KAYO MOTOR AU125 Service Manual
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KAYO MOTOR AU125 Service Manual

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ZHEJIANG KAYO MOTOR CO., LTD.
Model AU125
Service Manual
1
www.kayomoto.us

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Summary of Contents for KAYO MOTOR AU125

  • Page 1 ZHEJIANG KAYO MOTOR CO., LTD. Model AU125 Service Manual www.kayomoto.us...
  • Page 2 ZHEJIANG KAYO MOTOR CO., LTD. www.kayomoto.us...
  • Page 3 ZHEJIANG KAYO MOTOR CO., LTD. Instruction This manual contains detailed information for Kayo AU125(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 4 ZHEJIANG 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...

  • Page 5: Conversion Table

    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 following warnings seriously, it’s important for regular maintenance, especially important during engine maintenance.

  • Page 6: Service Information

    ZHEJIANG KAYO MOTOR CO., LTD. Service Information 1.1 Warnings 1.5 Torque tightening 1.2 VIN Number 1.6 Lubricant, sealant 1.3 Main parameters list 1.7 Cable, hose and wiring diagram 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...
  • Page 7 ZHEJIANG KAYO MOTOR CO., LTD. 4. Gaskets, o-rings, piston pin, piston ring, cotter pin and other onetime use parts must be replaced after disassembling. 5. Snap rings can be deformed if opened too much during disassembly. DO NOT re-use deform snap rings.
  • Page 8 ZHEJIANG KAYO MOTOR CO., LTD. 16. Brake fluid and coolant can damage surfaces, painted parts, plastic parts, rubber parts, etc., do not let brake fluid contact to these parts, if brake fluid contacts these parts rinse and dilute with water immediately.
  • Page 9 ZHEJIANG KAYO MOTOR CO., LTD. 1.2 VIN Number AU125 Model VIN number Engine number ① VIN number ② Nameplate ③ Engine number WWW.KAYOMOTO.COM...
  • Page 10 ZHEJIANG KAYO MOTOR CO., LTD. 1.3 Specifications, Model information Item Brand KAYO Type AU125 Name 110cc utility ATV Company ZHEJIANG KAYO MOTOR CO., LTD. ● Dimensions, Vehicle Specifications Dimension（L*W*H）（mm） 1400*850*925 Handlebar height（mm） Handlebar width（mm） Rear height（mm） Ground clearance of seat（mm）...

  • Page 11: Engine Specifications

    ZHEJIANG KAYO MOTOR CO., LTD. ● Engine Specifications No. Item Starting type Electric horizontal， Single cylinder, four stroke, oil cooling Type 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...
  • Page 12 ZHEJIANG KAYO MOTOR CO., LTD. ● Frame Drive sprocket ratio 37/13 Output type Chain drive, rear wheel drive Brake type Front and rear disc Suspension type Freestanding double rocker Frame type Steel tube and steel plate welded type ● Lubricating device...
  • Page 13 ZHEJIANG KAYO MOTOR CO., LTD. ● Wheel (front and rear wheels) Item Standard Limitation Vertical 1.0mm 2.0mm Rim jump Horizontal 1.0mm 1.8mm Residual groove 3.0mm Tire Air pressure 4.0 PSI ● Brake system Item Standard Limitation disc thickness 3.5mm Front brake（one...
  • Page 14 ZHEJIANG KAYO MOTOR CO., LTD. Peak voltage Primary ignition coil >150V Pulse ● Light / Instrument / Switch Item Standard Accessory inline fuse Light Headlight left and right 12V*3W*2 Taillight/brake light Gear indicator ● Valve mechanism + cylinder cover（see engine section）...
  • Page 15 ZHEJIANG KAYO MOTOR CO., LTD. 18~25（with Rear disc blue thread sealants） Front disc 10.9 15~20 Brake Disc pump 10.9 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 Clamp locking 10.9 18~25 bolt （hexagon）...
  • Page 16 ZHEJIANG KAYO MOTOR CO., LTD. ● Engine special tool（see engine section） 1.5 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 Installation axle for rear fork...
  • Page 17 ZHEJIANG KAYO MOTOR CO., LTD. Main Harness front brake line Throttle cable rear brake line Choke cable...
  • Page 18 ZHEJIANG KAYO MOTOR CO., LTD. Brake light switch wires Kill switch Neutral indicator Reverse indicator Key Switch Multi Function switch Headlight Battery Battery Stator, ign pickup positive negative connector Voltage regulator Gear indicator...
  • Page 19 ZHEJIANG KAYO MOTOR CO., LTD. Voltage Tail regulator/rect light ifier Ignition coil...

  • Page 20: Maintenance Cautions

    ZHEJIANG 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, please install new warning labels, stickers and riveted tags to the new plastics.
  • Page 21 ZHEJIANG KAYO MOTOR CO., LTD. 2.3.2 Handlebar Disassembly 1. Cut off power first. (disconnect battery). 2. Cut plastic cable ties, then disconnect the combination switch, stop switch and remove right grip. 3. Loose the fixed bolt from brake bar by tool and remove rear brake bar.

  • Page 22: Front Rack

    ZHEJIANG KAYO MOTOR CO., LTD. Installation In reverse order from disassembly, follow steps 5. 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.
  • Page 23 ZHEJIANG KAYO MOTOR CO., LTD. Disassemble rear rack 2 Installation Re install in reverse order. 2.3.6 Plastic Body Disassembly 1. Disconnect all necessary electrical connectors. 2. Disassemble plastic parts fixing bolts1,2， 3,4， 5,6， 7, 8,9, 10 in order on both sides 3.

  • Page 24: Front Guard

    ZHEJIANG KAYO MOTOR CO., LTD. Installation Install the plastic body in reverse order from disassembly. *check all electrical connectors, cable, and hose routing after installation. 2.3.7 front guard Disassembly 1. Disassemble mounting bolt in order. 2. Remove the front guard.

  • Page 25: Maintenance Information

    Engine maintenance is a regular periodic work, due at certain time intervals for engine maintenance, keeping up on standard maintenance will increase the lifespan and reliability of the components, the following is the AU125 engine maintenance period table. Note: the contents in the table is based on normal conditions, if bike is ridden in dusty muddy or wet areas maintenance should be performed more often and as needed.
  • Page 26 ZHEJIANG KAYO MOTOR CO., LTD. Engine suspension Air filter Sparking plug Fuel system carburetor I，L Driving wheel, driven wheel I，C clutch Item Period Criterion Parts Item ○ Steering wheel Operating flexibility ○ Steering Damage ○ Installation status of steering Steering system...
  • Page 27 ZHEJIANG KAYO MOTOR CO., LTD. Transmission and lubrication, Chain flapping>20mm ○ ○ Chain tightness Transmissi Transmission and lubrication, If chain wheel and chain Flywheel, ○ ○ tightness of fixing bolt wear severity, replace it. chain wheel ○ State of spark plug Ignition device ○...
  • Page 28 ZHEJIANG KAYO MOTOR CO., LTD. If there is a shaking, check it’s caused by steering column, linkages, ball joints, or fastening hardware then repair. If it’s caused by steering column, tighten the bottom lock nut on steering column, or you can also disassemble the steering column to check bearing and clamps.
  • Page 29 ZHEJIANG KAYO MOTOR CO., LTD. Note: the steering must be smooth, and move freely between left locked position to right locked position. Steering system freeplay: Check movement before operation. Freeplay in steering should be less than 10mm. Brake pump assembly Check the fluid level at the sight glass on the master cylinder.
  • Page 30 ZHEJIANG KAYO MOTOR CO., LTD. ● Check thickness of pads, If it’s less than 1.5mm, replace. ● Check for damage, cracks, and uneven wear. Replace pad set if out of specification Note: Replace pads in sets. Wheel With the atv on a jack of atv lift. Lift the front wheels off the ground.

  • Page 31: Suspension System

    ZHEJIANG KAYO MOTOR CO., LTD. make sure toe in is locked into place. Tire pressure Check the tire 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.

  • Page 32: Throttle Check

    ZHEJIANG KAYO MOTOR CO., LTD. 3.6 Gear shifter and fuel system Changing gears, with the shift lever should be smooth and gear changes should have a positive firm feeling. Shiftlever 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 33 ZHEJIANG KAYO MOTOR CO., LTD. and should snap back quickly when released. Freeplay: 3~5mm Adjust throttle free play if out of specification. Pull back rubber sleeves 1-2. Loosen lock nut 3 and barrels adjuster 4 then adjust throttle freeplay to within specification.

  • Page 34: Engine Systems

    ZHEJIANG KAYO MOTOR CO., LTD. For beginners, Throttle limiter should be adjusted inward to limit throttle as much as possible for safety. As the rider’s skills progress the limiter screw can be adjusted outward. *Throttle limiter is set from the factory at with a tamper proof screw. If necessary, the screw can be removed with pliers and replaced with a phillips head screw.

  • Page 35: Oil Pump

    ZHEJIANG KAYO MOTOR CO., LTD. 4.1 Maintenance information Precautions ● Before performing maintenance, please make sure that the engine is not running, battery is disconnected and that the heated parts have cooled, to avoid injury. ● To protect finishes, please wrap the frame, plastics or any vulnerable finishes before removing engine parts or performing maintenance on engine.

  • Page 36: Air Filter System

    ZHEJIANG KAYO MOTOR CO., LTD. remove tank mounting bolts and tank. *Fuel tank pictures may differ from tanks on U.S. models Fuel line Petcock 2 Tank mounting bolt 4.3 Air filter system Disassembly Loose the air filter clamp to remove air filter.

  • Page 37: Exhaust System

    ZHEJIANG KAYO MOTOR CO., LTD. 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. 4.4 Exhaust system Disassembly Disassemble the clamp between muffler and exhaust head pipe, then remove the muffler mounting bolt to remove muffler.
  • Page 38 ZHEJIANG KAYO MOTOR CO., LTD. Assembly Installation shall be in the reverse order of removal. *do not reuse exhaust head pipe gasket always replace, replace muffler gasket and any hardware for exhaust if damaged or deformed. 4.5 Disassembly and installation of engine...
  • Page 39 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 40 ZHEJIANG 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 41: Engine Oil And Fuel

    ZHEJIANG KAYO MOTOR CO., LTD. 5.2 Engine oil and fuel Fuel: Use octane 93# or higher Warning: 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...

  • Page 42: Engine Number

    ZHEJIANG KAYO MOTOR CO., LTD. 0～10 hours Avoid continuous operation, constantly changing speed and not operating in a fixed throttle position when the throttle is more than 50%; Cool the engine for 5 to 10 minutes after each hour of operation. Avoid rapid acceleration, throttle change should be slow.
  • Page 43 ZHEJIANG KAYO MOTOR CO., LTD. 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 Air cleaner...
  • Page 44 ZHEJIANG KAYO MOTOR CO., LTD. Left view of the 125 engine is shown in the figure125. Remove the acorn nuts of cylinder head from cylinder studs Remove cylinder head. Check the state of paper pad. Replace if necessary. Dismantle the fixing bolt of left cover.
  • Page 45 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.
  • Page 46 ZHEJIANG KAYO MOTOR CO., LTD. Remove the right cover of cylinder head. Inspect the gasket for damage and replace if necessary. Remove intake and exhaust valve caps. Check o-rings and replace if worn or if reuse is questionable Remove the fixing bolts of cam sprocket.
  • Page 47 ZHEJIANG KAYO MOTOR CO., LTD. Remove cylinder head assembly. 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...
  • Page 48 ZHEJIANG KAYO MOTOR CO., LTD. replace if necessary. Remove the cylinder head. Pour gasoline into inlet/exhaust pipe to inspect the seal condition. Grind the valve and valve seat if there is gasoline leak into the combustion chamber. Remove inlet/exhaust valve spring and check the state. Replace if necessary.
  • Page 49 ZHEJIANG KAYO MOTOR CO., LTD. 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 necessary.
  • Page 50 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 on Poor heat radiation of Remove the oil dirt or The engine overheats the cooling fins.
  • Page 51 ZHEJIANG KAYO MOTOR CO., LTD. 5.6.2Disassemble, assemble and maintain cylinder block Remove cylinder gasket and dowel pin to check Dismantle connecting bolt of cylinder block. for wear and damage. Replace if necessary. Dismantle the fixing bolt of timing chain of guide wheel.
  • Page 52 ZHEJIANG KAYO MOTOR CO., LTD. Remove the piston of piston pin to check whether it is damaged. Replace if necessary. Remove and replace gaskets. Check whether there is residual gasket on cylinder. Clean with gasoline if necessary.
  • Page 53 ZHEJIANG 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 54 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 dirt Poor heat radiation Remove the oil The engine overheats or sand on the...
  • Page 55 ZHEJIANG KAYO MOTOR CO., LTD. Check the condition of right crankcase cover and replace if necessary. Left view of right crankcase half is shown in fig and check whether bearing of main shaft and counter shaft are worn. Replace if necessary.
  • Page 56 ZHEJIANG KAYO MOTOR CO., LTD. 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 necessary. Right view of right crankcase half is shown in fig and check whether bearing of main shaft and counter shaft are worn.
  • Page 57 ZHEJIANG 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. Check the condition of left crankcase cover and replace if necessary.
  • Page 58 ZHEJIANG KAYO MOTOR CO., LTD. Troubleshooting of crankcase, please refer to the following table. Trouble Description Problem Cause Correction Oil leakage from the Repair or replace the Crack in the crank case crankcase crankcase Oil leakage from the The crankcase gasket is...
  • Page 59 ZHEJIANG KAYO MOTOR CO., LTD. 5.6.4 Maintenance 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 main shaft and counter shaft when removing the left crankcase.
  • Page 60 ZHEJIANG KAYO MOTOR CO., LTD. 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 61 ZHEJIANG 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 62 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 63 ZHEJIANG 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 64 ZHEJIANG KAYO MOTOR CO., LTD. Excessive fitting clearance The piston pin hole is Striking sound of the piston between the piston ring and the over worn pin and of the cylinder. hole. Radial and axes gap of the Striking sound of the big-end Replace 活塞环和孔之间的安装间隙...
  • Page 65 ZHEJIANG KAYO MOTOR CO., LTD. The big-end hole is over Radial and axes gap of the Striking sound of the big-end Replace the worn connecting rod big end is too bearing and of the cylinder. connecting rod large Timing The gear is over worn of...
  • Page 66 ZHEJIANG 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 67 ZHEJIANG KAYO MOTOR CO., LTD. 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. Check the external diameter of valve stem using a verier clipper. Replace the valve stem if the valve is beyond the maintenance limit valve.
  • Page 68 ZHEJIANG KAYO MOTOR CO., LTD. Check whether the valve stem is distorted. Replace if necessary. Inspect the timing camshaft bearing for wear and check the state of camshaft. Replace if necessary.
  • Page 69 ZHEJIANG KAYO MOTOR CO., LTD. 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 70 ZHEJIANG 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. Replace if necessary.
  • Page 71 ZHEJIANG KAYO MOTOR CO., LTD. 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. 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 72 ZHEJIANG KAYO MOTOR CO., LTD. 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.
  • Page 73 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 Valve The edge of valve oil seal is Thick blue and white fume form...
  • Page 74 ZHEJIANG KAYO MOTOR CO., LTD. The engine starts hard or fails to The working surface is over It is impossible to fit the start. Insufficient engine output; worn or has pits, pock valve and the valve seat Replace the valve Engine speed changes during idle marks, ablation or damage.
  • Page 75 ZHEJIANG KAYO MOTOR CO., LTD. Clean the carburetor as follows: Remove the dirt and clean inner oil way. Dismantle the fixing bolt of float chamber cap. Remove the float chamber cap. Remove the water and debris in the cap if necessary.
  • Page 76 ZHEJIANG 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 77 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 the jet with compressed air if necessary. Dismantle the mixture adjustment screw and inspect for worn. Replace if necessary.
  • Page 78 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 79 ZHEJIANG KAYO MOTOR CO., LTD. For the troubleshooting of the air cleaner, please refer to the following table. Damage Description Trouble Cause Correction form The engine starts hard or fails Engine start difficulty to start. Insufficient engine starting failure. Too much dust output;...
  • Page 80 ZHEJIANG KAYO MOTOR CO., LTD. Remove the washer of muffler to inspect for damage. Replace if necessary. For the troubleshooting or the exhaust muffler, please refer to the following table. Description Damage form Trouble Cause Correction Exhaust pipe gasket Engine exhaust noise is...
  • Page 81 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 82 ZHEJIANG KAYO MOTOR CO., LTD. For the troubleshooting of environment protection valve, please refer to the following table. Maintenance of environment protection valve Parts Damage form Trouble Cause Correction pump broken Emission fails to air pump defective air pump Replace...
  • Page 83 ZHEJIANG KAYO MOTOR CO., LTD. Dismount gear indicator fixing bolt, remove gear indicator to check the wear or damage condition, replace it if necessary. Remove left crankcase cover Remove gasket to check its condition. If the gasket is wearied or reusable, please...
  • Page 84 ZHEJIANG KAYO MOTOR CO., LTD. Remove fixing bolts of stator and trigger. Check stator status with multimeter. If wear and tear or re-use problems, please replace the new accessories...
  • Page 85 ZHEJIANG KAYO MOTOR CO., LTD. Remove rotor fixing nut Remove rotor with puller. Remove rotor to check magnetism, necessary replace.
  • Page 86 ZHEJIANG KAYO MOTOR CO., LTD. Remove starter 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...
  • Page 87 ZHEJIANG KAYO MOTOR CO., LTD. Disassemble start sprocket press board Dismount starter chain tensioner check the condition. If worn or damaged, replace it. Remove the snap ring from start motor sprocket.
  • Page 88 ZHEJIANG KAYO MOTOR CO., LTD. Disassemble the drive sprocket and chain. Dismount the fixing bolt of start motor. Remove start motor.
  • Page 89 ZHEJIANG KAYO MOTOR CO., LTD. Check the starter motor wiring and spline condition if necessary, replace it. Disassemble the oil separation disc and check the condition, if it necessary replace it. Check oil seal edges for wear. Replace as necessary.
  • Page 90 ZHEJIANG KAYO MOTOR CO., LTD. Remove the seal and check the oil ring condition, if it worn, replace. For 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.
  • Page 91 ZHEJIANG KAYO MOTOR CO., LTD. Circuit diagram...

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