KAYO MOTOR TS90 User manual

ZHEJIANG KAYO MOTOR CO., LTD.
KAYO MOTO
TS90
SERVICE MANUAL
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ZHEJIANG KAYO MOTOR CO., LTD.

ZHEJIANG KAYO MOTOR CO., LTD.
This service manual is edited by KAYO
No part of this publication may be reproduced without authorization.
ZHEJIANG KAYO MOTOR CO., LTD reserves the right to make changes at any time without
notice and without incurring any obligation.
The vehicle pictured in this owner’s manual may not match your actual vehicle.
PREFACE
Congratulations on your purchase of the 2021 TS90 Dirt Bike, and we believe that this choice won’t
let you down.
This manual will give you an understanding of the better use of our product,it has specialized the
maintenance and adjustment procedures, disassembly and assembly points, inspection and repair
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points, troubleshooting methods and maintenance technical data, in addition, there is a detailed
graphic information to guide the operation.
Please read this manual carefully and carry out maintenance according to the standard operation
techniques, which can effectively prolong the service life of each component, improve the engine
performance and the reliability of the vehicle.
For the sake of technical development, KAYO will reserve the right of modifying motorcycle
structure, equipment, and spare parts without notice. Due to that different markets have different
law’s requirement, we’ve adjusted model accordingly, the model image in this manual maybe not
match your actual vehicle. In addition, if there is any question concerning this manual, please visit
our website www.kayomoto.com and consult our customer service.
The contents of this manual are subject to change without prior notice due to vehicle
improvement. The actual state of the motorcycle shall prevail during maintenance.
ZHEJIANG KAYO MOTOR CO., LTD.
ENGINEERING OFFICE
AUGUST. 2021
CONTENT
MEANINGS OF REPRESENTATION…………………………………………………………….. 9
SYMBOLS USED………………………………………………………………………………9
DEGREES OF RISK AND SYMBOLS……………………………………………………...…9
ADVICE………………………………………………………………………………….………….10
COMPONENTS AND POSITIONS………………………….……………………………………..11
2021 TS90 COMPONENTS AND POSITIONS………………………………………….12
VIN CODE AND ENGINE NUMBER……………………………………………………….……..13
VIN CODE……….………………..............................................................................................13
ENGINE NUMBER…………….................................................................................................13
PARAMETER......................................................................................................................................14
2021 TS90 DIMENSION AND QUALITY PARAMETER.......................................................14
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CONTROLS........................................................................................................................................15
FRONT DISC BRAKE................................................................................................................15
THROTTLE LEVER...................................................................................................................15
STARTING...................................................................................................................................16
STOPPING...................................................................................................................................16
FUEL TANK SWITCH................................................................................................................16
SHIFTING....................................................................................................................................17
REAR DISC BRAKE...................................................................................................................17
PARKING SUPPORT..................................................................................................................18
PREPAREING FOR USE....................................................................................................................18
ADVICE ON FIRST USE............................................................................................................18
RUNNING-IN PROCESS............................................................................................................18
RIDING INSTRUCTIONS.................................................................................................................19
PREPARATION BEFORE RIDING....................................................................................19
PRECAUTIONS FOR STARTING.........................................................................................19
PREACUSTIONS STOPPING.............................................................................................20
PREACUTIONS FOR TURNING...…………………………………………………………..20
PRECAUTIONS FOR ACCELERATION…………………………………………………..20
PRECAUTIONS FOR SHIFTING……………………………………………………………..20
PRECAUTIONS FOR BRAKING…………………………………………………………….20
PRECAUTIONS FOR STOPPING & PARKING………………………………..….…….…20
SUGGESTED INSPECTION TIME FOR ALL PARTS OF THE VEHICLE……………….…….21
SUSPENSION SYSTEM..………………………………………………………………….…22
CHECK THE COMPRESSION AND REBOUND OF THE VEHICLE INCLUDING THE
DRIVER……………….…..............................................................................22
MEASURE THE DISTANCE BETWEEN THE CENTER OF THE REAR WHEEL AND THE
REAR FENDER IN SUSPENSION……………………………………………………..….....22
MEASURE DISTANCE BETWEEN CENTER OF REAR WHEEL AND REAR FENDER
UNDER NO LOAD……………………………………………………………………….…22
MEASURE DISTANCE BETWEEN REAR WHEEL CENTER AND REAR FENDER IN
DRIVING CONDITION………………………………………………………………….……23
ADJUSTING THE SPRING PRELOAD OF REAR SHOCK ABSORBER………………….23
CHECK FOR THE SETTING OF FRONT SHOCK ABSORBER………………………...….23
ADJUSTING THE HANDLEBAR…………………………………………………………….24
VEHICLE MAINTENANCE……… ……………………………………………………….……....24
PLACEMENT…………………………………………………………………………..………24
REMOVING OR INSTALLING THE FRONT DISC BRAKE………………………….….…24
REMOVING OR INSTALLING THE FRONT SHOCK ABSORBER………………….…….25
REMOVING OR INSTALLING THE LINKAGE……………………………………………25
CHECK THE FRONT STEERING…………………………………………………………...26
LUBRICATION AND INSTALLATION OF STEERING HEAD BEARING. ……………..26
REMOVING OR INSTALLING THE FRONT FENDER…………………………………..27
REMOVING OR INSTALLING THE REAR SHOCK ABSORBER……………………….27
REMOVING OR INSTALLING THE SEAT CUSHION…………………………………..27
REMOVING OR INSTALLING THE AIR FILTER…………………………………..……….27
CLEANING AND MAINTENANCE OF AIR FILTER……………………………………… 28
REMOVING OR INSTALLING THE EXHAUST PIPE…………………………………….28
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REMOVING OR INSTALLING THE MUFFLER TUBE……………………….................28
REMOVING OR INSTALLING THE FUEL TANK………………………………................29
CHECK AND CLEAN THE CHAIN…………...…………………………........................….29
REMOVING OR INSTALLING THE CHAIN……... …………………………….................29
CHECK AND ADJUST THE CHAIN TENSION. ………………………………............….29
CHECK THE STRUCTURE OF THE REAR SPROCKET, ENGINE SPROCKET AND
GUIDE
CHAIN……………...............................................................................................…………30
CHECK THE FRAME………………………………………………………..................……..30
CHECK THE FORK…………………………………………………………...........……31
CHECK THE THROTTLE CABLE……………………………………....................…………31
CHECK THE STEERING HANDLE…………………………………………………………..31
CHECK AND MAINTENANCE THE BRAKE SYSTEM………………………..................……..31
CHECK THE FREE-PLAY OF FRONT BRAKE LEVER………………………….....……..31
CHECK THE DISC BRAKE………………………………………………....................…….32
CHECK THE FRONT BRAKE LIQUID LEVEL…………………………...............………..32
REFUEL THE FRONT BRAKE LIQUID LEVEL…………………………...............……32
CHECK THE FRONT BRAKE PADS….... …………………………………..................……33
CHECK THE FREE-PLAY OF FOOT BRAKE…………………………………...........…….33
CHECK AND REFUEL THE REAR BRAKE DISK LIQUID LEVEL..............................33
CHECK THE REAR BRAKE PADS.......................................................................................... 34
TIRE INSPECTION AND MAINTENANCE.........................................................................35
REMOVING OR INSTALLING THE FRONT WHEEL........................................................35
REMOVING OR INSTALLING THE REAR WHEEL......................................................... 35
TIRE INSPECTION.................................................................................................................... 35
CHECK TIRE PRESSURE......................................................................................................... 36
CHECK SPOKE.......................................................................................................................... 36
INSTALLING THE ENGINE..............................................................................................................36
ENGINE MAINTENANCE AND
ADJUSTMENT.............................................................................37
INSTALLING THE CYLINDER HEAD AND BLOCK………………………….........…… 37
CHECK THE VALVE CLEARANCE........................................................................................ 37
COMPRESSION PRESSURE CHECK................................................................................... 37
THE ENGINE ADJUSTMENT.......................................................................................................... 38
IDLE SPEED ADJUSTMENT OF CARBURETOR............................................................ 38
CLEAN THE CARBURETOR...................................................................................................38
CHECK THE SHIFT LEVER POSITION..............................................................................39
ADJUST THE SHIFT LEVER POSITION......................................................................... 39
INSPECTION OR REPLACEMENT OF SPARK PLUGS......................................................39
THE LUBRICATION SYSTEM OF ENGINE.................................................................................40
LUBRICANT SELECTION................................................................................................. 40
LUBRICANT INSPECTION..................................................................................................... 40
LUBRICANT REPLACEMENT......................................................................................... 40
THE ENGINE INSPECTION.........................................................................................................41
CYLINDER HEAD AND VALVE..................................................................................................41
NOTICE.........................................................................................................................41
TROUBLE OCCURENCE AND CAUSE ANALYSIS............................................................41
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REMOVAL OF CYLINDER HEAD LEFT COVER...............................................................42
TIMING CHECKING..........................................................................................................42
REMOVAL OF VALVE
COVER.................................................................................................43
CHECK THE VALVE CLEARANCE...................................................................................43
REMOVAL OF CYLINDER HEAD....................................................................................43
DISASSEMBLE OF CYLINDER HEAD...............................................................................44
CHECK THE VALVE AND VALVE SPRING........................................................................45
CHECK THE LINKAGE AND LINKAGE AXLE....................................................................45
CHECK THE CAMSHAFT COMPENTS........................................................................ 45
CYLINDER HEAD INSPECTION.. .........................................................................................46
INSPECTION AND GRINDING OF THE VALVE SEAT.....................................................46
CHECK THE VALVE GUIDE........................................................................................46
REPLACEMENT OF THE VALVE GUIDE.........................................................................46
MEASURE THE VALVE SEAT-AREA WIDTH...............................................................47
ASSEMBLE THE CYLINDER HEAD......................................................................................47
INSTALLING THE CYLINDER HEAD.................................................................................48
CYLINDER BLOCK AND PISTON.......................................................................................50
NOTICE....................................................................................................................50
MAIN PARAMETERS AND MAINTENANCE STANDARD OF CYLINDER BLOCK......50
MAIN PARAMETERS AND MAINTENANCE STANDARD OF PISTON...........................50
TROUBLE OCCURENCE AND CAUSE ANALYSIS.....................................................51
REMOVAL OF CYLINDER BLOCK.................................................................................51
CYLINDER BLOCK INSPECTION. .................................................................................51
REMOVAL OF PISTON AND PISTON RING......................................................................52
PISTON AND PISTON RING INSPECTION. ..................................................................52
INSTALLING THE PISTON RING..............................................................................53
INSTALLING THE PISTON..................................................................................................53
INSTALLING THE CYLINDERBLOCK..................................................................................54
CLUTCH 、 DRIVING GEAR 、 DRIVEN GEAR 、 SHIFT
MECHANISM.......................................54
NOTICES..........................................................................................................................................54
MAIN PARAMETERS AND MAINTENANCE STANDARD..................................................54
TROUBLE OCCURENCE AND CAUSE ANALYSIS........................................................55
REMOVAL OF THE RIGHT COVER........................................................................................55
ADJUST THE CLUTCH STROKE....................................................................................56
CHECK THE RIGHT CRANKSHAFT COVER......................................................................56
REMOVAL OF THE CLUTCH.... ..............................................................................56
REMOVAL OF THE DRIVING GEAR AND DRIVEN GEAR..............................................57
REMOVAL OF THE OIL PUMB..........................................................................................57
REMOVAL OF THE SHIFT MECHANISM.......................................................................57
REMOVAL OF THE RIGHT CRANKSHAFT COVER...........................................................58
CLUTCH INSPECTION...............................................................................................58
DRIVING GEAR AND DRIVEN GEAR INSPECTION........................................................59
OIL PUMP INSPECTION.. ................................................................................................59
SHIFT MECHANISM INSPECTION...................................................................................59
ASSEMBLE THE SHIFT MECHANISM............................................................................59
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ASSEMBLE THE OIL PUMB.........................................................................................60
ASSEMBLE THE DRIVING DEAR AND DRIVN GEAR...................................................60
ASSEMBLE THE CLUTCH..........................................................................................60
INSTALLING THE CLUTH.......................................................................................................61
INSTALLING THE RIGHT CRANKSHAFT COVER………………………….........61
ASSEMBLE THE RIGHT CRANKSHAFT COVER.....................................................62
ASSEMBLE THE RIGHT DECORATIVE COVER..............................................................62
MAGNETO、TIMING CHAIN.....................................................................................62
NOTICES.....................................................................................................................62
REMOVAL OF THE REAR LEFT COVER....................................................................63
REMOVAL OF THE FRONT LEFT COVER......................................................................63
REMOVAL OF THE MAGNETO STATOR.....................................................................64
REMOVAL OF THE STARTER MOTOR AND STARTER
SPROCKET..................................64
REMOVAL OF THE TRANSITION PLATE..............................................................................64
REMOVAL OF THE TIMING CHAIN.....................................................................................64
REMOVAL OF THE TENSION ARMS AND THE TENSION
RODS......................................65
REMOVAL OF THE TENSION ROLLER...............................................................................65
FRONT LEFT COVER AND REAR LEFT COVER INSPECTION.................................65
TRANSITION PLATE AND STARTER MOTOR
INSPECTION..............................................65
STARTER CHAIN INSPECTION.............................................................................................65
MAGNETO STATOR AND ROTOR INSPECTION........................................................65
INSTALLATION OF THE TENSION ARMS AND THE TESION
RODS................................65
INSTALLATION OF THE TENSION ROLLER.....................................................................65
INSTALLATION OF THE TRANSITION PLATE..............................................................66
INSTALLATION OF THE STARTER MOTOR AND STARTER SPROCKET.......................67
INSTALLATION OF THE MAGNETO STATOR……………………......................................67
INSTALLATION OF THE MAGNETO ROTOR.............................................................68
INSTALLATION OF THE LEFT SIDE COVER.......................................................................68
CRANKCASE AND CRANKSHAFT............................................................................68
MAIN AND COUNTER SHAFT................................................................................................68
VARIABLE SPEED DRUM.......................................................................................................68
NOTICES................................................................................................................................68
MAIN PARAMETERS AND MAINTENANCE STANDARDS.........................................69
TROUBLE OCCURENCE AND CAUSE
ANALYSIS...............................................................69
DISASSEMBLE OF THE
CRANKCASE...................................................................................69
REMOVAL OF THE CRANK
SHAFT........................................................................................70
REMOVAL OF THE MAIN AND COUNTER
SHAFT..............................................................70
DISASSEMBLE OF THE VARIABLE SPEED DRUM..........................................................70
CRANK SHAFT INSPECTION............................................................................................70
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LEFT AND RIGHT CRANKCASE BEARING INSPECTION.......................................71
SHIFT FORK AND SHIFT FORK SHAFT INSPECTION……………………….............71
MAIN AND COUNTER SHAFT COMBINATION INSPECTION.................................71
STARTER SHAFT INSPECTION..............................................................................................71
VARIABLE SPEED DRUM INSPECTION........................................................................72
INSTALLATION OF THE VARIABLE SPEED DRUM............................................................72
INSTALLATION OF MAIN AND COUNTER SHAFT.............................................................72
INSTALLATION OF THE CRANK SHAFT AND THE STARTER SHAFT..........................72
INSTALLATION OF THE
CRANKCASE..................................................................................72
ENGINE TROUBLESHOOTING................................................................................73
MOTORCYCLE CLEANING AND STORAGE........................................................................77
MAINTENANCE POINTS..................................................................................................78
TIGHTENING TORQUE TABLE FOR THE WHOLE VEHICLE............................................83
MEANINGS OF REPRESENTATION
SYMBOLS USED
The meaning of specific symbols is described below
* All work marked with this symbol requires specialist knowledge and technical understanding. If
you do not have the confidence to perform that, you can go to an authorized KAYO workshop or
KAYO after-sale service point. There, your motorcycle will be optimally cared for by specially
trained experts using the specialist tools required.
→ Indicates a page reference (more information is provided on the specified page).
DEGREES OF RISK AND SYMBOLS
Your safety, and the safety of others, is very important. Operating this motorcycle safety is an
important responsibility. Please read this manual carefully.
Safety Messages preceded by a safety alert symbol and one of three signal words:
DANGER : Indicates a danger that will immediately and invariably lead to fatal or permanent injury
if the appropriate measures are not taken.
WARNING : Indicates a danger that is likely to lead to fatal or serious injury if the appropriate
measures are not taken.
CAUTION : Indicates a danger that may lead to minor injuries if the appropriate measures are not
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taken.
Other important information:
Please note that it is not practical or possible to warn you about all hazards associated with operating
or maintaining a motorcycle.
Therefore, you must have basic mechanical safety knowledge and use your own good judgement.
If you cannot complete the process of operating or maintaining, please consult a more experienced
senior technician before operation.
ADVICE
Most of off-road motorcycle fatalities are caused by head injuries. Without helmets, the chances of
serious injury or death caused by head injuries are much higher. So always wear an approved
motorcycle helmet and protective apparel such as goggles, gloves and boots while riding, which will
save your life at the critical moment.
Initially, this series of vehicles were designed for off-road racing, without considering the problem of
carrying passengers, and what’s more, there is no backseat, handlebar and pedal for carrying people.
So please be sure not to use this motorcycle to carry any other people except the driver, which may
easily lead to a safety accident.
Do not use non-original parts to modify the car, and do not arbitrarily remove the original
components from the vehicle. If you need to replace any parts, please use spare parts and accessory
products that are approved and/or recommended by KAYO and have them installed by an authorized
KAYO workshop. KAYO accepts no liability for any personal modification, other products and any
resulting damage or loss.
Please check your motorcycle carefully before riding and do the maintenance accordingly after use.
When the motorcycle fell, check the main parts first. It would lead to a accident easily and endanger
your own safety when riding a faulty vehicle.
When using this motorcycle, the temperature of the engine and exhaust pipe is very high, so it needs
to a period to cool down after parking. During this period, do not touch or move the engine or
exhaust pipe to avoid scald.
Do not wear shorts while riding, otherwise leg injuries may happen.
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APPEARANCE
2021 TS90 COMPONENTS AND POSITIONS
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16
No.
Name
No.
Name
1
Front fender
9
Front shock
2
Front panel
10
Fuel tank
3
Handlebar
11
Carburetor
4
Vent pipe
12
Gear shift lever
5
Fuel tank cap
13
Pedal
6
Fuel tank petcock
14
Chain
7
Chain guide cover
15
Chain guide
8
Front brake caliper
16
Rear sprocket
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19 20 21 22 23 24
25 26 27 28 29 30 31
No.
Name
No.
Name
19
Rear fender
26
Rear brake caliper
20
Exhaust pipe muffler
27
Swing arm
21
Seat
28
Rear brake oil cup
22
Rear shock
29
Brake pedal
23
Upper clamp
30
Exhaust pipe
24
Lower clamp
31
Front disc brake
25
Rear disc brake
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VIN CODE
Vin code of 2021 TS90 are located on the head pipe.
ENGINE NUMBER
The engine number of the 21 TS90 is located on the
engine box inside the shift lever.
PARAMETER
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DIMENSIONS AND QUALITY PARAMETER – 2021 TS90
L*W*H（mm）
1445×670×885
Wheelbase（mm）
1025
Net weight（kg）
60
Tire size
F:2.50-12；R:3.00-10
Seat height（mm）
625
Min ground clearance （
mm）
180
Tank volume（L）
3.5
Engine Parameters
Engine type
Single cylinder 、 four stroke 、air coooling、automatic clutch
Displacement
86cc
Max. Power（kw/r/min）
4.1/8000
Max. Torque （ NM/r/min
）
5.8/5000
Compression Ratio
8.8:1
Shift type
Usually engage four speed transmission
Starting
Electric/kick
Ignition type
CDI
Battery
12V 4Ah
Chain
#420；14T/39T
Frame/Shock/Brake/Wheel system Parameters
Frame type
Steel tube suspension frame
Front shock
Upright front shock，L=540mm，non-adjustable
Rear shock
Common rear shock，L=270mm，non-adjustable
Swing arm
Steel swing arm
Handlebar
Steel handlebar
F/R rims
F:1.40×12，R:1.85×10；Steel rims
F brake system
hydraulic brake system ，brake disc:Φ190mm
R brake system
hydraulic brake system ，brake disc:Φ190mm，Downward brake pedal
Others
Air filter type
Sponge filter core filter type
CONTROL
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FRONT DISC BRAKE
hand brake lever
front brake calipers
The front disc brake is controlled by the hand brake
lever, which is fitted on the right side of the handlebar
and functioned by the pinching the lever with your right
hand.
The front wheel adopts the floating-caliper disc brake,
which is installed under the left front shock and fixed
by two bolts.
THROTTLE LEVER
throttle lever
Turn the handle counterclockwise to increasing the
engine. It will back to normal smoothly once you
release the handle.
STARTING
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start button
The start button is a round yellow one and fitted on the
right side of the handlebars, near the throttle grip.
It needs long press on the button when starting.
Attention ： When starting, you should pinch the brake
with your left hand to prevent sudden starting when the
transmission is I gear.
Attention ： There should have fuel in the fuel tank
before starting the engine, and the fuel tank switch
should be in the open position.
STOPPING
stopping button
The stopping button is round red one and fitted on the
left side of the handlebar near the grip.
It needs long press on the button when stopping.
FUEL TANK SWITCH
fuel tank switch
The fuel tank switch is located on the bottom left side
of the fuel tank. By turning the switch, you can control
the entrance of the fuel into the carburetor, so as to
achieve the control purpose.
The meaning of symbols on the oil tank switch is
shown as the left picture.
“OFF”: indicates that the switch is closed, and the oil
discharge is stopped.
SHIFTING
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gearshift
The gearshift is located on the left side of the engine,
which is functioned by stepping on and hooking on the
shift lever.
2021 TS90 has engage four speed transmission.
REAR DISC BRAKE
foot brake pedal
The foot brake pedal is located on the right side of the
engine and is functioned by stepping.
Note ： In actual use, the brake operation should be
mainly through foot brake, use hand brake as a
supplement.
rear brake caliper
The rear brake adopts a floating clamp disc brake,
which one is located on the right side of the rear wheel
and fixed by a disc brake bracket.
PARKING SUPPORT
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2021 TS90 use a single side stand for parking. It locate
on the left side of the motorcycle. when using,
straighten the vehicle, kick the single stand to expend
it, and lean the motocycle to the left until its weight rest
on the side stand.
PREPARING FOR USE
ADVICE ON FIRST USE
1. Before your first trip, read the entire operating instructions carefully, especially the section of
“Controls” and “Riding Instructions”.
2. When driving, please carry out a standardized run-in first.
3. If any parts problems are found during using, you can repair that according to this manual or
contact KAYO Dealers for professional aid.
4. After each use, clean the vehicle with running water.
5. Do not drive in inclement weather (e.g. rainstorm, blizzard, etc.) unless necessary.
6. KAYO is not responsible for any vehicle problems caused by malicious acts.
RUN-IN PROCESS
Motorcycle engines have a lot of relative moving parts, such as pistons, piston rings, cylinder
blocks, meshing transmission gears, etc. Therefore, in the initial stage of use, the engine must be
standardized. The 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 larger loads. Only after standard
running-in can the engine have excellent performance and reliability.
The recommended running-in steps are as follows:
1. 0-2.5h stage: Using under the throttle level of 50% ~ 75%, the speed should be changed
frequently to avoid the motorcycle working at the same condition for a long time,
Let the engine rest and cool down for 5 ~ 10 minutes after each 1-hour work.
Do not accelerate suddenly to protect your throttle.
2. 2.5-4h stage: Using under the throttle level of 50% ~ 75% throttle and work for a long time at
the same condition.
In actual working, the throttle can be up to full level, but not more than 5 ~ 10 seconds;
3. 4-5h stage: Using under the throttle level of 75% ~ 100%
4. More than 5h: increase the speed to 50 ~ 60km/h, until the engine performance can be fully
played.
DANGER ： When riding a motorcycle, please do not speed up regardless of the consequences, this
behavior is easy to cause engine damage and causing safety accidents therewith.
So, please ride the vehicle properly.
RIDING INSTRUCTIONS
PREPARATION BEFORE RIDING
1. Check fuel level in fuel tank and replenish if necessary.
2. Check fluid level in hand brake fluid reservoir and replenish if necessary.
3. Check fluid level in foot brake fluid reservoir and replenish if necessary.
4. Check brake pad wear condition at the hand brake clamp system.
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5. Check brake pad wear condition at the foot brake clamp system.
6. Check braking system operate condition.
7. Check the chain.
8. Inspect rear sprocket, engine sprocket and chain guide structure.
9. Check the chain adjuster.
10. Check the outer surface of the tire.
11. Check tire pressure.
12. Check battery level.
13. Check the thickness of the front disc brake.
14. Check the thickness of the rear disc brake.
15. Check the torque of each fastener.
16. Check the engine gear.
17. Check cover parts.
18. Check the fuel tank switch.
19. Check protective apparels are all-ready worn.
PRECAUTIONS FOR STARTING
The steps of electric ignition are as follows:
1. Turn the oil tank switch to the "ON" position;
2. Open the electric lock;
3. Pinch the brake lever with the right hand;
4. Long Push the ignition switch with the fingers of the left hand;
5. Release the ignition switch after the engine works properly
That’s all for starting.
The steps of kick ignition are as follows:
1. Turn the oil tank switch to the "ON" position;
2. Pinch the brake lever with the right hand;
3.Tramp the foot starting rod vigorously with the right foot;
4. The engine works properly.
That is all for starting.
PRECAUTIONS FOR STOPPING
1. Check the condition of the vehicle and the rider’s Equipment before starting off.
2. Speed up slowly when just starting off.
3. Start in gear “1” for ensure safety.
PRECAUTIONS FOR TURNING
1.Take care to slow down in advance when turning.
2.Lower your center of gravity to reduce the risk of side rolling when turning.
3. Do not shift gears when turning.
PRECAUTIONS FOR ACCELERATION
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1.Do not accelerate in the corner
2. Remember to shift gears after acceleration
PRECAUTIONS FOR SHIFTING
1. Do not accelerate when shifting gear
2. Do not shift gears in the corner
PRECAUTIONS FOR BRAKING
1. Use foot brake as your first brake operation, if necessary, use hand brake as a supplement.
2. Check fluid lever in the brake fluid reservoir frequently
3. Replenish the brake fluid reservoir if necessary according to the procedure in the manual
PRECAUTIONS FOR STOPPING & PARKING
1. Slow down gradually to 0 and then stop, do not make an emergency brake
2. Slowly lean the motorcycle to the left until its weight rests on the side stand.
3. Shift the gear to “N” before stopping.
4.
5.
SUGGESTED INSPECTION TIME FOR ALL PARTS OF THE VEHICLE
every 30 hours
every 20 hours
every 10 hours/after every race
1 hour after each ride
●● Check the front disc brake plate ●●● Check the rear disc brake plate ●●● Check the front and rear
disc brake discs ●●● Inspect brake tubing for damage or leakage ●●● Check the rear disc brake fluid
level ●●● Check the free-play of the brake pedal ●●● Check the frame ●●● Check the top of the shock
absorber ●●● Check the shock absorber connecting ●●● Check tire surface condition ○●●●Check and
charge the battery
Check tire
pressure○●●●Check hub bearings for
To ensure the best driving characteristics of the vehicle
and avoid damage to swingarm, shock absorbers,
linkage and frame, the basic setting of the suspension
components must match the driver's weight.
The total standard rider mass of the 2021 TS90 off-road
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