ZHEJIANG KAYO MOTOR CO., LTD.
The removal steps of the right crankcase cover are as follows:
Drain the oil first (remove the oil drain plug M12×1.5 on the right, and wait for the oil in the box to run out).
Remove the 2 pieces of GB/T5787-M6×80 that fasten the right cover, 1 piece of GB/T 5787-M6×65, 5 pieces of
GB/T 5787-M6×40 bolts, remove the right crankcase cover, right crankcase cover gasket and 2 pieces of
positioning pins Φ8×12;
Remove the cross countersunk head screw M6×12 that fastens the shift plate assembly, and remove the clutch
adjusting nut and clutch adjusting bolt on the shift plate. (Manual clutch has this step)
Remove the clutch camshaft and return spring, and take out the clutch push rod.
Note:
1. There is an O-ring 17×1.5 on the clutch camshaft, please do not lose it.
2. Do not drop the positioning pin into the crankcase.
3. If the right crankcase cover gasket is damaged, scrape the remaining gaskets on the right crankcase cover
and the right crankcase body with a scraper. Then replace with a new gasket to prevent engine oil leakage
after reassembly.
REMOVAL OF THE CLUTCH
The removal steps of the clutch are as follows:
Remove the oil pipe and pass the oil pipe spring.
Remove the M5×10 4 cross countersunk screws that fasten the 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, friction plate, clutch drive plate, outer cover, damping spring, and spring in sequence.
（
This step is not
recommended to disassemble, because the reassembly requires special equipment to cooperate and press-fit
）
If the
clutch is damaged, you can replace it with a new one.
REMOVAL OF THE DRIVING GEAR AND DRIVEN GEAR
The removal steps of the driving and driven gears are as follows:
Remove the driving gear (18 teeth), driving gear bushing and driving gear ring (8mm).
Remove the driven gear retaining ring and take out the driven gear (67 teeth).
Note: When removing the driven gear retaining ring, prevent the driven gear retaining ring from falling into
the crankcase.
REMOVAL OF THE OIL PUMB
The removal steps of the oil pump are as follows:
Remove one cross recessed countersunk head screw GB/T819-M6×22 and two GB/T 819-M6×16 screws that
fasten the oil pump.
Remove the 3 pieces of M5x10 cross recessed countersunk screws that fasten the oil pump, and remove the oil
pump cover, oil pump body, oil pump inner and outer rotors, and oil pump shaft.
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