALLING THE REAR WHEEL 35 TIRE INSPECTION 35 CHECK TIRE PRESSURE 36 CHECK SPOKE 36 INSTALLING THE ENGINE 36 ENGINE MAINTENANCE AND ADJUSTMENT 37 INSTALLING THE CYLINDER HEAD AND BLOCK 37 CHECK THE VALVE CLEARANCE 37 COMPRESSION PR...

Page 7: ...ANCE STANDARD OF PISTON 50 TROUBLE OCCURENCE AND CAUSE ANALYSIS 51 REMOVAL OF CYLINDER BLOCK 51 CYLINDER BLOCK INSPECTION 51 REMOVAL OF PISTON AND PISTON RING 52 PISTON AND PISTON RING INSPECTION 52 INSTALLING THE PISTON RING 53 INSTALLING THE PISTON 53 INSTALLING THE CYLINDERBLOCK 54 CLUTCH DRIVING GEAR DRIVEN GEAR SHIFT MECHANISM 54 NOTICES 54 MAIN PARAMETERS AND MAINTENANCE STANDARD 54 TROUBLE ...

Page 8: ...ER AND REAR LEFT COVER INSPECTION 65 TRANSITION PLATE AND STARTER MOTOR INSPECTION 65 STARTER CHAIN INSPECTION 65 MAGNETO STATOR AND ROTOR INSPECTION 65 INSTALLATION OF THE TENSION ARMS AND THE TESION RODS 65 INSTALLATION OF THE TENSION ROLLER 65 INSTALLATION OF THE TRANSITION PLATE 66 INSTALLATION OF THE STARTER MOTOR AND STARTER SPROCKET 67 INSTALLATION OF THE MAGNETO STATOR 67 INSTALLATION OF T...

Page 9: ... have the confidence to perform that you can go to an authorized KAYO workshop or KAYO after sale service point There your motorcycle will be optimally cared for by specially trained experts using the specialist tools required Indicates a page reference more information is provided on the specified page DEGREES OF RISK AND SYMBOLS Your safety and the safety of others is very important Operating th...

Page 10: ...ebar and pedal for carrying people So please be sure not to use this motorcycle to carry any other people except the driver which may easily lead to a safety accident Do not use non original parts to modify the car and do not arbitrarily remove the original components from the vehicle If you need to replace any parts please use spare parts and accessory products that are approved and or recommende...

Page 11: ...0 11 12 13 14 15 16 No Name No Name 1 Front fender 9 Front shock 2 Front panel 10 Fuel tank 3 Handlebar 11 Carburetor 4 Vent pipe 12 Gear shift lever 5 Fuel tank cap 13 Pedal 6 Fuel tank petcock 14 Chain 7 Chain guide cover 15 Chain guide 8 Front brake caliper 16 Rear sprocket www kayomoto com ...

Page 12: ...29 30 31 No Name No Name 19 Rear fender 26 Rear brake caliper 20 Exhaust pipe muffler 27 Swing arm 21 Seat 28 Rear brake oil cup 22 Rear shock 29 Brake pedal 23 Upper clamp 30 Exhaust pipe 24 Lower clamp 31 Front disc brake 25 Rear disc brake www kayomoto com ...

Page 13: ...ANG KAYO MOTOR CO LTD VIN CODE Vin code of 2021 TS90 are located on the head pipe ENGINE NUMBER The engine number of the 21 TS90 is located on the engine box inside the shift lever PARAMETER www kayomoto com ...

Page 14: ...ft type Usually engage four speed transmission Starting Electric kick Ignition type CDI Battery 12V 4Ah Chain 420 14T 39T Frame Shock Brake Wheel system Parameters Frame type Steel tube suspension frame Front shock Upright front shock L 540mm non adjustable Rear shock Common rear shock L 270mm non adjustable Swing arm Steel swing arm Handlebar Steel handlebar F R rims F 1 40 12 R 1 85 10 Steel rim...

Page 15: ...of the handlebar and functioned by the pinching the lever with your right hand The front wheel adopts the floating caliper disc brake which is installed under the left front shock and fixed by two bolts THROTTLE LEVER throttle lever Turn the handle counterclockwise to increasing the engine It will back to normal smoothly once you release the handle STARTING www kayomoto com ...

Page 16: ...el tank switch should be in the open position STOPPING stopping button The stopping button is round red one and fitted on the left side of the handlebar near the grip It needs long press on the button when stopping FUEL TANK SWITCH fuel tank switch The fuel tank switch is located on the bottom left side of the fuel tank By turning the switch you can control the entrance of the fuel into the carbur...

Page 17: ...BRAKE foot brake pedal The foot brake pedal is located on the right side of the engine and is functioned by stepping Note In actual use the brake operation should be mainly through foot brake use hand brake as a supplement rear brake caliper The rear brake adopts a floating clamp disc brake which one is located on the right side of the rear wheel and fixed by a disc brake bracket PARKING SUPPORT w...

Page 18: ...riction surface that can withstand larger loads Only after standard running in can the engine have excellent performance and reliability The recommended running in steps are as follows 1 0 2 5h stage Using under the throttle level of 50 75 the speed should be changed frequently to avoid the motorcycle working at the same condition for a long time Let the engine rest and cool down for 5 10 minutes ...

Page 19: ...position 2 Open the electric lock 3 Pinch the brake lever with the right hand 4 Long Push the ignition switch with the fingers of the left hand 5 Release the ignition switch after the engine works properly That s all for starting The steps of kick ignition are as follows 1 Turn the oil tank switch to the ON position 2 Pinch the brake lever with the right hand 3 Tramp the foot starting rod vigorous...

Page 20: ...ift the gear to N before stopping 4 5 SUGGESTED INSPECTION TIME FOR ALL PARTS OF THE VEHICLE every 30 hours every 20 hours every 10 hours after every race 1 hour after each ride Check the front disc brake plate Check the rear disc brake plate Check the front and rear disc brake discs Inspect brake tubing for damage or leakage Check the rear disc brake fluid level Check the free play of the brake p...

Page 21: ...e for damage and sharp bend Clean air filter and air filter tank Check whether screws and nuts are tightened Replace the fuel filter Check carburetor idle Final inspection check whether the vehicle is running safely and conduct a test One off interval Periodic interval ATTENTION This table is for reference only Please adjust the maintenance cycle of the motorcycle according to the specific model a...

Page 22: ... of the rear wheel axle of the motorcycle to point 1 and record it as A2 3 Use a single stand to support the vehicle 4 Calculate the difference between A1 and A2 and denote it as D1 The value of D1 when 2021 TS90 motorcycle leaves factory is shown below D1 TS90 10 34mm MEASURE DISTANCE BETWEEN REAR WHEEL CENTER AND REAR FENDER IN DRIVING CONDITION The measurement procedure is as follows 1 The driv...

Page 23: ... 1 Place the whole motorcycle on the ground 2 Up right the vehicle 3 Hold the handlebars with both hands and press down on the front shock absorber 4 Observe the effect of pressure and rebound of front shock absorber ADJUSTING THE HANDLEBAR The handlebars of the vehicle can be adjusted according to the customer s driving habits The specific steps are as follows 1 Remove the sheath and sheath on th...

Page 24: ...SC BRAKE oil pipe clamp Install the bolts Removing Steps are as follow 1 Remove the mounting bolt of disc brake clamp 2 Remove the front brake oil pipe clamp 3 Remove the front brake handle 4 Remove the front cable panel 5 Remove the front disc brake Installing Steps The installment should be carried out in the reverse order of removal REMOVING OR INSTALLING THE FRONT SHOCK ABSORBER www kayomoto c...

Page 25: ...val REMOVING OR INSTALLING THE LINKAGE Removing Steps are as follows 1 Remove the front shock absorber 2 Remove the lock nut of the steering column 3 Remove the upper link board 4 Remove the adjusting nut of the steering column 5 Take out the lower link board 6 Remove the steering column 7 The installation is carried out in the reverse order of removal CHECK THE FRONT STEERING Check the front stee...

Page 26: ...steering of the front of the car is obstructive remove the link plate to check whether the steering bearing is normal LUBRICATION AND INSTALLATION OF STEERING HEAD BEARING bearing When installing the steering bearing on the head apply a layer of lithium based grease on the surface of the roller Refer to the figure on the left for specific installation REMOVING OR INSTALLING THE FRONT FENDER www ka...

Page 27: ...e Installation in the reverse order of removal REMOVING OR INSTALLING THE SEAT CUSHION Removing Steps are as follows 1 Remove the fixing bolt on both sides of the rear seat 2 Remove the fixing bolt of the seat and fuel tank 3 Take out the seat backwards 4 Remove the fixing bolt of the seat and plastic parts Installing Steps The installment should be carried out in the reverse order of removal REMO...

Page 28: ... Steps The installment should be carried out in the reverse order of removal NOTE install the exhaust pipe with a new gasket REMOVING OR INSTALLING THE MUFFLER TUBE The exhaust pipe and the muffler tube can guide the gas emission and reduce the noise f the exhaust pipe is rusty or ruptured or damaged by impact please replace it with a new one immediately If the noise is too high or the engine perf...

Page 29: ...erse order of removal CHECK AND ADJUST THE CHAIN TENSION The chain can transfer the output power from the engine to the wheels so that the motorcycle can move normally It is an important part of the motorcycle Therefore the chain needs frequent inspection and maintenance to ensure its normal use The chain tension can be adjusted according to requirements the steps are as follows 1 Stand the motorc...

Page 30: ...ow the correct lubrication method and select a suitable lubricant for lubrication NOTE If the chain needs to be tightened frequently or if you find any signs of wear on the front sprocket rear sprocket and the chain please contact KAYO dealer for a thorough inspection to avoid safety problems CHECK THE STRUCTURE OF THE REAR SPROCKET ENGINE SPROCKET AND GUIDE CHAIN Chain guide Chain protector Check...

Page 31: ...lly and feel whether the position of the clutch grip and brake grip are comfortable or not If you feel difficult to steering adjust the positions of the clutch and brake levers CHECK AND MAINTENANCE THE BRAKE SYSTEM CHECK THE FREE PLAY OF FRONT BRAKE LEVER Checking steps as below 1 Rest your right hand on the right hand grip naturally 2 Use the index finger and middle finger of your right hand to ...

Page 32: ...the brake fluid is mixed with water soil or other particles the brake fluid should also be replaced It is recommended to use DOT4 brake fluid Danger Do not mix different types of brake fluid and pour it into the brake system for use The use of brake fluid must meet the braking requirements Please do not use the brake fluid in an unsealed container The brake fluid may deteriorate when exposed to th...

Page 33: ...her than lower You should refuel it if it is insufficient NOTE Do not splash the brake fluid on the paint surface which may cause corrosion DANGER Please pay attention to check whether the brake fluid is leaking and whether the brake fluid pipe is damaged If so please contact KAYO dealer Refueling Steps are as follows 1 Remove the screw 2 Remove the cap 3 Refuel brake fluid to a proper level 4 Re ...

Page 34: ...ows Lift the motorcycle off the ground and Stabilize it by using a motorcycle stand Remove front disc brake cover if have Loosen the front wheel axle pinch bolts Holding the front wheel with one hand withdraw the front wheel axle gradually with another hand Remove the front wheel Installing Steps The installment should be carried out in the reverse order of removal REMOVING OR INSTALLING THE REAR ...

Page 35: ...uently with lower pressure problem find out if there is a deflation or not and contact the Kayo Dealer for help Pressure advice Front Tire Rear Tire TS90 250kPa 250kPa NOTE Do the checking work only on cold tires CHECK SPOKE spoke Use your fingers to move the adjacent spokes to check whether the tire spokes lack tension If you find that the spokes are loose and weak you must check all the spokes a...

Page 36: ...ccording to the following procedures Remove the valve cover Unscrew the magneto plug and timing screw plug on the left front cover and use a 14mm socket wrench to turn the magneto rotor until the piston reaches the top dead center of the compression stroke turn the magneto rotor until the engraved line on the rotor matches the left front cover Until the timing holes on the top are aligned Insert a...

Page 37: ...tle screw and air screw Proceed as follows 1 Rotate the air screw clockwise until it reaches the top of its stroke and then reverse one and a quarter of a turn 2 Adjust the throttle screw to ensure that the engine can run at a certain speed when the throttle lever is completely loosened 3 Adjust the throttle screw to reduce the engine speed as much as possible 4 Adjust the air screw to increase th...

Page 38: ... the position of the shift head 3 The shift head should be level with the tread surface or slightly lower than the tread surface If the shift head is higher than the tread surface the shift head should be adjusted downwards if the shift head is excessively lower than the tread surface the shift head should be adjusted upwards ADJUST THE SHIFT LEVER POSITION Shift lever fixing bolt Adjusting Steps ...

Page 39: ...ng the lubricating oil please drain the original lubricating oil in the crankcase and clean it with washing kerosene before adding new lubricating oil according to the regulations LUBRICANT INSPECTION Dipstick If the engine is running turn off the engine and wait a few minutes for the oil to reach the bottom of the crankcase Place the engine vertically on the ground and observe through the oil obs...

Page 40: ...nner 32 03 Outer 34 8 2 Valve clearance Intake valve 0 01 0 03 0 01 or 0 03 Exhaust valve 0 01 0 03 0 01 or 0 03 3 Camshaft base circle runout 0 02 0 04 4 Valve guide aperture φ5 φ5 012 φ5 035 5 Valve stem diameter Intake valve Φ4 97 φ4 985 Φ4 96 Exhaust valve Φ4 955 φ4 97 Φ4 94 6 Clearance between valve stem and valve guide Intake valve 0 013 0 04 0 07 Exhaust valve 0 025 0 052 0 08 7 Width of va...

Page 41: ...e left cover of the engine cylinder head whether the timing mark of the driven sprocket is aligned with the timing mark of the cylinder head Removal of the valve cover Valve cover 1 Remove the valve covers on the intake and exhaust sides of the cylinder head After the valve cover is disassembled check whether the thread is damaged and the sealing ring is damaged If damaged use new parts when reass...

Page 42: ...ved parts should be marked to ensure that they reach the original assembly position during assembly 3 When disassembling the gasket ensure that the gasket is in good condition If it is damaged replace it with a new gasket during assembly to avoid engine oil leakage Inspection of valves and valve springs The inspection steps for valves and valve springs are as follows 1 Check whether the valve is b...

Page 43: ...HE VALVE GUIDE Use a dial indicator to measure the inner diameter of each valve catheter and make a record Repair limit value φ5 035 mm Note Before measuring the inner diameter of the valve guide the carbon deposits in the guide should be completely removed If the valve guide needs to be replaced the valve seat should be polished again and each valve should be inserted into the guide observe its m...

Page 44: ...e the same as the oil passage hole of the right cover of the cylinder head when assemblingINSTALLING THE CYLINDER HEAD The installation steps of the cylinder head are as follows 1 Remove the old cylinder head gasket install the new cylinder head gasket and then install the positioning pin flange bushing and rectangular ring 2 Pull the piston to the top dead center and then install the timing drive...

Page 45: ...ning torque 8 12N m 8 Put the o ring into the groove of the valve cover and then install the valve cover on the cylinder head and tighten it Tightening torque 8 12N m Install the spark plug into the spark plug thread of the cylinder head and tighten it Tightening torque 10 12N m CYLINDER BLOCK AND PISTONNotice Cylinder head lubricating oil is sent to the cylinder head through the oil hole next to ...

Page 46: ... diameter φ13 002 φ13 008 φ13 017 Piston pin hole and piston pin clearance 0 001 0 012 0 025 3 PISTON RING Closed clearance First ring 0 1 0 25 0 4 Second ring 0 1 0 25 0 4 Oil ring 0 2 0 8 1 4 Side clearance First ring 0 03 0 06 0 08 www kayomoto com ...

Page 47: ...ECTING ROD φ13 012 φ13 022 Φ13 035 7 CLEARANCE BETWEEN SMALL END OF CONNECTING ROD AND PISTON PIN 0 016 0 033 0 05 TROUBLE OCCURENCE AND CAUSE ANALYSISNo TROUBLE OCCURENCE Analysis Remarks 1 Low pressure in cylinder Abnormal wear of cylinder block or piston ring 2 Black smoke in exhaust Abnormal wear of cylinder piston or piston ring Incorrect installation of piston ring www kayomoto com ...

Page 48: ...akage after reassembly 2 If the paper pad is immersed in gasoline it is easy to disassemble When doing this work avoid damaging the cylinder contact surface The removed parts must be properly placed to avoid damage and loss CYLINDER BLOCK INSPECTION The inspection steps of the cylinder are as follows 1 Check whether the cylinder is worn or damaged 2 Measure the inner diameter of the cylinder take ...

Page 49: ...80 and cannot be aligned with the piston pin holes The rings of the piston should rotate flexibly The gap between the rings in the oil ring should match the gap of the spacer ring when installing the oil ring the spacer ring should be installed first and then the side rails should be installed INSTALLING THE PISTON IN towards the intake side of the engineThe installation steps of the piston are as...

Page 50: ...ain guide roller should be located in the middle of the chain after it is installed in the cylinder block CLUTCH DRIVING GEAR DRIVEN GEAR SHIFT MECHANISMNOTICES After the right cover is removed the clutch oil pump and gear shift mechanism can be removed installed and repaired without removing the engine If the operation of the clutch fails it can usually be better corrected by adjusting the free s...

Page 51: ...ysis Remarks 1 Clutch slips when accelerating Not enough free travel Bent clutch plate Clutch disc wear 2 Excessive handle pressure The clutch cable is sticky damaged or dirty The clutch cam release mechanism is damaged 3 Oil pressure is too low The oil pump is faulty Broken oil pump drive gear 4 Clutch operation is difficult www kayomoto com ...

Page 52: ...ssed countersunk head screw GB T820 M6 22 of the right decorative cover 2 Remove the right decorative cover ADJUST THE CLUTCH STROKE Loosen the adjusting nut first turn the adjusting bolt clockwise To increase the free rotation stroke of the small end of the clutch camshaft rotate the adjusting bolt counterclockwise and at the same time the small end of the clutch camshaft is automatically rotated...

Page 53: ... end cover of the clutch Remove the clutch cover and gasket Pry the locked clutch anti return washer remove the big round nut that fastens the clutch and remove the butterfly shaped washer and clutch anti return washer Take out the clutch Remove the clutch driving gear cover Remove the elastic retaining ring under the clutch and take out the clutch upper plate friction plate clutch lower plate fri...

Page 54: ...tarting shaft oil seal 13 7 24 5 clutch push rod oil seal 12 21 4 When assembling the marked side should face outward Check whether the clutch adjusting nut and the clutch adjusting bolt rotate flexibly and whether the return spring is intact Whether the right crankcase cover is broken and whether the oil passage is unobstructed If damaged replace the right crankcase cover with a new one CLUTCH IN...

Page 55: ...te is bent and whether the spring is deformed Check whether the boom and forearm of the shift arm are deformed the spring is deformed and the shaft is bent ASSEMBLE THE SHIFT MECHANISM Shift arm positioning shaft The assembly steps of the shift mechanism are as follows Smoothly fit the shift arm into the left and right crankcase holes and press down the shift arm assembly so that the forearm is lo...

Page 56: ...c and then install the friction plate the lower clutch plate the friction plate and the upper clutch plate in sequence Use special equipment to press down the clutch drive disc and install it into the clutch elastic retaining ring and then install 4 damping springs Install the clutch driving gear casing Note The two friction lining teeth need to be aligned after the clutch is assembled INSTALLING ...

Page 57: ...the right cover The plane of the semicircular rod is attached to the cam plate The end of the spring is completely hooked on the clutch camshaft and cannot fall off Pass the positioning pin through the right cover pin The hole snaps into the groove of the clutch camshaft Note The clutch camshaft is flexible to reset and the push rod does not fall off ASSEMBLE THE RIGHT CRANKSHAFT COVER The assembl...

Page 58: ... the left front cover over and place it on a flat surface Remove the 2 GB T 5787 M6 20 bolts that fasten the stator of the magneto the 2 GB T 5783 M5 12 bolts that fasten the trigger and the 1 cross recessed pan head screw GB that fastens the small crimping plate T 818 M5 61 1 bolt GB T 5787 M6 14 for fastening the wire harness pressing plate Remove the magneto stator Note If the magneto stator is...

Page 59: ...lt 1 GB T 5787 M6 35 bolt GB T 5787 M6 25 bolt and 1 aluminum washer that fasten the transition plate Remove the transition plate REMOVAL OF THE TIMING CHAIN The method and steps for disassembling the timing chain are as follows Method one Remove the left cover of the cylinder head Remove the 3 bolts that fasten the timing driven sprocket Remove the chain guide roller pin that fastens the chain gu...

Page 60: ...to rotor with a new one Check that there is no foreign matter on the inner wall of the rotor whether the rollers of the rotor unidirectional device have fallen off or severely worn If so replace with a new one Check whether the magneto stator is worn or damaged If so replace it with a new magneto stator INSTALLATION OF THE TENSION ARMS AND THE TESION RODS INSTALLATION OF THE TENSION ROLLER The sma...

Page 61: ... Note The gap between the starting sprocket pressing plate and the end surface of the starting sprocket should be in the range of 1mm 2mm INSTALLATION OF THE MAGNETO STATOR The installation steps of the magneto stator are as follows Install the magneto stator on the left front cover After the stator is installed align the screw holes with the threaded holes of the left front cover insert the harne...

Page 62: ...w gasket Assemble the left crankcase cover in place and fasten it with 3 pieces of GB T 5787 M6 32 bolts and 1 piece of GB T 5787 M6 50 bolt Tightening torque 10 14 N m CRANKCASE AND CRANKSHAFT MAIN AND COUNTER SHAFT VARIABLE SPEED DRUM NOTICE This section introduces the installation and inspection of the transmission and crankshaft When performing the above work the crankcase should be disassembl...

Page 63: ... 027 φ16 025 Axial backlash of connecting rod big end 0 1 0 3 0 4 Big end radial backlash of connecting rod 0 004 0 012 0 015 TROUBLE OCCURENCE AND CAUSE ANALYSIS NO TROUBLE OCCURENCE Analysis Note 1 Difficult shifting Bending deformation of shift fork Variable speed drum washers and bolts are loose and fall off 2 Skip gear The gear pawl is worn out www kayomoto com ...

Page 64: ...llows Place the engine right crankcase up and remove the starting shaft retainer ring return spring and spring seat Place the left crankcase of the engine upward take out one GB T 5787 M6 12 bolt and baffle at the hole of the transmission drum the rubber plug one GB T 5787 M6 16 bolt and the transmission drum washer Remove 4 GB T5787 M6 65 bolts 2 GB T5787 M6 6 bolts and 1 GB T5787 M6 50 bolts tur...

Page 65: ...ckness gauge Repair limit value 0 4mm Use a dial indicator to measure the runout of the crankshaft shaft diameter and the actual runout of the crankshaft Repair limit value 0 1 mm Measure the radial clearance between two points in the X and Y directions of the big end of the connecting rod Repair limit value 0 015mm LEFT AND RIGHT CRANKCASE BEARING INSPECTION The inspection steps of the left and r...

Page 66: ...gears STARTER SHAFT INSPECTION The inspection steps of the starting shaft are as follows Check whether the starting ratchet starting gear and starting shaft are excessive or abnormally worn Check whether the clamp ring is deformed or fallen off Check whether the gasket is deformed or missing VARIABLE SPEED DRUM INSPECTION The assembly steps of the variable speed drum are as follows Put the shift f...

Page 67: ...que 10 14 N m Install rubber stopper baffle and 1 GB T 5787 M6 12 bolt at the variable speed drum hole to tighten and turn over the engine Note The bolts are not loose and the countershaft rotates flexibly without jamming Turn the main shaft clockwise When the main shaft does not move combine the return spring of the start shaft with the return spring seat The spring hook hooks the limit block of ...

Page 68: ...tank Blocked tubing from the fuel tank to the carburetor Fuel flows into the carburetor The float in the carburetor is stuck The vent on the fuel tank cap is blocked Remove the spark plug to test the spark Weak sparks or no sparks at all Spark plug failure The spark plug is not clean Electronic ignition is malfunctioning The magneto is faulty Good sparks Bad wiring broken www kayomoto com ...

Page 69: ...ircuited The ignition switch is faulty Test cylinder pressure Low Pressure The starting mechanism is slipping and the engine cannot be turned Normal pressure Valve clearance is too small Valve opening blocked Cylinder or piston ring wear Cylinder head gasket is broken Improper valve timing www kayomoto com ...

Page 70: ... Incorrect ignition timing Remove the spark plug Wet spark plug The carburetor oil level is too high The carburetor choke is closed too tightly Spark plug dry Excessive throttle The engine performs poorly at low or idling speeds Check valve timing and valve clearance Incorrect Improper valve clearance adjustment or poor quality of rocker arm adjustment screws Correct Improper adjustment of gas tim...

Page 71: ...r gasket is leaking Air leak Deterioration of carburetor seal ring Airtight Loose carburetor Damaged carburetor gasket Remove the spark plug and perform a spark test Weak sparks or intermittent sparks The spark plug is faulty or carbon deposits The electronic igniter is malfunctioning The magneto is faulty Good spark plug The spark plug cap is faulty www kayomoto com ...

Page 72: ...stment The magneto is faulty Valve clearance and ignition timing are correct Disassemble the connection of the fuel pipe of the carburetor and check if the fuel pipe is blocked Insufficient fuel flow The fuel tank has run out Blocked fuel pipe The fuel pipe has sufficient flow Blocked fuel tank cap vent Check if the filter and carburetor nozzle are blocked Blockage Blocked carburetor measuring hol...

Page 73: ...spring The engine has abnormal noise Check whether there is abnormal noise in the valve Abnormal noise in the valve Valve clearance is too large Valve wear Check whether there is abnormal noise in the cylinder Cylinder has abnormal noise Piston and cylinder wear The small end holes of the piston pin and connecting rod are worn Crank pin and connecting rod large end wear www kayomoto com ...

Page 74: ...iven gears is too small or too large MOTORCYCLE CLEANING The cleaning of the vehicle is also an important part of the daily use and maintenance of the motorcycle Frequent cleaning of your motorcycle can keep your car in a good state of motion and prolong its service life You can clean your motorcycle through the following steps Cover the exhaust system to prevent water from entering Seal the elect...

Page 75: ...cate the chain Apply oil to all unpainted metal surfaces to avoid rust When storing the motorcycle keep the motorcycle wheels suspended If this condition cannot be achieved you can use cardboard to pad under the motorcycle tires Cover the motorcycle to prevent dust and dirt Move the motorcycle into a dry room and place it NOTE When applying anti rust oil please do not splash the oil on the brake a...

Page 76: ...e water intake First drain the mixed fuel out the engine and remove the crankcase of the engine clean it with a strong cleaning agent then remove the spark plug blow it dry with a fan the machine that inflates the tires and then wipe the air filter element Finally remove the exhaust pipe of the engine and blow it dry with a fan After everything is done the car owner should add new mixed fuel to th...

Page 77: ...ks in the cooling system Clogged water tank fins Use low pressure water to clean the fins of the water tank and replace them if necessary Unbalanced engine operation The spark plug is dirty damaged or adjusted incorrectly Remove the spark plug for cleaning adjustment and replacement if necessary There is a problem with the spark plug cap Check the condition of the spark plug cap check whether the ...

Page 78: ... KAYO Service Center overheat See Engine Overheating section Exhaust pipe backfire phenomenon Carbon deposits in the combustion chamber Contact KAYO Service Center Poor gasoline Change fuel The spark plug is in poor condition or the specification is wrong Replace with a new spark plug with the correct specification Exhaust system gasket aging Check whether the exhaust system is damaged check wheth...

Page 79: ...k and adjust the fork Damaged gear lever Replace the gear lever Damaged gear shift drum Replace the shift drum Damaged ratchet device Replace the ratchet device Loose or broken spring at the selector position Replace the selector position spring Gear bounce Fork wear Replace the fork Tooth wear Check gears and replace if necessary Gear damage Change gear Damaged displacement drum groove Replace th...

Page 80: ... clutch The motorcycle is difficult to steer The cable makes it difficult to turn the handlebars Move the cable to reduce its interference The steering shaft nut is too tight Adjust the steering shaft nut Worn or damaged steering bearings Check the steering bearing and replace if necessary Bent steering shaft Contact KAYO Service Center Damping is too hard Fork oil level is too high Lower the fron...

Page 81: ...oo low Check whether the tires are leaking if the tires are complete pump them to the proper pressure Damping adjustment error Re adjust damping There is abnormal noise when the motorcycle is driving Improper chain adjustment Re adjust the chain tension Chain wear Replace the chain and front and rear sprockets Wear of rear sprocket teeth Replace the sprocket Insufficient chain lubrication Follow t...

Page 82: ... smooth Readjust the gasket and replace if necessary Motorcycle front wheel shimmy Tire wear Change tires Rim offset Contact KAYO Service Center Whether the front wheel bearing is worn Check the bearing and replace if necessary The vehicle is not aligned Check the spokes and adjust the spoke tension if necessary Steering shaft tolerance is too large Check the steering shaft pressure bearing cleara...

Page 83: ... Disc brake disc wear Replace the disc brake Insufficient brake fluid Replenish brake fluid Deteriorating brake fluid Replace brake fluid Piston damaged Contact KAYO Service Center Brake pad wear Check the brake pads if the thickness is less than the minimum friction thickness replace the brake pads TIGHTENING TORQUE TABLE FOR THE WHOLE VEHICLE NOTE Before installing the thread apply anti rust gre...

Page 84: ...silver 1 3 Upper pressure block mounting screws M8 25 4 20 32 4 Front disc brake rotor mounting bolt M8 16 4 25 35 5 Front axle mounting nut M14 1 5 1 124 165 6 Shift lever mounting bolt M6 20 1 7 11 7 Engine mounting bolt M8 110 2 20 32 8 Engine mounting nut M8 2 20 32 9 Exhaust pipe mounting nut M8 2 www kayomoto com ...

Page 85: ...t M10 1 25 1 40 70 12 Chain bolt M8 40 S10 2 20 25 13 Adjusting chain nut M8 2 20 25 14 Rear shock mounting bolt M10 45 1 25 2 40 70 15 Rear shock mounting nut M10 1 25 2 40 70 16 Rear brake disc mounting bolt M8 16 4 25 35 17 Rear sprocket mounting screws M8 25 10 9 level 6 27 35 18 Rear axle nut www kayomoto com ...

Page 86: ...1 21 High voltage package mounting bolt M6 20 1 7 11 22 Voltage stabilizer mounting bolt M6 16 full thread 1 7 11 23 Front fender bolt M6 16 3 7 11 24 Screws connecting the left and right guard plates to the fuel tank M6 10 full thread 4 7 11 25 Left and right guard plate limit bolts M6 16 2 7 11 26 Fuel tank mounting bolt M8 25 2 25 30 www kayomoto com ...

Page 87: ...ZHEJIANG KAYO MOTOR CO LTD 27 Spark plug 1 25 30 www kayomoto com ...

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