KAYO MOTO AU200 User manual

KAYO MOTO
AU200
Assembly Manual
WWW.KAYOMOTO.COM

1. The above picture shows the tools needed to
unpack and install the vehicle
① Torque wrench
② Additional rod for electric wrench socket
③ 12mm socket
④ 14mm socket
⑤ 27mm socket
⑥ 6mm hexagon socket
⑦ No. 8 wrench
⑧ No. 10-12 wrench
⑨ No. 13 wrench
⑩ No. 12-14 wrench
⑪ No. 17-19 wrench
⑫ Needle nose pliers
⑬ No. 8 T-socket
⑭ Phillips screwdriver
2. Remove the straps and cardboard cover.
3. Take out the parts attached on the vehicle and
the packaging iron frame, remove the iron frame
screws, wait for subsequent installation.
4. The parts shown above need to be
subsequently installed on the vehicle.
5. Above photo shows the accessories in the
carton. Please read the user’s manual (A) before
installation.

Name Quantity
A User’s manual 1
B Bracket for gear indicator
cover
1
C Air pressure gauge 1
D Cable tie 2
E Spark plug socket 1
F Rear central reflector 1
G Rubber dust caps 4
H Reflector (front & rear) 4
I Front rack
cover
hardware
Flange bolt
M6*12
2
Flange bolt
M6*16
4
J Rear rack
cover
hardware
Flange bolt
M6*12
2
Flange bolt
M6*16
4
K Hardware
for rear
rack & rear
plastics
Screw M6*16 2
Rubber washer
Φ5.5*14.5*2
2
Toothed nut
M6
2
6. The picture shows the details of the standard
parts in the accessory box
Name Quantity
L Front wheel
nut
Nut M10*1.25 8
M
Rear rack
hardware
Bolt M8*16 4
N Rear central
reflector
fixing screw
Toothed nut
M5 1
O Rear axle
hardware
slotted nut
M18*1.5
2
cotter pin
4*28
2
dust cap
washer Φ
18.5*53*2
2
spring washer
Φ18*27*4.5
2
P Front fork
hardware
Bolt
M10*40*1.25
2
Nut M10*1.25 2
7.Install bracket for gear indicator cover(B), use
tool ①⑥ to lock the handlebar clamps, the distance
between the two ends of the mark is close, tighten
evenly, first start by hand tightening all four clamp
bolts. (The handlebar is tilted 3-5° vertically to the
rear after installation, and the torque is required to
be 25-30N·m).

8. Use tool ⑭ to tighten the gear indicator cover
screw (B).
9. Use tool ⑭ to install the combination switch
10. Use tools ① ② ③ to tighten the rear rack
screws(M).(torque requirement 25-30N.m)
11. Use tools ⑧⑭ to tighten rear rack hardware for
rear rack & rear plastics(K).

12. Use tool ⑬ to tighten rear rack plastic cover
hardware (J) (the circles in the picture use
M6*16 the rest use M6*12)
13. Use tool ⑬ to tighten front rack plastic cover
hardware (I) (the circles in the picture use M6*16
the rest use M6*12)
14.Install the rear central reflector(F) on the
rear rack and use the tool ⑦ to tighten the fixing
screw (N).
15. Install reflectors(H) on the front and rear racks.

16. Use tools ⑧ ⑩ to remove the fixing screws of
the iron frame.
17. Put the vehicle on the stand for easy
installation of other accessories.
18.Use tool ⑫ to remove the cable fixing the
shock absorber, then use ① ② ④ ⑨ to
tighten front shock fixing hardware(P) (torque
requirement 30-40N.m).
19. Please refer to user’s manual (A) for air
pressure requirements. Use compressed air to
inflate the tires and use the air pressure gauge (B)
to inflate to the standard value of 5psi.

20. As shown in the picture, install the front
wheel on the front hub, and use the tool ④ (No.
14# gun head) ① (torque wrench) ② Additional
rod for electric wrench socket to tighten L (self-
locking nut M10*② 5) and fix screw (torque
requirement 49-59N.m)
21.Align the rear wheel with the splines and push
on the rear axle, with the air nozzle cap facing
outward, install the slotted nut, dust cap washer
and spring washer(O), and use tools ①②⑤ to
lock them. Then insert the cotter pin(O), the
bending angle is greater than 180° (torque
requirement is 77-92N.m)
22. Insert the rubber dust cover (G) into the
position shown above of the front and rear
wheels.
23. Take out rearview mirror from accessory box
and install it on mirror stand, use tool
①
to tighten
screws .

24. Pull the latch as above shown and remove
the seat cushion, waiting for the subsequent
installation of the battery
25.Connect the positive and negative poles as
shown in the picture, use tool ⑭ to tighten the
screws, then install the seat. (Red is positive, black
is negative)
26. Unscrew the fuel tank cap, add gasoline,
and tighten the fuel tank cap clockwise. 27. Please read the user’s manual (A) carefully
before riding to better understand the performance
of the vehicle.