KAYO MOTOR AU110, Maintenance Manual

Page 1: ...ZHEJIANG KAYO MOTOR CO LTD WWW KAYOMOTO COM AU110 model Maintenance Manual...

Page 2: ...nd adjustment process disassembly and installation notes inspection and maintenance points trouble shooting methods and maintenance technical data also with graphical data Please read the manual caref...

Page 3: ...Chapter 3 Body and Covering Chapter 4 Regular Maintenance and adjustment Chapter 5 Places around engine Chapter 6 Engine Appendix Electrical schematic diagram ZHEJIANG KAYO MOTOR CO LTD All contents i...

Page 4: ...ual may doesn t contain some potential risks in engine work and maintenance so besides the above explanations the service operator should also have basic mechanical knowledge If the operator is unsure...

Page 5: ...ive it is strictly prohibited to set off fireworks in the work site Pay attention to sparks as well as open flames Besides the vaporized gasoline may explode please choose well ventilated sites 6 Atte...

Page 6: ...and dimensions outwards 14 Let the chamfered side towards force direction when install the rectangular ring Do not use the ring without elasticity After assembly rotate the rectangular ring to confirm...

Page 7: ...ous operation under the condition of 1 2 throttle the speed should be changed frequently and it is not recommended to operate for a long time with a fixed throttle position Cool the engine for 5 to 10...

Page 8: ...ar height mm 855 3 Handlebar width mm 675 4 Rear height mm 740 5 Ground clearance of seat mm 665 6 Min terrain clearance mm 115 7 Wheelbase mm 910 8 Front track mm 840 9 Rear track mm 870 10 Turning r...

Page 9: ...matic clutch 16 Gearshift method 1 1shiftear with foot with reverse gear 17 Gear range 1 forward gear 1 reverse gear 18 Shift type R N D 19 Reduction ratio Forward gear D Reverse gear R Primary Gear h...

Page 10: ...0 055 mm 0 12 mm 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 Cooling device without Wheel front and rear w...

Page 11: ...ing crank connecting link see engine section 1 5 Tightening moment of fastener Note When installing threads please manually attach 2 3 turns of thread first Tightening moment at specified position who...

Page 12: ...gine section Engine service tool see engine section Engine special tool see engine section 1 6 lubricating grease and sealant No Position Effect Grease 1 Dust cap for rocker arms lubrication XHP222 2...

Page 13: ...ZHEJIANG KAYO MOTOR CO LTD 10 Main cable Oil tube for front brake Throttle cable Oil tube for rear brake Damper cable...

Page 14: ...G KAYO MOTOR CO LTD 11 Positive pole Negative pole Magneto connector Gear indicator Voltage regulator Headlight Functional switch Electrical lock Reverse gear display Neutral display Stop switch Brake...

Page 15: ...ZHEJIANG KAYO MOTOR CO LTD 12 CDI Ignition coil Voltage stabilizer Rear light...

Page 16: ...Check if the seat is installed in place and firm 2 3 2 Front rack Disassembly Disassemble the mounting bolts from rack 1 left and right each one Disassemble front rack 2 Installation Take it back in r...

Page 17: ...rried out by referring to this chapter Pipe inhaul cable should be equipped according to wiring diagram of cable hosepipe and inhaul cable 3 2 Installation torque M8 bolt 18 25N m TM6 bolt 7 11 N m M6...

Page 18: ...from accelerator cap to remove the throttle cable 7 Dismounting fixed bolt then the lower raiser remove handlebar at last Installation Take it back in reverse order from disassembly then check if it...

Page 19: ...Disassembly 1 Disconnect electric plug neutral indicator plug reverse indicator plug and headlight plug 2 Disassemble plastic parts fixing bolts 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 3 Twist the oil cap remov...

Page 20: ...uch the engine when the engine just stops working If it must be please wear long sleeves work clothes and gloves As gasoline is flammable and explosive it is strictly prohibited to set off fireworks i...

Page 21: ...ng flexibility Steering system Damage Installation status of steering system Ball pin shaking Braking device Brake pedal Pedal travel Braking effect Connecting rod and oil pipe Slackness looseness and...

Page 22: ...Chain flapping 20mm Flywheel chain wheel Transmission and lubrication tightness of fixing bolt If chain wheel and chain wear severity replace it Electrical device Ignition device State of spark plug...

Page 23: ...d by steering column or other parts then repair If it s caused by steering column fastening the lock nut on steering column or you can also disassemble the steering column Keep vehicle in steady place...

Page 24: ...ote When adding brake fluid do not mix with dust and water In order to prevent chemical changes please choose the specified brand of brake fluid As brake fluid will damage the plastic and rubber surfa...

Page 25: ...osition and measure the size of the front wheel toe in The front wheel relative to the forward direction of the vehicle is A in front and B behind the wheel Toe in size B A 4 10mm If not in this range...

Page 26: ...horizontal position and compress up and down for several times according to the pictures If there is shaking or abnormal sound check whether there is oil leakage in the shock absorber and whether the...

Page 27: ...nd bends and replace with a new one if there is any damage 4 8 Throttle check Check the free stroke of the throttle button Press the accelerator several times according to the direction shown in the d...

Page 28: ...Inspect the thread length limit of speed limit screw Thread length a 25mm Adjustment Loosen the lock nut then adjust it with a phillips screwdriver Note For beginners the speed limiter should be in a...

Page 29: ...s Before operation and maintenance please ensure that the vehicle is shut down and static for no less than 1 hour and make sure that the heating parts are cooled so as to avoid injury Do not damage th...

Page 30: ...line is flammable fireworks are strictly prohibited in workplace Not only open fire but also electric spark shall be given high attention Besides as there is a risk of explosion after the evaporation...

Page 31: ...lation Installation shall be in the reverse order of removal Make the exhaust pipe connect with the connector head and clamp connect with pipe groove 5 4 Exhaust system Disassembly Disassemble the con...

Page 32: ...at once 5 5 Disassembly and installation of engine Disassembly Note Remove pedal first 1 Remove the engine side cover retaining bolts 1 first then remove chain 2 Remove the ground lead gear indicator...

Page 33: ...Hg 133 322Pa 0 133322kPa Torque 1kgf m 9 80665N m Volume 1mL 1cm3 1cc 1L 1000cm3 Moment 1kgf 9 80665N Danger warning attention Take it seriously it s important for maintenance Danger Be on high alert...

Page 34: ...nment oil replacement parts can t be disposed Warning If parts need to be replaced during maintenance please choose parts which recommended or provided by Kayo Disassembled parts that need to be reuse...

Page 35: ...s use it can make the moving parts to adapt to each other correction work form good heavy load to bear a smooth friction surface Through this process the engine will has excellent performance and reli...

Page 36: ...ation Replace Replace once per 2000km Filter media Clean Clean Clean Clean Timing chain Check Adjust Adjust Adjust Carburetor idle speed Adjust Adjust Adjust Adjust Drive chain Adjust and lubricate pe...

Page 37: ...mble assemble and maintain cylinder head Right view of the 125 engine is shown in the figure Left view of the 125 engine is shown in the figure Remove the lock nut of cylinder head from its holding pl...

Page 38: ...he fixing bolt of left cover Remove left cover and inspect the paper pad for damage Replace if necessary Dismantle the fixing bolt of right cover Remove the right cover of cylinder head Inspect the ga...

Page 39: ...LTD 36 Remove inlet exhaust valve cap Check the state of seal ring of valve cap and replace if worn or if reuse is questionable Remove the fixing bolt of timing driven sprocket Remove the connecting...

Page 40: ...ove cylinder head assembly Remove timing driven sprocket Inspect the timing driven sprocket for wear and damage Replace if necessary Check whether there is excessive carbon deposit in combustion chamb...

Page 41: ...exhaust pipe to inspect the seal condition Grind the valve and valve seat if there is gasoline leak into the combustion chamber Remove inlet exhaust valve spring and check the state Replace if necess...

Page 42: ...ZHEJIANG KAYO MOTOR CO LTD 39 Remove the spark plug to clean the carbon Deposit and dust Check the spark plug gap and set it to 0 6 to 0 7 if necessary...

Page 43: ...linder head and cylinder The engine starts hard or fails to start Insufficient engine output Engine speed changes during idle run Grind the cylinder head end surface or replace the cylinder head There...

Page 44: ...d or fails to star Remove the carbon deposit between the electrodes Excessive carbon deposit or oil dirt in the spark plug Weak or no sparking from the spark plug electrodes The engine starts hard or...

Page 45: ...dowel pin to check for wear and damage Replace if necessary Dismantle the fixing bolt of timing chain of guide wheel Remove the guide wheel of timing chain to inspect for wear and damage Replace if ne...

Page 46: ...Remove the piston of piston pin to check whether it is damaged Replace if necessary Inspect the paper pad for worn or damage Replace if necessary Check whether there is residual gasket on cylinder Cle...

Page 47: ...inner wall Replace if worn or if reuse is questionable Check whether the internal diameter has exceed the limit value Measure the diameter form upper middle and lower position The limit value is 50 05...

Page 48: ...the cylinder and cylinder head The engine starts hard or fails to start Insufficient engine output poor idle speed and high fuel consumption Grind cylinder end surface or replace the cylinder body Th...

Page 49: ...alf Check whether the oil seal of starting shaft and seal edge of gearshift lever are worn Replace if necessary Check the state of right crankcase cover and replace if necessary Left view of right cra...

Page 50: ...y Left view of left crankcase is shown below and check whether the oil seal of counter shaft and oil seal edge of gearshift lever are worn Replace if necessary Right view of right crankcase half is sh...

Page 51: ...ZHEJIANG KAYO MOTOR CO LTD 48 Remove the neutral indicator and check the state Replace if necessary Dismantle the fixing bolt of magneto stator and remove the...

Page 52: ...ZHEJIANG KAYO MOTOR CO LTD 49 Check the condition of left crankcase cover and replace if necessary...

Page 53: ...air the threaded or replace the crankcase The bolt of the cylinder is broken The same as front The same as front Replace the cylinder bolt The oil seal is damaged or the oil Oil leakage is ineffective...

Page 54: ...ot to forget the washer of main shaft and counter shaft when removing the left crankcase Remove the paper pad to inspect for wear and damage Replace if necessary Remove the connecting rod assembly Ins...

Page 55: ...pin using a micrometer Replace the piston pin if the value is over the maintenance limit value Check the axial and radial jumping of connecting rod bearing Replace the conrod if the jumping is large...

Page 56: ...ecessary Check the state of piston and replace if worn or if reuse is questionable Measure diameter of piston skirt Replace it if the value is beyond the maintenance limit value Assemble the piston ri...

Page 57: ...ufficient engine output Thick blue and white fume form the exhaust muffler pipe Replace the piston The piston pin hole is over worn Excessive fitting clearance between the piston ring and the hole Str...

Page 58: ...ctin g rod The connecting rod small end hole is over worn The fitting clearance between the piston pin and the small end is too wide Striking sound of the piston and of the cylinder Replace the connec...

Page 59: ...t exhaust valve and check the state Remove the timing cam rocker arm rocker arm shaft to inspect for worn Replace if necessary Remove the circlip of inlet and exhaust valve Remove inlet vale stem and...

Page 60: ...nspect for wear and damage Note when assemble the valve spring make sure its dense end downward Check the external diameter of valve stem using a verier clipper Replace the valve stem if the valve is...

Page 61: ...ve stem is distored Replace if necessary Inspect the timing camshaft bearing for wear and check the state of camshaft Replace if necessary Check the gap of rocker arm shaft and rocker arm Replace the...

Page 62: ...ometer Replace the rocker arm shaft if the valve is beyond the maintenance limit valve Remove the guide wheel of timing chain to inspect for wear and damage Replace if necessary Remove the fixing bolt...

Page 63: ...pect for wear and damage Replace if necessary Remove the oil tube and spring and check the state Replace if necessary Remove the small timing chain and check the state Replace if necessary Adjust valv...

Page 64: ...djust if necessary Set the valve clearance of rear cylinder to 0 05mm 0 06mm For the troubleshooting of engine distribution mechanism please refer to the followingtable Maintenance of Distribution Mec...

Page 65: ...shaft Valve The valve clearance is too small The valve is impossible to close completely The engine starts hard or fails to start Insufficient engine output Engine speed changes during idle run Readj...

Page 66: ...ed It is impossible to fit the valve and the valve seat tightly The engine starts hard or fails to star Sound of the cylinder head Replace the valve spring 6 6 Disassemble assemble and maintain carbur...

Page 67: ...ce if necessary Remove the throttle and oil needle and check the condition replace if necessary Check the state of float case and replace as necessary Adjust the height of float case by moving the flo...

Page 68: ...air if necessary Remove the idle jet and check for plugged Clean the jet with compressed air if necessary Dismantle the mixture adjustment screw and inspect for worn Replace if necessary Adjust mixtu...

Page 69: ...e becomes dilute and if falls it becomes thick 6 7 Maintenance of Intake Exhaust System 6 7 1 Disassemble assemble and maintain intake system Remove the air filter snap ring then take air filter out R...

Page 70: ...suction noise is too loud Replace the filter element 6 8 Disassemble assemble and maintain exhaust system Dismantle lock nut of muffler Dismantle suspension bolt of muffler to check whether the suspe...

Page 71: ...environmental protection Maintenance of Exhaust Muffler valve Inspect the lock nut for tightness and tighten as necessary Description Damage form Trouble Cause Correction Exhaust pipe gasket The gaske...

Page 72: ...r pump and check the state of air pump Replace the air pump if it is worn or if reuse is questionable Remove the secondary inlet air cleaner and inspect for wear and damage Clean and replace if necess...

Page 73: ...ir pump broken defective air pump Emission fails Replace air cleaner air cleaner damaged or plugged defective air cleaner Emission fails to meet the standard Replace connecting hose connecting hose ge...

Page 74: ...ZHEJIANG KAYO MOTOR CO LTD 71 Remove left crankcase cover Remove gasket to check it s condition If the gasket is wearied or reusable please replace it Remove fixing bolts of stator and trigger...

Page 75: ...D 72 Check stator status with multimeter If wear and tear or re use problems please replace the new accessories Remove rotor fixing nut Remove rotor by special tools Remove rotor to check magnetism ne...

Page 76: ...ng bolt Remove clutch to check the weary and damage condition of clutch seat pulley and spring If it necessary replace it Check the weary damage condition of drive sprocket and transmission gear If it...

Page 77: ...TD 74 Dismount tension band of clutch and check the condition If it wearied or reused replace it Remove the snap ring from start motor sprocket Disassemble the drive sprocket and chain Dismount the fi...

Page 78: ...TD 75 Disassemble start motor Check the start motor winding if it necessary replace it Disassemble the oil separation disc and check the condition if it necessary replace it Check oil seal edges for w...

Page 79: ...cient rotation force Replace carbon brush spring Armature commentator surface is fouled Starter motor has insufficient rotation force Clean the commentator surface with gasoline or alcohol Armature co...

Page 80: ...ZHEJIANG KAYO MOTOR CO LTD 77 Circuit diagram...