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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

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

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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