KAYO MOTOR BULL 150 Page 91 Maintenance Manual Download

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5.10 Dis-assembly, assembly, maintenance and management of electric start motor

Dis-assemble fixing bolt on

left crankcase

Dis-assemble gear indicator fixing bolt

Dis-assemble gear indicator to check damage

and wear. Change if necessary.

connectin

g hose

connecting hose get loose

noise is too big

Emission fails to

meet the standard

Replace

Gasket

large noise from

secondary inlet

air leaks form secondary

inlet

Emission fails to

meet the standard

Replace

muffler

exhaus

too much carbon deposit

on muffler exhaust

Poor combustion

Emission fails to

meet the standard

Remove

and clean

Summary of Contents for BULL 150

Page 1: ...1 KAYO AU150 BULL 150 Maintenance Manual WWW KAYOMOTO US VERSION CODE 20190316 VERSION NAME AU150 Maintenance Manual...

Page 2: ...to assemble and dis assemble the plastics Chapter3 introduce the regular maintenance and adjustment Chapter4 introduce how to dis assemble the parts in the places around engine Chapter5 introduce the...

Page 3: ...3...

Page 4: ...esn t contain some potential risks in engine work and maintenance so besides the above explanations the service operator should also have basic mechanical knowledge and if you are not sure whether can...

Page 5: ...strictly out of reach of children Battery charging can produce flammable and explosive Hydrogen There is an explosion risk if exposed to source of fire or spark Please charge batteries in well ventil...

Page 6: ...lubricate If the bearings still feel stuck after cleaning replace it If it can t be cleaned replace it If the bearing is originally compaction fit with vehicle or axle diameter but it gets unsuitable...

Page 7: ...each other correction work form a smooth friction surface which can bear heavy load by this way the engine will have excellent performance and reliability Recommended break in time is 10 hours as foll...

Page 8: ...4 1 2 VIN number VIN number Metal plate Engine number MODEL AU150 VIN NUMBER ENGINE NUMBER 1 3 2...

Page 9: ...enger Max loading quality 1 person 60kg 120kg Tire spec Front tire AT20 7 10 Rear tire AT19 10 9 Ground clearance 135mm Turning radius mm 2350mm Engine Start Electric Engine type Single cylinder 4 str...

Page 10: ...everse gear Gears Forward gears 1 2 3 Reverse gear R Gear changing order By foot R N 1 2 3 Drive mode Chain driven rear axle Engine drive rotating direction clockwise Steering equipment Biggest steeri...

Page 11: ...y cause accidents Oil pump rotor Radial clearance of inner and outer rotors 0 12mm Radial clearance between outer rotor and pump body 0 12mm Axial clearance between rotor surface and pump body 0 05 0...

Page 12: ...coil peak voltage 1V 200r min 8 5V 2000r min Rectifier type Full wave rectification Battery Capacity 12V 7Ah Voltage Fullcharge 14 4V Not full charge 11 8V Ignition device ITEM STANDARD Ignition meth...

Page 13: ...A Light bulb Front light 12V 35W Tail light brake light 12V 2 8W Valve mechanism cylinder cover see 05 engine section Cylinder piston piston ring crank connecting link see 05 engine section Clutch Tra...

Page 14: ...bolt M8 1 25 20 8 22 30 10 Rear brake caliper bolt GB5789 M8 25 2 22 30 11 Rear brake disc mounting screw GB70 85 M8 16 4 22 30 12 Handle bar raisers mounting bolt GB5783 M10 1 5 30 2 45 59 13 Oil co...

Page 15: ...10 25 Cross head tapping screw GB845 85 ST4 2 26 Cross head machine screw GB828 88 M5 16 2 27 Cross head big fat machine screw TM6 28 Rim mounting nut GB6187 86 M10 1 25 16 45 59...

Page 16: ...grease Throttle perch connectingplace A arm bushing Steering column inner surface Seatlockmovepart Gear shift mechanism move part Lubricating grease for Handle cable bearding and all rotating parts P...

Page 17: ...17 2 Digital gear indicator connector 3 Headlight connector 4 Neutral indicator connector older models 2017 5 Key switch connector 6 Multifunction switch Connector 7 CDI connector Note To inspect the...

Page 18: ...r 2 carburetor overflow hose 3 Starter motor cable 4 Crankcase vent hose 5 Stator ignition pickup connector 6 Gear indicator connector 7 Voltage regulator connector Note To inspect the above parts mus...

Page 19: ...13 8 Starter Relay 9 Battery negative terminal 10 Starter cable 11 Battery positive terminal 12 Voltage regulator rectifier 1 Tail light connector 2 Tail light 1 2 8 10 9 11 12 2...

Page 20: ...on 2 4 1 Front number plate 17 2 4 2 Gear display front cover 18 2 4 3 Gear display 18 2 4 4 Shift lever mounting combination 18 2 5 Disassembly and Assembly of left and right footrest 2 5 1 Left foot...

Page 21: ...escribes the order of dis assembly and assembly of plastics This chapter describes the dis assembly and assembly of racks seat outer plastic parts Hoses cables brake lines should be through the right...

Page 22: ...ckward 2 Remove the seat Assembly Install in reverse order from dis assembly Check if the seat is installed in place and firm 2 3 2 Front rack Dis assembly Dis assemble the mounting bolts from rack 3...

Page 23: ...ht Dis assemble rear rack 2 Assembly Install in reverse order from dis assembly 2 4 Front plate gear display front cover gear display foot gear rod mounting combination 2 4 1 Hood Dis assemble front r...

Page 24: ...4 3 Gear display Dis assembly Dis assemble meter front cover 2 4 2 Back out 2 nuts 3 Dis assemble gear display 4 Assembly Re assemble in reverse order from dis assembly 2 4 4 Shift lever mounting com...

Page 25: ...plate Dis assembly Dis assemble fasten screw 4 Dis assemble fasten screw 5 Dis assemble right footrest from lower to upper 6 Assembly Install in reverse order from dis assembly 2 6 Dis assembly of fr...

Page 26: ...ssemble gear display front cover 2 4 2 Dis assemble front rack 2 3 2 Dis assemble front plate 2 4 1 Dis assemble foot gear rod 2 4 4 Dis assemble left footrest plate 2 5 3 Dis assemble right footrest...

Page 27: ...2 4 4 Dis assemble left footpeg plate 2 5 3 Dis assemble right footpeg plate 2 5 4 Dis assemble mounting screw 2 Dis assemble rear assy plate3 Assembly Re install in reverse order from dis assembly No...

Page 28: ...cautions Note Do not run the engine in unventilated areas exhaust contains carbon monoxide CO and other toxic components Do not touch the engine or exhaust Please wear long sleeves work clothes and gl...

Page 29: ...or showing wear inspect or replace earlier Maintenance item Item Milometer km Circle 1000km 4000km 8000km 12000km Remarks Fuel system access I I I Fuel filter C C C C Carburetor chock Air filter I I R...

Page 30: ...ness is less than 3mm Brake pad Tear and damage of brake pad The minimum brake pad friction plate thickness 1mm less than 1mm replace it Driving device Wheel Tire pressure Front wheel 35kPa 0 35kgf cm...

Page 31: ...12 fuel should be reach the opening...

Page 32: ...gap 0 6mm 0 7mm Ignition period Battery Terminal connection status Electric circuit Looseness and damage of joints Fuel device Fuel leak Throttle condition Throttle knob clearance 2 6mm Lightdeviceand...

Page 33: ...th the vehicle on a sturdy flat surface Turn the handlebar slowly all the way left then all the way right to check if it turns smoothly If it is rough hard to turn or loose check the wire and cable ro...

Page 34: ...a routine to check brakes condition and brake function before using the vehicle Remove screws 1 Remove master cylinder cover 2 Add brake liquid to the upper limit Note When adding brake fluid do not...

Page 35: ...pad thickness 2 The minimum thickness should be 1 mm at grooves if less replace If the brake pads are damaged or showing cracks or abnormal wear replace them Note Please check brake fluid levels frequ...

Page 36: ...the upper limit Note When adding brake fluid do not mix with dust dirt or water Use brake fluid from a new unopened container Brake fluid can damage plastic rubber and painted surfaces Be careful not...

Page 37: ...ecking brake rotors Check the surface of brake disc blueing discoloration or warping 1 If its thickness 3 0mm replace Rear brake disc thickness limits no less than 3 0mm Check the brake pad thickness...

Page 38: ...check and replace the bearing ball joints or A arm bushings Front wheel size Put the atv in a horizontal position and measure the size of the front wheel toe in The front wheel relative to the forward...

Page 39: ...cold for a more accurate reading Appointed pressure Tire Front tire Rear tire Pressure 35kPa 0 35kgf cm2 35kPa 0 35kgf cm2 Tiresize See chapter 1 See chapter 1 Wheel pattern Check tread depth if is l...

Page 40: ...up the front wheel turn the wheels as per the axle direction when there is no other acting force on the vehicle then check whether the vehicle will shake If there is shack then dis assemble the front...

Page 41: ...operation should be smooth with firm clicks between each gear Shift down with toe until you reach neutral come to a complete stop then shift down with toe to engage neutral If shift lever is misadjust...

Page 42: ...limiting device Throttle limiting device is used to restrict throttle opening Inspect the thread length limit of the limiting screw Factory set thread length should be 12mm To adjust Loosen the lock...

Page 43: ...h back to turn lights off slide forward one position to illuminate fog lights slide all the way forward to illuminate headlights Push high beam button in to turn high beams on If any of the lights do...

Page 44: ...oled completely 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 When the engine is...

Page 45: ...ration should be carried out in a well ventilated place When disassemble the plastic parts loose the tube 1 of oil throttle then dismount the oil switch bolt 2 and remove switch remove tank mounting b...

Page 46: ...filter 2 Assembly In reverse order from dis assembly Re install all components 4 3 Exhaust system Dis assembly Dis assemble foot gear rod seat gear display front cover front assy Plate rear assy Plat...

Page 47: ...ssembly 4 4 Dis assembly and assembly of engine Dis assembly Dis assemble shift lever seat gear display front cover left and right footpeg plate rear assy Plate see 02 plastics Dis assemble fuel tank...

Page 48: ...oved to prevent oil leaking Disconnect gear display connect wire 1 7 Disconnect magneto trigger connect wires 1 7 Disconnect starter motor plug 4 Disconnect carburetor hoses 3 Remove engine mounting b...

Page 49: ...47 5 5 Maintenance of machine 69 5 6 Dis assembly assembly and maintenance of carburetor 78 5 7 Maintenance of air in take and out put system 81 5 8 Dis assembly assembly and maintenance of air out p...

Page 50: ...r more people working together more attention should be paid for safety When starting the engine indoors be sure to vent the exhaust outside If toxic or flammable substances are used handle in accorda...

Page 51: ...required Use special lubricants binders and sealants When fastening bolts screws and nuts tighten the large to small and tighten from inside to outside in a cross pattern to the specified torque Use a...

Page 52: ...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 Through this process the engine will has exc...

Page 53: ...place Replace once per 2000km Filter media Clean Clean Clean Clean Timing chain Check Adjust Adjust Adjust Carburetor idle speed Adjust Adjust Adjust Adjust Drive chain Adjust and lubricate per 5000km...

Page 54: ...ble assemble and maintenance cylinder head Right view of the 150 engine Left view of the 150 engine Remove the locknut of cylinder head from its holding place Remove cylinder head Check the state of p...

Page 55: ...4 Dismantle the fixing bolt of left cover Remove left cover and inspect the paper pad for damage Replace Dismantle the fixing bolt of right cover...

Page 56: ...Remove the right cover of cylinder head Inspect the gasket for damage and replace Remove inlet exhaust valve cap Check the state of seal ring of valve cap and replace if worn or if reuse is questionab...

Page 57: ...6 Remove the fixing bolt of timing driven sprocket Remove the connecting bolt of cylinder head Remove cylinder head assembly...

Page 58: ...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 con...

Page 59: ...nd 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 deposit and dust Check the spark plug gap...

Page 60: ...d cylinder The engine starts hard or fails to start Insufficient engine output Engine speed changes during idle run Grind the cylinder head end surface or replace the cylinder head There are pits abla...

Page 61: ...star Remove the carbon deposit between the electrodes Excessive carbon deposit or oil dirt in the spark plug Weak or no sparking from the spark plug electrodes The engine starts hard or fails to start...

Page 62: ...check for wear and damage Replace if necessary Dismantle the fixing bolt of timing chain of guide wheel Remove the guide wheel of timing chain to inspect for wear and damage Replace if necessary Disma...

Page 63: ...ston 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 gasol...

Page 64: ...place 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 The limit value is 50 05mm Replace th...

Page 65: ...er head The engine starts hard or fails to start Insufficient engine output poor idle speed and high fuel consumption Grind the cylinder end surface or replace the cylinder body The cylinder is badly...

Page 66: ...her 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 Left view of right crankcase half is...

Page 67: ...16 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...

Page 68: ...ace the gasket The threaded hole of oil drain plug screw is ineffective Oil leakage from the threaded hole of plug screw Repair of replace the crankcase The threaded holes of cylinder bolt are ineffec...

Page 69: ...ight crankcase is broken Oil leakage between the case cover and the case Replace the gasket Left crankcase cover The left crankcase cover is worn or cracked Oil leakage form the case cover Repair or r...

Page 70: ...the washer of main shaft and countershaft when removing the left crankcase Remove the paper pad to inspect for wear and damage Replace if necessary Remove the connecting rod assembly Inspect connectin...

Page 71: ...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 islarge Check the side...

Page 72: ...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 Assemble the piston ring according to...

Page 73: ...and ring groove are over worn Excessive fitting clearance between the piston and the cylinder The engine starts hard or fails to start Insufficient engine output Thick blue and white fume form the exh...

Page 74: ...ed Thick blue and white fume form the exhaust muffler pipe Fixing again the piston ring set Piston pin The piston pin is over worn The fitting clearance between the piston pin and the hole is too wide...

Page 75: ...amage Abnormal sound during sprocket driving Replace the timing sprocket 5 5 Maintenance of Mechanism 5 5 1Disassemble assemble and maintain valve mechanism Remove rocker arm shaft Remove the rocker a...

Page 76: ...alve 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 Replace if necessary Remove the...

Page 77: ...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 Replace the valve stem if the valve is lar...

Page 78: ...r 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 bey...

Page 79: ...place 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 Re...

Page 80: ...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...

Page 81: ...haft The bearing of the camshaft is over worn or damaged The axial or radial clearance of the bearing is too wide Ineffective bearing swiveling or abnormal sound during swiveling Abnormal sound heard...

Page 82: ...lve seat tightly The engine starts hard or fails to start Insufficient engine output Engine speed changes during idle run Remove the carbon deposit The working surface is over worn or has pits pock ma...

Page 83: ...letely The engine starts hard or fails to star Replace the valve Valve spring The spring is ineffective or fractured It is impossible to fit the valve and the valve seat tightly The engine starts hard...

Page 84: ...ean throttle cap 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...

Page 85: ...state of float case and replace as necessary Adjust the height of float case by moving the float up or down Take out the main jet to check whether the jet hole is clogged Clean if necessary Remove th...

Page 86: ...etor as the following Standard Tighten mixture screw and turn it one And a half turns clockwise Measure height of float case to check whether it is distorted or there is oil in the case If height is i...

Page 87: ...ease refer to the followingtable Description Damage form Trouble Cause Correction Air filter Too much dust on the filter core The engine starts hard or fails to start Insufficient engine output poor p...

Page 88: ...ffler 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 ne...

Page 89: ...r tightness and tighten as necessary Inspect the connecting circlip of air pump for tightness Tighten if necessary Description Damage form Trouble Cause Correction Exhaust pipe gasket The gasket is br...

Page 90: ...n and replace if necessary For the troubleshooting of environment protection valve please refer to the followingtable Maintenance of environment protectionvalve Parts Damage form Trouble Cause Correct...

Page 91: ...to check damage and wear Change if necessary connectin g hose connecting hose get loose noise is too big Emission fails to meet the standard Replace Gasket large noise from secondary inlet air leaks f...

Page 92: ...41 Dis assemble left crankcase cover Dis assemble gasket to check condition Change if damage or can t use Dis assemble magneto stator fixing bolt trigger bolt...

Page 93: ...Check stator condition with a multiple use meter Replace if damage or can t use Dis assemble rotor fixing bolt Dis assemble rotor with a dedicated tool Check if rotor is with magneto Change if necessa...

Page 94: ...fixing bolt Dis assemble clutch check clutch holder ball and spring for damage and ware Change if necessary Check transmission sprocket and gear for damage and ware change if necessary Dis assemble s...

Page 95: ...44 Dis assemble tension band of clutch and check condition for damage and problem change if necessary Dis assemble retainer ring of start motor sprocket Dis assemble driving sprocket and chain...

Page 96: ...5 Dis assemble start motor fixing bolt Dis assemble start motor Check if the start motor winding is damaged change if necessary Dis assemble oil separating plate and check condition change if necessar...

Page 97: ...46 Check the oil seal edge if damaged change if necessary Dis assemble seal ring and check condition change if damaged...

Page 98: ...spring Armature commentator surface is fouled Starter motor hasinsufficient rotation force Clean the commentator surface with gasoline or alcohol Armature commentator surface is spotted burnt or dama...

Page 99: ......

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KAYO MOTOR BULL 150, Maintenance Manual

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Summary of Contents for BULL 150

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