KAYO MOTO S200 User manual

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S200
Service Manual
www.kayomoto.com
KAYO MOTO

4
Version Code：20230315
Version Name：S200 Service Manual Chinese Version.pdf
www.kayomoto.com
Zhejiang Kayo Motor Co., Ltd.
March 2023

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Preparation instructions
This Service Manual provides a
detailed introduction to the maintenance
and adjustment procedures, disassembly
and assembly essentials, inspection and
maintenance points, troubleshooting
methods, and maintenance technical data
of the S200 four-wheel all terrain
vehicle (SSV), and is accompanied by
detailed graphical materials to guide
operation.
Please read this manual carefully
and carry out maintenance according to
the standard operation method, which
can effectively prolong the service life
of each component, improve the engine
performance and the reliability of the
whole vehicle.
The first chapter mainly introduces
general operating items, tools used,
basic techniques and maintenance
parameters.
The second chapter introduces the
assembly and disassembly operation
methods of the vehicle cover parts
The third chapter introduces the
regular inspection and adjustment of the
whole vehicle
The fourth chapter introduces the
dismantling of the assembly parts
around the engine
The fifth chapter introduces the
disassembly, inspection, maintenance
and assembly methods and precautions
of various parts of the engine
The sixth chapter introduces the
relevant information of the vehicle
chassis
The seventh chapter introduces the
inspection and maintenance information
of the vehicle signal and lighting system
Appendix: Electrical schematic
diagram
If the content involved in this
manual is changed due to vehicle
improvement and other reasons, no
prior notice will be given. Performing
maintenance should be based on the
actual condition of the vehicle.
Zhejiang Kayo Motor Co., Ltd.
Research and development department
March 2023
Contents
Maintenance information
1
Covering parts of the body of
the vehicle
2
Regular inspection and
adjustment
3
Around the engine
4
Engine
5
Vehicle chassis
6
Signal and lighting systems
7
Electrical schematic diagram
Appen
dix

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The unit conversion table in this book
Item
Unit conversion
Pressure
1kgf/cm2=98.0665kPa；1kPa=1000Pa
1mmHg=133.322Pa=0.133322kPa
Torque
1kgf·m=9.80665N·m
Volume
1mL=1cm3=1cc
1L=1000cm3
Force
1kgf=9.80665N
Length
1in=25.4mm
Danger/Warning/Caution
Please read the following explanations carefully, which emphasizes the special meanings of the
words "Danger", "Warning" and "Caution", and special attention should be paid to their prominent
meanings when repairing the engine.
Danger: means to be vigilant to high danger
Warning: means to be vigilant to moderate danger
Caution: means to pay attention to minor danger
However, Attention please the "Danger" and "Warning" contained in this Service Manual cannot
cover all potential dangers during engine use and maintenance. Therefore, in addition to the relevant
provisions of "Danger" and "Warning", maintenance personnel must also have basic knowledge of
mechanical safety. If you are not sure about completing the entire maintenance operation process,
please consult a more experienced senior technician.

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1 Maintenance information
1.1 Precautions for operation……………………………………………………………………1-1
1.2 Vehicle identification number………………………………………………………………1-5
1.3 Main parameter table……………………………………………………………………….1-6
1.4 Maintenance parameter table………………………………………………………………1-8
1.5 Tightening torque……………………………………………………………………………1-10
1.6 Lubricants, sealants………………………………………………………………………….1-13
1.7 Wiring diagrams for cables, hoses, and cables……………………………………………..1-14
1.1 Precautions for operation
Safety precautions
1. Work clothes (one-piece work clothes, etc.), hats, safety boots suitable for the operation must be
worn, and if necessary, dust-proof glasses, dust-proof mask, gloves and other safety protection
articles should be worn to protect your body.
2. Due to the harmful components contained in the exhaust gas, it is forbidden to run the engine for a
long time in a closed place or a place with poor ventilation.
3. When the engine is just stopped, the temperature of the engine and muffler is still very high. Do
not touch it before cooling to avoid burns.
4. Battery solution (dilute sulfuric acid) is a strong corrosive agent that poses a risk of burns and
blindness when it comes into contact with the skin and eyes. If clothes or skin accidentally come into
contact with battery solution, please wash it with plenty of water immediately and go to the hospital
for treatment. Batteries and battery solutions should be strictly stored and must be kept in a safe
place out of reach of children. When charging a battery, flammable and explosive hydrogen gas is
generated, and there is a risk of explosion once there is an ignition source or electric spark
approaching. Therefore, please charge in a well ventilated area.
5. Due to the fact that gasoline is a flammable substance, fireworks are strictly prohibited in the
workplace. Pay attention not only to open flames, but also to electric sparks. In addition, the
evaporated gasoline poses a risk of explosion. Please choose a well-ventilated site for operations.
6. During maintenance, be careful not to let the rear wheel, clutch, other rotating parts and movable
parts clamp your hands and clothes.
7. When two or more people are working, they must constantly greet each other to confirm safety.
Warning!
Always fill up with gasoline in a well-ventilated area. Do not refuel near any open flames or fuel tanks with the engine running. Do
not smoke when filling the fuel tank.

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8. Since gasoline will expand with the increase of temperature, the fuel tank can only be filled to its
specified capacity. The expansion chamber must remain in the tank, especially if the tank is filled
with cold gasoline and then moved to a warmer area.
9. After filling gasoline, the fuel tank cap needs to be tightened.
Precautions for disassembly and assembly
1. Parts, lubricating oil and grease must use products recommended by Kayo brand.
2. The parts of each system should be sorted and kept separately, so that each part can be reinstalled
in their original position.
3. Please clean the soil and dust on the vehicle before maintenance.
4. Gaskets, O-rings, piston pin retaining rings, cotter pins, etc. must be replaced with new ones after
disassembly.
5. If the opening of the elastic retaining ring is too large during disassembly, it will be deformed, and
it will easily fall off after reassembly. Please do not use the elastic retaining ring that has loosened its
strength and lost its elasticity.
6. After the parts are disassembled and inspected, they should be cleaned before measurement and
the cleaning agent should be blown off with compressed air. Lubricating oil should be applied to the
moving surface before assembly.
7. When disassembling, necessary places should be inspected and relevant data should be measured
so that it can be restored to the state before disassembly during assembly.
8. Fasteners such as bolts, nuts, and screws should be pre-tightened first, and then tightened
according to the specified tightening torque on the diagonal according to the principle of from large
to small, from inside to outside.
9. When the rubber parts are disassembled, check whether they are aging, and replace them in
advance if necessary. In addition, as rubber parts are not resistant to corrosion from gasoline,
kerosene, etc., try not to let volatile oils and greases attach to them.
10. According to the requirements of the Service Manual, apply or inject the recommended grease on
the designated parts.
11. Correct special tools should be used for disassembly and assembly operations.
12. Ball bearings can be rotated with fingers to confirm whether the rotation is flexible and smooth.
If force is applied to the ball during disassembly, the disassembled bearing should not be used again:
If the axial and radial clearance of the bearing is too large, replace it.
Bearings that feel stuck when rotating should be cleaned, and those that still feel stuck after
cleaning should be replaced, and those that cannot be cleaned should be replaced directly.
!Warning
Do not overflow gasoline when filling with gasoline. There may be a fire hazard. Always allow the engine to cool before filling
with gasoline.

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It was originally a tight fit with the body or the shaft diameter, but if the fit is not tight after
disassembly, the bearing should be replaced.
13. Bearings should be coated with engine oil or grease before assembly. Pay attention to the
installation direction when assembling single-sided dust-proof bearings. When assembling open-type
or double-sided dust-proof bearings, install the side engraved with the manufacturer's logo and size
facing outward during assembly.
14. When installing the rectangular retaining ring, the chamfered side should face the direction of the
force. Do not use the retaining ring that has been loosened and lost its elasticity. After assembly, turn
the rectangular retaining ring to confirm that it has been firmly installed in the groove.
15. After assembly, it is necessary to check whether all fastening parts are tightened and whether the
work is normal.
16. Brake fluid and coolant can damage the coating surface, plastic parts, rubber parts, etc. Do not let
them adhere to these parts. In box of adhesion, rinse them with water immediately.
17. The oil seal should be installed with the side marked by the manufacturer facing outward (in the
direction without oil)：
When assembling, pay attention not to curl the lip of the oil seal or scratch the lip of the oil seal
with burrs.
Apply lubricating grease to the oil seal lip before assembly.
18. When installing rubber hose parts, insert the rubber hose to the root of the joint. If there is a pipe
clip, install the pipe clip in the dent of the pipe. Replace the rubber hose that is not tight during
installation.
19. Do not get dust, mud, etc. into the interior of the engine or the hydraulic system of the brake.
20. The gasket materials attached to the joint surfaces of the engine boxes must be cleaned before
assembly, and the scratches on the contact surfaces must be evenly polished and removed with an oil
stone.
21. Do not twist or bend the cables excessively. A deformed or damaged cable may cause poor
movement or damage.
22. When assembling protective cap parts, if there is a groove, the protective cap must be inserted
into the groove.
Running-in of the engine
The engine has many parts that do relative motion, such as pistons, piston rings, cylinder blocks, and
transmission gears that mesh with each other, etc. Therefore, in the early stage of its use, it is
necessary to carry out standardized running-in. Running-in can make the moving parts adapt to each
other, correct the working gap, and form a good smooth friction surface that can withstand heavy
loads. An engine that has been run-in according to specifications can have excellent performance and
reliability.
The recommended break-in time is 10 hours, with the following specifications:
0 to 10 hours: avoid continuous operation with more than 1/2 throttle, and change the speed
frequently. It is not recommended to run for a long time at a fixed throttle position; after every 1 hour

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of work, cool down the engine for 5 to 10 minutes; Avoid rapid acceleration, the throttle should be
changed slowly, not suddenly large and small, and do not drag the cargo during the running-in
period.
Attention：
During the running-in period, maintenance should be carried out according to daily maintenance
regulations, and any faults found should be promptly eliminated;
After the running-in period is over, the whole machine can be maintained after the running-in period
before it can enter the normal driving stage.
Sealed vehicle storage
It is recommended to store the vehicle in the following ways:
Attention
Before storing this vehicle, it must be properly maintained to prevent rust and component deterioration.
1. Clean the seat cushion with a damp cloth and let it dry.
2. Thoroughly clean the vehicle by washing dirt, oil, grass and other foreign objects from the entire
vehicle, let the vehicle dry thoroughly, and do not allow water to enter any part of the engine or air
intake.
3. Drain the gasoline in the fuel tank.
4. Replace the engine oil.
5. Block the holes on the exhaust system with a clean cloth.
6. Apply anti-rust oil to the upper steering shaft bushing and plunger of the shock absorber.
7. Tighten all fasteners, and the calibrated fasteners must be tightened according to the torque.
8. Disconnect the battery cable (disconnect the negative cable first); then take out the battery, clean
the battery and cable, and store it in a clean and dry place.
9. Attention：Please ensure that the battery is fully charged during storage
10. 9.Store the vehicle in a horizontal position indoors.
Attention
Avoid storing in direct sunlight and avoid using plastic covers as moisture can collect on the vehicle and cause rust.
Unseal the vehicle
Take out the vehicle from the warehouse. In order to ensure trouble-free operation in the next few
hours, the following methods are recommended:
Thoroughly clean the vehicle.
Clean the engine, remove the cloth from the engine.
Inspect all control wires and cables for wear or signs of wear and replace them if necessary.

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Replace the engine gearbox oil and filter.
Charge the battery and install it. (Make sure to connect the positive cable first when connecting the
battery)
Attention
Before installing the battery, make sure the ignition switch is in the OFF position.
1. Check the entire braking system (fluid level, brake pads, etc.), all controls, headlights, taillights,
brake lights and turn signal lights; adjust or replace if necessary.
2. Check the tire pressure and inflate to the recommended pressure if necessary.
3. Tighten all fasteners. It is recommended to tighten the calibrated fasteners according to the torque.
4. Make sure that the steering device can move freely without restriction.
5. Check the spark plug and clean or replace it if necessary.
6. Check the gasoline filter and air filter housing, and clean or replace them if necessary.
1.2 Vehicle identification number
①Frame number
②Vehicle nameplate
③Engine number
Vehicle model
S200
Frame number
L6JUCMZA~
Engine number
163FML ~

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1
3
2

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1.3 Main parameter table
Items
Parameters
Vehicle model
S200
Length (mm)
2517
Width (mm)
1487
Height (mm)
1446
Wheelbase (mm)
1900
Engine model
CVT200
Total displacement (ml)
196.2
Fuel type
92 and above gasoline
Curb weight of the whole vehicle (kg)
320
Number of passengers
2 people (including the driver)
Rated loading mass
2 people= 160kg
Tire
specificatio
ns
Front wheel
AT22*7.0-10
Rear wheel
AT22*10-10
Minimum ground clearance
230mm
Turning circle radius (minimum turning radius at
the closest point)
4800mm
Engine
Starting method
Electric starter
Engine type
Single cylinder, vertical, four
stroke, oil cooled
Gas distribution method
Shaft drive
Cylinder diameter × stroke (mm)
63.5×62
Compression ratio
9.3：1
Maximum power
10/7000
Maximum torque
15/5500
Lubrication method
Wet type
Oil pump type
Rotor type
Lubricating oil filter type
Full flow filtration rotary type
Oil grade
SF 10W/40
Cooling method
Oil cooled

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Items
Parameters
Air filter type
Sponge filter element filtration type
Throttle body
Type
Plunger throttle
Mixture valve diameter
30mm
Fuel tank capacity
15L
Transmission
system
Clutch type
Dry automatic clutch
Variable speed mode
Automatic continuously variable transmission
(CVT)
Gearshift
One forward gear, one neutral gear, one
reverse gear
Transmission
mode/sequence
Manual operation/D—N—R
(CVT) continuously
variable ratio
0.703~2.413
Output type
Rear axle output
Engine output rotation
direction
When in forward gear, it is clockwise when
viewed from the rear of the vehicle
Steering device
Steering angle
Inner
45°
Outer
36°
Brake device type
Front
Hydraulic pressure
disc type
Rear
Hydraulic pressure
disc type
Buffering
method
Suspension method
Independent suspension of front and rear
wheels with double rocker arms
Frame type
Steel pipe and steel plate welding type

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1.4 Maintenance parameter table
 Lubrication device
Items
Standards
Usage
limit
Engine oil
capacity
Change oil
900ml（without changing the oil filter
element）
－
Change oil
1000ml（in the same time change the oil filter
element）
Full capacity
1100ml
－
Recommended engine oil
Only SF 10W/40 engine oil can be used, and
do not replace or mix different grades of
engine oil as this can cause engine damage and
accidents
Oil
pump
rotor
Radial clearance between inner
and outer rotors
－
0.12mm
Radial clearance between outer
rotor and pump body
－
0.12mm
Axial clearance between rotor
surface and pump body
0.05~0.1
0.2mm
 Air intake system (see 05 Engine section for details)
 Wheels (same front and rear wheels)
Items
Standards
Usage
limit
Rim runout
Longitudinal
0.8mm
2.0mm
Lateral
0.8mm
2.0mm
Tire
Residual
groove
－
3mm
Air pressure
35kPa（0.35kgf/cm2）
－

 Braking System
Items
Standards
Usage limit
Front brake
Brake disc thickness
3.5mm
3.0mm
Rear brake
Brake pedal travel
2 ~ 6mm
－
Brake disc thickness
4.0mm
3.0mm

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 Battery/charging device/trigger coil
 Ignition device
Items
Standards
Magneto
Type
Permanent magnet AC generator
Output
Three phase full wave
Magneto trigger coil resistance
120Ω±20Ω
Magneto no-load voltage (engine in cold
state)
None
Maximum output power of magneto
217W（5000r/min）
Stabilized voltage
14.5V±0.5V
Trigger coil peak voltage
Vp≥1.5V（300r/min）,
Vp≥5V（1500r/min）
Rectifier type
Full wave rectification
Battery
Capacity
12V14AH
Voltage between terminals
Fully charged
14.4V
Insufficient
charge
Less than 11.8V
Items
Standards
Ignition type
Capacitive discharge DC-CDI direct-current
Spark plug
Type
Resistance type spark plug
Standard
D8RTC
Spark plug gap
0.6~0.7mm
Spark
characteristics
Blue and white light
Ignition coil
resistance
Primary
0.3 Ω
Secondary
3.8 kΩ
Peak voltage
Ignition coil
primary
300~450V
Pulse generator
20kV~30kV
Starting relay coil resistance
3.5 Ω

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 Lights / Meters / Switches
Valve mechanism + cylinder head (see 05-engine part for details)
Cylinder + piston + piston ring + crank connecting rod (see 05-engine part for details)
Clutch + transmission mechanism (see 05-engine part for details)
Items
Standards
Fuse
15A
Lights, light bulbs
Headlamps (high beam)
12V—12W
Headlamp (low beam)
12V—6W
Daytime running lights
12V-4W
Tail lights/brake lights
12V—2W

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1.5 Tightening torque
Attention：
Before installing the thread, apply anti-rust grease on the threaded part and joint
surface
Tightening torques at designated parts - whole vehicle parts
Serial
numbe
r
Items
Fastener code
Quantity
Tightening torque
(N · m)
1
Front disc brake main pump
mounting bolts and nuts
GB6187-86 M8
2
25-30
2
Brake pedal fixing bolts and
nuts
GB6187-86 M10*1.25
1
55-66
3
Accelerator pedal fixing bolts
and nuts
GB6187-86 M8
1
25-30
4
Carburetor fixing bolts and
nuts
M8（Included in the engine）
2
25-30
5
Mounting screws for gear
shift bracket assembly
M6（Included in the engine）
3
10-12
6
Front wheel hub and disc
brake disc fixing screws
GB70.3 M6*16 10.9 grade
12
14-17
7
Rear wheel hub and disc
brake disc fixing bolts
M8（Step bolts, included in
disc brake rotors）
8
25-30
8
Fixing screw for steering
wheel
GB70-85 M6*16
6
10-12
9
Fixing screw for upper air
suction cover
GB5787 M6*12
2
10-12
10
Tail light fixing nuts
GB6187-86 M6
2
10-12
12
Door lock fixing screws
GB5787 M6*16
4
10-12
13
Disc brake oil cup fixing
bolts
GB5787 M6*20
2
10-12
14
Foot pedal fixing plate fixing
bolts and nuts
GB6187-86 M8
4
25-30
15
Carburetor fixing bolts and
nuts
M8（Included in the engine）
2
25-30
16
Engine installation fixing
bolts and nuts
GB6187-86 M10*1.25
2
55-66
17
Engine shock absorber fixing
nuts
GB6187-86 M10*1.25
4
55-66
18
Engine hanging plate fixing
bolts and nuts
GB6187-86 M10*1.25
1
55-66
19
Engine hanging plate fixing
bolts and nuts
GB6187-86 M8
2
25-30
20
Differential fixing bolts and
nuts
GB6187-86 M10*1.25
2
55-66

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21
Front upper and lower rocker
arm fixing bolts and nuts
GB6187-86 M10*1.25
8
55-66
22
Rocker arm ball head fixing
slotted nut
GB6187-86 M10*1.25
4
33~45
23
Steering rod fixing slotted
nuts
GB6187-86 M10*1.25
2
33~45
24
Front and rear shock
absorbing fixing bolts and
nuts
GB6187-86 M10*1.25
8
55-66
25
Front wheel hub fixing
slotted nuts
GB9457-1988 M14*1.5*H18
2
72~89
26
Front and rear disc brake left
and right pump fixing bolts
GB5789 M8*25
8
25-30
27
Steering gear fixing bolts and
nuts
GB6187-86 M8
4
25-30
28
Rear sheep horn fixing bolts
and nuts
GB6187-86 M12*1.25
4
94-114
29
Rear wheel hub fixed slotted
nuts
M20（Included in the rear axle
shaft）
2
72-89
30
Lower suction pipe fixing
bolts and nuts
GB6187-86 M6
2
10-12
31
Handbrake fixing bolts and
nuts
GB6187-86 M8
2
25-30
32
Fuel tank fixing bolts
GB5789 M8*25
4
25-30
33
Cross pan head self-tapping
screws
GB845-85 ST2.9*14
8
—
34
Cross large flat head machine
tooth screws
TM6*20
8
—
35
Cross large flat head machine
tooth screws
TM6*16
—
—
36
Cross flat head self tapping
screws
GB845-85 ST4.2*12
—
—
37
Rim mounting nuts
M10*1.25 60°
16
45~59
38
Door rocker seat fixing bolts
GB6187-86 M8
2
25-30
39
Rear shelf fixing bolts
GB5789 M8*16
7
25-30
40
Front protective fixing bolts
GB5789 M8*16
4
25-30
41
Trailer ball fixing plate bolts
and nuts
GB6187-86 M10×1.5
4
76-90
42
Left and right ceiling frame
fixing bolts
GB70-85 M10*20*1.5
12
45-59
43
Backrest crossbeam fixing
bolts and nuts
GB6187-86 M8
2
25-30
44
Upper suction pipe fixing
bolts and nuts
GB6187-86 M10×1.5
2
76-90

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45
Ceiling beam fixing bolts
GB70-85 M8*16
8
25-30