KAYO MOTOR JACKAL 200 User manual

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Model A200
JACKAL 200
Service Manual

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Introduction
This manual contains detailed information for Kayo A200 (ATV), maintenance,
adjustments, disassembly, installation, inspection points and specifications.
Please read the manual carefully and follow the instructions closely when performing
inspections and repairs, this will increase the reliability, performance and overall
lifespan of the vehicle .
All contents in this manual are subject to improve and
update without notice.

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Content
Chapter 1; Maintenance information
Chapter 2: Plastics and Body parts
Chapter 3: Regular Maintenance and adjustment
Chapter 4: Outer parts of engine
Chapter 5: Engine internals
Appendix: Electrical schematic diagram
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Conversion table
Item
Unit conversion
pressure
1kgf/cm2=98.0665kPa；1kPa=1000Pa
1PSI=0.0689kgf/cm2
1mmHg=133.322Pa=0.133322kPa
Torque
1kgf·m=9.80665N·m
volume
1mL=1cm3=1cc
1L=1000cm3
Moment
1kgf=9.80665N
Length
1in=25.4mm
Danger/warning/attention
Take the the following warnings seriously, it’s important for regular maintenance,
especially important during engine maintenance.
Danger: Be on high alert for danger.
Warning: Be on alert for moderate danger.
Attention: Be on alert for minor danger.
This manual may contain some potential risks when performing engine work and
maintenance, Please pay close attention to the above explanations, Service technician
or mechanics should have basic mechanical knowledge before performing any
service, maintenance, or inspection.
Service Information
1.1 Warnings 1.5 Torque tightening
1.2 VIN Number 1.6 Lubricant, sealant
1.3 Main parameters list 1.7 Cable, hose and wiring diagram
1.4 Maintenance parameters list

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1.1 Safety precautions
Safety first
1. Wearing work clothes (coveralls), hat and safety boots suitable for the operation.
In some conditions safety glasses, dust masks, gloves and other safety protective
supplies are needed to protect you from injury.
2. Do not run the engine in unventilated places.
3. To prevent burns, do not touch the engine or exhaust until cooled.
4. Battery solution (dilute sulfuric acid) is a strong corrosive agent; contact with the
skin, contact with eyes may cause blindness. If the battery solution accidentally
touches clothes or skin, rinse immediately with clean cold water. If the battery
solution is touches eyes, please flush immediately with plenty clean cold water and
get medical treatment as soon as possible. Battery and battery solution should be kept
out of reach of children. Battery charging will produce flammable and explosive gases,
if exposed to a source of fire or spark there is a risk of explosion or fire. Please charge
in well-ventilated places.
5. As gasoline is flammable and explosive. Pay attention to sparks as well as open
flames. Vaporized gasoline may explode if exposed to open flame or sprks , please
choose well-ventilated areas away from these hazards when refueling.
6. Attention, the rear wheel, clutch or sprockets and other rotating parts and
movable parts as hands and clothes may be caught during maintenance.
Disassembly and installation precautions
1. All Parts, lubricants oils and fluids must be Kayo brand parts or Kayo recommends.
2. During disassembly, Please sort and separate out the parts and fasteners of each
system to ensure that everything is put back together properly.
3. Clean the vehicle or parts to be serviced before inspection.
4. Gaskets, o-rings, piston pin, piston ring, cotter pin and other one time use parts
must be replaced after disassembling.
5. Snap rings can be deformed if opened too much during disassembly. DO NOT
re-use deformed snap rings.

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6. After disassembly and inspection, clean parts and blow the cleaning agents away
with compressed air before measuring. Grease the moving surfaces before assembly.
7. During disassembly, check all the necessary specifications and measure according
to directions in this manual. Make sure measurements and conditions are within
specification.
8. Bolts, nuts, screws and other fasteners shall be pre-tightened and then tightened in
accordance with the specified torque in a diagonal sequence. From large to small, and
from inside to outside.
9. Inspect all rubber parts during disassembly and replace if necessary. In addition, as
some rubber pieces are not resistant to corrosive materials, please keep them from
contacting volatile oils, grease, or liquids.
10. Pack or inject recommended grease in specific places as stated in service manual .
11. Use special tools when needed for disassembly and installation.
12. Ball bearings can be rotated with finger to confirm whether the rotation is flexible
and smooth.
Bearing axial and radial clearance is oversized.
Clean and grease bearings with a tight spots when rotated. If the bearings still feel
stuck after cleaning, replace. If the bearings can’t be cleaned, replace.
If the bearing is a press fit, and becomes deformed after disassembling, replace it.
13. Bearings should be lubricated or packed with grease before assembly. Take note
of the direction of installation when assembling. When installing open or double-sided
dustproof bearing, make the manufacturer's logo and dimensions outwards.
14. Let the chamfered side towards force direction when install the Snap-ring. Do not
use the rings without elasticity. After assembly, rotate the snap-ring to confirm that it
is firmly installed in the slot.
15. It’s important to check that all fastening parts are tightened and that functions are
normal after assembling.
16. Brake fluid and coolant can damage surfaces, painted parts, plastic parts, rubber
parts, etc., do not let brake fluid contact to these parts, If brake fluid contacts these

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parts rinse and dilute with water immediately.
17. When installing oil seals manufacturer’s mark and sizes face outward.
Check the oil seal before using.
Grease the oil seal lip before assembly.
18. When installing rubber hose parts, insert the rubber pipe into the fitting . If there is
a hose-clamp, install the hose-clamp in the hose indentation. Replace rubber hoses if
dried, cracked, or deformed
19. Clean all gasket material from surfaces of before installing new parts or
reassembling.
20. Do not bend cables excessively. Kinked or damaged cables may cause poor
response and inner cables to fray and eventually break.
21. When assembling any protective caps, covers or boots make sure they are seated
correctly in the respective grooves.
Break-in of engine
Proper Engine break in is necessary on new engines and newly rebuilt engines
to help ensure that longevity and reliability of the engine components.
Recommended break-in time is 20 hours, as follows:
0~10 hours: Operate at no more than ½ throttle, keep gear changes and speed
variances to a minimum. Do not operate for extended amounts of time with a fixed
throttle position. Let the engine cool for 5 to 10 minutes after each hour of operation.
Avoid quick acceleration.
0~20 hours: Operate at no more than 3/4 throttle, Do not operate for extended
amounts of time with a fixed throttle position. Change gears and vary speeds as
necessary. Let the engine cool for 5 to 10 minutes after each hour of operation. Avoid

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quick acceleration.
Note:
During break-in period, do everyday maintaining, and eliminate hidden trouble in
time.
Break-in period ended, make a maintenance for the vehicle, then putted into
formal use.
1.2 VIN Number
Model
A200
VIN number
Engine number
1VIN number
2Name plate
3Engine number
1
3

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1.3 Specifications, Model information
No.
Item
1
Brand
KAYO
2
Type
A200
3
Name
200cc UtilityATV
4
Company
ZHEJIANG KAYO MOTOR CO., LTD.
● Dimensions, Vehicle Specifications
1
Dimension（L*W*H）（mm）
1700*1050*1080
2
Handlebar height（mm）
1080
3
Handlebar width（mm）
860
4
Rear height（mm）
1010
5
Ground clearance of seat（mm）
830
6
Min. terrain clearance（mm）
120
7
Wheelbase（mm）
1100
8
Front track（mm）
860
9
Rear track（mm）
790
2

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10
Turning radius（mm）
2500
11
Turning angle（degree）
38°±2°
12
Net weight（Kg）
155
13
Curb weight（battery+fuel）（ Kg）
164.8
14
Max. Speed Km/h
70（limited speed）
No.
Item
1
Start type
Electric
2
Engine type
Single cylinder, four stroke, air cooling
3
Distribution
SOHC/by chain
4
Cylinder diameter × mileage
65X59mm
5
Compression ratio
9.2:1
6
Lubrication mode
Combination splash and pressure feed
7
Fuel pump
Rotor
8
Lubricating oil and filter
Complete filtrate, sponge filter
9
Oil brand
10W/40-SJ
10
Cooling type
Natural cooling
11
Cooling liquid
/
12
Air filter type
Sponge element
13
Carburetor
SG30·VM26· choke switch reinforce.
14
Tank volume
6L

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15
Clutch type
Manual
16
Gear change
1+5 by foot
17
Gear range
Step on rear direction to add gear and front
to reduce.
18
Shift type
R~N~1-2-3-4-5
19
Reduction
ratio
Forward gear
1-2-3-4-5
Reverse gear R
Primary
Gear hub of clutch/primary gear
Single-stage
Gear ratio of
forward gear
Gear ratio of
forward gear
Overall
●Frame
20
Drive sprocket ratio
45/14
21
Output type
Chain drive, rear wheel drive
22
Brake type
Front and rear disc
23
Suspension type
Freestanding double rocker
24
Frame type
Steel tube and steel plate welded type
●Engine Specifications
●Lubricating device
Item
Standard
Limitatio
n
Engine oil
capacity
Change oil
800mL （No oil filter element replaced
）
－
Change oil
800mL （replace the oil filter element）
Full capacity
800mL
－

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Recommended engine oil （ see original
）
·four-strokesmotorcycles SAE-15W-40
For replacements, it must be within
following scope:
· APIclassification ： SGor upper grade engine
oil
· SAE specification ： refer to left table
Oil
pump
rotor
Radial clearance of inner and
outer rotors
0.07 mm～0.15mm
0.2mm
Radial clearance between outer
rotor and pump body
0.03 mm～0.10mm
0.12mm
Axial clearance between rotor
surface and pump body
0.023 mm ～ 0.055mm
0.12mm
Oil pressure
1500r/min ， 90℃: 200 kPa ~400kPa ，
General 240 kPa
6000r/min ， 90℃:600 kPa ~700kPa ，
general 600 kPa
●Air intake system（see engine section）
●Oil cooling device Mesh oil cooler
●Wheel (front and rear wheels)
Item
Standard
Limitation
Rim jump
Vertical
1.0mm
2.0mm
Horizontal
1.0mm
1.8mm
Tire
Tread
~
3.0mm
Air pressure
4.0 PSI
~
●Brake system
Item
Standard
Limitation

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Front brake（one
with two）
disc thickness
3.5mm
3mm
Brake handle
stroke
5~10mm
~
Braking force
400N*m
~
Rear brake
disc thickness
3.5mm
~
Brake handle
stroke
10~20mm
~
Braking force
500 N*m
~
●Ignition device
Item
Standard
Ignition method
CDI electric ignition
Sparking
plug
Type
Resistor type spark plug
Standard
ATR7C/（torch）
Gap
0.6~0.7mm
Spark character
>8mm, one bar
Spark advance angle
Ignition coil
resistance
Primary
0.43~0.57Ω
Secondary
10.1~11KΩ
Peak
voltage
Primary ignition
coil
>150V
Pulse
2V
●Light / Instrument / Switch

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Item
Standard
Relay insert fuse
15A
Light
Headlight
12V*55W*2
Taillight/brake
light
LED
Gear indicator
LED
●Valve mechanism + cylinder cover（see engine section）
●Cylinder + piston + piston ring + crank connecting link（see
engine section）
1.4 Tightening moment of fastener
Note: When installing threads, please manually attach 2~3 turns of thread first.
Torque Specifications chart
No.
Item
install position
Bolt
specification
Class
Moment
N*m
1
Engine
Rear power bolt
M10
10.9 class
37~50
2
Up power bolt
M8
10.9 class
37~50
3
Down power bolt
M10
10.9 class
37~50
4
Suspension
Front bolt
M10*1.25
8.8 class
35~45
Rear bolt
M12*1.25
10.9 class
37~50
5
Axle of upper
M10*1.25
10.9 class
37~50

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rocker arm
6
Rear rocker arm
bolt
M10*1.25
10.9 class
58~71
7
Fork axle
M16*1.25
10.9 class
50~60
8
Brake
Rear disc
M8
8.8 class
18~25（with
blue thread
sealants）
9
Front disc
M8
10.9 class
15~20
10
Disc pump
M8
10.9 class
29~35
11
Front brake tee
M8
8.8
18~25
12
Rear axle
Rear axle
M12*1.25
8.8
55~65
13
Nut
M27*1.5
80~90
14
Chain bolt
M6
8.8
8~12
15
Turning
Clamp locking bolt
（hexagon）
M8
10.9
18~25
16
Steering column
locking
M10*1.25
8.8
18~25
17
Bolt of lower raiser
M10*1.5
10.9
50~60
18
Electrical
elements
Battery box
M6
8.8
7~11
19
Muffler
installation
M8
8.8
15~20
20
Voltage regulator
ignition coil
M6
8.8
7~11
21
Oil tank,
Oil tank
M8
8.8
7~11

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22
body parts,
plastic
Oil tank switch
M8
8.8
18~25
23
Pedal
M8
8.8
8~12
24
Reinforced pedal
TM6
7~11
25
Plastic screw
ST4.2
3~5
●Tightening moment at specified position - engine（see engine
section）
●Engine service tool（see engine section）
●Engine special tool（see engine section）
1.5 lubricating grease and sealant
No.
Position
Effect
Grease
1
Dust cap for rocker arms
lubrication
XHP222
2
Ball joint of rocker arms
3
Steering column bottom
4
Joints of knuckle and wheel
hub
5
Installation axle for rear fork
6
Inner sleeves of rear fork
7
Rear axle liner pipe
8
Rear axle bearing and oil seal
9
Steering column clamp

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Note: please coat inside of handlebar grip with grip glue before
installing.
Engine operating materials and installation accessories (see engine
section) Engine operating materialsinclude lubricating oil (engine oil), Grease andmay
require thread sealant orthread lock.
1.6 Cable and hose routing
Main
Harness
Brake pipe
Throttle cable
Damper cable
Clutch cable

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headlight
Electric lock/ Key
switch
For clutch switch
Reverse gear indicator
(analog models)
Neutral gear connector
(analog models)
Headlights
combination switch
connector
Voltage regulator

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Regulator/rectifier
Tail light
Igntition
coil
Relay connector
Battery positive
Ignition
Battery negative
Start motor cable
Brake light
switch connector
Rear light connector

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2 Plastic body
2.1 Maintenance warnings
2.2 Installation torques
2.3 Seat, front guard, hood, rear body, left and right guard, plastics foot guards,
dismounting left and right footpegs
2.1 Maintenance cautions
Operation cautions
1. When replacing plastics parts, please install new warning labels, stickers and
riveted tags to the new plastics.
2. This chapter is about the dismounting the body plastics.
2.2 Installation torque
M8 bolt：18~25N*m
TM6 bolt：7~11 N*m
M6* bolt：8~12 N*m
2.3 Hood, handlebar, seat, plastic parts ( rear body, front body and
middle guard), front guard, plastic pedals
2.3.1 Hood
Disassembly
1. Remove the bolts 1 and 2. 2. Push down and gently pull the hood
forward to remove. (Be careful as the
tabs are easy to break)