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KAYO MOTOR AU110 Maintenance Manual
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KAYO MOTOR AU110 Maintenance Manual

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ZHEJIANG KAYO MOTOR CO., LTD.
AU110 model
Maintenance Manual
WWW.KAYOMOTO.COM

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Summary of Contents for KAYO MOTOR AU110

  • Page 1 ZHEJIANG KAYO MOTOR CO., LTD. AU110 model Maintenance Manual WWW.KAYOMOTO.COM...
  • Page 2 ZHEJIANG KAYO MOTOR CO., LTD. Instruction This manual contains detailed operation for AU110 (ATV), maintenance and 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 carefully and follow the instructions strictly among inspection period, that would enhance the reliability of motor and all parts.
  • Page 3 ZHEJIANG KAYO MOTOR CO., LTD. Content Chapter 1 Service Information Chapter 2 Seat and Rack Chapter 3 Body and Covering Chapter 4 Regular Maintenance and adjustment Chapter 5 Places around engine Chapter 6 Engine Appendix Electrical schematic diagram All contents in this manual are subject to improve and update without notice.
  • Page 4 ZHEJIANG KAYO MOTOR CO., LTD. Conversion table Unit conversion Item 1kgf/cm =98.0665kPa；1kPa=1000Pa 1PSI=0.0689kgf/cm pressure 1mmHg=133.322Pa=0.133322kPa 1kgf·m=9.80665N·m Torque 1mL=1cm =1cc volume 1L=1000cm Moment 1kgf=9.80665N Length 1in=25.4mm Danger/warning/attention Take the below explanations seriously, it’s important for maintenance, especially for engine. Danger Be on high alert for danger.
  • Page 5 ZHEJIANG KAYO MOTOR CO., LTD. Service Information 1.1 Operation note 1.2 VIN Number 1.3 Main parameters list 1.4 Maintenance parameters list 1.5 Torque tightening 1.6 Lubricant, sealant 1.7 Cable, hose and wiring diagram 1.1 Operation note Security 1. Wearing work clothes (coveralls), hat and safety boots suitable for the operation.
  • Page 6 ZHEJIANG KAYO MOTOR CO., LTD. 9. Inspect the rubber parts before disassembling and replaced in advance if necessary. In addition, as the rubber pieces are not resistant to gasoline, kerosene and other erosion, do keep them from volatile oil and grease.
  • Page 7 ZHEJIANG KAYO MOTOR CO., LTD. There is a lot of relative motion components in engine, such as piston, piston ring, cylinder, mutually meshing gear, etc., it’s very important to have a standard break-in at the beginning of using. Break-in can help the moving parts adapt to each other, correction work, form a smooth friction surface which can bear heavy load, by this way the engine will have excellent performance and reliability.
  • Page 8 ZHEJIANG KAYO MOTOR CO., LTD. 1.3 Main parameters list Item Brand KAYO Type AU110 Name 110cc utility ATV Company ZHEJIANG KAYO MOTOR CO., LTD. ● Main parameters Dimension（L*W*H）（mm） 1430*860*890 Handlebar height（mm） Handlebar width（mm） Rear height（mm） Ground clearance of seat（mm） Min. terrain clearance（mm）...
  • Page 9 ZHEJIANG KAYO MOTOR CO., LTD. SOHC/chain drive Distribution way Cylinder diameter × 52.4*49.5 mileage（mm） Compression ratio 9.0:1 Combination splash and pressure feed Lubrication mode Rotor Oil pump type Lubricating oil filter All-flow filter, paper filter type Oil trademark SAE15W-40 Cooling type...
  • Page 10 ZHEJIANG KAYO MOTOR CO., LTD. Recommended engine oil （original） ·four-strokes motorcycles SAE-15W-40 For replacements, it must be within following scope: Viscosity ·API classification：SG or upper grade grade engine oil ·SAE specification：refer to left table temperature Radial clearance of inner 0.2mm 0.07 mm～0.15mm...
  • Page 11 ZHEJIANG KAYO MOTOR CO., LTD. Type Resistor type spark plug Sparking plug Standard A7RTC/（torch） 0.6~0.7mm Spark character >8mm, one bar Spark advance angle Ignition coil Primary 0.43~0.57Ω resistance Secondary 10.1~11KΩ Peak voltage Primary ignition coil >150V Pulse ● Light / Instrument / Switch...
  • Page 12 ZHEJIANG KAYO MOTOR CO., LTD. Rear axle M12*1.25 55~65 Rear axle M27*1.5 80~90 Chain bolt 8~12 Clamp locking bolt 10.9 18~25 （hexagon） Turning Steering column 18~25 locking Bolt of lower raiser M10*1.5 10.9 50~60 Electrical Battery box 15~20 elements Muffler installation...
  • Page 13 ZHEJIANG KAYO MOTOR CO., LTD. Oil tube for front brake Main cable Throttle cable Oil tube for rear brake Damper cable...
  • Page 14 ZHEJIANG KAYO MOTOR CO., LTD. Brake cable Stop switch Neutral display Reverse gear display Electrical lock Functional switch Headlight Positive Negative Magneto pole pole connector Voltage regulator Gear indicator...
  • Page 15 ZHEJIANG KAYO MOTOR CO., LTD. Voltage Rear stabilizer light Ignition coil...
  • Page 16 ZHEJIANG KAYO MOTOR CO., LTD. 2. Seat and rack 2.1 Seat Disassembly Lift up the seat hook Lift up the rear of seat, and then pull it backward. 2 Remove the seat. Installation Take it back in reverse order from disassembly.
  • Page 17 ZHEJIANG KAYO MOTOR CO., LTD. 3 Body covering 3.1 Maintenance cautions 3.2 Installation torque 3.3 Seat, front guard, clay, hood, rear body, left and right guard,front body， plastic pedal, dismounting left and right pedal 3.1 Maintenance cautions Operation cautions When replacing the covering parts, please stick the tags and riveting warning labels to the new covering.
  • Page 18 ZHEJIANG KAYO MOTOR CO., LTD. After installation, pay attention to check whether the seat cushion is installed in place and firmly. (Note: if the buckle is broken, replace it in time) 3.3.2 Handlebar Disassembly 1. Cut off power first. 5. Pull the damper cable as picture 2.
  • Page 19 ZHEJIANG KAYO MOTOR CO., LTD. Mounting bolt Installation Take it back in reverse order from disassembly (note: if the mounting bolt or nut is broken, replace it to same specification in time) 3.3.4 Plastic parts Disassembly 1. Disconnect electric plug, neutral indicator plug, reverse indicator plug and headlight plug.
  • Page 20 ZHEJIANG KAYO MOTOR CO., LTD. （note: if the mounting bolt or nut is broken, replace it to same specification in time. After installation, check headlight connector, electric connector, reverse indicator connector etc., in case of looseness or misconnect. Regular maintenance and adjustment 4.1 Maintenance information...
  • Page 21 ZHEJIANG KAYO MOTOR CO., LTD. per 50 hours or 1500km per 100 hours or 3000km or one 年 per 200hours or 6000km 或 2 years Remark Engine Lubricating oil and air filter Damper adjustment I，A I，A Engine leakprofness Engine suspension...
  • Page 22 ZHEJIANG KAYO MOTOR CO., LTD. Crack and damage of ○ ○ ○ wheel Tyre groove depth and If there’s no tear abnormal wear indicator wheel, the residual ○ ○ groove depth should greater than Loose of wheel nut and ○ ○...
  • Page 23 ZHEJIANG KAYO MOTOR CO., LTD. 4.4 Steering column and brake system Keep vehicle in steady place and hold handlebar firmly as it shown in the picture to check if it’s shaking. If there is a shaking, check it’s caused by steering column or other parts then repair.
  • Page 24 ZHEJIANG KAYO MOTOR CO., LTD. blocked or damaged. Note: the steering handlebar must be smoothly, or it may cause accidents due to out of control. Clearance for front and rear handlebars: Check the effect and movement before operation. The clearance is 5-10mm.
  • Page 25 ZHEJIANG KAYO MOTOR CO., LTD. 4.5 Wheel Lift the front wheel with the tool in a horizontal position, and make sure there is no force on the wheel. Shake the front wheel left and right to check whether the connection of the front wheel is firm and if there is shaking.
  • Page 26 ZHEJIANG KAYO MOTOR CO., LTD. Wheel pattern Check wheel pattern, if the thickness is less than 3mm, replace it. The inspection of rear wheel is the same as front wheel. 4.6 Suspension system Keep vehicle in a horizontal position and compress up and down for several times according to the pictures.
  • Page 27 ZHEJIANG KAYO MOTOR CO., LTD. gearshift Fuel device Remove the plastic parts first. Check fuel pipe for aging and damage.Replace the fuel pipe when it is aging or damaged add. Check the adsorption tube of the fuel evaporation system for cracks and bends, and replace with a new one if there is any damage.
  • Page 28 ZHEJIANG KAYO MOTOR CO., LTD. Remove sleeve for 1/2, adjust regulator 3, then turn the throttle to normal free stoke.tight the nut 4, install sleeve back. If the above method is useless, replace a new throttle cable. Speed limiting device adjustment(EPA state is not suitable) Speed limit device is used for restrict throttle opening.
  • Page 29 ZHEJIANG KAYO MOTOR CO., LTD. Front brake is unadjustable. Rear brake can be adjust from 1 to 5. the factory default state is gear 3. It can be adjusted according to rider's needs for riding comfort. Adjustment: 1. By absorber adjusting wrench (crescent).
  • Page 30 ZHEJIANG KAYO MOTOR CO., LTD. －carburetor, air filter －cylinder head cover, start motor, cylinder head, cylinder block, camshaft －left cover, AC magneto －piston, piston ring, piston pin ● Remove the engine in following operations. －Crankshaft, main and counter shaft Tightening torque See 1.5...
  • Page 31 ZHEJIANG KAYO MOTOR CO., LTD. 5.3 Air intake system Disassembly 1. Remove air filter retaining bolts. 2. Remove the air filter retaining bracket. 3. Loosen the the exhaust pipe and the clamp of the air filter, then remove the air filter (Note: remove the handlebar and the front body before removing the...
  • Page 32 ZHEJIANG KAYO MOTOR CO., LTD. Disassembly Installation shall be in the reverse order of removal. Note if exhaust pipe seal pad 4, graphite sleeve 5 for muffler mounting and locking nut damaged, replace at once. 5.5 Disassembly and installation of engine Disassembly (Note: Remove pedal first) 1.
  • Page 33 ZHEJIANG KAYO MOTOR CO., LTD. 3. Remove the power bolts, lug, and bolt of engine bottom. 发 动 机 吊 耳 4. Remove the engine from the right side of vehicle. Installation Installation shall be in the reverse order of removal.
  • Page 34 ZHEJIANG KAYO MOTOR CO., LTD. please consult a more experienced senior technician. General precautions Warning: Proper maintenance is very important to engine reliability and personnel safety. ● When there is two or more people work together, more attention should be paid for safety.
  • Page 35 ZHEJIANG KAYO MOTOR CO., LTD. 6.2 Engine oil and fuel Warning: Fuel: Use octane 93# or higher Engine oil shall not be mixed unleaded gasoline with engine oil of other brands Engine oil：Use sae15w-40 oil for 4 stroke motorcycle, quality grade...
  • Page 36 ZHEJIANG KAYO MOTOR CO., LTD. label 6.4 Maintenance Subsidiary maintain times Odometer reading 1000km 4000km 8000km 12000km Items Fuel system Clean Clean Clean Clean Oil filter Clean Clean Clean Clean Control Adjust Adjust, clean Adjust, clean Adjust, clean Carburetor Clean...
  • Page 37 ZHEJIANG KAYO MOTOR CO., LTD. 6.4 Maintenance of Engine Body 6.4.1 Disassemble, 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 place.
  • Page 38 ZHEJIANG KAYO MOTOR CO., LTD. Dismantle the 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. and replace if necessary. Remove the right cover of cylinder...
  • Page 39 ZHEJIANG KAYO MOTOR CO., LTD. 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 bolt of...
  • Page 40 ZHEJIANG KAYO MOTOR CO., LTD. Remove cylinder head assembly. Remove timing driven sprocket. Inspect the timing driven sprocket for wear damage. Replace necessary. necessary. Check whether there is excessive carbon deposit combustion chamber. Clean replace...
  • Page 41 ZHEJIANG KAYO MOTOR CO., LTD. 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 the combustion chamber. Remove inlet/exhaust valve spring and check the state. Replace if necessary.
  • Page 42 ZHEJIANG KAYO MOTOR CO., LTD. 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 ZHEJIANG KAYO MOTOR CO., LTD. For the troubleshooting of cylinder head ,please refer to the following table Description Damage Form Problem Cause Correction Poor heat radiation of Too much oil dirt or sand Remove the oil dirt or the fins on cylinder The engine overheats on the cooling fins.
  • Page 44 ZHEJIANG KAYO MOTOR CO., LTD. The engine starts hard or fails Air leakage between to start. Insufficient engine The fixing nut is not the cylinder head and Tighten the fixing nut. properly tightened. output; Engine speed changes cylinder. during idle run.
  • Page 45 ZHEJIANG KAYO MOTOR CO., LTD. 6.4.2Disassemble, assemble and maintain cylinder block Remove cylinder gasket and dowel pin to Dismantle connecting bolt of cylinder block. check for wear and damage. Replace if necessary. Dismantle the fixing bolt of timing chain of Remove the cylinder block.
  • Page 46 ZHEJIANG 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...
  • Page 47 ZHEJIANG KAYO MOTOR CO., LTD. Check the state of cylinder inner wall .Replace if worn or if reuse is questionable. Check whether internal diameter has exceed the limit value. Measure the diameter form upper, middle and lower position. limit value 50.05mm.Replace...
  • Page 48 ZHEJIANG 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 Poor heat Excessive oil dirt radiation Remove the oil or sand on the The engine overheats...
  • Page 49 ZHEJIANG KAYO MOTOR CO., LTD. 6.4.3Disassemble, 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 50 ZHEJIANG 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 counter shaft and oil seal edge of gearshift lever are worn.Replace if...
  • Page 51 ZHEJIANG KAYO MOTOR CO., LTD. Remove the neutral indicator and check state. Replace necessary. Dismantle the fixing bolt of magneto stator and remove the.
  • Page 52 ZHEJIANG KAYO MOTOR CO., LTD. Check the condition of left crankcase cover and replace if necessary.
  • Page 53 ZHEJIANG KAYO MOTOR CO., LTD. Troubleshooting of crankcase, please refer to the following table. Trouble Description Problem Cause Correction Oil leakage from Repair or replace Crack in the crank case the crankcase the crankcase Oil leakage from crankcase Replace the gasket...
  • Page 54 ZHEJIANG KAYO MOTOR CO., LTD. Remove left crankcase half. Take care not to forget the washer of main shaft counter shaft when removing the left crankcase. Remove the paper pad to inspect for wear damage. Replace necessary. Remove connecting assembly.
  • Page 55 ZHEJIANG 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 56 ZHEJIANG KAYO MOTOR CO., LTD. Check whether there is excessive carbon deposit on piston top and groove. Remove it if necessary. Check the state of piston and replace if worn or if reuse is questionable. Measure diameter of piston skirt.
  • Page 57 ZHEJIANG KAYO MOTOR CO., LTD. For the troubleshooting of crankshaft connecting rod mechanism, please refer to the following table. Maintenance of Crankshaft Connecting Rod Mechanism Description Damage from Trouble Cause Correction The engine over- heats Carbon deposit Carbon deposit in the...
  • Page 58 ZHEJIANG KAYO MOTOR CO., LTD. The piston ring is over The piston ring opening gap worn or the side gap is too wide 活塞环磨损过度 活塞环开口间隙或侧隙太宽 It is impossible to tight the Insufficient elasticity of piston ring and the cylinder piston ring...
  • Page 59 ZHEJIANG KAYO MOTOR CO., LTD. Remove rocker inlet/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 exhaust valve stem take care and don`t miss the valve clip.
  • Page 60 ZHEJIANG KAYO MOTOR CO., LTD. Valve spring Measure length of valve spring to check whether spring damaged worn. Replace necessary. Remove the spring of inlet and exhaust valve to inspect for wear and damage. Note: when assemble the valve spring, make sure its dense end downward.
  • Page 61 ZHEJIANG KAYO MOTOR CO., LTD. Check whether the valve 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 rocker arm shaft and rocker arm if the gap is large.
  • Page 62 ZHEJIANG KAYO MOTOR CO., LTD. Check the external diameter of rocker arm using a micrometer. 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.
  • Page 63 ZHEJIANG KAYO MOTOR CO., LTD. Remove the timing tensioner arm to inspect wear damage. Replace if necessary. Remove the oil tube and spring and check state. Replace necessary. Remove the small timing chain and check state. Replace necessary. Adjust valve clearance as follows;...
  • Page 64 ZHEJIANG KAYO MOTOR CO., LTD. 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. Check whether the O-mark on cam sprocket is aimed to the gap of cylinder head.
  • Page 65 ZHEJIANG KAYO MOTOR CO., LTD. axial radial clearance of the bearing bearing Abnormal sound heard during is too wide. Ineffective Replace camshaft is over worn camshaft camshaft transmission. bearing swiveling or damaged abnormal sound during swiveling. The working surface is...
  • Page 66 ZHEJIANG KAYO MOTOR CO., LTD. fitting clearance Sound of valve leakage, Thick The valve stem is over between the valve stem blue and white fume form the Replace the valve worn and the valve guide exhaust muffler pipe. too wide.
  • Page 67 ZHEJIANG KAYO MOTOR CO., LTD. Remove the float needle valve to inspect wear damage. Replace 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 float up or down.
  • Page 68 ZHEJIANG KAYO MOTOR CO., LTD. Remove the main nozzle to check whether small hole is clogged. Clean with compressed air if necessary. Remove the idle jet and check for plugged. Clean with compressed air if necessary. Dismantle the mixture adjustment screw and inspect for worn.
  • Page 69 ZHEJIANG KAYO MOTOR CO., LTD. Measure height of float case to check whether it is distorted or there is oil in the case If height is incorrect which indicates carburetor leaks or the oil supply is insufficient. Adjust the oil needle to the third tier. If the clip rises, concentration of mixture becomes dilute and if falls it becomes thick.
  • Page 70 ZHEJIANG KAYO MOTOR CO., LTD. The engine starts hard or Engine start difficulty fails to start. Insufficient starting failure. Too much dust engine output; poor Insufficient engine Clean filter on the filter core performance engine output; The engine element Air filter during idle run.
  • Page 71 ZHEJIANG KAYO MOTOR CO., LTD. Remove the washer of muffler to inspect for damage. Replace if necessary. Washer For the troubleshooting or the exhaust muffler, please refer to the following table. Description Damage form Trouble Cause Correction Exhaust pipe gasket...
  • Page 72 ZHEJIANG KAYO MOTOR CO., LTD. Inspect the connecting circlip of air pump tightness. Tighten necessary. Dismantle the fixing bolt of air pump and check the state of air pump. Replace the air pump if it is worn or if reuse is questionable.
  • Page 73 ZHEJIANG KAYO MOTOR CO., LTD. Parts Damage form Trouble Cause Correction air pump defective air pump Replace pump broken Emission fails Emission fails air cleaner damaged or air cleaner defective air cleaner Replace to meet plugged the standard Emission fails...
  • Page 74 ZHEJIANG KAYO MOTOR CO., LTD. Remove left crankcase cover Remove gasket check it’s condition. If the gasket is wearied or reusable, please replace it. Remove fixing bolts of stator and trigger .
  • Page 75 ZHEJIANG KAYO MOTOR CO., LTD. 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, necessary replace it if it.
  • Page 76 ZHEJIANG KAYO MOTOR CO., LTD. Remove overrunning clutch fixing 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 necessary replace it.
  • Page 77 ZHEJIANG KAYO MOTOR CO., LTD. Dismount tension band of clutch and check the condition. If it wearied or reused, replace Remove the snap ring from start motor sprocket. Disassemble the drive sprocket and chain. Dismount the fixing bolt of start...
  • Page 78 ZHEJIANG KAYO MOTOR CO., LTD. Disassemble start motor. Check the start motor winding, if it necessary replace it. Disassemble the oil separation disc check condition, necessary replace it. Check oil seal edges for wear. Replace necessary.
  • Page 79 ZHEJIANG KAYO MOTOR CO., LTD. Remove the seal and check the oil ring condition, if it wearied, replace it. For troubleshooting of engine electric starter, please refer to the following table Maintenance of Electric Starter Description Damage form Trouble Cause...
  • Page 80 ZHEJIANG KAYO MOTOR CO., LTD. Circuit diagram...