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KAYO MOTOR AT125-B Service Manual
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KAYO MOTOR AT125-B Service Manual

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ZHE JIANG KAYO MOTOR CO., LTD
Model AT125-B
Service Manual
1
www.RideKayo.com

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Summary of Contents for KAYO MOTOR AT125-B

  • Page 1 ZHE JIANG KAYO MOTOR CO., LTD Model AT125-B Service Manual www.RideKayo.com...
  • Page 2 ZHE JIANG KAYO MOTOR CO., LTD Instruction This manual contains detailed information for Kayo AT125-B (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.
  • Page 3 ZHE JIANG KAYO MOTOR CO., LTD Contents 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 All contents in this manual are subject to improve and update without notice.
  • Page 4 ZHE JIANG KAYO MOTOR CO., LTD Conversion table Item Unit Conversion 1kgf/cm2=98.0665kPa；1kPa=1000Pa Pressure 1PSI=0.0689kgf/cm2 1mmHg=133.322Pa=0.133322kPa Torque 1kgf·m=9.80665N·m 1mL=1cm3=1cc Volume 1L=1000cm3 moment 1kgf=9.80665N Length 1in=25.4mm Danger/warning/attention Take the following warnings seriously, it’s important for regular maintenance, especially important during engine maintenance.
  • Page 5 ZHE JIANG KAYO MOTOR CO., LTD 1.4 Maintenance parameters list 1.1 Safety precautions Safety first 1. Wearing work clothes (coveralls), hat and safety boots suitable for the operation. In some condition’s safety glasses, dust masks, gloves and other safety protective supplies are needed to protect you from injury.
  • Page 6 ZHE JIANG KAYO MOTOR CO., LTD 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.
  • Page 7 ZHE JIANG KAYO MOTOR CO., LTD 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.
  • Page 8 ZHE JIANG KAYO MOTOR CO., LTD 1.2 VIN Number HY110AT（AT125-B） Model VIN number Engine number 1 VIN number 2 Name plate 3 Engine Number 1.3 Specifications, Model information Item www.RideKayo.com...
  • Page 9 ZHE JIANG KAYO MOTOR CO., LTD Brand KAYO Type AT125-B Name 125cc utility ATV Company ZHEJIANG KAYO MOTOR CO., LTD. ● Dimensions, Vehicle Specifications Dimension（L*W*H） （mm） 1380*880*930 Handlebar height（mm） Handlebar width（mm） Rear fender height（mm） Seat height （mm） Min. ground clearance（mm）...
  • Page 10 ZHE JIANG KAYO MOTOR CO., LTD Horizontal Single cylinder, four stroke, air Engine type cooling Air distribution SOHC/Chain drive Cylinder diameter × stroke（mm） 52.4*49.5 Compression ratio 9.0 :1 Lubrication mode Pressure + splash lubrication Oil pump type Rotor type Lubricating oil filter type Full flow filter rotary, Paper filter core No.
  • Page 11 ZHE JIANG KAYO MOTOR CO., LTD Output type Chain drive, rear wheel drive Brake type Front and rear disc brake Suspension type Double rocker independent type Frame type Welded steel tube sheet ● Engine Specifications ● Lubrication system Item Standard Limitation －...
  • Page 12 ZHE JIANG KAYO MOTOR CO., LTD Vertical 1.0mm 2.0mm Rim jump Horizontal 1.0mm 1.8mm Thread 3.0mm Tire Air Pressure 4.0 PSI ●Brake system Item Standard limited disc thickness 3.5mm Front brake Brake lever stroke 5~10mm Braking force 400N*m disc thickness 3.5mm...
  • Page 13 ZHE JIANG KAYO MOTOR CO., LTD Pulse 2Vac ●Light / Instrument / Switch Item Standard Accessory inline fuse Light Headlight 12V*3W*2 Taillight / brake light Gear Indicator ●Valve mechanism + cylinder cover（see engine section） ●Cylinder + piston + piston ring + crank connecting link（see engine section）...
  • Page 14 ZHE JIANG KAYO MOTOR CO., LTD 18~25（with Rear disc 8.8 Grade blue thread sealants） Front disc 10.9 Grade 15~20 Brake Caliper 10.9Grade 29~35 Front Brake Tee 18~25 Rear Axle M12*1.25 55~65 Rear Axle M27*1.5 80~90 Chain bolt 8~12 Handlebar 10.9...
  • Page 15 ZHE JIANG KAYO MOTOR CO., LTD ● 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 Smear Position Function Grease Dust cap for rocker arms...
  • Page 16 ZHE JIANG KAYO MOTOR CO., LTD 1.6 Wiring and cable Routing diagrams Front brake line Main Harness Throttle Cable Rear brake line Choke cable www.RideKayo.com...
  • Page 17 ZHE JIANG KAYO MOTOR CO., LTD Brake cable connector Kill switch connector Neutral indicator connector Reverse indicator connector Key switch Combination switch connector Headlight connector Positive Negative Stator connector battery battery cable cable Rectifier regulator connector Gear display connector www.RideKayo.com...
  • Page 18 ZHE JIANG KAYO MOTOR CO., LTD Tail Rectifier light Regulator Ignition Coil www.RideKayo.com...
  • Page 19 ZHE JIANG KAYO MOTOR CO., LTD 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.
  • Page 20 ZHE JIANG KAYO MOTOR CO., LTD 1 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 5．Pull out the air door line according to battery) the graphic direction, then remove the choke cable.
  • Page 21 ZHE JIANG KAYO MOTOR CO., LTD Installation In reverse order from disassembly, follow steps 7. Through 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 remove the seat.
  • Page 22 ZHE JIANG KAYO MOTOR CO., LTD Mounting bolt Installation 1. position the front bumper lining up mounting holes install the mounting bolts loosely. Then adjust bumper into position and tighten bolts. 2.3.5 Plastic Body Disassembly 1. Disconnect all necessary electrical connectors.
  • Page 23 ZHE JIANG KAYO MOTOR CO., LTD Installation Install the plastic body in reverse order from disassembly. *check all electrical connectors, cable, and hose routing after installation. 2.3.6 Middle guard Disassembly 1. Remove the mounting bolts of the left fender in turn.
  • Page 24 ZHE JIANG KAYO MOTOR CO., LTD (Note: replace mounting bolts, nuts and rubber washers if damaged or worn) 2.3.7 Rear body Disassembly 1. Remove the mounting bolt 1/2,3/4,5/6,7/8, (and corresponding bolts on opposite side). 2. Take the rear body off.
  • Page 25 ZHE JIANG KAYO MOTOR CO., LTD Push the left guard plate according to the direction showed on the picture, loosen the buckle on the plastic part, and remove the left guard plate. Installation Installation is done in reverse order. (Note: replace locking nuts and rubber washers as needed.) 2.3.9 Front body...
  • Page 26 ZHE JIANG KAYO MOTOR CO., LTD remove the handlebar (Note: 1. Remove the front body mounting bolts 1/2, 3/4 and oil tank cap. 2. Remove the key switch, headlight connector, then remove the front body. fuel tank Installation 1. Install in reverse order from disassembly.
  • Page 27 ZHE JIANG KAYO MOTOR CO., LTD 2.3.10 Foot peg guards Disassembly 1. Remove mounting bolts 1, 2 and 3. 2. Remove the foot guard. 2，3 Installation Install in reverse order of disassembly. （Note: replace mounting bolts, nuts and rubber washers in time, once they worn).
  • Page 28 ZHE JIANG KAYO MOTOR CO., LTD Installation Install in reverse order of disassembly. （Note: replace mounting bolts, nuts and rubber washers in time, once they worn). 3. Regular maintenance and adjustment 3.1 Maintenance information 3.5 Suspension system 3.2 Maintenance period 3.6 Gear box and fuel system...
  • Page 29 ZHE JIANG KAYO MOTOR CO., LTD  To prevent burns, don’t touch the engine or exhaust until it has cooled down., please wear long sleeves work clothes and gloves.  Gasoline is flammable and explosive. Pay attention to sparks as well as open flames.
  • Page 30 ZHE JIANG KAYO MOTOR CO., LTD Inspection and maintenance items Period of maintenance Judging Standard Half Maintenance Parts Inspection Item Daily Year year ○ Handle Bar Operation Flexibility Steering ○ Damage Device Steering System ○ Installation conditions ○ Shaking of Ball pin ○...
  • Page 31 ZHE JIANG KAYO MOTOR CO., LTD ○ Battery Terminal connection status ○ Electric circuit Loosening and damage at ○ joints Fuel System Fuel leaking Throttle turn handle with clearance ○ Throttle Condition 3~5mm ○ ○ Light & Indicators Function loose...
  • Page 32 ZHE JIANG KAYO MOTOR CO., LTD 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 and clamps. Keep vehicle in steady place and turn the handlebars slowly making sure movement is smooth.
  • Page 33 ZHE JIANG KAYO MOTOR CO., LTD Brake fluid lower limit Note: ● When adding brake fluid, do not mix with dust or water, always add fluid from a new sealed container. ● Brake fluid can damage plastic, painted, and rubber surfaces. Wipe clean...
  • Page 34 ZHE JIANG KAYO MOTOR CO., LTD bearings, ball joints, a-arm bushings. Replace if worn or damaged. Front wheel size On a level surface with handle bars straight check 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 specification：B-A=4 ~ 10mm...
  • Page 35 ZHE JIANG KAYO MOTOR CO., LTD Tire tread Check Tire tread, if tread is less than 3mm, replace it. 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 in the shock absorber, or check for damage or loosening in the fastening parts.
  • Page 36 ZHE JIANG KAYO MOTOR CO., LTD Changing gears, with the shift lever should be smooth and gear changes should have a positive firm feeling. Gear lever Fuel device Remove the plastic parts first. Check fuel vacuum and vent lines for aging, dry rot cracks and damage. Replace if any damages are found or if more than 2 years old.
  • Page 37 ZHE JIANG KAYO MOTOR CO., LTD Pull back rubber sleeves 1-2. Loosen lock nut 3 and barrel adjuster 4 then adjust throttle freeplay to within specification. Speed limiting device adjustment Speed limit device is used to restrict throttle opening. 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.
  • Page 38 ZHE JIANG KAYO MOTOR CO., LTD Suspension pre-load adjustment Front shock is nonadjustable. Rear shock can be adjusted from 1 to 5. This is set in the middle at 3 from the factory. Spanner wrench Adjustment: 1. Using a shock absorber Spanner wrench.
  • Page 39 ZHE JIANG KAYO MOTOR CO., LTD －oil pump －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 40 ZHE JIANG KAYO MOTOR CO., LTD mounting bolt of fuel tank Installation Install tank in reverse order from disassembly. *Check for aged, worn, dried or cracked hoses replace before installing when necessary 4.3 Air filter system Disassembly Loose the air filter clamp to remove air filter.
  • Page 41 ZHE JIANG KAYO MOTOR CO., LTD Exhaust system Disassembly Disassemble the clamp between muffler and exhaust head pipe, then remove the muffler mounting bolt to remove muffler. Mounting bolt clamp 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.
  • Page 42 ZHE JIANG KAYO MOTOR CO., LTD oil cooler first) 1. Remove the engine front sprocket side cover, then remove chain. 2. Remove the ground lead, and all electrical connectors, exhaust pipe, and gear shifter. starter motor ground Stator Crankcase gear indicator...
  • Page 43 ZHE JIANG KAYO MOTOR CO., LTD 4. Remove the engine from the right side of vehicle. Installation Installation shall be in the reverse order of removal. 5. Engine Maintenance information Conversion table refers item Unit conversion 1kgf/cm =98.0665kPa 1kPa=1000Pa pressure 1mmHg=133.322Pa=0.133322kPa...
  • Page 44 ZHE JIANG KAYO MOTOR CO., LTD Warn to be alert to moderate danger. Attention to be alert to minor danger. This manual may doesn’t contain some potential risks in engine work and maintenance; the service operator should also have basic mechanical knowledge.
  • Page 45 ZHE JIANG KAYO MOTOR CO., LTD 5.2 Engine oil and fuel Fuel: Use octane 93# or higher unleaded gasoline. Engine oil： Use sae15w-40 oil for 4 stroke motorcycle, quality grade according to the classification of the API SG level or by the superior, if no SAE15W - 40 oil, according to the engine using the environment temperature, as the picture on the below is shown.
  • Page 46 ZHE JIANG KAYO MOTOR CO., LTD block, mutually meshing transmission gear wheel, etc. 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, correction work, form good heavy load to bear a smooth friction surface.
  • Page 47 ZHE JIANG KAYO MOTOR CO., LTD Engine head displacement label Label Maintenance Subsidiary 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...
  • Page 48 ZHE JIANG KAYO MOTOR CO., LTD 5.4.1 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 acorn nuts of cylinder head from cylinder studs Dismantle the fixing bolt of left cover.
  • Page 49 ZHE JIANG KAYO MOTOR CO., LTD Remove left cover and inspect the paper pad/gasket for damage. Replace if necessary Dismantle the fixing bolt of right cover. Remove the right cover of cylinder head. Inspect the gasket for damage and replace if necessary.
  • Page 50 ZHE JIANG KAYO MOTOR CO., LTD 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. Remove the fixing bolts of cam sprocket.
  • Page 51 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 52 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 deposits and dirt. Check the spark plug gap and set it to 0.6 to 0.7 if necessary.
  • Page 53 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 on Poor heat radiation of the The engine overheats. Remove the oil dirt or sand the cooling fins.
  • Page 54 ZHE JIANG KAYO MOTOR CO., LTD 5.4.2 Disassemble, assemble and maintain cylinder Remove cylinder gasket and dowel pin to check Dismantle fixing bolt of timing chain of guide for wear and damage. Replace if necessary. wheel. Remove the guide wheel of timing chain to Dismantle connecting bolt of cylinder block.
  • Page 55 ZHE JIANG KAYO MOTOR CO., LTD www.RideKayo.com...
  • Page 56 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 57 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 exceeded the limit value. Measure the diameter form upper, middle and lower position. The limit value is 50.
  • Page 58 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 59 ZHE JIANG KAYO MOTOR CO., LTD Left view of right crankcase half is shown in fig and check whether bearing of main shaft and countershaft are worn. Replace if necessary. Right view of right crankcase half is shown in fig and check the state of right crankcase half.
  • Page 60 ZHE JIANG KAYO MOTOR CO., LTD Right view of right crankcase half is shown in fig and check whether bearing of main shaft and countershaft are worn. Replace if necessary. Dismantle fixing bolt of left crankcase cover. Remove the neutral indicator and check the state. Replace if necessary.
  • Page 61 ZHE JIANG KAYO MOTOR CO., LTD Dismantle the fixing bolt of magneto stator and remove the stator. Check the condition of left crankcase cover and replace if necessary. www.RideKayo.com...
  • Page 62 ZHE JIANG KAYO MOTOR CO., LTD Troubleshooting of crankcase, please refer to the following table. Trouble Description Problem Computation Correction Oil leakage from the Repair or replace the Crack in the crank case crankcase crankcase Replace the gasket Oil leakage from the...
  • Page 63 ZHE JIANG KAYO MOTOR CO., LTD cover The gasket of left Oil leakage between Replace the gasket crankcase is broken the case cover and the case 5.4.4 Maintenance of Crankshaft Connecting Rod Disassemble, assemble and maintain crankshaft connecting rod Remove the fixing bolt of crankcase from its holding place.
  • Page 64 ZHE JIANG KAYO MOTOR CO., LTD Remove the paper pad to inspect for wear and damage. Replace if necessary. Remove the connecting rod 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.
  • Page 65 ZHE JIANG KAYO MOTOR CO., LTD 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. Replace the conrod if the jumping is large.
  • Page 66 ZHE JIANG KAYO MOTOR CO., LTD Replace the piston if the gap is too wide. 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.
  • Page 67 ZHE JIANG KAYO MOTOR CO., LTD Assemble the piston ring according to the finned and check whether piston ring is damaged or the elasticity is weakened. Replace if necessary. For the troubleshooting of crankshaft connecting rod mechanism, please refer to the following table.
  • Page 68 ZHE JIANG KAYO MOTOR CO., LTD big-end needle Radial and axes gap of the Striking sound of the big-end Replace crankshaft Bearing bearing is over worn connecting rod big end is too large bearing; and of the cylinder connecting rod...
  • Page 69 ZHE JIANG KAYO MOTOR CO., LTD Disassemble, assemble and maintain valve mechanism Remove rocker arm shaft Remove the rocker arm of inlet/exhaust valve and check the state Remove the timing cam, rocker arm, rocker arm shaft to inspect for worn. Replace if necessary.
  • Page 70 ZHE JIANG KAYO MOTOR CO., LTD Measure length of valve spring to check whether the spring is damaged or worn. Replace if 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 71 ZHE JIANG KAYO MOTOR CO., LTD Check the external diameter of valve stem using a Vernier 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 72 ZHE JIANG KAYO MOTOR CO., LTD 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 using a micrometer. Replace the rocker arm shaft if the valve is beyond the maintenance limit valve.
  • Page 73 ZHE JIANG KAYO MOTOR CO., LTD necessary. 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.
  • Page 74 ZHE JIANG KAYO MOTOR CO., LTD 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 valve cap and check the condition.
  • Page 75 ZHE JIANG KAYO MOTOR CO., LTD crankcase cover. Check whether the O-mark on cam sprocket is aimed to the gap of cylinder head. Readjust if necessary. Set the valve clearance of rear cylinder to 0.05mm~0.06mm. www.RideKayo.com...
  • Page 76 ZHE JIANG KAYO MOTOR CO., LTD For the troubleshooting of engine distribution mechanism, please refer to the following table Maintenance of Distribution Mechanism Descriptions Damage form Trouble Cause Correction Valve oil seal The edge of valve oil seal is Thick blue and white fume form Replace the worn, age or damage.
  • Page 77 ZHE JIANG KAYO MOTOR CO., LTD Valve striking sound The rocker arm shaft hole is Big gap between the rocker Replace the rocker over worn arm and rocker arm shaft Valve striking sound The rocker arm shaft is over Big gap between the rocker...
  • Page 78 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 of float chamber cap.
  • Page 79 ZHE JIANG KAYO MOTOR CO., LTD Remove the float needle valve to inspect for wear and 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 80 ZHE JIANG KAYO MOTOR CO., LTD 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 compressed air if necessary. www.RideKayo.com...
  • Page 81 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: Tighten mixture screw,...
  • Page 82 ZHE JIANG KAYO MOTOR CO., LTD Adjust the oil needle to the third tier. If the clip rises, concentration of mixture becomes dilute and if falls it becomes thick. 5.7 Maintenance of Intake/Exhaust System 5.7.1 Disassemble, assemble and maintain intake system...
  • Page 83 ZHE JIANG KAYO MOTOR CO., LTD 5.8 Disassemble, assemble and maintain exhaust system Remove the fixing bolt from left crankcase cover. Dismantle suspension bolt of muffler to check whether the suspension support is damaged. Repair or replace if necessary. Remove the muffler to inspect for broken and damage. Replace or repair if necessary.
  • Page 84 ZHE JIANG KAYO MOTOR CO., LTD Remove the washer of muffler to inspect for damage. Replace if necessary. www.RideKayo.com...
  • Page 85 ZHE JIANG KAYO MOTOR CO., LTD 5.9 Disassemble, assemble maintain the environmental protection Valve Inspect the locknut for tightness and tighten as necessary. Inspect the connecting circlip of air pump for tightness. Tighten if necessary. Description Damage form Trouble Cause...
  • Page 86 ZHE JIANG KAYO MOTOR CO., LTD 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. Maintenance of environment protection valve...
  • Page 87 ZHE JIANG KAYO MOTOR CO., LTD 5.10 Disassembly, assembly, maintenance and management of electric starter Remove the fixing bolts on the cover of left crankcase Remove the fixing bolts of file display. Then remove the file display and check for wear and damage.
  • Page 88 ZHE JIANG KAYO MOTOR CO., LTD Remove the gasket and check the condition. If it is worn, please replace it. Remove the fixing bolt of magnetic stator and bolt of trigger. Check the status of stator with a multimeter. If it is worn, please replace with the new one.
  • Page 89 ZHE JIANG KAYO MOTOR CO., LTD Remove the rotor and check if the rotor is demagnetized. Replace it when necessary. Remove the fixing bolt of overrunning clutch Remove the clutch. Check for wear and damage to the clutch seats, rollers and springs.
  • Page 90 ZHE JIANG KAYO MOTOR CO., LTD Disassemble the pressing plate of start sprocket 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 it. www.RideKayo.com...
  • Page 91 ZHE JIANG KAYO MOTOR CO., LTD Remove the snap ring from start motor sprocket Remove the drive sprocket and chains Remove the fixing bolt of electric starter www.RideKayo.com...
  • Page 92 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. www.RideKayo.com...
  • Page 93 ZHE JIANG KAYO MOTOR CO., LTD Check the edges of the oil seal for wear. Replace it when necessary. Remove the seal ring. Check the status of oil seal ring and replace it when necessary. www.RideKayo.com...
  • Page 94 ZHE JIANG KAYO MOTOR CO., LTD www.RideKayo.com...
  • Page 95 ZHE JIANG KAYO MOTOR CO., LTD For the troubleshooting of engine electric starter, please refer to the following table. Maintenance of Electric Starter Description Damage form Trouble Cause Correction Carbon brush is over worn. Starter motor has insufficient Replace carbon brush The carbon brush spring is rotation force or it is out of work.
  • Page 96 ZHE JIANG KAYO MOTOR CO., LTD www.RideKayo.com...