KAYO MOTOR HY110AT Maintenance Manual
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KAYO MOTOR HY110AT Maintenance Manual

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ZHE JIANG KAYO MOTOR CO., LTD
AT110 model
Maintenance Manual
1
WWW.KAYOMOTO.COM

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Summary of Contents for KAYO MOTOR HY110AT

  • Page 1 ZHE JIANG KAYO MOTOR CO., LTD AT110 model Maintenance Manual WWW.KAYOMOTO.COM...
  • Page 2 ZHE JIANG KAYO MOTOR CO., LTD Compilation Illustration This maintenance manual introduces the maintenance adjustment procedure, disassembly and assembly essentials, inspection and maintenance points, troubleshooting methods and maintenance technical data of AT110 model (ATV) (four-wheel all-terrain vehicle) in detail, with detailed graphic data attached to guide the operation.
  • Page 3 ZHE JIANG KAYO MOTOR CO., LTD Content Chapter 1: Maintenance Information Chapter 2: Vehicle Body & Plastic Parts Chapter 3: Check and adjust regularly Chapter 4: External Components of the Engine Chapter5: Engine Note: Please understand that the contents in this maintenance manual which subject to change due to vehicle improvement, upgrading will not notify again.

  • Page 4: Maintenance Information

    ZHE JIANG KAYO MOTOR CO., LTD Unit Conversion Covered in the Manual Item Unit Conversion 1kgf/cm2=98.0665kPa；1kPa=1000Pa 1PSI=0.0689kgf/cm2 Pressure 1mmHg=133.322Pa=0.133322kPa Torque 1kgf·m=9.80665N·m 1mL=1cm3=1cc Volume 1L=1000cm3 moment of 1kgf=9.80665N force Length 1in=25.4mm Danger/warning/caution Please read the following explanation carefully. It emphasizes the special meaning of the words "danger", "warning"...
  • Page 5 ZHE JIANG KAYO MOTOR CO., LTD equipment such as dustproof glasses, dustproof masks and gloves should be put on to protect yourself from injury. 2. Because the exhaust gas contains harmful components, it is prohibited to operate the engine in closed places and places with poor ventilation for a long time.
  • Page 6 ZHE JIANG KAYO MOTOR CO., LTD small and from inside out according to the prescribed tightening torque. 9. Rubber parts should be inspected for aging during disassembly and replaced in advance if necessary.Rubber parts are not resistant to gasoline and kerosene corrosion, try not to allow volatile oil, grease kind of touch.
  • Page 7 ZHE JIANG KAYO MOTOR CO., LTD Engine Running-in The engine has many relative moving parts, such as piston, piston ring, cylinder body, crankshaft, crank, connecting rod, intermeshing transmission gear and so on.Therefore, in the early use of these parts, the specification of running-in is necessary.The run-in can make the relative moving parts adapt to each other, correct...

  • Page 8: Main Parameters

    ZHE JIANG KAYO MOTOR CO., LTD 1.4 Main Parameters Item TRADE MARK KAYO MODEL HY110AT NAME ATV 110cc Sport ATV COMPANY Zhejiang Kayo Motor Co., Ltd Main dimension parameters Dimension(L*W*H) (mm) 1380*880*930 Height of Handle bar (mm) Width of Handle bar (mm)

  • Page 9: Engine Parameters

    ZHE JIANG KAYO MOTOR CO., LTD Rear wheel base Turning radius 1650 Steering angle(Degree) 38°±2° Dry Weight(kg) 97.4±2 Curb Weight(Battery + Fuel)（Kg） Max. Speed Km/h (Speed limitation) 40 Engine parameters Item Starting method Electric start Engine type Horizontal Single cylinder, four stroke, air...

  • Page 10: Lubricating Device

    ZHE JIANG KAYO MOTOR CO., LTD Suspension Double rocker independent type Frame Welded steel tube sheet Lubricating device Item Standard limited Change oil 800mL（No oil filter replaced） － Engine oil Change oil 800mL（oil filter replaced） capacity Full capacity － 800mL...

  • Page 11: Ignition Device

    ZHE JIANG KAYO MOTOR CO., LTD Brake disc strength 500 N*m Ignition device Item Standard Ignition methord CDI Ignition Sparking plug Type Resistive spark plug Standard ATR7C/（torch） Spark plug gap 0.6~0.7mm Spark >8mm,1 atmospheres characteristics Ignition advance angle High voltage Primary Resistance 0.43~0.57Ω...
  • Page 12 ZHE JIANG KAYO MOTOR CO., LTD bolt Lower power 8.8 Grade 18~25 bolt Suspensio Front and rear M10*1.25 8.8 Grade 35~45 Suspension bolts Upper rocker M10*1.25 8.8 Grade 35~45 shaft Lower rocker M10*1.25 10.9 Grade 58~71 bolt Fork shaft M12*1.25 8.8 Grade...
  • Page 13 ZHE JIANG KAYO MOTOR CO., LTD package Fuel tank, Fuel Tank 7~11 Vehicle Installation Body, Fuel Tank 7~11 Plastic Switch parts Pedal 18~25 Installation Steel Pedal 8~12 Plastic Flat 7~11 head Self tapping ST4.2 pins for connection headlight with Plastic Parts.
  • Page 14 ZHE JIANG KAYO MOTOR CO., LTD Front brake tubing Main Cable Throttle Cable Rear brake tubing Choke cable WWW.KAYOMOTO.COM...
  • Page 15 ZHE JIANG KAYO MOTOR CO., LTD Brake cable connector Emergency flameout switch connector Neutral display connector Reverse display connector Switch lock connector Functional switch connector Headlight connector Power Power cathode Magneto connector anode Rectifier regulator connector Gear display connector WWW.KAYOMOTO.COM...
  • Page 16 ZHE JIANG KAYO MOTOR CO., LTD Rear Rectifier lamp Regulator Ignition Coil WWW.KAYOMOTO.COM...
  • Page 17 ZHE JIANG KAYO MOTOR CO., LTD 2 Vehicle Covers 2.1 Maintenance information 2.2 Mounting torque 2.3 Disassembly and assembly of seat cushion, front and rear protectives, front and rear mud plate, head cover, rear body, left and right protective plate, front body, left and right plastic pedals and left and right pedals 2.1 Maintenance information...
  • Page 18 ZHE JIANG KAYO MOTOR CO., LTD 2.3.2 Handle Bar Disassemble 1, when dismantling the direction, first 4, the front brake dismantling the rear disconnect the vehicle power supply. brake. 2. Use scissors to cut the plastic tie, and 5,Pull out the air door line according to...
  • Page 19 ZHE JIANG KAYO MOTOR CO., LTD Assemble Follow the reverse sequence of dismantling, and check to see if the installation is in place. (Note: 1) After the installation of the handle bar, the flameout switch connector, multi-functional switch connector and brake connector must be checked to prevent misconnection and loosening.
  • Page 20 ZHE JIANG KAYO MOTOR CO., LTD Installation is done in reverse order. (Note: If bolts and nuts are damaged, please replace new parts of the same specification in time.) 2.3.5 Vehicle plastic parts Disassemble Disconnect the electric lock plug, the neutral indicator lamp plug, the reverse indicator lamp plug, the left and right headlight plug.
  • Page 21 ZHE JIANG KAYO MOTOR CO., LTD Installation is done in reverse order. (Note: If bolts and nuts are damaged, please replace new parts of the same specification in time. After installation, check the headlamp connector, the electric lock connector, the reverse indicator connector, the neutral indicator connector and so on to prevent loosening and misconnection.)
  • Page 22 ZHE JIANG KAYO MOTOR CO., LTD (Note: If bolts, nuts and rubber pads are damaged, please replace new parts of the same specification in time.) Dismantling & Installation of the right rear fender are same with the left rear fender.
  • Page 23 ZHE JIANG KAYO MOTOR CO., LTD Assemble Installation is done in reverse order. (Note: If bolts, nuts and rubber pads are damaged, please replace new parts of the same specification in time.) Dismantling of the right guard plate are same with the left guard plate.
  • Page 24 ZHE JIANG KAYO MOTOR CO., LTD fuel tank Assemble According to the reverse order of disassembly. (Note: 1 If the bolts, nuts and rubber flat washer are damaged, please replace the new parts of the same specification in time. 2. Inspect headlamp connector, electric lock connector, reverse indicator connector and neutral indicator connector after installation to prevent loosening and misconnection.
  • Page 25 ZHE JIANG KAYO MOTOR CO., LTD 1. Remove the plastic mounting bolts 1, 2 and 3. 2. Remove the left plastic parts Assemble According to the reverse order of disassembly. (Note: If bolts, nuts and rubber flat washer are damaged, please replace new parts of the same specification in time.)

  • Page 26: Regular Inspection And Adjustment

    ZHE JIANG KAYO MOTOR CO., LTD (Note: when the bolts are damaged, please replace the new parts of the same specification in time. 3. Regular inspection and adjustment 3.1 Maintenance information 3.6 Suspension system 3.2 Set maintenance period 3.7 Gear shift & fuel devices 3.3 Inspection and maintenance...
  • Page 27 ZHE JIANG KAYO MOTOR CO., LTD operation and economic durability. Here is the maintenance periodic table of A125 engine. Note: The following table is designed according to the normal working condition. Under bad conditions, the maintenance cycle of the engine should be shortened accordingly.
  • Page 28 ZHE JIANG KAYO MOTOR CO., LTD Wear and damage of brake pads The minimum brake pad (friction plate) thickness≥1.5mm; when less Brake disc ○ ○ than 1.5mm, please replace it. Tire Pressure Front Tyre 45kPa（0.45kgf/ cm2） (4.0PSI) Rear Tyre：45kPa （ 0.45kgf/cm ○...
  • Page 29 ZHE JIANG KAYO MOTOR CO., LTD 3.4 Steering stem, brake system Stop the vihicle in a horizontal position and shake it as the direction shown in the picture to check if there is any shaking. If you feel the shaking, check if the steering stem is shaking or other components are shaking and then make the corresponding maintenance.
  • Page 30 ZHE JIANG KAYO MOTOR CO., LTD If there is any obstruction in some places, check the main cable, other cables, brake hose, etc.. If there isn’t any problem, check if the powder metallurgy spacer which is at the end of the steering stem is stuck.
  • Page 31 ZHE JIANG KAYO MOTOR CO., LTD 3.5 Wheel still shaking, check the rocker shaft bushing, the ball cap and replace Lift the front wheel with the tool in them. the horizontal position, make sure that the bodyof vehicle has no...
  • Page 32 ZHE JIANG KAYO MOTOR CO., LTD Use a gauge of tire pressure to check the air pressure. (The normal range of tire pressure is 4~6PSI) Note: The check of tire pressure should be carried out under the condition which the tire is cooled. If the vehicle is driving in a state which the tire air pressure is not suitable, the operation and driving feel will be deteriorated, also will cause adverse effects such as eccentric wear of the tire.
  • Page 33 ZHE JIANG KAYO MOTOR CO., LTD 3.7 Gear shift &Fuel device Change the gear position and check whether the gear shift is flexible and comfortable. If the gear shift is not comfortable, the angle of shift lever can be adjusted appropriately.
  • Page 34 ZHE JIANG KAYO MOTOR CO., LTD Check if the fuel pipe is aging or damaged. When the fuel pipe is aging or damaged, it should be replaced immediately. Check the vent pipe of fuel tank for cracks, bends, deformation, and replace it with new one if it is damaged.
  • Page 35 ZHE JIANG KAYO MOTOR CO., LTD Remove the protective kit 1&2, turn the adjuster 3, and adjust the throttle to the normal flexible moving. Then adjust the rear tightening nut 4 and put on the protective kit 1&2. If it does not reach the specified clearance or the operation is still not flexible after the adjustment , replace a new throttle line.
  • Page 36 ZHE JIANG KAYO MOTOR CO., LTD adjustment wrench of shock absorber Place for adjusting the soft and hard of shock absorber 4 Engine periphery 4.3 Intake system 4.1 Maintenance 4.4 Exhaust system 4.2 Fuel System 4.5 Disassembly and installation of engine 4.1 Maintenance...
  • Page 37 ZHE JIANG KAYO MOTOR CO., LTD 4.2 Fuel System Note Gasoline is very easy to catch fire, so fire and smoking are strictly prohibited in the workplace. Not only paying attention to the fire, but also high attention to electric sparks. In addition to the danger of explosion after the gasoline evaporates, so work should be carried out in a well ventilated area.

  • Page 38: Installation

    ZHE JIANG KAYO MOTOR CO., LTD air filter clamp Installation In reverse order of disassembly. The oil pipe needs to be inserted into the joint head, and the clamp must be installed in the groove of the tube joint. Installation In the reverse order of disassembly.
  • Page 39 ZHE JIANG KAYO MOTOR CO., LTD Remove the self-lock nut 3 which is connected to the exhaust pipe and the exhaust vent of the engine, and then remove the exhaust pipe. Installation In the reverse order of disassembly, pay attention to check the seal 4 of the exhaust pipe and the graphite sleeve 5 which is installed in the muffler during the operation, and replace with the new ones when they are broken.
  • Page 40 ZHE JIANG KAYO MOTOR CO., LTD high pressure cap shift lever 3.Remove the bolt of upper power and then remove the lifting lug, bolt of rear power, bolt from bottom of the engine. 4.Remove the engine from the right side of the vehicle.
  • Page 41 ZHE JIANG KAYO MOTOR CO., LTD 1kgf=9.80665N torque Warning Please read the following explanation carefully, which emphasizes the specific meaning of the words “dangerous”, “warning” and “attention”, and pay special attention to the meaning of them when repair the engine.
  • Page 42 ZHE JIANG KAYO MOTOR CO., LTD ·Disassembled parts, which need to be reused, keep them in order, so that the assembly is not messy. · Ensure the use of special tools as specified in the service manual · Ensure that the components used in the assembly are clean, and the areas that require lubrication must be lubricated.
  • Page 43 ZHE JIANG KAYO MOTOR CO., LTD making the running-in could have excellent performance and reliability. The recommended running-in time is 20 hours and the specifications are as follows: 0 to 10 hours Avoid continuous operation or continuously change the speed of the vehicle, or operate under a unfixed throttle position when the throttle state≥50%;...
  • Page 44 ZHE JIANG KAYO MOTOR CO., LTD Maintain of engine Maintain maintain times Odometer reading 1000km 4000km 8000km 12000km Fuel system Clean Clean Clean Clean Oil filter Clean Clean Clean Clean Control Adjust Adjust, clean Adjust, clean Adjust, clean Carburetor Clean...
  • Page 45 ZHE JIANG KAYO MOTOR CO., LTD Right view of the 125 engine is shown in the figure. Left view of the 125 engine is shown in the figure Remove the locknut of cylinder head from its holding place WWW.KAYOMOTO.COM...
  • Page 46 ZHE JIANG KAYO MOTOR CO., LTD Remove cylinder head. Check the state of paper pad. Replace if necessary. Dismantle the fixing bolt of left cover. Remove left cover and inspect the paper pad for damage. Replace if necessary. WWW.KAYOMOTO.COM...
  • Page 47 ZHE JIANG KAYO MOTOR CO., LTD Dismantle the fixing bolt of right cover. Remove the right cover of cylinder head. Inspect the gasket for damage and replace if necessary. Remove inlet/exhaust valve cap .Check the state of seal ring of valve cap and replace if worn or if reuse is questionable.
  • Page 48 ZHE JIANG KAYO MOTOR CO., LTD Remove the fixing bolt of timing driven sprocket. Remove the connecting bolt of cylinder head. Remove cylinder head assembly. WWW.KAYOMOTO.COM...
  • Page 49 ZHE JIANG KAYO MOTOR CO., LTD 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 chamber. Clean and replace if necessary. Remove the cylinder head. Pour gasoline into inlet/exhaust pipe to inspect the seal condition.
  • Page 50 ZHE JIANG KAYO MOTOR CO., LTD Remove inlet/exhaust valve spring and check the state. Replace if necessary. Inspect the oil seal of inlet/exhaust valve for damage. Replace if necessary. 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...
  • Page 51 ZHE JIANG KAYO MOTOR CO., LTD For the troubleshooting of cylinder head ,please refer to the following table Description Damage Form Problem Cause Correction Too much oil dirt or sand Poor heat The engine overheats. Remove the oil dirt or on the cooling fins.
  • Page 52 ZHE JIANG KAYO MOTOR CO., LTD The fixing nut is not Air leakage between The engine starts hard or fails to Tighten the fixing nut properly tightened the cylinder head and start. Insufficient engine output; cylinder Engine speed changes during...
  • Page 53 ZHE JIANG KAYO MOTOR CO., LTD 5.4.2 Disassemble, assemble and maintain cylinder block Dismantle connecting bolt of cylinder block. Remove cylinder gasket and dowel pin to check for wear and damage. Replace if necessary. Dismantle the fixing bolt of timing chain of guide wheel.
  • Page 54 ZHE JIANG KAYO MOTOR CO., LTD 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. Clean with gasoline if necessary.
  • Page 55 ZHE JIANG KAYO MOTOR CO., LTD Check the state of cylinder 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 50.05mm.Replace the cylinder block if it...
  • Page 56 ZHE JIANG KAYO MOTOR CO., LTD Troubleshooting of the cylinder body, please refer to the following table Maintenance of Cylinder Body Description Damage form Trouble Cause Correction Excessive oil Poor heat The engine overheats Remove the oil dirt or sand on...
  • Page 57 ZHE JIANG KAYO MOTOR CO., LTD 5.4.3 Disassemble, assemble and maintain crankcase Remove the cover of right crankcase half. 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.
  • Page 58 ZHE JIANG KAYO MOTOR CO., LTD Right view of right crankcase half is shown in fig and check the state of right crankcase half. Replace if 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.
  • Page 59 ZHE JIANG KAYO MOTOR CO., LTD Remove the neutral indicator and check the state. Replace if necessary. Dismantle the fixing bolt of magneto stator and remove the stator. Check the condition of left crankcase cover and replace if necessary. WWW.KAYOMOTO.COM...
  • Page 60 ZHE JIANG KAYO MOTOR CO., LTD Troubleshooting of crankcase, please refer to the following table. Trouble Description Problem Compucation Correction Crack in the crank case Oil leakage from the Repair or replace the crankcase crankcase Oil leakage from the The crankcase gasket is...
  • Page 61 ZHE JIANG KAYO MOTOR CO., LTD The oil seal is damaged Oil leakage is ineffective Oil leakage from the oil Replace the oil seal or the oil seal edge is seal damage/worn/aged Right crankcase The right crankcase Oil leakage form the...
  • Page 62 ZHE JIANG KAYO MOTOR CO., LTD Remove left crankcase half. Take care not to forget the washer of mainshaft and countershaft when removing the left crankcase. Remove the paper pad to inspect for wear and damage. Replace if necessary. Remove the connecting rod assembly.
  • Page 63 ZHE JIANG KAYO MOTOR CO., LTD Check gap of big-end of connecting rod. Reset the gap if necessary. Check diameter of piston 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.
  • Page 64 ZHE JIANG KAYO MOTOR CO., LTD Check whether there is excessive carbon deposit on piston top and groove. Remove if necessary. 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.
  • Page 65 ZHE JIANG KAYO MOTOR CO., LTD For the troubleshooting of crankshaft connecting rod mechanism, please refer to the followingtable. Maintenance of Crankshaft Connecting Rod Mechanism Description Damage from Trouble Cause Correction The engine over- heats Carbon deposit on piston Remove the carbon top 活塞顶部积碳...
  • Page 66 ZHE JIANG KAYO MOTOR CO., LTD The crankshaft bearing is Abnormal sound during Replace over worn or damaged crankshaft bearing transmission crankshaft bearing The piston ring is fractured piston ring The engine starts hard or fails to Replace the piston fractured start.
  • Page 67 ZHE JIANG KAYO MOTOR CO., LTD Timing The gear is over worn of Abnormal sound during sprocket Replace the timing sprocket damage driving sprocket 5.5 Maintenance of Mechanism 5.5.1 Disassemble, assemble and maintain valve mechanism Remove rocker arm shaft Remove the rocker arm of inlet/exhaust valve and check the state WWW.KAYOMOTO.COM...
  • Page 68 ZHE JIANG KAYO MOTOR CO., LTD 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 exhaust valve stem take care and don`t miss the valve clip.
  • Page 69 ZHE JIANG KAYO MOTOR CO., LTD Check the external diameter of valve stem using a verier 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.
  • Page 70 ZHE JIANG KAYO MOTOR CO., LTD 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 rocker arm shaft and rocker arm if the gap is large.
  • Page 71 ZHE JIANG KAYO MOTOR CO., LTD Remove the fixing bolt of timing tensioner and check the state. Replace if worn or if reuse is questionable. Remove the timing tensioner arm to inspect for wear and damage. Replace if necessary. Remove the oil tube and spring and check the state.
  • Page 72 ZHE JIANG KAYO MOTOR CO., LTD Adjust valve clearance as follows; Remove the valve cap and check the condition. Adjust valve clearance of front cylinder. Turn magnetic rotor counterclockwise to make piston locate at top dead center and make T mark aimed to the mark of left crankcase cover.
  • Page 73 ZHE JIANG KAYO MOTOR CO., LTD For the troubleshooting of engine distribution mechanism, please refer to the followingtable Maintenance of Distribution Mechanism Descriptions Damage form Trouble Cause Correction Valve oil seal The edge of valve oil seal Thick blue and white fume form Replace the is worn, age or damage.
  • Page 74 ZHE JIANG KAYO MOTOR CO., LTD Valve The valve clearance is too The valve is impossible to The engine starts hard or fails to Readjust the valve small close completely start. Insufficient engine output; clearance to 0.05~0.06mm Engine speed changes during idle...
  • Page 75 ZHE JIANG KAYO MOTOR CO., LTD Replace the valve valve stem It is impossible to close the The engine starts hard or fails to deformed valve completely star Valve spring It is impossible to fit the The engine starts hard or fails to...
  • Page 76 ZHE JIANG KAYO MOTOR CO., LTD 5.6 Disassemble, assemble and maintain carburetor Dismantle the fixing bolt of carburetor and circlip of air cleaner. Remove the carburetor .Remove and clean throttle cap Clean the carburetor as follows: Remove the dirt and clean inner oil way.Dismantle the fixing bolt...
  • Page 77 ZHE JIANG KAYO MOTOR CO., LTD 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 float up or down.
  • Page 78 ZHE JIANG KAYO MOTOR CO., LTD 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 mixture screw of carburetor as the following. Standard:...
  • Page 79 ZHE JIANG KAYO MOTOR CO., LTD 5.7.1 Disassemble, assemble and maintain intake system Remove the air filter retaining ring Remove the air filter Remove the air filter to remove dust from the casing and remove the air filter to clean For the troubleshooting of the air cleaner, please refer to the followingtable.
  • Page 80 ZHE JIANG KAYO MOTOR CO., LTD Dismantle locknut of muffler Dismantle suspension bolt of muffler to check whether the suspension support is damaged. Repair or or replace if necessary. Remove the muffler to inspect for broken and damage. Replace or repair if necessary.
  • Page 81 ZHE JIANG KAYO MOTOR CO., LTD 5.9 Disassemble, assemble maintain the environmental protection Valve Description Damage form Trouble Cause Correction Exhaust pipe leakage Exhaust pipe gasket Engine exhaust noise is Replace exhaust pipe gasket broken too loud. gasket enclosure broken...
  • Page 82 ZHE JIANG KAYO MOTOR CO., LTD 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 necessary. For the troubleshooting of environment protection valve, please refer to the following table.
  • Page 83 ZHE JIANG KAYO MOTOR CO., LTD connecting hose get loose noise is too big Replace connecting Emission fails to hose meet the standard Gasket Replace large noise from air leaks form secondary Emission fails to secondary inlet inlet meet the standard...
  • Page 84 ZHE JIANG KAYO MOTOR CO., LTD Remove the cover of left crankcase replace it. Remove the gasket and check the condition. If it is worn,please Remove the fixing bolt of magnetic stator and bolt of trigger. WWW.KAYOMOTO.COM...
  • Page 85 ZHE JIANG KAYO MOTOR CO., LTD Check the status of stator with a multimeter. If it is worn, please replace with the new one. Disassemble the fixing nut of rotor Remove the rotor with special tools Remove the rotor and check if the rotor is demagnetized.
  • Page 86 ZHE JIANG KAYO MOTOR CO., LTD Remove the fixing bolt of overrunning clutch Remove the clutch. Check for wear and damage to the clutch seats, rollers and springs. Replace it when necessary. Check the wear and damage of the drive sprocket and drive gear. replace it when necessary.
  • Page 87 ZHE JIANG KAYO MOTOR CO., LTD Remove the tension strip of the clutch and check its condition. If the tension strip is found to be worn or problems in use,replace Remove the circlip of the sprocket of starter. Remove the drive sprocket and...
  • Page 88 ZHE JIANG KAYO MOTOR CO., LTD Remove the electric starter Check the electric starter for damage. Replace it when necessary. Remove the disc of oil separation and check the condition. Replace it when necessary. wear. Replace it when necessary. Check the edges of the oil seal for...
  • Page 89 ZHE JIANG KAYO MOTOR CO., LTD status of oil seal ring and replace it when necessary. Remove the seal ring. Check the For the troubleshooting of engine electric starter, please refer to the following table. Maintenance of Electric Starter Description...
  • Page 90 ZHE JIANG KAYO MOTOR CO., LTD Polish the surface against Armature commentator Starter motor has insufficient Commentator with fine abrasive surface is spotted, burnt rotation force. Paper. Make the cut on the mica damaged. Plate between each commentator Piece with broken saw bit 0.5~0.

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At110

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