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ZHEJIANG KAYO MOTOR CO., LTD.

3.3 Inspection ways

Inspection and maintenance items

Period

Criterion

Checkpoints

Inspection item

Da
il

Ha
lf ye

One

ye
ar

Steering

device

Steering
wheel

Operating flexibility

○

Steering

system

Damage

○

Installation status of
steering system

○

Ball pin shaking

○

Braking

device

Brake pedal

Pedal travel

○

Braking effect

○

Connecting
rod and oil
pipe

Slackness, looseness and
damage

○

Hydraulic
brake and
brake disc

Brake fluid

○

Above

the

brake

fluid

lower limit

Tear and damage of brake disc

○

Replace

the

disc in time,
when front or
rear

brake

working disc’s
thickness is less
than 3mm.

Brake pad

Tear and damage of brake

pad

○

The minimum
brake pad

（

friction plate

）

thickness

≥

1mm

；

less

than

1mm,

replace

it.

Driving

device

Wheel

Tire pressure

○

Front wheel:
35kPa

（

0.35kgf/

）

(5PSI)

Rear wheel:
35kPa

（

0.35kgf/

）

(5PSI)

Crack and damage of wheel

○

Tyre groove depth and

abnormal wear

○

If there’s no tear
indicator on the
wheel,

the

residual

groove

depth

should

greater than 3mm

Loose of wheel nut and axle

○

Front wheel bearing
vibration

○

Rear wheel bearing
vibration

○

Содержание AU180

Страница 1: ...ZHEJIANG KAYO MOTOR CO LTD WWW RIDEKAYO COM Model AU180 Service Manual...

Страница 2: ...tments disassembly installation inspection points and specifications Please read the manual carefully and follow the instructions closely when performing inspections and repairs this will increase the...

Страница 3: ...enance information Chapter 2 Plastics and Body parts Chapter 3 Regular Maintenance and adjustment Chapter 4 Outer parts of engine Chapter 5 Engine internals Chapter 6 Chassis Chapter 7 Signal and Ligh...

Страница 4: ...sly it s important for regular maintenance especially important during engine maintenance Danger Be on high alert for danger Warning Be on alert for moderate danger Attention Be on alert for minor dan...

Страница 5: ...al treatment as soon as possible Battery and battery solution should be kept out of reach of children Battery charging will produce flammable and explosive gases if exposed to a source of fire or spar...

Страница 6: ...tion 12 Ball bearings can be rotated with finger to confirm whether the rotation is flexible and smooth Bearing axial and radial clearance is oversized Clean and grease bearings with a tight spot when...

Страница 7: ...in is necessary on new engines and newly rebuilt engines to help ensure that longevity and reliability of the engine components Recommended break in time is 20 hours as follows 0 10 hours Operate at...

Страница 8: ...ZHEJIANG KAYO MOTOR CO LTD WWW RIDEKAYO COM Model AU180 VIN number Engine number 1 VIN number frame stamp 2 VIN plate 3 Engine number 1 3 Main parameters list 1 2 3...

Страница 9: ...wheel AT22 10 10 Min Ground clearance 160mm Turning radius min Turning radius of the closest point 2400mm Engine Starting mode Electric Type Single cylinder four stroke oil cooling Distribution way CH...

Страница 10: ...Rotate direction of engine output shaft Forward gear viewed from the rear of the vehicle the front is clockwise Steering gear Maximum steering Angle 45 1 Brake type Front Hydraulic disc Rear Hydrauli...

Страница 11: ...Change oil 800ml No oil filter element replaced Change oil 850ml replace the oil filter element Full capacity 900ml Recommended engine oil Please choose SF MA 15W 40 or it may cause engine damage and...

Страница 12: ...pe Full wave rectification Storage battery Ca pacity 12V 7Ah Voltage between ter minals Full charge 14 4V Insufficient Less than 11 8V Ignition device Item Standard Ignition method CDI electric igniti...

Страница 13: ...1 25 50 1 45 59 4 Rear brake bolts GB5787 M10 1 25 45 1 45 59 5 Slotted nut for front hub installation GB9457 M14 1 5 H18 2 126 218 6 Slotted nut steering link ball pin GB9457 M10 1 25 4 33 45 7 Cover...

Страница 14: ...ing screw Pan Head GB845 85 ST4 2 26 Cross recessed pan head screws GB828 88 M5 16 2 27 Cross recessed flat head screw TM6 28 Mounting nut of wheel rim GB6187 86 M10 1 25 16 45 59 Tightening moment at...

Страница 15: ...ion Content Grease Spherical bushing for steering shaft lubrication General Purpose Lithium Lubricating Grease for Automobile GB T5671 Rear axle support Joints of front and rear brake Throttle handle...

Страница 16: ...Headlight connector 4 Alternate neutral display connector 5 Electric door lock switch connector 6 Multifunctional switch connector of left handlebar 7 Ignite connector Note Removing the front panel b...

Страница 17: ...let pipe for carburetor 3 Starter motor cable 4 Engine exhaust pipe 5 Magneto trigger connector 6 Gear display connector 7 Regulated rectifier connector Note please disassemble the gear lever and peda...

Страница 18: ...KAYO MOTOR CO LTD WWW RIDEKAYO COM 8 Starter Relay 9 Battery negative wire 10 Starting motor wire 11 Battery positive wire 12 Voltage regulator rectifier 1 1 Tail light connector 2 rear light 8 9 10 1...

Страница 19: ...replacing plastics parts please install new warning labels stickers and riveted tags to the new plastics 2 This chapter is about the dismounting the body plastics 2 2 Installation torques M8 bolt 21 2...

Страница 20: ...mounting screw from front rack 3 left and right Remove mounting bolts 1 Remove front rack 2 Installation in reverse order of disassembly 2 3 3 Rear rack Disassembly Disassemble the mounting bolts fro...

Страница 21: ...lever 2 4 1 Front panel Disassembly Remove front rack 2 3 2 Remove front panel 1 Installation in reverse order of disassembly 2 4 2 Front cover of gear indicator Disassembly Pull out air tube from fue...

Страница 22: ...e order of disassembly 2 4 4 Gear lever Disassembly Remove mounting bolt from gear lever 6 Detach gear lever 5 Installation in reverse order of disassembly 1 2 5 Dismounting of footpegs 2 5 1 Left foo...

Страница 23: ...and bumper 2 6 1 Front ventilating board Disassembly Remove front rack 2 3 2 Remove mounting bolt 7 left right each 2 Remove front ventilating board 8 Installation in reverse order of disassembly 2 6...

Страница 24: ...Remove front plate 2 4 1 Remove gear lever 2 4 4 Remove left pedal 2 5 3 Remove right pedal 2 5 4 Remove mounting screw of front assembly plate 1 Detach screws 2 left and right each2 Detach screws 3 R...

Страница 25: ...ght pedal Remove mounting screw 1 Remove rear assembly plate 2 Installation in reverse order of disassembly Note Before disassembly disconnect cables between taillight and turning signal When dismantl...

Страница 26: ...lothes and gloves Gasoline is flammable and explosive Pay attention to sparks as well as open flames Vaporized gasoline may explode if exposed to open flame or sparks please refuel in well ventilated...

Страница 27: ...of carburetor Air filter element Note Sparking plug I I I I Valve clearance I I I I engine lubricating oil Annual R R R R lubricating oil strainer Annual R C Clutch I I I I Carburetor idle I I I I Th...

Страница 28: ...Brake fluid Above the brake fluid lower limit Tear and damage of brake disc Replace the disc in time when front or rear brake working disc s thickness is less than 3mm Brake pad Tear and damage of bra...

Страница 29: ...ose Electrical device Ignition device State of spark plug Ignition period Battery Terminal connection status Spark plug gap 0 6mm 0 7mm Looseness and damage of joints Fuel device Fuel leak Fuel device...

Страница 30: ...nkages ball joints or fastening hardware then repair If it s caused by steering column tighten the bottom lock nut on steering column or you can also disassemble the steering column to check bearing a...

Страница 31: ...volume through the observation hole 3 When the brake fluid volume decreases to the lower limit of hole 3 stop using the vehicle It is necessary to check the leakage of the brake pump brake tube and a...

Страница 32: ...takeoff the oil lid 1 Lower limit 2 Observation hole Front brake disc and brake pads wear of brake pads The brake pads caliper and disc are normal wear and tear items Note The brake pads should be rep...

Страница 33: ...ake off the oil cup lid 2 Replenish the brake fluid recommended by KAYO to the upper limit Note When adding brake fluid do not mix with dust and water In order to prevent chemical changes please choos...

Страница 34: ...by a full set Check or replace the brake disc Check if the surface of brake disc 1 is wearied or damage If the disc thickness is less than 3 0mm replace it Limit thickness of front brake disc 3 0mm C...

Страница 35: ...aged Front wheel size On a level surface with handle bars straight check the front wheel toe in The front wheel relative to the forward direction of the vehicle is A in front and B behind the wheel To...

Страница 36: ...ure wear and or damage to tire tread Specific air pressure tire Tir e tread Check Tire tread if tread is less than 3mm replace it Wheel nuts and axle Check the latches and nuts 1 on front and rear axl...

Страница 37: ...uspension system Keep vehicle in a horizontal position and compress up and down several times according to the pictures If there is shaking or abnormal sounds check whether there is oil leakage in the...

Страница 38: ...the angel of gear box rod 2 Loosen lock nuts 3 4 5 and remove gear lever to adjust angel of gear box rod Fuel device Remove the plastic parts first Check fuel vacuum and vent lines for aging dry rot...

Страница 39: ...throttle opening Inspect the thread length limit of speed limit screw 4 Thread length limit a 12mm Adjustment Loosen the lock nut Note For beginners the speed limiter should be in a tight position an...

Страница 40: ...d out 3 9 Light installation Note Electrify the vehicle before light installation checking Inspect headlight Move the headlight switch 1 forward to the first gear observe whether the front fog proof l...

Страница 41: ...ease wrap the frame plastics or any vulnerable finishes before removing engine parts or performing maintenance on engine Please dispose of liquid such as oils and coolants properly Use drain pans to p...

Страница 42: ...nents Fuel tank removal Remove the plastic body parts remove fuel lines from tank and fuel valve then remove tank mounting bolts and tank Fuel tank pictures may differ from tanks on U S models Install...

Страница 43: ...em Disassembly Disassemble the clamp between muffler and exhaust head pipe then remove the muffler mounting bolt to remove muffler Assembly Installation shall be in the reverse order of removal Do not...

Страница 44: ...ly Remove gear lever seat gear display meter left pedal right pedal and rear assembly body Chapter 2 body covering Remove fuel tank 4 2 fuel system Remove air filter and electronic injection 4 3 air i...

Страница 45: ...gh alert for danger Precautions To be alert to moderate danger Oil SF MA 15W 40 Grease KING MATE G 3 Gear oil 85W 90 GL 5 Fixation Smear fixative Oil seal Smear fluid glue Update Replace before instal...

Страница 46: ...ufacturer s instructions strictly and make sure workplace must be well ventilated Don t use gasoline as a cleaning fluid To avoid burns do not touch uncooled engine oil exhaust system parts If the fue...

Страница 47: ...small and tighten from inside to outside according to the specified torque Use a torque wrench to tighten the torque required bolts Always clean grease and oil from threads Used thread locker where n...

Страница 48: ...r carburetor connect 2 6 0 7 1 1 Smear oil Engine bolt 1 12 3 5 4 5 Filter screen 1 30 1 3 1 7 Gear bolt 1 8 0 8 1 2 Gear inject bolt 1 10 1 0 1 4 Oil pump screw 3 3 0 1 0 3 Left crankcase bolt 7 6 1...

Страница 49: ...m 6mm screw SH nut 0 70 1 10 kgf m 12mm bolt nut 5 00 6 00 kgf m 6mm flange screw nut 1 00 1 40 kgf m 8mm flange screw nut 2 40 3 00 kgf m 10mm flange screw nut 3 50 4 50 kgf m 5 1 3 Troubleshooting...

Страница 50: ...Spark Remove Dry Wet Much gas mixture gas valve larger valve opening Carburetor pipe Blow Smoothly Blocked Automatic side starter worn Low speed and weak power Check as the sequences of below form Ite...

Страница 51: ...al Overheated Cylinder and piston worn low gas mixture fuel poor quality carbon deposit ignition advance cool water system Speed up Normal Instable knock Carbon deposit low gas mixture fuel poor quali...

Страница 52: ...up Normal Abnormal Little fuel filter stuck air hole stuck Carburetor mouth Normal Abnormal Clean Clutch driven and transmission Trouble Reason Engine start bike doesn t move Driven belt worn or broke...

Страница 53: ...1000 km 6 Bolt locking I I 7 Crankcase leakage I I 8 Spark check and replace I I 9 Gear oil replace I Per 1000 km 10 Ignition time I I 11 Carburetor throttle I I 12 Engine screw torque I I 13 CVT dri...

Страница 54: ...Replace 850cc Clean filter screen Flow out oil remove it our from engine right bottom Clean it replace damaged washer Torque 1 3 1 7 kgf m Gear oil Check if the crankcases leakages Stop engine then t...

Страница 55: ...n rind or full throttle condition Valve clearance adjustment After engine cooled below 35 Remove cylinder head and timing cap on cooling fan Use T type wrench to turn crank axle until the T mark is fa...

Страница 56: ...best time is warm bile about 10 minutes Idle speed 1700 100 rpm Adjustment 1 Install engine tachometer 2 Adjust idle screw until engine speed to 1700 100 rpm 3 Adjust screw which is related to air vol...

Страница 57: ...speed to 1700 rpm if the F mark is faced to timing means it s normal 4 Add engine speed to 5000 rpm if the mark faces to mark it s normal if not check CDI Spark Specific spark A7TC A7RTC 1 Dismantle...

Страница 58: ...ble about 4 7 seconds Compressive pressure 10 1kg cm2 Check below items when compressive force low 1 Wrong valve clearance 2 Valve leakage 3 Cylinder head piston piston ring and cylinder worn If the c...

Страница 59: ...IANG KAYO MOTOR CO LTD Clutch disc Check the clutch movement by increase throttle If it s shakes check the clutch disc Specific tools Item Picture For crankcase For valve spring For valve clearance ad...

Страница 60: ...4 1 ZHEJIANG KAYO MOTOR CO LTD For oil seal insert For bearing install For clutch spring For clutch Universal fixer For generator...

Страница 61: ...system maintenance Specification Engine oil volume resolve 900cc replace 850cc Oil viscosity SF MA 15W 40 Gear oil resolve add 400cc replace add 350cc Gear oil viscosity 85W 90 GL 5 Item Standard Lim...

Страница 62: ...0 1 0 3 kgf m Troubleshooting Low oil level oil leakage valve sleeve or oil seal worn piston ring worn Oil pollution replace oil regularly cylinder head gasket worn piston ring worn Oil pressure lack...

Страница 63: ...Stop engine for 3 5 minutes to check if the oil level is standard and if there is leakage If the oil volume is low add it standard 900cc replace 850cc Oil pump disassembly Remove generator and left e...

Страница 64: ...NG KAYO MOTOR CO LTD Install driving gear and clip make sure the oil pump works smoothly Oil pump installation Install oil pump 2 bolts pump chain lock and cover 2 bolts Install start gear and generat...

Страница 65: ...the oil meets standard value or add it Gear oil viscosity standard volume 400cc replace volume 350cc Gear oil replace Remove inject and drain bolts to drain oil out Install drain bolts and tights it...

Страница 66: ...take 29 810 29 440 Air exhaust 29 530 29 160 Rocket arm Inner diameter 10 000 10 015 10 100 Axle outer diameter 9 966 9 984 9 910 Gas valve Lever outer diameter Air intake 4 975 4 990 4 900 Air exhaus...

Страница 67: ...8 2 2 kgf m Timing chain tensioner seal bolt 0 8 1 2 kgf m Timing chain tensioner bolt 1 0 1 4 kgf m Valve adjust fixed nut 0 7 1 1 kgf m Spark 1 0 1 4 kgf m Specific tools Gas valve stem reamer 5 0m...

Страница 68: ...worn or spring damaged cam shaft worn or damaged cam chain worn or loosen tensioner worn or damaged cam chain gear worn rocket arm or arm axle worn Exhaust pipe with white smoke valve pipe or lever w...

Страница 69: ...t the T mark face the crankcase mark and make sure chain hole to compressive mark refer to picture Remove cam shaft fixed seat nut and screw Remove fixed seat and rocket arms Take chain out from cam r...

Страница 70: ...fixed seat valve rocket arm and rocket arm axle especially sliding surface of rocket arm and fixed surface of cam shaft Rocket arm axle inner diameter greater than 10 1mm replace it Outer diameter of...

Страница 71: ...irst remove fan cover and cover 4 bolts Second remove cam shaft Third remove 2 bolts from left cylinder head then gasket 2 located pins and guide plate clean surfaces last Note do not damage the surfa...

Страница 72: ...or Remove valve bolt spring and valve Remove guide lever oil seal clean carbon deposit and cylinder head surface Check spark hole condition and measure cylinder head flatness Limitation 0 5mm Free len...

Страница 73: ...er Air intake 4 9mm exhaust 4 9mm Valve guide pipe Clean carbon deposit before measure pipe inner diameter with a reamer 5mm limitation is 5 03mm Clearance between valve stem and pipe Limitation air i...

Страница 74: ...or oven Remove pipe with specific tool Install new guide pipe with a driver 5mm at 100 150 make guide pipe height at 13mm insert from arm side After cooling trim the pipe with reamer Gas valve seat c...

Страница 75: ...face worn rough or damaged replace it The contract area still doesn t seal after running in replace Check valve seat Valve seat width 1 6mm If not in this range adjust valve seat with specific tool 45...

Страница 76: ...mear Prussian blue or red lead If the contact area high cut seat with 32 cutting machine then cut seat surface to certain width with 45 cutting machine If the contact area low cut inner seat face with...

Страница 77: ...o guide pipe after lubricating Install new oil seal valve spring and braking Press spring down by compressor to install valve bolt Knock valve stem with rubber rob to keep sealing Cylinder head instal...

Страница 78: ...then rocket arm and rocket arm axle Turn the crank shaft with T type wrench and let the T mark face the crankcase mark Make the cylinder head tip in line with cam chain mark The hole on the other side...

Страница 79: ...Valve clearance adjust Loose nuts and bolts on rocket arm adjust clearance to standard value and fix bolts and nuts Standard value 0 03 0 05mm Adjust tensioner to touch guide plate closely Install sme...

Страница 80: ...4 1 ZHEJIANG KAYO MOTOR CO LTD head cover 5 5cylinder and piston Precautions Remove engine from bike before maintenance...

Страница 81: ...nd 9mm Piston and cylinder clearance 0 050 0 100 0 200 Inner diameter of piston pin hole 15 002 15 008 15 040 Piston pin outer diameter 14 994 15 000 14 960 Piston and piston pin clearance 0 002 0 014...

Страница 82: ...in adjustor from cylinder head then remove guide plate and cylinder Remove cylinder gasket and fixed pin clean contact face of crankcase and cylinder Block crankcase and cam chain holes with clean clo...

Страница 83: ...Y the three positions differences Limitation roundness greater than 0 05mm revise or replace Deviations greater than 0 05mm revise or replace Piston disassembly Block the crankcase and cam chain hole...

Страница 84: ...s on the engine bottom then push piston ring to the 20mm height of cylinder top end measure all the clearance Limitation top ring greater than 0 5mm replace Second ring greater than 0 65mm replace Mea...

Страница 85: ...Measure inner diameter of piston pin Limitation 15 04mm Count the clearance of piston pin and pin hole limitation is 0 02mm Measure piston outer diameter From 9mm bottom height to piston 90 position...

Страница 86: ...shows Note do not damage rings and piston all the marks up keep all rings smoothly after installation Install piston and pin the IN mark faces air intake side Install a new piston pin at last Cylinde...

Страница 87: ...inner cylinder piston and piston ring Install cylinder to piston carefully press piston ring at the same time ring by ring Install cam chain guide plate cylinder head gasket and located pin Install c...

Страница 88: ...ease on drive belt and drive plate Specification Item Standard Limitation Drive belt width 22 30mm 20 8mm Inner diameter of sliding drive belt wheel 23 989 24 052mm 24 060mm Outer diameter of sliding...

Страница 89: ...ol Spring compressor bearing extractor fixed bolt wrench and general fixed clamp Troubleshooting Engine works but wheel doesn t work drive belt broken inclined plate worn clutch pad damaged or worn sp...

Страница 90: ...4 1 ZHEJIANG KAYO MOTOR CO LTD Assembly In reverse order of disassembly Drive belt Disassembly Remove left crankcase bolts and drive plate Remove nuts and clutch cover with specific tool...

Страница 91: ...thickness if it less than 20 88mm replace it Note drive belt brand should be recommended by kayo keep the belt clean before installation Assembly Pull drive belt plate first then insert the belt on t...

Страница 92: ...rds side of belt faces to assembly direction Sliding drive plate Disassembly Remove left crankcase first Then fix the drive plate with fixed clamp to remove nuts and drive plate Take out drive belt sl...

Страница 93: ...9 45mm replace If the hub of axle worn or damaged badly replace Measure its outer diameter if it s less than 23 94mm replace Measure if the drive plate inner diameter is greater than 24 06mm replace H...

Страница 94: ...on belt face Install sliding drive plate on crank shaft Drive plate assembly Install drive belt on sliding drive plate then press the up and down sides to make the belt and drive plate separately Ins...

Страница 95: ...lutch transmission belt plate Disassembly Remove drive plate clutch transmission belt Install spring compressor on clutch turn compressor moderately Knap the compressor on jaw vice use wrench to remov...

Страница 96: ...asure inner diameter of clutch cover surface If the limitation is greater than 135 40mm replace Clutch disc Measure thickness of each disc if less than 1 5mm replace Drive pully spring Measure its len...

Страница 97: ...ve to see if its deformed or damaged Measure the outer diameter of drive belt axle and the inner diameter of transmission plate axle hole Limitation outer diameter 33 94mm inner diameter 34 06mm Check...

Страница 98: ...ove clutch pad and spring to check the spring condition Check if the rubber if its damaged or deformed replace Smear fixed pin make sure clutch pad clean Install clutch pad on fixed pin Insert the spr...

Страница 99: ...ng smear G 3 grease at last Install a new inner bearing The seal end faces out install needle bearing and ball bearing with oil press Install new oil seal Clutch drive pulley assembly Install new oil...

Страница 100: ...belt plate spring and clutch into spring compressor turn compressor handlebar until the bolt installed Torque 5 0 6 0 kgf m Install clutch transmission belt plate and transmission belt on transmission...

Страница 101: ...r oil 4 stroke lubricating oil Volume 400cc replace 350cc Toque Gear cover 2 0 2 4 kgf m drain bolt 1 0 1 4 kgf m inject bolt 0 8 1 2 kgf m Troubleshooting 1 Start engine car doesn t move Transmission...

Страница 102: ...worn short out or damaged bearing worn Reducing gear Disassembly Drain gear oil and remove clutch Remove gearbox cover bolts 10 pcs M6 35 gearbox cover and transmission shaft At last remove gaskets a...

Страница 103: ...he inner side of bearing and check the outer side condition If the bearing turns not smoothly with abnormal noise or doesn t connect well with gearbox and cover replace it Once remove driven shaft its...

Страница 104: ...bearing still connects with transmission shaft after pulling out drive shaft use bearing extractor to remove Install new bearing first and drive shaft later Install new bearing on gearbox cover Use C...

Страница 105: ...grease on oil seal of drive shaft output shaft and gearshift shaft then install them on gearbox cover tight with 10 bolts Torque 2 0 2 4 kgf m Install clutch belt and left crankcase cover inject gear...

Страница 106: ...4 1 ZHEJIANG KAYO MOTOR CO LTD Specification Limitation of gear inner diameter 22 1mm Torque Fly wheel nut 5 0 6 0 kgf m Bolt 8mm 1 5 2 0 kgf m Oil filter screen cover 1 3 1 7 kgf m...

Страница 107: ...lutch 1 0 1 4 kgf m add binder Specific tools Fly wheel extractor general fixer Alternator Disassembly Remove fly wheel drain out engine oil remove cooling fan cover 4 bolts Hold the fly wheel with ge...

Страница 108: ...out coil joint and pulser connector Then remove pulser coil and 6 bolts on fixed plate pull out coil assembly at last Remove right crankcase cover remove 9 bolts located pin and gasket Clean the conne...

Страница 109: ...h and idle gear Check Install idle gear on starting motor then fix the motor and turn idle gear in clockwise at the same time Check starting motor condition and measure inner diameter Limitation less...

Страница 110: ...9 94mm Disassembly Remove 3 allen bolts on clutch separate cover and clutch body Then remove rotors plunger and spring check the rotors and plunger Install rotors plunge and spring Assembly In revers...

Страница 111: ...LTD Install idle gear shaft idle gear and starting clutch Install drive and drive gears on starting clutch Fix drive and driven gear with general fixer tight 22mm and gasket Note smear grease on thre...

Страница 112: ...al on the right of crankshaft Install right crankshaft cover on crankcase 9 bolts Torque 1 5 2 0 kgf m Alternator oil assembly Install coil on right crankcase cover 2 screws then install the pulser 2...

Страница 113: ...ctor Fly wheel assembly Keep the fly wheel clean Let crankshaft key in right position to fly wheel and assemble the fly wheel Fixed the fly wheel with a general fixer tight nut at last Torque 5 0 6 0...

Страница 114: ...ft balance shaft Precautions Before disassemble crankcase remove cylinder head piston cylinder V type belt alternator and staring clutch first Once replace crankshaft bearing or timing chain the whole...

Страница 115: ...er bolt of cam chain 0 8 1 2 kgf m Specific tool Inner plug in bearing extractor outer extractor bearing press machine oil press machine Troubleshooting Abnormal noise large bearing clearance large cl...

Страница 116: ...may cause oil leakage Take out cam chain before separate crankcases Remove crankshaft and balance shaft from left crankcase Remove gasket and 2 located pins clean up the crankcase surface with gasket...

Страница 117: ...O MOTOR CO LTD Crankshaft check Measure the radial clearance of connecting rod If it greater than 0 55mm replace Put crankshaft on V groove pad measure its vibration as pictures shows Limitation 0 10m...

Страница 118: ...all cam chain into the chain hole of right crankcase enlarge chain at the same time Note do not damage the chain when install crankshaft Fix the driven gear of balance shaft with a 5mm located needle...

Страница 119: ...4 1 ZHEJIANG KAYO MOTOR CO LTD Install right crankcase and tight the 2 crankcase bolts Torque 1 5 2 0 kgf m Install the tension rod of cam chain tight with 3 lock fixed bolts...

Страница 120: ...4 1 ZHEJIANG KAYO MOTOR CO LTD...

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