KAYO MOTOR FOX 70 Service Manual
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KAYO MOTOR FOX 70 Service Manual

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ZHEJIANG KAYO MOTOR CO., LTD.
Model AY70-2
FOX 70
Service Manual
1
WWW.RIDEKAYO.COM

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Summary of Contents for KAYO MOTOR FOX 70

  • Page 1 ZHEJIANG KAYO MOTOR CO., LTD. Model AY70-2 FOX 70 Service Manual WWW.RIDEKAYO.COM...
  • Page 2 ZHEJIANG KAYO MOTOR CO., LTD. Instruction This manual contains detailed information for AY70-2 (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: Conversion Table

    ZHEJIANG KAYO MOTOR CO., LTD. ZHEJIANG KAYO MOTOR CO., LTD. Conversion table Unit conversion Item 1kgf/cm =98.0665kPa；1kPa=1000Pa pressure 1PSI=0.0689kgf/cm 1mmHg=133.322Pa=0.133322kPa 1kgf·m=9.80665N·m Torque 1mL=1cm =1cc volume 1L=1000cm Moment 1kgf=9.80665N 1in=25.4mm Length Danger/warning/attention Take the below explanations seriously, it’s important for maintenance, especially important during engine maintenance.

  • Page 4: Service Information

    ZHEJIANG KAYO MOTOR CO., LTD. Service Information 1.1 Warnings 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 Safety precautions Safety first 1. Wearing work clothes (coveralls), hat and safety boots suitable for the operation. In some conditions safety glasses, dust masks, gloves and other safety protective supplies are needed to protect you from injury.
  • Page 5 ZHEJIANG KAYO MOTOR CO., LTD. 1. All the Parts, lubricants oils and fluids must be Kayo brand parts or Kayo recommends. 2. During disassembly, Please sort and separate out the parts and fasteners of each system to ensure that everything is put back together properly.
  • Page 6 ZHEJIANG KAYO MOTOR CO., LTD. bearing, make the manufacturer's logo and dimensions outwards. 14. Let the chamfered side towards force direction when install the Snap-ring. Do not use the rings without elasticity. After assembly, rotate the Snap-ring to confirm that it is firmly installed in the slot.

  • Page 7: Vin Number

    ZHEJIANG KAYO MOTOR CO., LTD. smooth friction surface which can bear heavy load, by this way the engine will have excellent performance and reliability. Recommended break-in time is 20 hours, as follows: 0~10 hours: Operate at no more than ½ throttle, keep gear changes and speed variances to a minimum.
  • Page 8 ZHEJIANG KAYO MOTOR CO., LTD. VIN Number Frame stamp Engine number VIN/ Nameplate WWW.RIDEKAYO.COM...
  • Page 9 ZHEJIANG KAYO MOTOR CO., LTD. 1.4 Specifications, Model information Item KAYO Brand AY70-2 Type 70cc utility ATV Name Company ZHEJIANG KAYO MOTOR CO., LTD. ● Dimensions, Vehicle Specifications 1230*800*870 Dimension（L*W*H）（mm） Handlebar height（mm） Handlebar width（mm） Rear height（mm） Ground clearance of seat（mm）...
  • Page 10 ZHEJIANG KAYO MOTOR CO., LTD. 76±2 Net weight（Kg） Kerb weight （ battery+fuel） （Kg） 40（limited speed） Max. Speed Km/h ● Engine parameters Item Starting type Electric horizontal，Single cylinder, four stroke, oil Type cooling SOHC/chain drive Distribution way 47*41.4 Cylinder diameter × mileage （mm）...
  • Page 11 ZHEJIANG KAYO MOTOR CO., LTD. Gearshift method CVT without reverse gear Gear range Shift type R~N~D Forward gear D Reverse gear R Primary Gear hub of clutch/primary gear Reduction ratio Single-sta Gear ratio of forward Gear ratio gear forward gear Overall ●...
  • Page 12 ZHEJIANG KAYO MOTOR CO., LTD. 0.023 mm ～0.055 mm Axial clearance between 0.12 mm rotor surface and pump body 1500r/min ，90℃: 200 kPa ~400kPa， pump Oil pressure General 240 kPa rotor 6000r/min ，90℃:600 kPa ~700kPa， ● general 600 kPa Air intake system（ see engine section）...
  • Page 13 ZHEJIANG KAYO MOTOR CO., LTD. Item Standard Ignition method CDI electric ignition Type Resistor type spark plug Sparking plug Standard ATR7C/（torch） 0.6~0.7mm Spark character >8mm, one bar Spark advance angle 0.43~0.57Ω Ignition coil Primary resistance 10.1~11KΩ Secondary Peak voltage Primary ignition coil >150V...

  • Page 14: Fastener Torque Specifications

    ZHEJIANG KAYO MOTOR CO., LTD. 1.5 Fastener Torque Specifications Note: When installing threads, please manually attach 2~3 turns of thread first. Torque Specifications chart Bolt Moment Item install position Class specification 10.9 37~50 Lower mounting bolt Engine 10.9 37~50 Upper...
  • Page 15 ZHEJIANG KAYO MOTOR CO., LTD. 8~12 Chain bolt 10.9 18~25 Clamp locking bolt （hexagon） Turning 18~25 Steering column locking M10*1.5 10.9 50~60 Bolt of lower raiser 15~20 Electrical Battery box elements 15~20 Muffler installation 7~11 Voltage regulator ignition coil 7~11...
  • Page 16 ZHEJIANG KAYO MOTOR CO., LTD. ● ） Engine special tool（ see engine section 1.6 lubricating grease and sealant Position Effect Grease Dust cap for rocker arms Ball joint of rocker arms Steering column bottom Joints of knuckle and wheel hub...
  • Page 17 ZHEJIANG KAYO MOTOR CO., LTD. 1.7 Wiring diagram of cable, hosepipe and inhaul cable Main cable Front Brake Line Throttle cable Rear Brake Line Choke cable WWW.RIDEKAYO.COM...
  • Page 18 ZHEJIANG KAYO MOTOR CO., LTD. Brake switch wires Kill tether switch Neutral display Reverse gear display Electrical lock MultiFunctional switch Headlight Positive Negative Starter relay battery battery connector cable cable Voltage regulator Gear indicator WWW.RIDEKAYO.COM...
  • Page 19 ZHEJIANG KAYO MOTOR CO., LTD. Voltage Taillight Regulator Ignition coil WWW.RIDEKAYO.COM...

  • Page 20: Maintenance Cautions

    ZHEJIANG KAYO MOTOR CO., LTD. 2 Plastic body 2.1 Maintenance warnings 2.2 Installation torque 2.3 Seat, front guard, clay, hood, rear body, left and right guard, plastic pedal, dismounting left and right pedal 2.1 Maintenance cautions Operation cautions When replacing plastics parts, please install new warning labels, stickers and riveted tags to the new plastics.
  • Page 21 ZHEJIANG KAYO MOTOR CO., LTD. Disassembly 1. Remove the bolts 1 and 2. 2. Push down and gently pull the hood forward to remove. (Be careful as the tabs are easy to break) Installation In reverse order of disassembly. Locate...
  • Page 22 ZHEJIANG KAYO MOTOR CO., LTD. Throttle MultiFunction Rear brake Front brake assembly switch Choke lever Tether kill switch Installation In reverse order from disassembly, then check if it installed well. note:1. after installation, check the flame-out switch connector, function switch connector, brake connector etc., in case of misconnection or looseness.

  • Page 23: Front Bumper

    ZHEJIANG KAYO MOTOR CO., LTD. 2.3.3 Seat Disassembly 1. Press the back of the seat cushion meanwhile open the seat cushion hook 2. Lift the seat cushion tail and pull the seat cushion back Seat release lever Installation Take it back in reverse order from disassembly.
  • Page 24 ZHEJIANG KAYO MOTOR CO., LTD. Bumper Mounting bolts 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) 2.3.5 Plastic Body Disassembly 1. Disconnect all necessary electrical connectors.
  • Page 25 ZHEJIANG KAYO MOTOR CO., LTD. Oil tank cap 安装 WWW.RIDEKAYO.COM...
  • Page 26 ZHEJIANG KAYO MOTOR CO., LTD. Installation Install the plastic body in reverse order from disassembly. （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.)
  • Page 27 ZHEJIANG KAYO MOTOR CO., LTD. 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.) The removal of the left pedal is the same as the right one.

  • Page 28: Maintenance Information

    ZHEJIANG KAYO MOTOR CO., LTD. 3.1 Maintenance information Warnings Note:  Do not run the engine in unventilated places, because the exhaust contains carbon monoxide (CO) and other toxic components.  To prevent burns, don’t touch the engine or exhaust until it has cooled down., please wear long sleeves work clothes and gloves.
  • Page 29 ZHEJIANG KAYO MOTOR CO., LTD. A： adjustment 10 hours or 300km 20 hours or 750km C： clean per 50 hours or 1500km per 100 hours or 3000km or one 年 I： inspection per 200hours or 6000km L： lubrication 或 2 years...
  • Page 30 ZHEJIANG KAYO MOTOR CO., LTD. Replace the disc in time, Hydraulic when front or rear brake brake and working disc’s thickness Tear and damage of brake disc ○ ○ brake disc is less than 3mm. The minimum brake pad （ friction plate ）...
  • Page 31 ZHEJIANG KAYO MOTOR CO., LTD. Frame Looseness and damage ○ Other state of grease in frame each part ○ Exception can be indentified in Make sure relevant parts are normal. ○ operation. 3.4 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.
  • Page 32 ZHEJIANG KAYO MOTOR CO., LTD. is smooth. If it is hard to turn, check cable, hose and wire routing, if there is no problem, check steering rods and connecting points for damage. Note: the steering handlebar must be smooth, or it may cause accidents due to out of control.
  • Page 33 ZHEJIANG KAYO MOTOR CO., LTD. Brake fluid lower limitation Note: ● When adding brake fluid, do not mix with dust and water. ● In order to prevent chemical changes, please choose the specified brand of brake fluid. ● As brake fluid will damage the plastic and rubber surfaces, please do not splash it on the parts.
  • Page 34 ZHEJIANG KAYO MOTOR CO., LTD. Wheel With the atv on a jack of atv lift. Lift the front wheels off the ground. Push and pull the wheel in and out as shown in the diagram. If there is movement, check torques on hub, steering shafts, spindles.
  • Page 35 ZHEJIANG KAYO MOTOR CO., LTD. Check the tyre pressure with a tire pressure gauge. (pressure range: 4~6PSI) Note: Check the tire pressures while the tire is cool . If tire pressure is out of specification please adjust to within range specified. Riding with tires out of...

  • Page 36: Suspension System

    ZHEJIANG KAYO MOTOR CO., LTD. Suspension system Keep vehicle in a horizontal position and compress up and down for several times according to the pictures. If there is shaking or abnormal sound, check whether there is oil leakage in the shock absorber, and whether there is damage or loosening in the fastening parts.
  • Page 37 ZHEJIANG KAYO MOTOR CO., LTD. Freeplay : 3~5mm Adjust throttle free play if out of specification. WWW.RIDEKAYO.COM...
  • Page 38 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 39: Engine Systems

    ZHEJIANG KAYO MOTOR CO., LTD. adjust the softness and hardness of absorber Absorber adjusting wrench Engine systems 4.1 Maintenance information 4.3 Air intake system 4.2 Fuel system 4.4 Exhaust system 4.5 Disassembly and installation of engine Maintenance information Precautions ● Before performing maintenance, please make sure that the engine is not running,...
  • Page 40 ZHEJIANG KAYO MOTOR CO., LTD. battery is disconnected and that the heated parts have cooled, to avoid injury. ● Do not damage the frame, engine body, bolts and cables during maintenance. ● In order to protect the engine frame, please wrap the engine before operating.

  • Page 41: Fuel System

    ZHEJIANG KAYO MOTOR CO., LTD. Fuel system Gasoline is flammable and explosive. Pay attention to sparks and open flame. Vaporized gasoline may explode if exposed to open flame or sparks , please choose well-ventilated areas away form these hazards when refueling or working on the fuel system and its related components.

  • Page 42: Air Intake System

    ZHEJIANG KAYO MOTOR CO., LTD. Air intake system Disassembly Loosen the air filter clamp and exhaust pipe to remove air filter. Air filter Exhaust clamp pipe Installation Installation shall be in the reverse order of removal. Make hose clamp is in the groove and any vacuum lines are hooked up correctly.
  • Page 43 ZHEJIANG KAYO MOTOR CO., LTD. Remove the self locking nut 3 between exhaust mouth and exhaust pipe,then remove exhaust pipe. 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.
  • Page 44 ZHEJIANG KAYO MOTOR CO., LTD. Gearshift ignition lever coil cap 3. Remove the power bolts, lug, and bolt of engine bottom. 4. Remove the engine from the right side of vehicle. Installation Installation shall be in the reverse order of removal.
  • Page 45 ZHEJIANG KAYO MOTOR CO., LTD. Engine Maintenance information Conversion table refers Item Unit conversion 1kgf/cm =98.0665kPa 1kPa=1000Pa Pressure 1mmHg=133.322Pa=0.133322kPa Torque 1kgf · m = 9 . 8 0 6 6 5 N ·m 1mL=1cm =1cc Volume 1L =1000cm Moment 1kgf=9.80665N Danger/warning/attention Take it seriously, it’s important for maintenance.
  • Page 46 ZHEJIANG KAYO MOTOR CO., LTD. ● When starting the engine indoors, be sure to vent the exhaust outside . ● If toxic or flammable substances are used, handle that in accordance with the manufacturer's instructions strictly and make sure workplace must be well ventilated.

  • Page 47: Engine Oil And Fuel

    ZHEJIANG KAYO MOTOR CO., LTD. 5.2 Engine oil and fuel temperature, as the picture on the right is Fuel: Use octane 93# or higher Warning: shown. unleaded gasoline Engine oil：Use sae15w-40 oil for 4 stroke motorcycle, quality grade according to the classification of the API...

  • Page 48: Maintenance

    ZHEJIANG KAYO MOTOR CO., LTD. Engine number Engine Number Engine head displacement label displacement 5.4 Maintenance WWW.RIDEKAYO.COM...
  • Page 49 ZHEJIANG KAYO MOTOR CO., LTD. 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 Clean Clean Clean...
  • Page 50 ZHEJIANG KAYO MOTOR CO., LTD. Left view of the 125 engine is shown in the figure. Remove the locknut of cylinder head from its holding place WWW.RIDEKAYO.COM...
  • Page 51 ZHEJIANG KAYO MOTOR CO., LTD. Remove cylinder head. Check the state of paper pad. Replace if necessary. Dismantle the fixing bolt of left cover. WWW.RIDEKAYO.COM...
  • Page 52 ZHEJIANG KAYO MOTOR CO., LTD. Remove left cover and inspect the paper pad for damage. Replace if necessary. Dismantle the fixing bolt of right cover. Remove the right cover of cylinder head. Inspect the gasket for damage and replace if necessary.
  • Page 53 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. WWW.RIDEKAYO.COM...
  • Page 54 ZHEJIANG KAYO MOTOR CO., LTD. Remove the connecting bolt of cylinder head. Remove cylinder head assembly. WWW.RIDEKAYO.COM...
  • Page 55 ZHEJIANG 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 56 ZHEJIANG 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. WWW.RIDEKAYO.COM...
  • Page 57 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. WWW.RIDEKAYO.COM...
  • Page 58 ZHEJIANG 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 59 ZHEJIANG KAYO MOTOR CO., LTD. 5.4.2Disassemble, assemble and maintain cylinder block Remove cylinder gasket and dowel pin to check for Dismantle connecting bolt of cylinder block. wear and damage. Replace if necessary. Dismantle the fixing bolt of timing chain of guide wheel.
  • Page 60 ZHEJIANG KAYO MOTOR CO., LTD. WWW.RIDEKAYO.COM...
  • Page 61 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 gasoline if necessary.
  • Page 62 ZHEJIANG KAYO MOTOR CO., LTD. Check state 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. limit value 52.05mm.Replace the cylinder block if it has beyond this value.
  • Page 63 ZHEJIANG KAYO MOTOR CO., LTD. WWW.RIDEKAYO.COM...
  • Page 64 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 Excessive oil Poor heat The engine overheats Remove the oil dirt or sand on...
  • Page 65 ZHEJIANG KAYO MOTOR CO., LTD. 5.4.3Disassemble, 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 66 ZHEJIANG KAYO MOTOR CO., LTD. Left view of right crankcase half is shown in fig and check whether bearing main shaft 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 67 ZHEJIANG KAYO MOTOR CO., LTD. Left view of left crankcase is shown below check whether the oil seal of countershaft and oil seal edge of gearshift lever are worn .Replace if necessary. Right view of right crankcase half is shown in fig and check whether bearing of main shaft and countershaft are worn.
  • Page 68 ZHEJIANG KAYO MOTOR CO., LTD. Dismantle fixing bolt of left crankcase cover. 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...
  • Page 69 ZHEJIANG KAYO MOTOR CO., LTD. cover and replace if necessary. 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 Replace the gasket...
  • Page 70 ZHEJIANG KAYO MOTOR CO., LTD. 5.4.4Maintenance of Crankshaft Connecting Rod Disassemble, 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 when removing the left crankcase.
  • Page 71 ZHEJIANG 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. WWW.RIDEKAYO.COM...
  • Page 72 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 value. micrometer. Replace the piston pin if the value is over the maintenance limit WWW.RIDEKAYO.COM...
  • Page 73 ZHEJIANG KAYO MOTOR CO., LTD. Check the axial and radial jumping 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.
  • Page 74 ZHEJIANG 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 75 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 on piston Remove the carbon...
  • Page 76 ZHEJIANG KAYO MOTOR CO., LTD. Crank pin The crank pin is over Radial and axes gap of the Striking sound of the big-end Replace worn connecting rod big end is too large bearing; Striking sound of the crankshaft cylinder connecting rod...
  • Page 77 ZHEJIANG KAYO MOTOR CO., LTD. 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 Remove the timing cam, rocker arm , rocker arm shaft to inspect for worn.Replace if necessary.
  • Page 78 ZHEJIANG KAYO MOTOR CO., LTD. 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. Measure length of valve spring to check whether the spring is damaged or worn.
  • Page 79 ZHEJIANG 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 80 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 81 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. WWW.RIDEKAYO.COM...
  • Page 82 ZHEJIANG KAYO MOTOR CO., LTD. Remove the guide wheel 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.
  • Page 83 ZHEJIANG 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 84 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 85 ZHEJIANG 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 WWW.RIDEKAYO.COM...
  • Page 86 ZHEJIANG KAYO MOTOR CO., LTD. The edge of valve oil seal Thick blue and white fume form Replace the Valve oil seal is worn, age or damage. the exhaust muffler pipe complete set of valve oil seal The cam is cover worn...
  • Page 87 ZHEJIANG KAYO MOTOR CO., LTD. Replace the valve The working surface is over It is impossible to fit the The engine starts hard or fails to worn or has pits, pock valve and the valve seat start. Insufficient engine output;...
  • Page 88 ZHEJIANG KAYO MOTOR CO., LTD. 5.6 Disassemble, assemble and maintain carburetor ） EPA model is not adjustable here Dismantle the fixing bolt of carburetor and circlip of air cleaner. Remove the carburetor .Remove and clean throttle Clean the carburetor as follows: 。Remove the dirt...
  • Page 89 ZHEJIANG 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.
  • Page 90 ZHEJIANG 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. Remove the idle jet and check for plugged.
  • Page 91 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 92 ZHEJIANG KAYO MOTOR CO., LTD. Remove air filter clasp Remove the air filter Remove the air filter to clean shell dust,and open the filter to clean. As the filter is made of paper,so it can not be cleaned. Please replace the new air filter.
  • Page 93 ZHEJIANG 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 94 ZHEJIANG KAYO MOTOR CO., LTD. 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 Exhaust The muffler enclosure Engine exhaust noise is Replace...
  • Page 95 ZHEJIANG KAYO MOTOR CO., LTD. Inspect the connecting circlip of air pump for tightness. Tighten if 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 96 ZHEJIANG 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 97 ZHEJIANG 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 98 ZHEJIANG KAYO MOTOR CO., LTD. Remove the left crankcase cover Remove washer and check condition. Replace if worn or reused. Remove the magnetic stator fixing bolt and trigger bolt WWW.RIDEKAYO.COM...
  • Page 99 ZHEJIANG KAYO MOTOR CO., LTD. Check stator state with multimeter. if worn or reused, replace the parts with new ones Remove rotor retaining nut WWW.RIDEKAYO.COM...
  • Page 100 ZHEJIANG KAYO MOTOR CO., LTD. Remove the rotor with a special tool Remove the rotor and check for demagnetization. Replace if necessary Remove the overclutch retaining bolt. WWW.RIDEKAYO.COM...
  • Page 101 ZHEJIANG KAYO MOTOR CO., LTD. Remove clutch. Inspect clutch seats, rollers and springs for wear and damage. Replace if necessary. Check for wear and damage of drive sprocket and drive gear and replace if necessary Remove the sprocket wheel press board...
  • Page 102 ZHEJIANG KAYO MOTOR CO., LTD. Remove the tension band of the clutch and check its condition. If the tension belt is found to be worn or has problems , the tension belt should be replaced. Remove the snap ring of the starting...
  • Page 103 ZHEJIANG KAYO MOTOR CO., LTD. Remove starter motor retaining bolts. Remove the starting motor. are damaged. Replace if necessary. Check whether the starter windings Remove oil separation disc and check condition. Replace if necessary. WWW.RIDEKAYO.COM...
  • Page 104 ZHEJIANG KAYO MOTOR CO., LTD. Check whether the oil seal is worn. Replace if necessary. Remove the seal ring.Check the Condition of the oil seal ring and replace it is worn. For the troubleshooting of engine electric starter, please refer to the following table.
  • Page 105 ZHEJIANG KAYO MOTOR CO., LTD. Description Damage form Trouble Cause Correction Starter motor has insufficient Carbon brush is over worn. rotation force or it is out of work. The carbon brush spring is Replace carbon brush Starter motor has insufficient...

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