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KAYO MOTOR JACKAL 200 - User Manual

KAYO MOTOR JACKAL 200
106 pages
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ZHEJIANG KAYO MOTOR CO., LTD.
WWW.RIDEKAYO.COM
Model A200
JACKAL 200
Service Manual

Questions and Answers

Summary

Introduction

Service Information

Conversion Table

Lists unit conversions for measurements used in the manual.

Safety Alert Levels

Classifies safety alerts by severity (Danger, Warning, Attention).

Service Information Overview

Overview of service sections and their importance.

Safety Precautions

Essential safety measures for vehicle operation and maintenance.

Disassembly and Installation Precautions

Precautions for safely disassembling and installing vehicle parts.

Engine Break-in Procedures

Recommended break-in period and operating guidelines for new engines.

VIN Number Identification

Details VIN number identification and its location on the vehicle.

Model and Vehicle Specifications

General model details and vehicle dimensions.

Engine Specifications

Detailed technical specifications for the engine.

Lubricating Device Specifications

Specifications for oil capacity and lubrication system.

Ignition Device Specifications

Specifications for ignition system components.

Light;Instrument;Switch Specifications

Specifications for lighting and instrumentation.

Fastener Tightening Moments

Torque specifications for various fasteners on the vehicle.

Lubricants and Sealants

Recommended lubricants and sealants for maintenance procedures.

Cable and Hose Routing

Illustrates cable and hose routing for the vehicle.

Plastics and Body Parts

Plastic Body Maintenance Warnings

Safety warnings related to plastic parts and maintenance.

Plastic Body Installation Torque

Specifies torque values for plastic body fasteners.

Hood Disassembly and Installation

Step-by-step instructions for removing and installing the hood.

Handlebar Disassembly and Installation

Procedures for removing and installing the handlebars.

Seat Disassembly and Installation

Instructions for removing and installing the vehicle seat.

Front Bumper Disassembly and Installation

Steps for removing and installing the front bumper.

Plastic Body Panel Disassembly and Installation

Procedures for removing and installing the main plastic body panels.

Rear Body Disassembly and Installation

Steps for removing and installing the rear body section.

Middle Guard Disassembly and Installation

Instructions for removing and installing the middle guard.

Front Body Disassembly and Installation

Procedures for removing and installing the front body panels.

Foot Peg Guard Disassembly and Installation

Steps for removing and installing the foot peg guards.

Floorboard;Foot Peg Disassembly

Instructions for removing the floorboard and foot pegs.

Regular Maintenance and Adjustment

Maintenance Information and Warnings

General maintenance guidelines and safety warnings.

Maintenance Schedule

Outlines the recommended schedule for maintenance tasks.

Inspection Methods

Details methods for inspecting various vehicle systems.

Steering Column and Brake System Checks

Covers checks and adjustments for steering and braking systems.

Wheel and Tire Maintenance

Instructions for checking wheels, tire pressure, and tread.

Suspension System Checks

Guidelines for inspecting the suspension system.

Gear Shifter and Fuel System Checks

Procedures for checking the gear shifter and fuel system.

Throttle Lever Checks and Adjustment

Instructions for checking and adjusting throttle lever free-play.

Suspension Pre-load Adjustment

Details how to adjust rear shock absorber pre-load.

Engine Systems

Engine Maintenance Precautions

General precautions for engine maintenance.

Fuel System Operations

Information and precautions for the fuel system.

Fuel Tank Removal

Steps for removing the fuel tank.

Air Filter System Disassembly

Instructions for disassembling and removing the air filter.

Exhaust System Disassembly

Procedures for disassembling and removing the exhaust system.

Engine Disassembly and Installation

Steps for removing and installing the engine.

Cylinder and Valve Maintenance

Information and service parameters for cylinder and valve checks.

Valve and Spring Inspection

Procedures for checking valve and spring condition.

Swing Arm and Shaft Inspection

Guidelines for checking swing arm and shaft wear.

Cam Shaft Parts Inspection

Procedures for inspecting camshaft components.

Cylinder Head Checks

Steps for checking cylinder head sealing and flatness.

Valve Seat Check and Adjustment

Procedures for checking and adjusting valve seats.

Valve Guide Pipe Check

Instructions for measuring valve guide pipe inner diameter.

Cylinder Head Assembly

Steps for assembling the cylinder head.

Cylinder Head Cap Assembly

Procedures for assembling the cylinder head cap.

Cylinder Head Installation

Steps for installing the cylinder head.

Engine Timing Adjustment

Instructions for adjusting the engine timing.

Cylinder and Piston Specifications

Maintenance and specifications for cylinder and piston.

Piston Disassembly

Steps for disassembling the piston.

Piston and Piston Ring Inspection

Procedures for checking piston and piston rings.

Piston Ring Assembly

Instructions for assembling piston rings.

Piston Assembly

Steps for assembling the piston with rings and pin.

Cylinder Body Assembly

Procedures for assembling the cylinder body.

Drivetrain Components

Drivetrain Component Precautions

General precautions for working with drivetrain components.

Clutch Specifications and Troubleshooting

Clutch system specifications and common issues.

Water Pump Impeller Disassembly

Steps for removing the water pump impeller.

Right Crankcase Disassembly

Procedures for disassembling the right crankcase.

Clutch Disassembly

Step-by-step guide for disassembling the clutch.

Gear Disassembly

Instructions for disassembling gears.

Oil Pump Disassembly

Procedures for disassembling the oil pump.

Starting Motor Disassembly

Procedures for removing the starting motor.

Gearshift Disassembly

Instructions for disassembling the gearshift mechanism.

Water Pump Component Checks

Checks and installation for water pump components.

Drivetrain Assembly Procedures

Procedures for installing drivetrain components.

Starting Motor Installation

Steps for installing the starting motor.

Right Crankcase Installation

Procedures for installing the right crankcase.

Crankcase, Shafts, and Transmission

Crankcase Separation Precautions

General precautions before separating crankcases.

Crankcase Disassembly

Steps for disassembling the crankcase.

Shaft Disassembly

Procedures for disassembling crankshaft and shafts.

Crankshaft Inspection

How to check crankshaft radial clearance.

Crankcase Bearing Inspection

Procedures for checking crankcase bearings.

Gearshift Fork;Shaft;Drum Checks

Checks for gearshift fork, shafts, and drum.

Oil Filter Component Checks

Procedures for checking oil filter components.

Transmission;Shaft Assembly

Steps for assembling transmission, crankshaft, and balance shaft.

Crankcase Assembly

Procedures for assembling the crankcase.

Electrical Schematic Diagram

KAYO MOTOR JACKAL 200 Specifications

General IconGeneral
BrandKAYO MOTOR
ModelJACKAL 200
CategoryOffroad Vehicle
LanguageEnglish

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