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KAYO MOTOR TS90 - User Manual

KAYO MOTOR TS90
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ZHEJIANG KAYO MOTOR CO., LTD.
KAYO MOTO
TS90
SERVICE MANUAL
www.kayomoto.com

Table of Contents

Questions and Answers

  • Т
    ТренболонApr 20, 2025
    Какой размер ведущей звезды на kayo ts 90 (2022)

    Summary

    Preface

    Controls

    Front Disc Brake

    Details the front disc brake system, including lever and caliper operation.

    Throttle Lever

    Describes the function and operation of the throttle lever for engine speed control.

    Starting

    Instructions for starting the engine using electric or kick start methods.

    Stopping

    Details the procedure for safely stopping the motorcycle.

    Fuel Tank Switch

    Explains the location and function of the fuel tank switch for fuel flow.

    Shifting

    Describes the gear shifting mechanism and operation for transmission.

    Rear Disc Brake

    Details the rear disc brake system, including pedal and caliper.

    Parking Support

    Explains how to use the side stand for parking the motorcycle.

    Preparing for Use

    Advice on First Use

    Recommendations for new owners for initial operation and maintenance.

    Run-in Process

    Recommended steps for breaking in the engine for optimal performance.

    Riding Instructions

    General guidelines and precautions for riding the motorcycle safely.

    Preparation Before Riding

    Checklist of items to inspect before starting to ride.

    Precautions for Starting

    Steps and safety measures for starting the engine.

    Precautions for Stopping

    Safety procedures for stopping the motorcycle.

    Precautions for Turning

    Guidelines for safe turning maneuvers.

    Precautions for Acceleration

    Advice on safe acceleration techniques.

    Precautions for Shifting

    Precautions to take while shifting gears.

    Precautions for Braking

    Proper techniques and checks for braking.

    Precautions for Stopping & Parking

    Steps for safely stopping and parking the vehicle.

    Suggested Inspection Time for All Parts of the Vehicle

    Suspension System

    Check the Compression and Rebound of the Vehicle Including the Driver

    Procedure to check suspension reaction to weight and movement.

    Measure Distance Between Center of Rear Wheel and Rear Fender Under No Load

    Method to measure rear suspension travel without load.

    Measure Distance Between Rear Wheel Center and Rear Fender in Driving Condition

    Procedure to measure rear suspension travel with a rider.

    Adjusting the Spring Preload of Rear Shock Absorber

    How to adjust the rear shock absorber's spring preload for ride comfort.

    Check for the Setting of Front Shock Absorber

    Procedure to inspect the front shock absorber's condition.

    Adjusting the Handlebar

    Steps to adjust the handlebar position for optimal ergonomics.

    Vehicle Maintenance

    Placement

    Guidance on positioning the motorcycle for maintenance.

    Removing or Installing the Front Disc Brake

    Step-by-step guide for removing and installing the front disc brake.

    Removing or Installing the Front Shock Absorber

    Procedure for removing and installing the front shock absorber.

    Removing or Installing the Linkage

    Steps for removing and installing the suspension linkage components.

    Check the Front Steering

    How to inspect the motorcycle's steering system for proper function.

    Lubrication and Installation of Steering Head Bearing

    Procedure for lubricating and installing the steering head bearings.

    Removing or Installing the Front Fender

    Guide for removing and installing the front fender.

    Removing or Installing the Rear Shock Absorber

    Steps for removing and installing the rear shock absorber.

    Removing or Installing the Seat Cushion

    Procedure for removing and installing the seat cushion.

    Removing or Installing the Air Filter

    Guide for removing and installing the air filter assembly.

    Cleaning and Maintenance of Air Filter

    How to clean and maintain the motorcycle's air filter.

    Removing or Installing the Exhaust Pipe

    Steps for removing and installing the exhaust pipe.

    Removing or Installing the Muffler Tube

    Guide for removing and installing the muffler tube.

    Removing or Installing the Fuel Tank

    Procedure for removing and installing the fuel tank.

    Check and Clean the Chain

    Instructions for inspecting and cleaning the drive chain.

    Removing or Installing the Chain

    Steps for removing and installing the drive chain.

    Check and Adjust the Chain Tension

    How to check and adjust the drive chain tension correctly.

    Check the Structure of the Rear Sprocket, Engine Sprocket and Guide Chain

    Inspection of the drive chain, sprockets, and guide components.

    Check the Frame

    How to inspect the motorcycle's frame for damage or deformation.

    Check the Fork

    Procedure for inspecting the front forks.

    Check the Throttle Cable

    How to inspect the throttle cable for proper operation.

    Check the Steering Handle

    Checking the comfort and position of the handlebars.

    Check and Maintenance the Brake System

    Overall checks and maintenance for the braking system.

    Check the Free-Play of Front Brake Lever

    How to check the free play of the front brake lever.

    Check the Disc Brake

    Inspection of the disc brake components for wear and damage.

    Check the Front Brake Liquid Level

    How to check the brake fluid level in the front brake system.

    Refuel the Front Brake Liquid Level

    Procedure for refilling the front brake fluid reservoir.

    Check the Front Brake Pads

    How to check the thickness of the front brake pads.

    Check the Free-Play of Foot Brake

    Checking the free play of the rear brake pedal.

    Check and Refuel the Rear Brake Disk Liquid Level

    How to check and refill the rear brake fluid level.

    Check the Rear Brake Pads

    Checking the thickness of the rear brake pads.

    Tire Inspection and Maintenance of the Wheel

    Removing or Installing the Front Wheel

    Steps for removing and installing the front wheel assembly.

    Removing or Installing the Rear Wheel

    Steps for removing and installing the rear wheel assembly.

    Tire Inspection

    General inspection of tire condition, wear, and damage.

    Check Tire Pressure

    How to check and set the correct tire pressure.

    Check Spoke

    Inspecting the tension and condition of wheel spokes.

    Installing the Engine

    Engine Maintenance and Adjustment

    Check the Valve Clearance

    How to check and adjust valve clearance for optimal engine performance.

    Compression Pressure Check

    Procedure to test engine cylinder compression pressure.

    The Engine Adjustment

    Adjustments for engine performance parameters.

    Idle Speed Adjustment of Carburetor

    Steps to adjust the carburetor for correct idle speed.

    Clean the Carburetor

    Instructions for cleaning the motorcycle's carburetor.

    Check the Shift Lever Position

    Inspecting the position and alignment of the gear shift lever.

    Adjust the Shift Lever Position

    How to adjust the gear shift lever for proper engagement.

    Inspection or Replacement of Spark Plugs

    Checking and replacing the spark plug for ignition system maintenance.

    Engine Lubricant System

    Lubricant Selection

    Guidance on choosing the correct lubricating oil for the engine.

    Lubricant Inspection

    How to check the engine oil level and condition.

    Lubricant Replacement

    Step-by-step guide for changing the engine oil.

    Engine Inspection

    Cylinder Head and Valve

    Inspecting the cylinder head, valves, and related parts.

    Trouble Occurence and Cause Analysis

    Troubleshooting common engine problems and their causes.

    Low Air Pressure in the Cylinder

    Diagnosing and fixing low cylinder pressure issues.

    Black Smoke in Exhaust

    Identifying causes and solutions for black smoke from exhaust.

    Removal of the Left Cover of the Cylinder Head

    Disassemble the Cylinder Head

    Inspection of Valves and Valve Springs

    Inspection of Rocker Arm and Rocker Shaft

    Cylinder Head Inspection

    Inspection and Grinding of the Valve Seat

    Procedure for inspecting and grinding valve seats.

    Check the Valve Guide

    How to inspect the valve guides for wear.

    Replacement of the Valve Guide

    Steps to replace the valve guides.

    Measure the Valve Seat-Area Width

    Measuring the width of the valve seat contact area.

    Cylinder Block and Piston

    Main Parameters and Maintenance Standard of Cylinder Block

    Technical specifications and maintenance standards for the cylinder block.

    Main Parameters and Maintenance Standard of Piston

    Technical specifications and maintenance standards for the piston.

    Trouble Occurence and Cause Analysis

    Low Pressure in Cylinder

    Diagnosing and resolving low cylinder pressure.

    Black Smoke in Exhaust

    Identifying causes and solutions for black exhaust smoke.

    Removal of Cylinder Block

    Cylinder Block Inspection

    Removal of Piston and Piston Ring

    Piston and Piston Ring Inspection

    Installing the Piston Ring

    Installing the Piston

    Installing the Cylinderblock

    Clutch, Driving Gear, Driven Gear, Shift Mechanism

    Notices

    Important notes regarding clutch, oil pump, and gear shift mechanism.

    Main Parameters and Maintenance Standards

    Technical specifications and maintenance standards for clutch components.

    Trouble Occurence and Cause Analysis

    Troubleshooting common clutch and related issues.

    Clutch Slips When Accelerating

    Diagnosing clutch slippage during acceleration.

    Excessive Handle Pressure

    Identifying causes for excessive clutch lever pressure.

    The Clutch Cable Is Sticky, Damaged or Dirty

    Troubleshooting clutch cable issues.

    The Clutch Cam Release Mechanism Is Damaged

    Inspecting the clutch cam release mechanism for damage.

    Oil Pressure Is Too Low

    Diagnosing and resolving low oil pressure issues.

    The Oil Pump Is Faulty

    Identifying and fixing issues with the oil pump.

    Broken Oil Pump Drive Gear

    Troubleshooting a broken oil pump drive gear.

    Clutch Operation Is Difficult

    Diagnosing reasons for difficult clutch operation.

    Removal of the Right Cover

    Adjust the Clutch Stroke

    Check the Right Crankshaft Cover

    Removal of the Clutch

    Removal of the Driving Gear and Driven Gear

    Removing of the Oil Pump

    Removal of the Shift Mechanism

    Removal of the Right Crankshaft Cover

    Clutch Inspection

    Driving Gear and Driven Gear Inspection

    Oil Pump Inspection

    Shift Mechanism Inspection

    Assemble the Shift Mechanism

    Assemble the Oil Pump

    Assemble the Driving Gear and Drivn Gear

    Assemble the Clutch

    Installing the Clutch

    Installing the Right Crankshaft Cover

    Assemble the Right Crankshaft Cover

    Assemble the Right Decorative Cover

    Magneto, Timing Chain

    Removal of the Rear Left Cover

    Steps to remove the rear left cover.

    Removal of the Front Left Cover

    Steps to remove the front left cover.

    Removal of the Magneto Stator

    Procedure for removing the magneto stator.

    Removal of the Magneto Rotor

    Procedure for removing the magneto rotor.

    Removal of the Starter Motor and Starter Sprocket

    Removal of the Transition Plate

    Removal of the Timing Chain

    Removal of the Tension Arms, the Tension Rods the Tension Roller

    Front Left Cover and Rear Left Cover Inspection

    Transition Plate, Starter Motor Inspection and Starter Chain Inspection

    Magneto Stator and Rotor Inspection

    Installation of the Tension Arms and the Tesion Rods

    Installation of the Tension Roller

    Installation of the Transition Plate

    Installation of the Starter Motor and Starter Sprocket

    Installation of the Magneto Stator

    Installation of the Magneto Rotor

    Installation of the Left Side Cover

    Crankcase and Crankshaft

    Main and Counter Shaft

    Installing main and counter shafts.

    Variable Speed Drum

    Installing the variable speed drum.

    Main Parameters and Maintenance Standards

    Technical specs and maintenance standards for crankcase/shafts.

    Shift Fork and Shift Fork Shaft Inspection

    Main and Counter Shaft Combination Inspection

    Starter Shaft Inspection

    Variable Speed Drum Inspection

    Installation of the Variable Speed Drum

    Installation of Main and Counter Shaft

    Installation of the Crank Shaft and the Starter Shaft

    Installation of the Crankcase

    Engine Troubleshooting

    Faults

    List of potential engine faults.

    Inspection Method

    Methods for diagnosing engine faults.

    Results

    Expected outcomes from inspection methods.

    Possible Cause

    Potential reasons for engine malfunctions.

    Motorcycle Cleaning

    Storage

    Preparing for Long Storage

    Steps for preparing the motorcycle for extended storage.

    Preparing for Use After Long Storage

    Steps for bringing the motorcycle back into use after storage.

    Maintenance Points

    Tightening Torque Table for the Whole Vehicle

    KAYO MOTOR TS90 Specifications

    General IconGeneral
    Fuel SystemCarburetor
    Front SuspensionTelescopic fork
    Front BrakeDisc
    Rear BrakeDrum
    Fuel Tank Capacity4.5L
    Engine TypeSingle cylinder, 4-stroke, air-cooled
    Transmission4-speed
    Starting SystemElectric and kick start

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