KAYO MOTOR STORM 150, Service Manual

Page 1: ...ZHEJIANG KAYO MOTOR CO LTD WWW RIDEKAYO COM Model A150 STORM 150 Service Manual...

Page 2: ...ents 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 r...

Page 3: ...ontents 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...

Page 4: ...e 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 Attentio...

Page 5: ...e 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 child...

Page 6: ...o 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 nee...

Page 7: ...d 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 Engine Break in Proper Engine break in...

Page 8: ...O MOTOR CO LTD WWW RIDEKAYO COM schedule After Break in period is complete schedule the unit for an inspection and service 1 2 VIN Number Model STORM 150 A150 VIN number Engine number 1 VIN number 2En...

Page 9: ...LTD Dimensions Vehicle Specifications 1 Dimension L W H mm 1535 920 950 2 Handlebar height mm 930 3 Handlebar width mm 730 4 Rear fender height mm 700 5 Seat height mm 705 6 Min ground clearance mm 90...

Page 10: ...inder diameter mileage mm mm 57 56 5 Compression ratio 9 2 1 6 engine weight kg 21 7 Max Power kg rpm 8 2 8000 8 Max torque N m rpm 8 0 5500 9 Ignition method CDI non adjustable ignition 10 Lubricatio...

Page 11: ...er 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 s...

Page 12: ...ressure 4 0 PSI Brake system Item Standard Limitation Front brake disc thickness 3 5mm 3mm Brake lever stroke 5 10mm Braking force 400N m Rear brake disc thickness 3 5mm Brake lever stroke 10 20mm Bra...

Page 13: ...e fuse 15A Light Headlight E4 35W Taillight brake light LED Gear indicator Digital Valve mechanism cylinder cover see engine section Cylinder piston piston ring crank connecting link see engine sectio...

Page 14: ...8 8 35 45 7 Rear swing arm bolt M10 1 25 10 9 58 71 8 Shock bolts M12 1 25 8 8 50 60 9 Brake Rear disc M8 8 8 18 25 with blue thread sealants 10 Front disc M6 10 9 15 20 with blue thread sealants 11...

Page 15: ...coil M6 8 8 7 11 21 Fuel tank body parts plastic fuel tank M6 8 8 7 11 22 fuel tank switch M6 8 8 7 11 23 Pegs floorboards M8 8 8 18 25 with blue thread sealants 24 Brush guards M6 8 8 8 12 25 Plastic...

Page 16: ...bolts swing arm a arms 6 Bushings Bearings 7 Rear axle liner bushings tubes 8 Rear axle bearing and oil seal 9 Steering column clamp Note please coat inside of handlebar grip with grip glue before in...

Page 17: ...ZHEJIANG KAYO MOTOR CO LTD WWW RIDEKAYO COM Main Harness front brake line Combination switch wires Choke cable Throttle cable Brake light switch wires...

Page 18: ...switch Neutral gear connector analog models Gear indicator connector Digital indicator models combination switch connector Electric lock Key switch Starter Relay Reverse gear indicator analog models...

Page 19: ...ZHEJIANG KAYO MOTOR CO LTD WWW RIDEKAYO COM Ignition coil Voltage regulator Rear light Brake light switch connector...

Page 20: ...ZHEJIANG KAYO MOTOR CO LTD WWW RIDEKAYO COM Stator ignition pickup gear indicator connector Ground cable...

Page 21: ...nance 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 plast...

Page 22: ...and 2 note replace hood plastic if any of the tabs broke during disassembly 2 3 2 Handlebar Disassembly 1 Cut off power first disconnect battery 2 Cut plastic cable ties then disconnect the combinati...

Page 23: ...1 after install make sure to double check electrical connections wire cable and hose routing 2 3 3 Seat Disassembly Locate the seat latch under the seat Pull the latch to release Then pull and lift to...

Page 24: ...neously push down and forward until the latch locks into place 2 3 4 Front Bumper Disassembly 1 The mounting bolts in order Then remove the front bumper Installation 1 Position the front bumper lining...

Page 25: ...ody Disassembly 1 Disconnect all necessary electrical connectors 2 Disassemble plastic parts fixing bolts1 2 3 4 5 6 7 8 9 10 in order on both sides 3 Remove the plastic body note remove the handlebar...

Page 26: ...y check all electrical connectors cable and hose routing after installation 2 3 6 Middle guard Disassembly 1 Remove the mounting bolt 1 and 2 2 Remove the middle guard Installation Install in reverse...

Page 27: ...e the rear body off Installation Install in reverse order from disassembly Note replace locking nuts and rubber washers as needed 2 3 8 Front body Disassembly Note remove the handlebar hood and middle...

Page 28: ...COM Installation 1 Install in reverse order from disassembly Replace mounting bolts nuts and rubber washers as needed when worn check all electrical connectors cable and hose routing after installati...

Page 29: ...2 3 4 2 Remove the foot guard Installation Install in reverse order of disassembly Note replace mounting bolts nuts and rubber washers in time once they worn 2 3 10 Pedal Disassembly floorboard foot...

Page 30: ...hers in time once they worn 3 Regular maintenance and adjustment 3 1 Maintenance information 3 2 Maintenance period 3 3 Inspection ways 3 4 Steering column and brake system 3 5 Wheel 3 6 Suspension sy...

Page 31: ...period Engine maintenance is a regular periodic work due at certain time intervals for engine maintenance keeping up on standard maintenance will increase the lifespan and reliability of the component...

Page 32: ...Tear and damage of brake disc Replace the disc in time when front or rear brake working disc s thickness is less than 3mm Brake pad Tear and damage of brake pad The minimum brake pad friction plate t...

Page 33: ...smission and lubrication tightness of fixing bolt If chain wheel and chain wear severity replace it Electrical device Ignition device State of spark plug timing Battery Terminal connections Electric c...

Page 34: ...linkages ball joints or fastening hardware then repair If it s caused by steering column tighten the bottom lock nut on steering column or you can also disassemble the steering column to check bearing...

Page 35: ...0mm Brake pump assembly Check the fluid level at the sight glass on the master cylinder If brake is below the lower limit stop using the vehicle immediately and ispect for leaks at master cylinder hos...

Page 36: ...ads Check thickness of pads If it s less than 1 5mm replace Check for damage cracks and uneven wear Replace pad set if out of specification Note Replace pads in sets 3 5 Wheel With the atv on a jack o...

Page 37: ...place Note after the adjustment of front toe in drive the vehicle slowly and make sure vehicle tracks straight and true After test ride check measurement again to make sure toe in is locked into place...

Page 38: ...3 6 Suspension system Keep vehicle in a horizontal position and compress up and down several times according to the pictures If there is shaking or abnormal sounds check whether there is oil leakage i...

Page 39: ...s for aging dry rot cracks and damage Replace if any damages are found or if more than 2 years old 3 8 Throttle check Check the free stroke of the thumb throttle lever Press the accelerator several ti...

Page 40: ...YO COM Freeplay 3 5mm Adjust throttle free play if out of specification Pull back rubber sleeves 1 2 Loosen lock nut 3 and barrell adjuster 4 then adjust throttle free play to within specification Spe...

Page 41: ...le as much as possible for safety As the riders skills progress the limiter screw can be adjusted outward Throttle limiter is set from the factory with a tamper proof screw If necessary the screw can...

Page 42: ...injury To protect finishes please wrap the frame plastics or any vulnerable finishes before removing engine parts or performing maintenance on engine Please dispose of liquid such as oils and coolant...

Page 43: ...areas away form these hazards when refueling or working on the fuel system and its related components Fuel tank removal Remove the plastic body parts remove fuel lines from tank and fuel valve then re...

Page 44: ...nstallation Installation shall be in the reverse order of removal Make hose clamp is in the groove and any vacuum lines are hooked up correctly 4 4 Exhaust system Disassembly Disassemble the clamp bet...

Page 45: ...aust flange nuts then remove exhaust pipe Assembly Installation shall be in the reverse order of removal do not reuse exhaust head pipe gasket always replace replace muffler gasket and any hardware fo...

Page 46: ...e Remove floorboards pegs carburetor intake manifold and oil cooler first 1 Remove the engine front sprocket side cover then remove chain Remove the ground lead and all electrical connectors exhaust p...

Page 47: ...MOTOR CO LTD www kayomoto us 47 Remove the 3 engine mounting bolts 2 Remove the engine from the right side of vehicle Installation Ignition coil cap Gear shift lever Engine mounting bolt Bottom engine...

Page 48: ...1000cm3 Moment 1kgf 9 80665N Danger Warning attention Danger Be on high alert for danger Warning to be alert to moderate danger Attention to be alert to minor danger This manual may doesn t contain so...

Page 49: ...other toxic chemicals properly Warning If parts need to be replaced during maintenance please use parts recommended or provided by Kayo Disassembled parts that need to be reused should be arranged in...

Page 50: ...c therefore a standard break in is very important at the beginning of the its use it can make the moving parts to adapt to each other correctly work form a smooth mating surface Through this process t...

Page 51: ...us 51 5 4 Engine number Engine head displacement label 5 4 Maintenance Subsidiary maintain times Items Odometer reading 1000km 4000km 8000km 12000km Fuel system Clean Clean Clean Clean Oil filter Clea...

Page 52: ...ust Adjust Adjust Adjust Drive chain Adjust and lubricate per 5000km Battery Charge Charge Charge Charge Brake disc Check Adjust Adjust Replace Brake system Adjust Adjust Clean Clean Brake light switc...

Page 53: ...to us 53 Left view of the 150 engine is shown in the figure Remove the acorn nuts of cylinder head from cylinder studs Remove cylinder head Check the state of paper pad gasket Replace if necessary Dis...

Page 54: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 54 Remove left cover and inspect the paper pad gasket for damage Replace if necessary Dismantle the fixing bolt of right cover...

Page 55: ...us 55 Remove the right cover of cylinder head Inspect the gasket for damage and replace if necessary Remove intake and exhaust valve caps Check o rings and replace if worn or if reuse is questionable...

Page 56: ...MOTOR CO LTD www kayomoto us 56 Remove the connecting bolt of cylinder head Remove cylinder head assembly Remove timing driven sprocket Inspect the timing driven sprocket for wear and damage Replace...

Page 57: ...tion chamber Clean and replace if necessary Remove the cylinder head Pour gasoline into inlet exhaust pipe to inspect the seal condition Grind the valve and valve seat if there is gasoline leak into t...

Page 58: ...TD www kayomoto us 58 Inspect the oil seal intake and exhaust valves for damage Replace if necessary Remove the spark plug to clean the carbon deposits and dirt Check the spark plug gap and set it to...

Page 59: ...muffler pipe Replace the valve guide The cylinder gasket is broken Air leakage between the cylinder head and cylinder The engine starts hard or fails to start Insufficient engine output Engine speed...

Page 60: ...et and dowel pins 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...

Page 61: ...CO LTD www kayomoto us 61 Remove the piston of piston pin to check whether it is damaged Replace if necessary Remove and replace gaskets Check whether there is residual gasket on cylinder Clean and s...

Page 62: ...r walls Replace if worn or if reuse is questionable Check whether the internal diameter has exceed the limit value Measure the diameter at top middle and bottom of cylinder The limit value is 52 05 mm...

Page 63: ...or idle speed and high fuel consumption Grind the cylinder end surface or replace the cylinder body The cylinder is badly worn The fitting clearance between the cylinder and position position ring is...

Page 64: ...www kayomoto us 64 Check the conditon of right crankcase cover and replace if necessary Left view of right crankcase half is shown in fig and check whether bearing of main shaft and countershaft are...

Page 65: ...necessary Left view of left crankcase is shown below and check whether the oil seal of countershaft and oil seal edge of gearshift lever are worn Replace if necessary Right view of right crankcase ha...

Page 66: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 66 Remove the neutral indicator and check the state Replace if necessary Dismantle the fixing bolt of magneto stator and remove the stator...

Page 67: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 67 Check the condition of left crankcase cover and replace if necessary...

Page 68: ...ylinder The engine starts hard or fails to start Insufficient engine output Engine speed changes during idle run Repair the threaded or replace the crankcase The bolt of the cylinder is broken The sam...

Page 69: ...assemble and maintain crankshaft connecting rod Remove the fixing bolt of crankcase from its holding place Remove left crankcase half Take care not to forget the washer of mainshaft and countershaft w...

Page 70: ...od assembly Inspect connecting rod bearing for wear and damage Replace if necessary Check gap of big end of connecting rod Reset the gap if necessary Check diameter of piston pin using a micrometer Re...

Page 71: ...of connecting rod bearing Replace the conrod if the jumping is large Check the side gap between piston ring and piston groove using a feeler gauge Replace the piston if the gap is too wide Check wheth...

Page 72: ...value Assemble the piston ring according to the size and check whether piston ring is damaged or the elasticity is weaken Replace if necessary For the troubleshooting of crankshaft connecting rod mech...

Page 73: ...inder Replace the crankshaft connecting rod Bearing The big end needle bearing is over worn Radial and axes gap of the connecting rod big end is too large Striking sound of the big end bearing and of...

Page 74: ...or twisted Striking sound of the cylinder Replace the connecting rod The big end hole is over worn Radial and axes gap of the connecting rod big end is too large Striking sound of the big end bearing...

Page 75: ...of inlet and exhaust valve Remove inlet vale stem and exhaust valve stem take care and don t miss the valve clip Measure length of valve spring to check whether the spring is damaged or worn Replace i...

Page 76: ...clipper Replace the valve stem if the valve is beyond the maintenance limit valve Measure the width of valve contact surface to check whether the contact surface is rough or abnormal Replace the valv...

Page 77: ...k the state of camshaft Replace if necessary Check the gap of rocker arm shaft and rocker arm Replace the rocker arm shaft and rocker arm if the gap is large Check the external diameter of rocker arm...

Page 78: ...heel of timing chain to inspect for wear and damage Replace if necessary Remove the fixing bolt of timing tensioner and check the state Replace if worn or if reuse is questionable Remove the timing te...

Page 79: ...omoto us 79 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 valve clearance as follows Remove the...

Page 80: ...n magnetic rotor counterclockwise to make piston locate at top dead center and make T mark aimed to the mark of left crankcase cover Check whether the O mark on cam sprocket is aimed to the gap of cyl...

Page 81: ...MOTOR CO LTD www kayomoto us 81 For the troubleshooting of engine distribution mechanism please refer to the followingtable Maintenance of Distribution Mechanism Descriptions Damage form Trouble Caus...

Page 82: ...cker arm The rocker arm shaft is over worn Big gap between the rocker arm and rocker arm shaft Valve striking sound Replace the rocker arm shaft Valve The valve clearance is too small The valve is imp...

Page 83: ...It is impossible to close the valve completely The engine starts hard or fails to star Replace the valve Valve spring The spring is ineffective or fractured It is impossible to fit the valve and the...

Page 84: ...fixing bolt of float chamber cap Remove the float chamber cap Remove the water and debris in the cap if necessary Check the state of seal ring and replace if it is aging Remove the float needle valve...

Page 85: ...of float case by moving the float up or down Take out the main jet to check whether the jet hole is clogged Clean if necessary Remove the main nozzle to check whether small hole is clogged Clean with...

Page 86: ...Standard Tighten mixture screw and turn it one And a half turns clockwise Measure height of float case to check whether it is distorted or there is fuel inside If height is incorrect which indicates c...

Page 87: ...r to the followingtable Description Damage form Trouble Cause Correction Air filter Too much dust on the filter core The engine starts hard or fails to start Insufficient engine output poor performanc...

Page 88: ...assemble maintain and manage motor starter Remove the fixing bolt from left crankcase cover Dismount gear indicator switch fixing bolt remove gear indicator to check the wear or damage condition repl...

Page 89: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 89 Remove gasket to check it s condition If the gasket is worn or reusable please replace Remove fixing bolts of stator and trigger...

Page 90: ...HEJIANG KAYO MOTOR CO LTD www kayomoto us 90 Check stator status with multimeter If wear and tear or re use problems please replace the new accessories Remove rotor fixing nut Remove rotor with puller...

Page 91: ...check magnets if necessary replace Remove starter clutch fixing bolt Remove clutch to check for wear and damage condition of clutch seat pulley and spring If it necessary replace it Check the conditio...

Page 92: ...G KAYO MOTOR CO LTD www kayomoto us 92 Disassemble start sprocket press board Dismount starter chain tensioner check the condition If worn or damaged replace it Remove the snap ring from start motor s...

Page 93: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 93 Disassemble the drive sprocket and chain Dismount the fixing bolt of start motor Remove starter motor...

Page 94: ...motor wiring and spline condition if necessary replace it Disassemble the oil separation disc and check the condition if it necessary replace it Check oil seal edges for wear Replace as necessary Remo...

Page 95: ...Replace carbon brush spring Armature commentator surface is fouled Starter motor has insufficient rotation force Clean the commentator surface With gasoline or alcohol Armature commentator surface is...

Page 96: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 96 Circuit diagram...