KAYO MOTOR AU180 Service Manual
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KAYO MOTOR AU180 Service Manual

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ZHEJIANG KAYO MOTOR CO., LTD.
Model AU180
Service Manual
WWW.RIDEKAYO.COM

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Summary of Contents for KAYO MOTOR AU180

  • Page 1 ZHEJIANG KAYO MOTOR CO., LTD. Model AU180 Service Manual WWW.RIDEKAYO.COM...
  • Page 2 ZHEJIANG KAYO MOTOR CO., LTD. Instruction This manual contains detailed information for Kayo BULL180 /AU180 (ATV), maintenance, adjustments, disassembly, installation, inspection points 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 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 Chapter 6 Chassis Chapter 7 Signal and Lighting Systems Electrical Schematic Diagram ZHEJIANG KAYO MOTOR CO., LTD.

  • Page 4: Conversion Table

    ZHEJIANG KAYO MOTOR CO., LTD. Conversion table Unit conversion Item 1kgf/cm =98.0665kPa；1kPa=1000Pa pressure 1PSI=6.8948kPa 1kgf·m=9.80665N·m Torque 1mL=1cm 3 =1cc volume 1L=1000cm 3 Moment 1kgf=9.80665N 1in=25.4mm Length Danger/warning/attention Take the following warnings seriously, it’s important for regular maintenance, especially important during engine maintenance.
  • Page 5 ZHEJIANG KAYO MOTOR CO., LTD. 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.
  • Page 6 ZHEJIANG KAYO MOTOR CO., LTD. 5. Snap rings can be deformed if opened too much during disassembly. DO NOT re-use deformed snap rings. 6. After disassembly and inspection, clean parts and blow the cleaning agents away with compressed air before measuring. Grease the moving surfaces before assembly.

  • Page 7: Vin Number

    ZHEJIANG KAYO MOTOR CO., LTD.  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. Replace rubber hoses if dried, cracked, or deformed 19.
  • Page 8 ZHEJIANG KAYO MOTOR CO., LTD. Model AU180 VIN number Engine number 1 VIN number frame stamp 2 VIN plate 3 Engine number 1.3 Main parameters list WWW.RIDEKAYO.COM...
  • Page 9 ZHEJIANG KAYO MOTOR CO., LTD. Item Parameters Model AU180 L（mm） 1710 W（mm） H（mm） 1030 Wheelbase（mm） 1100 Engine model 1P63QML Displacement（ml） Fuel type No.92 gasoline and higher grade Kerb weight（kg） passengers 1 person（Driver） Max. Loading weight 1 person＋ 80kg = 140kg Front wheel AT23×7-10...
  • Page 10 ZHEJIANG KAYO MOTOR CO., LTD. Throttle body Tank volume 5.6L Clutch type Automatic clutch Gearshift method Gear range F-N-R Drive system Shift type Manual/F-N-R Output mode Rear axle output Rotate direction Forward gear, viewed from the rear of the engine output shaft vehicle, the front is clockwise.
  • Page 11 ZHEJIANG KAYO MOTOR CO., LTD. ●Lubrication system Item Standard Limitation 800ml（No oil filter element － Change oil replaced） Engine oil 850ml（replace the oil filter Change oil capacity element） － Full capacity 900ml Recommended engine oil Please choose SF MA 15W-40, or it may cause engine damage －...
  • Page 12 ZHEJIANG KAYO MOTOR CO., LTD. Item Standard Type permanent magnet alternator Output three-phase full-wave Magneto trigger coil resistance Magneto no-load voltage (engine in None cold state) Magneto Maximum output 180w Stable voltage 14.5 ± 0.5V ≥1V，200r/min；≥8.5V，2000r/min Peak voltage of trigger coil...

  • Page 13: Fastener Torque Specifications

    ZHEJIANG KAYO MOTOR CO., LTD. Item Standard Accessory inline fuse Headlight 12V—35W Light Taillight/brake light 12V—2.8W ●Valve mechanism + cylinder cover（see engine section） ●Cylinder + piston + piston ring + crank connecting link（see engine section） 1.5 Fastener Torque Specifications Note:...
  • Page 14 ZHEJIANG KAYO MOTOR CO., LTD. GB5789 M6×25 Mounting bolt in front of 9~12 GB5789 M6×30 tank Mounting bolt behind tank 9~12 GB5787 M6×16 Mounting bolt of 9~12 GB5787 M6×16 horns Bolt of negative 9~12 GB5787 M10×1.25×160 pressure switch Mounting bolt of engine...
  • Page 15 ZHEJIANG KAYO MOTOR CO., LTD. Position Note Grease Steering bearing Connection of throttle and cable Movable part of rocker arm Light lithium base grease Inner of steering column Movable parts of seat lock Movable parts of gearshift ● Lubrication of control cable, bearing and other movable parts...
  • Page 16 ZHEJIANG KAYO MOTOR CO., LTD. 1. Alternate reverse gear display connector 2. Instrument connector 3. Headlight connector 4. Alternate neutral display connector 5. Electric door lock switch connector 6. Multifunctional switch connector of left handlebar 7. Ignite connector Note: Removing the front panel before inspection and repair for above parts. For details, please refer to chapter 2, plastic cover.
  • Page 17 ZHEJIANG KAYO MOTOR CO., LTD. 8.Brake sensor (left, right) 9. Throttle cable 10. Brake lines 1. Carburetor 2. outlet pipe for carburetor 3. Starter motor cable 4. Engine exhaust pipe 5. Magneto trigger connector 6. Gear display connector 7. Regulated rectifier connector Note: please disassemble the gear lever and pedal before inspection and repair for above parts.
  • Page 18 ZHEJIANG KAYO MOTOR CO., LTD. 8. Starter Relay 9. Battery negative wire 10. Starting motor wire 11. Battery positive wire 12. Voltage regulator rectifier 1. Tail light connector 2. rear light WWW.RIDEKAYO.COM...

  • Page 19: Maintenance Warnings

    ZHEJIANG KAYO MOTOR CO., LTD. 2 Plastics and Body parts 2.1 Maintenance warnings 2.2 Installation torques 2.3 Seat and carrier 2.4 Front guard of gear indicator, gear display and gear lever 2.5 Dismounting left and right footpegs 2.6 Dismounting of front ventilating boardand bumper 2.7 Dismounting of front assembly plate and rear assembly plate...
  • Page 20 ZHEJIANG KAYO MOTOR CO., LTD. 2.3.2 Front rack Disassembly Disassemble the mounting screw from front rack 3(left and right） Remove mounting bolts Remove front rack Installation in reverse order of disassembly. 2.3.3 Rear rack Disassembly Disassemble the mounting bolts from rear rack 1（left, right）...
  • Page 21 ZHEJIANG KAYO MOTOR CO., LTD. 2.4 Front guard of gear indicator, gear display and gear lever 2.4.1 Front panel Disassembly Remove front rack（→ 2.3.2） Remove front panel Installation in reverse order of disassembly 2.4.2 Front cover of gear indicator Disassembly...
  • Page 22 ZHEJIANG KAYO MOTOR CO., LTD. 2.4.3 Gear display Disassembly Remove instrument cover（→ 2.4.2） Take the 2 nuts out Remove gear display Installation in reverse order of disassembly. 2.4.4 Gear lever Disassembly Remove mounting bolt from gear lever 6 Detach gear lever Installation in reverse order of disassembly.
  • Page 23 ZHEJIANG KAYO MOTOR CO., LTD. 2.5.2 Right footpeg Disassembly Remove fastening screws 4 Remove retaining screws 5 Detach left footpeg downwards 6 Installation in reverse order of disassembly. 2.6 Dismounting of front ventilating boardand bumper 2.6.1 Front ventilating board Disassembly Remove front rack（→2.3.2）...
  • Page 24 ZHEJIANG KAYO MOTOR CO., LTD. 2.7 Dismounting of front assembly plate and rear assembly plate 2.7.1 Front assembly plate Disassembly Remove front cover of gear display（→2.4.2） Remove front rack（→2.3.2） Remove front plate（→ 2.4.1） Remove gear lever（→2.4.4） Remove left pedal（→ 2.5.3）...
  • Page 25 ZHEJIANG KAYO MOTOR CO., LTD. 2.7.2 Rear assembly plate Disassembly Remove front panel Detach mounting screw of front assembly Remove gear lever Remove left pedal Remove right pedal Remove mounting screw 1 Remove rear assembly plate 2 Installation in reverse order of disassembly.

  • Page 26: 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 AU180 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 27 ZHEJIANG KAYO MOTOR CO., LTD. Item Odometer km Maintenance item Period 1000km 4000km 8000km 12000k Remark Fuel transit system Fuel filter Damper of carburetor Note ① Air filter element Sparking plug Valve clearance engine lubricating oil Annual lubricating oil strainer Annual R...
  • Page 28 ZHEJIANG KAYO MOTOR CO., LTD. 3.3 Inspection ways Inspection and maintenance items Period Criterion Checkpoints Inspection item Steering Operating flexibility ○ wheel Damage Steering ○ Steering Installation status of ○ device system steering system Ball pin shaking ○ Pedal travel ○...
  • Page 29 ZHEJIANG KAYO MOTOR CO., LTD. Buffer Suspension Shaking of connection part ○ ○ device and damage of rocker arm Damper Leakage and damage ○ ○ Function ○ Front axle Transmission ○ ○ lubrication Transmis Rear axle Transmission ○ ○ sion...
  • Page 30 ZHEJIANG KAYO MOTOR CO., LTD. 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. If there is a shaking, check it’s caused by steering column, linkages, ball joints, or fastening hardware then repair.
  • Page 31 ZHEJIANG KAYO MOTOR CO., LTD. Note: the steering must be smooth, and move freely between left locked position to right locked position. Clearance of front brake lever: Check the effect and movement before operation. Check the clearance of front brake lever.
  • Page 32 ZHEJIANG KAYO MOTOR CO., LTD. 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 33 ZHEJIANG KAYO MOTOR CO., LTD. Rear brake pump assembly 〈 liquid volume〉 Check the liquid volume Look at the liquid volume through the observation hole 3. When the brake fluid volume decreases to the lower limit of hole 3, stop using the vehicle.
  • Page 34 ZHEJIANG KAYO MOTOR CO., LTD. Rear brake disc and brake pads <wear of brake pads> The brake pads, caliper and disc are normal wear and tear items Note The brake pads should be replaced by a full set. Check or replace the brake disc.
  • Page 35 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 36 ZHEJIANG KAYO MOTOR CO., LTD. Tire pressure Check the tire pressure with a tire pressure gauge. 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 specified range will affect vehicle handling and may cause premature wear and or damage to tire tread.

  • Page 37: Suspension System

    ZHEJIANG KAYO MOTOR CO., LTD. Shake of front wheel hub Lift the front wheel with tools. Make sure there is no force on the front wheels. Shake the wheel axially to check if there is any shaking. If there is a shaking, remove the front wheel and check hub.

  • Page 38: Throttle Check

    ZHEJIANG KAYO MOTOR CO., LTD. 3.7 Gear shifter and fuel system Gear box Change gear, check if the gear box (2) is flexible and if it in shift position. If it’s inflexible, adjust the angel of gear box rod (2).
  • Page 39 ZHEJIANG KAYO MOTOR CO., LTD. When the clearance is not within the range, it shall be adjusted. Remove cover 3 Loosen lock nut (2) of throttle inhaul cable. Turn the regulator to adjust the free stroke of the throttle button, after that tight lock nut (2), assemble throttle inhaul cable cover at last.

  • Page 40: Light Installation

    ZHEJIANG KAYO MOTOR CO., LTD. 3.8 Speedometer Check the display meter When the whole vehicle system is powered on for the first time (or after changing th e gear display meter for the first time), plug in the power and start the engine. Check if the gear is consistent with the display meter in drive process.

  • Page 41: Engine Systems

    ZHEJIANG KAYO MOTOR CO., LTD. Engine systems 4.1 Maintenance information 4.2 Fuel system 4.3 Air intake 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, battery is disconnected and that the heated parts have cooled, to avoid injury.

  • Page 42: Air Filter System

    ZHEJIANG KAYO MOTOR CO., LTD. 4.2 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 from these hazards when refueling or working on the fuel system and its related components.

  • Page 43: Exhaust System

    ZHEJIANG KAYO MOTOR CO., LTD. Remove fuel tank Loosen clamp Remove air filter 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...
  • Page 44 ZHEJIANG KAYO MOTOR CO., LTD. 4.5 Disassembly and installation of engine Disassembly (Note: Remove floorboards/ pegs, carburetor, intake manifold and oil cooler first) Disassembly Remove gear lever, seat, gear display meter, left pedal, right pedal and rear assembly body. (Chapter 2 body covering).
  • Page 45 ZHEJIANG KAYO MOTOR CO., LTD. Engine General information Warn Be on high alert for danger. Precautions To be alert to moderate danger. SF MA 15W‐40 Grease KING MATE G‐3。 Gear oil 85W/90 GL‐5。 Fixation Smear fixative Oil seal Smear fluid glue...
  • Page 46 ZHEJIANG KAYO MOTOR CO., LTD. maintenance; the service operator should also have basic mechanical knowledge. 5.1.1 Precautions Warning: Proper maintenance is very important to engine reliability vehicle lifespan and safety. ● When starting the engine indoors, be sure to vent the exhaust outside.
  • Page 47 ZHEJIANG KAYO MOTOR CO., LTD. Choose special tools as specified in the maintenance manual. · Ensure that parts used in assembly are clean and lubricated where required · ·Use special lubricants, binders and sealants. ·When fastening bolts, screws and nuts, tighten from large to small, and tighten from inside to outside according to the specified torque.
  • Page 48 ZHEJIANG KAYO MOTOR CO., LTD. 5.1.2 Torque Item Quantity Dimension Torque kgf-m Remark Cylinder head bolt 1.0-1.4 Cylinder head nut 1.8-2.2 Smear oil Two heads bolt 0.7-1.0 Crankcase Cylinder head left 1.0-1.4 bolt Nut for valve 0.7-1.4 Smear oil adjustment Spark 1.0-1.4...

  • Page 49: Troubleshooting

    ZHEJIANG KAYO MOTOR CO., LTD. Exhaust pipe 1.0-1.4 connect bolt Above are the torques for important parts, others refer to standard value Item Torque Item Torque 5mm bolt, nut 0.45-0.60 kgf-m 3mm screw 0.05-0.08 kgf-m 6mm bolt, nut 0.80-1.20 kgf-m 4mm screw 0.10-0.15 kgf-m...
  • Page 50 ZHEJIANG KAYO MOTOR CO., LTD. Compressive force Abnormal Piston ring, gas valve, cylinder or piston ring, washer, sand hole Ignition on compressive pospart No ignition with Gas valve, air Engine Start spark intake pipe, ignition time Much gas mixture, Spark...
  • Page 51 ZHEJIANG KAYO MOTOR CO., LTD. Compressive With cylinder Cylinder and piston ring force pressure gauge worn, cylinder washer; Abnormal sand hole on compressive position, air valve, piston ring stuck Carb mouth Smooth Stuck Clean Spark Good condition Worn, discolor Clean...
  • Page 52 ZHEJIANG KAYO MOTOR CO., LTD. Carburetor washer Air intake Washer, carb lock, O-ring, pressure pipe broken Flame out normal Spark, CDI, Spark Touch with engine generator, ignition Abnormal coil, spark high voltage wire, main switch Engine failure (high speed) Check as the sequences of below form...
  • Page 53 ZHEJIANG KAYO MOTOR CO., LTD. 5.2 Maintenance information First One year per Item Once a month Three months Six months 300km 12000km per1000km per 3000km per 6000km Air filter Second air filter Fuel filter Oil filter Oil replace Per 1000 km...
  • Page 54 ZHEJIANG KAYO MOTOR CO., LTD. Oil replacement Replace oil gauge and oil bolt below crankcase, Then flow out oil, clean washer and bolt, if they damaged, replace. Torque: 3.5-4.5 kgf-m Oil specification: SF MA 15W-40 Oil volume: work:900cc Replace: 850cc...
  • Page 55 ZHEJIANG KAYO MOTOR CO., LTD. Crankcase blowout system Remove block from pipe bottom to let deposit out. Keep maintenance when use in rind or full throttle condition. Valve clearance adjustment After engine cooled (below 35℃) Remove cylinder head and timing cap on cooling fan. Use T type wrench to turn crank axle until the T mark is faced with crankcase mark, as picture shows.
  • Page 56 ZHEJIANG KAYO MOTOR CO., LTD. Carburetor idle speed adjustment Note: After all engine parts checked and adjusted, and note the best time is warm bile (about 10 minutes) Idle speed: 1700±100 rpm Adjustment: 1. Install engine tachometer. 2. Adjust idle screw until engine speed to 1700±100 rpm.
  • Page 57 ZHEJIANG KAYO MOTOR CO., LTD. Ignition system Ignition timing Note: 1) the CDI can’t adjust. 2.) This procedure is for confirming CDI. 1. Remove right cover of bike and cooling fan cap. 2. Check ignition timing with timing light. 3. Start engine and let speed to 1700 rpm, if the F mark is faced to timing, means it’s normal.
  • Page 58 ZHEJIANG KAYO MOTOR CO., LTD. Cylinder compressive force Remove spark first, then put pressure gauge into spark hole. Last start engine and turn it. Note: turn engine until the gauge value stable, about 4-7 seconds. Compressive pressure: 10 ±1kg/cm Check below items when compressive force low: 1.
  • Page 59 ZHEJIANG KAYO MOTOR CO., LTD. Clutch disc Check the clutch movement by increase throttle. If it’s shakes, check the clutch disc. Specific tools Item Picture For crankcase For valve spring For valve clearance adjustment...
  • Page 60 ZHEJIANG KAYO MOTOR CO., LTD. For oil seal insert For bearing install For clutch spring For clutch Universal fixer For generator...
  • Page 61 ZHEJIANG KAYO MOTOR CO., LTD. 5.3 Lubricating system maintenance Specification Engine oil volume: resolve: 900cc replace: 850cc Oil viscosity: SF MA 15W-40 Gear oil: resolve: add 400cc replace: add 350cc Gear oil viscosity: 85W/90 GL-5 Item Standard Limitation Inner outer rotors 0.12...
  • Page 62 ZHEJIANG KAYO MOTOR CO., LTD. Oil pump Outer rotors body 0.12 clearance Rotor end face and body 0.05-0,10 0.20 clearance Torque ● Oil drain bolt 3.5-4.5 kgf-m ● Oil filter screen 1.3-1.7 kgf-m ● Gear oil drain bolt 0.8-1.2 kgf-m ●...
  • Page 63 ZHEJIANG KAYO MOTOR CO., LTD. Remove screen cap, then take out screen and spring to clean the screen. If the gasket worn, replace it. Install screen, spring and cap back after cleaning. Torque: 1.3-1.7 kgf-m Inject oil (SF MA 15W-40) into oil hole, install dipstick.
  • Page 64 ZHEJIANG KAYO MOTOR CO., LTD. Install driving gear and clip, make sure the oil pump works smoothly. Oil pump installation Install oil pump (2 bolts), pump chain, lock and cover (2 bolts). Install start gear and generator at last.
  • Page 65 ZHEJIANG KAYO MOTOR CO., LTD. Gear oil check Stop engine and remove inject and drain bolts. Drain out oil to a cup, check if the oil meets standard value, or add it. Gear oil viscosity standard volume；400cc, replace volume: 350cc Gear oil replace Remove inject and drain bolts to drain oil out.
  • Page 66 ZHEJIANG KAYO MOTOR CO., LTD. Precautions Specification (unit: mm) Item Standard Limitation Compressive force 10±1 kg/cm Height Air intake 29.810 29.440 Air exhaust 29.530 29.160 Rocket arm Inner diameter 10.000-10.015 10.100 Axle outer diameter 9.966-9.984 9.910 Lever outer Air intake 4.975-4.990...
  • Page 67 ZHEJIANG KAYO MOTOR CO., LTD. Spring free length (out spring) 37.000 33.500 Spring free length (inner spring) 35.000 31.500 Connect surface flatness of cylinder head 0.050 Torque ● Cylinder head cap bolt 1.0-1.4 kgf-m ● Left cylinder head bolt 1.0-1.4 kgf-m ●...
  • Page 68 ZHEJIANG KAYO MOTOR CO., LTD. ● Gasket worn or leaked ● Cylinder surface worn or sloped 3.Piston ● Piston ring worn High compressive force: Too much carbon deposit Abnormal sound ● incorrect valve clearance ● valve worn or spring damaged ●...
  • Page 69 ZHEJIANG KAYO MOTOR CO., LTD. Remove O-ring from cam chain regulator. Lock cam regulator bolt to release regulator. Turn fly wheel with wrench, to let the T mark face the crankcase mark and make sure chain hole to compressive mark, refer to picture.
  • Page 70 ZHEJIANG KAYO MOTOR CO., LTD. Fixed seat disassembly Remove rocket arm axle by a 5mm bolt, then remove rocket arm. Check fixed seat, valve rocket arm and rocket arm axle, especially sliding surface of rocket arm and fixed surface of cam shaft.
  • Page 71 ZHEJIANG KAYO MOTOR CO., LTD. Cylinder head disassembly First remove fan cover and cover (4 bolts). Second remove cam shaft Third remove 2 bolts from left cylinder head, then gasket, 2 located pins and guide plate, clean surfaces last. Note: do not damage the surface of cylinder and cylinder head; keep the crankcase clean.
  • Page 72 ZHEJIANG KAYO MOTOR CO., LTD. Remove valve spring by spring compressor. Remove valve bolt, spring and valve. Remove guide lever oil seal, clean carbon deposit and cylinder head surface. Check spark hole condition and measure cylinder head flatness. Limitation: 0.5mm Free length of valve spring Limitation；...
  • Page 73 ZHEJIANG KAYO MOTOR CO., LTD. Valve stem If stem worn, bent or damaged, replace. Measure outer diameter. Air intake 4.9mm exhaust 4.9mm Valve guide pipe Clean carbon deposit before measure pipe inner diameter with a reamer (5mm, limitation is 5.03mm).
  • Page 74 ZHEJIANG KAYO MOTOR CO., LTD. When replace guide pipe, heating cylinder head to 100-150℃ by heating plate or oven. Remove pipe with specific tool. Install new guide pipe with a driver (5mm) at 100-150℃, make guide pipe height at 13mm, insert from arm side. After cooling, trim the pipe with reamer.
  • Page 75 ZHEJIANG KAYO MOTOR CO., LTD. running in. Remove gas valve and check the sealing of contract area. If the valve face worn, rough or damaged, replace it. The contract area still doesn’t seal after running in, replace. Check valve seat Valve seat width: 1.6mm.
  • Page 76 ZHEJIANG KAYO MOTOR CO., LTD. 。 Cut seat surface to certain width with 45 cutting machine and make sure it smoothly. Valve face adjust Smear Prussian-blue or red lead. 。 If the contact area high, cut seat with 32 cutting machine, then cut seat surface to certain 。...
  • Page 77 ZHEJIANG KAYO MOTOR CO., LTD. Cylinder head assembly Install valve into guide pipe after lubricating. Install new oil seal, valve spring and braking. Press spring down by compressor to install valve bolt. Knock valve stem with rubber rob to keep sealing.
  • Page 78 ZHEJIANG KAYO MOTOR CO., LTD. Cam shaft installation Install rocket arm on the EX mark side of fixed seat, then rocket arm and rocket arm axle. Turn the crank shaft with T type wrench and let the T mark face the crankcase mark. Make the cylinder head tip in line with cam chain mark.
  • Page 79 ZHEJIANG KAYO MOTOR CO., LTD. Lock cylinder head nuts (4 nuts), then lock the 2 fixed bolts on cylinder head. Torque: 1.8-2.2 kgf-m Install spark with torque: 1.0-1.2 kgf-m Valve clearance adjust Loose nuts and bolts on rocket arm, adjust clearance to standard value and fix bolts and nuts.
  • Page 80 ZHEJIANG KAYO MOTOR CO., LTD. head cover. 5.5 cylinder and piston Precautions Remove engine from bike before maintenance.
  • Page 81 ZHEJIANG KAYO MOTOR CO., LTD. Specification Item Standard Limitation Inner diameter 62.450-62.550 62.650 Top parallelism 0.050 Cylinder Deviations 0.050 Roundness 0.050 Clearance Top ring 0.025-0.060 0.090 Second ring 0.015-0.050 0.090 Clearance Top ring 0.100-0.250 0.500 piston Second ring 0.250-0.400 0.650...
  • Page 82 ZHEJIANG KAYO MOTOR CO., LTD. Cylinder head disassembly Remove 2 bolts and cam chain adjustor from cylinder head, then remove guide plate and cylinder. Remove cylinder gasket and fixed pin, clean contact face of crankcase and cylinder. Block crankcase and cam chain holes with clean cloth, clean contact face of cylinder and crankcase.
  • Page 83 ZHEJIANG KAYO MOTOR CO., LTD. There are three divided position in cylinder, measure the inner diameter based on X and Y directions separately. Limitation: 62.650mm Count the roundness (X-Y) and deviations (the max value among X or Y the three positions differences).
  • Page 84 ZHEJIANG KAYO MOTOR CO., LTD. Install piston rings on the engine bottom, then push piston ring to the 20mm height of cylinder top end, measure all the clearance. Limitation: top ring: greater than 0.5mm, replace Second ring: greater than 0.65mm, replace Measure piston pin outer diameter Limitation: 14.96mm...
  • Page 85 ZHEJIANG KAYO MOTOR CO., LTD. Measure inner diameter of connected rod Limitation； 15.06mm Measure inner diameter of piston pin Limitation: 15.04mm Count the clearance of piston pin and pin hole, limitation is 0.02mm Measure piston outer diameter 。 From 9mm bottom height to piston 90 position.
  • Page 86 ZHEJIANG KAYO MOTOR CO., LTD. Piston installation Clean piston head, ring and piston bottom. Install ring to piston as picture shows. Note: do not damage rings and piston; all the marks up; keep all rings smoothly after installation. Install piston and pin, the IN-mark faces air intake side. Install a new piston pin at last.
  • Page 87 ZHEJIANG KAYO MOTOR CO., LTD. Smear oil on inner cylinder, piston and piston ring. Install cylinder to piston carefully, press piston ring at the same time, ring by ring. Install cam chain guide plate, cylinder head gasket and located pin.
  • Page 88 ZHEJIANG KAYO MOTOR CO., LTD. 5.6 V type belt drive system Precautions Drive plate, clutch and transmission plate can repair on the bike. There is no grease on drive belt and drive plate. Specification Item Standard Limitation Drive belt width 22.30mm...
  • Page 89 ZHEJIANG KAYO MOTOR CO., LTD. Clutch pad thickness 2.500 1.500 Spring length 130.00 125.00 Wheel set outer diameter 33.965-33.985 33.940 Wheel inner diameter 34.000-34.025 34.060 Torque Nut of sliding drive belt plate: 5.0-6.0 kgf-m Nut of clutch cover: 5.0-6.0 kgf-m Nut of drive belt plate: 5.0-6.0 kgf-m...
  • Page 90 ZHEJIANG KAYO MOTOR CO., LTD. Assembly In reverse order of disassembly. Drive belt Disassembly Remove left crankcase, bolts and drive plate. Remove nuts and clutch cover with specific tool.
  • Page 91 ZHEJIANG KAYO MOTOR CO., LTD. Make drive belt into wheel groove, then take out with clutch. If the drive belt has cranks or worn, replace. Measure thickness, if it less than 20.88mm, replace it. Note: drive belt brand should be recommended by kayo; keep the belt clean before installation.
  • Page 92 ZHEJIANG KAYO MOTOR CO., LTD. Note: the belt side with arrow mark faces to turn direction. If there is no mark, the words side of belt faces to assembly direction. Sliding drive plate Disassembly Remove left crankcase first. Then fix the drive plate with fixed clamp to remove nuts and drive plate.
  • Page 93 ZHEJIANG KAYO MOTOR CO., LTD. Check If the hammer rotors worn or damaged, replace it. Then measure the outer diameter, if it less than 19.45mm, replace. If the hub of axle worn or damaged badly, replace. Measure its outer diameter, if it’s less than 23.94mm, replace.
  • Page 94 ZHEJIANG KAYO MOTOR CO., LTD. Smear the drive plate axle hole with 4-5kg button before install axle hub. Note: no grease on belt face. Install sliding drive plate on crank shaft. Drive plate assembly Install drive belt on sliding drive plate, then press the up and down sides to make the belt and drive plate separately.
  • Page 95 ZHEJIANG KAYO MOTOR CO., LTD. Install left crankcase cover. Smear the axle hole, then install axle hub. Install the sliding drive plate on crank shaft. The installation is as same as sliding drive plate. Clutch/ transmission belt plate Disassembly Remove drive plate, clutch/transmission belt. Install spring compressor on clutch, turn compressor moderately.
  • Page 96 ZHEJIANG KAYO MOTOR CO., LTD. Check clutch cover Measure inner diameter of clutch cover surface. If the limitation is greater than 135.40mm, replace. Clutch disc Measure thickness of each disc, if less than 1.5mm, replace. Drive pully spring Measure its length, if the free length is greater than 125mm, replace.
  • Page 97 ZHEJIANG KAYO MOTOR CO., LTD. Transmission disc Check the disc surfaces, if its worn or damaged, replace. Check the groove to see if its deformed or damaged. Measure the outer diameter of drive belt axle, and the inner diameter of transmission plate axle hole.
  • Page 98 ZHEJIANG KAYO MOTOR CO., LTD. Clutch pad replaces Remove ring and gasket, then remove clutch pad and spring to check the spring condition. Check if the rubber, if its damaged or deformed, replace. Smear fixed pin, make sure clutch pad clean. Install clutch pad on fixed pin. Insert the spring with vice.
  • Page 99 ZHEJIANG KAYO MOTOR CO., LTD. Remove oil seal and inner bearing. Replace the clamp from outer bearing, then push it to the side of inner bearing. Install new bearing, smear G-3 grease at last. Install a new inner bearing. The seal end faces out; install needle bearing and ball bearing with oil press.
  • Page 100 ZHEJIANG KAYO MOTOR CO., LTD. Install transmission belt plate, spring and clutch into spring compressor, turn compressor handlebar until the bolt installed. Torque: 5.0-6.0 kgf-m Install clutch/ transmission belt plate and transmission belt on transmission shaft. 5.7 Reducing gear and reverse gear mechanism...
  • Page 101 ZHEJIANG KAYO MOTOR CO., LTD. Precautions Specification: Gear oil: 4 stroke lubricating oil. Volume: 400cc (replace:350cc) Toque: Gear cover: 2.0-2.4 kgf-m drain bolt: 1.0-1.4 kgf-m inject bolt: 0.8-1.2 kgf-m Troubleshooting 1. Start engine, car doesn’t move. Transmission gear damaged; transmission gear short out; drive belt broken...
  • Page 102 ZHEJIANG KAYO MOTOR CO., LTD. 2. Gear oil leakage High oil level; oil seal worn or damaged 3. Abnormal noise Gear worn, short out or damaged; bearing worn Reducing gear Disassembly Drain gear oil and remove clutch. Remove gearbox cover bolts (10 pcs M6*35), gearbox cover and transmission shaft. At last remove gaskets and located pin.
  • Page 103 ZHEJIANG KAYO MOTOR CO., LTD. Check the gear shaft, gear and other parts of reverse gear mechanism and gear shaft assembly. Check gearbox and bearing on crankcase cover Use finger to turn the inner side of bearing and check the outer side condition. If the bearing turns not smoothly, with abnormal noise or doesn’t connect well with gearbox and...
  • Page 104 ZHEJIANG KAYO MOTOR CO., LTD. Pull out drive shaft from gearbox, then remove oil seal from gearbox, remove transmission shaft bearing with specific tool. If the bearing still connects with transmission shaft after pulling out drive shaft, use bearing extractor to remove.
  • Page 105 ZHEJIANG KAYO MOTOR CO., LTD. drum and fork. Then install 2 located pins and new gasket. Smear grease on oil seal of drive shaft, output shaft and gearshift shaft, then install them on gearbox cover, tight with 10 bolts. Torque: 2.0-2.4 kgf-m Install clutch, belt and left crankcase cover, inject gear oil (85W/90 GL-5).
  • Page 106 ZHEJIANG KAYO MOTOR CO., LTD. Specification Limitation of gear inner diameter: 22.1mm Torque: Fly wheel nut: 5.0-6.0 kgf-m Bolt 8mm: 1.5-2.0 kgf-m Oil filter screen cover: 1.3-1.7 kgf-m...
  • Page 107 ZHEJIANG KAYO MOTOR CO., LTD. Fixed bolt of starting clutch: 9.0-10.0 kgf-m inject oil on thread Allen bolt of staring clutch: 1.0-1.4 kgf-m add binder, Specific tools: Fly wheel extractor, general fixer Alternator Disassembly Remove fly wheel: drain out engine oil, remove cooling fan cover (4 bolts).
  • Page 108 ZHEJIANG KAYO MOTOR CO., LTD. Remove coil assembly: take out coil joint and pulser connector. Then remove pulser, coil and 6 bolts on fixed plate, pull out coil assembly at last. Remove right crankcase cover: remove 9 bolts, located pin and gasket. Clean the connecting surface, do not damage it.
  • Page 109 ZHEJIANG KAYO MOTOR CO., LTD. Hold gear by general fixer to remove 22mm bolt and gasket. Remove gear. Remove clutch and idle gear. Check Install idle gear on starting motor, then fix the motor and turn idle gear in clockwise at the same time.
  • Page 110 ZHEJIANG KAYO MOTOR CO., LTD. Outer diameter limitation: greater than 9.94mm Disassembly Remove 3 allen bolts on clutch, separate cover and clutch body. Then remove rotors, plunger and spring, check the rotors and plunger. Install rotors, plunge and spring. Assembly In reverse order of disassembly.
  • Page 111 ZHEJIANG KAYO MOTOR CO., LTD. Install idle gear shaft, idle gear and starting clutch. Install drive and drive gears on starting clutch. Fix drive and driven gear with general fixer, tight 22mm and gasket. Note: smear grease on threads. Torque: 9.0-10.0 kgf-m...
  • Page 112 ZHEJIANG KAYO MOTOR CO., LTD. Right crankcase cover assembly Install located pin and new gasket. Replace the smeared oil seal on the right of crankshaft. Install right crankshaft cover on crankcase (9 bolts). Torque: 1.5-2.0 kgf-m Alternator oil assembly Install coil on right crankcase cover (2 screws), then install the pulser (2 screws) and fixed plate.
  • Page 113 ZHEJIANG KAYO MOTOR CO., LTD. Install alternator connector and pulser connector. Fly wheel assembly Keep the fly wheel clean. Let crankshaft key in right position to fly wheel and assemble the fly wheel. Fixed the fly wheel with a general fixer, tight nut at last.

  • Page 114: Crankcase/Crankshaft / Balance Shaft

    ZHEJIANG KAYO MOTOR CO., LTD. 5.9 Crankcase/crankshaft / balance shaft Precautions ● Before disassemble crankcase, remove cylinder head, piston, cylinder, V type belt, alternator and staring clutch first. ● Once replace crankshaft bearing or timing chain, the whole crankshaft should be replace together.
  • Page 115 ZHEJIANG KAYO MOTOR CO., LTD. Item Standard Limitation Connecting rod tip clearance 0.100-0.350mm 0.550mm Radial clearance of connecting rod 0.006-0.016mm 0.050mm Crankshaft vibration 0.100mm Torque Crankcase bolt 1.5-2.0 kfg-m Cylinder/cylinder head double-head bolt 0.7-1.0 kgf-m Engine drain bolt 3.5-4.5 kgf-m Tensioner bolt of cam chain 0.8-1.2 kgf-m...
  • Page 116 ZHEJIANG KAYO MOTOR CO., LTD. Note: don’t separate by hitting surface, it may cause oil leakage. Take out cam chain before separate crankcases. Remove crankshaft and balance shaft from left crankcase. Remove gasket and 2 located pins, clean up the crankcase surface with gasket.
  • Page 117 ZHEJIANG KAYO MOTOR CO., LTD. Crankshaft check Measure the radial clearance of connecting rod. If it greater than 0.55mm, replace. Put crankshaft on V groove pad, measure its vibration as pictures shows. Limitation: 0.10mm Bearing check...
  • Page 118 ZHEJIANG KAYO MOTOR CO., LTD. Turn bearing with finger, check its movement and inner connect condition. If there is noise or bad connect, replace the full crankshaft. Crankcase assembly Install cam chain into the chain hole of right crankcase, enlarge chain at the same time.
  • Page 119 ZHEJIANG KAYO MOTOR CO., LTD. Install right crankcase and tight the 2 crankcase bolts. Torque: 1.5-2.0 kgf-m Install the tension rod of cam chain, tight with 3 lock fixed bolts.
  • Page 120 ZHEJIANG KAYO MOTOR CO., LTD.

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