KAYO MOTO S200 User manual

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KAYO MOTO
S200
Assembly Manual

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WWW.KAYOMOTO.COM

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1.The above picture shows the tools required for disassembling
package and installing the whole vehicle
①8 #wrench
②10 # wrench
③13 # wrench
④14 # wrench
⑤12 # T sleeve
⑥19 # wrench
⑦21 # wrench
⑧Cross screwdriver
⑨12mm socket
⑩13mm socket
⑪14mm socket
⑫17mm socket
⑬Extension rod of socket
⑭Torque wrench
⑮6 # Hexagonal wrench
⑯8 # Hexagonal wrench
⑰Needle nose pliers
2.R2.Remove the straps and outer
pacpacking PE bag.


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4.The parts shown in the picture need to be subsequently
installed on the vehicle
Name
Quantity
A
F/R wheel essy.
4
B
Front guard assembly
1
C
Seats
2
D
Accessory box
1
E
Left and right roof
scaffolding
2
F
Ceiling beam
2
G
Backrest crossbar
1
H
Flagpole
1
3. Use ⑰(Needle nose pliers or
side cutters) to cut the wire ties
and metal
wires ,take out the parts fixed on
the vehicle and metal crate, use
⑪(14mm socket) to remove the
metal crate bolts,
Waiting for subsequent installation.

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5.The picture shows the parts and standard parts of 4.4 accessory box. Please read the instructions
before install and follow the steps above to install the vehicle
Name
Quantity
I
Fixing screws and nuts of
upper suction pipe and
upper cross bar of backrest
M10 * 30 * 1.5 bolts and 2
2
M10 * 1.5 self-locking nuts
2
J
Front guard and backrest
crossbar fixed spring washer
spring washer Φ 8 * 13 * 2
8
K
Tire nuts
chrome plated M10 * 1.25 60°
16
L
Rear shock assembly
2
M
Upper suction pipe
2
N
Fixing screws and nuts of
rear shock and front
shock
M10 * 1.25 bolts
6
M10X55X1.25 self-locking
nuts
6
O
Ceiling beam fixing screws
M8 * 16 hexagon socket bolts
8
P
Fixing screws of roof truss
M10 * 20 * 1.5 hexagon
socket bolts
12
Q
Fix the upper suction pipe
with the lower cross bar of
the backrest
M6 * 16 bolts
2
M6 self-locking nuts
2
R
Seat belt fixing screws, nuts,spring washers and thickened
pads
4 sets

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S
Ceiling cloth and flag
1
T
Seat fixing nuts
8
U
Flag pole fixed base
1
V
Upper suction pipe lower
fixing clamp
Φ51-70
2
W
Front protective fixing
screws
M8 * 12 bolts
4
X
Tire dust cover
4
Y
Backrest cross bar fixing
screws
M8 * 16 bolts
4
Z
Fixing bushing for upper
intake pipe and upper cross
bar of backrest
Φ10.1*20*H9
2
6. As shown in the picture, use tool ④(14 #
wrench) to remove the hoop screws fixed
between the rear of the car and iron frame.
7.Raise the front body, use tool ⑰(Needle
nose pliers) to remove the cable ties that fix
the shock absorber, and then use ⑭(torque
wrench) ⑩(13mm socket) ④(14 # wrench) to
tighten N (M10 * 1.25 bolts*2, two M10 *
1.25 nuts*2) fixing screws (bolt in front, nut
in back, torque requirements 49-59 N·m).

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8. Raise the rear body, install the upper end of L
(rear shock assembly) on the rear shock
mounting base of the frame, and use ⑭(torque
wrench) ⑩(13mm socket)
④(14 # wrench) to tighten N ( M10 * 1.25 bolts*2
and M10 * 1.25 nuts*2) fixing screws (the bolts are
front, the nuts are back, and the torque
requirement is 49-59 N·m).
9. As shown in the picture, install the lower end
of L (rear shock assembly) on the lower rocker
arm damping mounting base, and use ⑭(torque
wrench) ⑩(13mm socket)④(14 # wrench) to
tighten N (M10 * 1.25 bolts *2 and M10 *
1.25 nuts*2) fixing screws (the bolts are back, the
nuts are front, and the torque requirement is 49-
59 N·m).
**Insert Tie rod end from bottom of
knuckle/spindle. This is a tapered bolt that will
only fully seat if inserted from the bottom.
Please note Inserting from the top and tightening
will cause the tierod end and castle nut threads
to strip and tierod end will rub the rim
10.Use compressed air to inflate the tire. Check
the instructions for air pressure requirements and
inflate it to the standard value of 5psi.

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
11.The rear wheel is wider than the front wheel as
shown above. Install all the four wheels to the
appropriate hub, use tool ⑫(No. 17# socket)
⑭(torque wrench) ⑬(Extension rod of socket)to
tighten k ( nut M10*1.25 60°16pcs) and fix
screw,bolt taper toward the hub (torque
requirement 55-66 N m)

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12.As shown in the picture, install the front
guard at the front of the frame, and use tool ⑨
(12mm socket) ⑭(torque wrench) to tighten W
(M8 * 12 bolts*4) and J （Φ 8 * 13 * 2 spring
washer*4) fixing screws (torque requirements
25-30 N·m).
13. As shown in the picture, put V (fixing clamp Φ
51-70)into the lower suction pipe orifice of the
engine, insert M (upper suction pipe) into suitable
position of pipe orifice , and tighten it with tool
⑧(cross screwdriver).
14. As shown in the picture, use tool ①(8 #
wrench) ②(10 # wrench) to tighten the fixing
point at the lower end of the upper suction pipe
with screws Q (M6 * 16 bolts*2 and
self-locking nuts M6*2) and the frame beam
(pay attention to the installation strength and
do not crack the plastic parts).

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15. As shown in the picture, align the mounting
screw of C (seat) with the mounting hole of the
frame, and screw it with tool ⑨(12mm socket),
⑬(extension rod of socket), ⑭(torquewrench)
and T (self-locking nuts M8*8) (torque
requirement is 25-30 N·m).
16.As shown in the picture, straighten the
safety belt and put it through the inner through
hole of the seat back and then out of outer
side of seat back. Use tool④(14 # wrench)
⑥(19 # wrench), R(Seat belt fixing screws, nuts,
spring washers, and thickened pads) to
tighten the seat belt and the frame (screw
installation sequence: bolt - seat belt - frame-
thickened pad - spring washer - nut).
17. As shown in the picture, align E (ceiling
frame) to the frame left and right, and tighten it
with tool ⑯(8 # Hexagonal wrench) and P ( M10
* 20 * 1.5 hexagon socket bolts*12).

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18. As shown in the picture, align the fixing end of
F (ceiling beam) inside and the beam outside, and
use tool ⑮(6 # hexagonal socket wrench) and
screw O (M8 * 16 hexagonal socket bolts*8) to
tighten.
19. As shown in the picture, align G (backrest
beam) with ceiling frame mounting base, and use
tool ⑨(12mm socket) ⑭(torque wrench) to
tighten Y (M8 * 16 bolts*4) and J (Φ 8 * 13 * 2
spring washer*4) (torque requirement 25-30
N·m).
20. As shown in the picture, use tool ④(14 #
wrench) ⑥(19 # wrench) R (Seat belt fixing
screws, nuts, spring washers and thickened
pads) to tighten the seat belt and the backrest
cross beam mounting base (screw installation
sequence: bolt - seat belt - frame- thickened pad
- spring washer - nut).
21. As shown in the picture, plug Z flat bush(blue
white zinc Φ10.1*20*H9 2pcs )into the fixed point
at the top of upper suction pipe,use tool ③(13 #
wrench) ④(14 # wrench) to tighten I screw、
nut(bolt M10*30*1.5 2pcs、self-lock nut M10*1.5
2pcs) with backrest beam (torque requirement 49-
59 N m)

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22. As shown in the picture, use tool ⑤(12 # T-
shaped sleeve) to unscrew the angle adjusting
screw of the steering wheel, adjust the steering
wheel to a proper position, and re-tighten it.
23. As shown in the picture, install U (flag pole
fixing base) to the mounting hole at the end of the
frame, insert H (flag pole) into the flag pole fixing
base, tighten it with tool ⑥(19 # wrench), and
insert S (triangular flag) into the flag pole (pay
attention to installation strength, and do not crack
the plastic parts).
24. As shown in the picture, tile S (ceiling cloth) to
the ceiling in the direction and fasten it with velcro
on the four sides of the ceiling cloth.

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25. As shown in the picture, install X (tire dust
cover) on the front and rear wheels without gaps.
26. Unscrew the fuel tank cap, add gasoline, and
tighten the fuel tank cap clockwise.
27.Use tool ⑧(Cross screwdriver)
to loosen the two bolts on the upper end of the
instrument panel, gently remove the cover of the
cart head, unscrew the battery wiring bolt, insert it
into the wiring terminal, and tighten it (red end +
pole, black end - pole). Install the cover back to its
original position and tighten the bolts above the
cover.
28. Please read the instructions carefully before
riding, so that you can better understand the
performance of vehicle.
cover fix bolt