KAYO MOTOR AT125-B Service Manual Download

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ZHE JIANG KAYO MOTOR CO., LTD

www.RideKayo.com

Model AT125-B

Service Manual

Summary of Contents for AT125-B

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

Page 2: ...n for Kayo AT125 B ATV maintenance adjustments disassembly installation inspection points and specifications Please read the manual carefully and follow the instructions closely when performing inspections and repairs this will increase the reliability performance and overall lifespan of the vehicle ...

Page 3: ...ation 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 ZHEJIANG KAYO MOTOR CO LTD All contents in this manual are subject to improve and update without notice ...

Page 4: ...ially important during engine maintenance Danger Be on high alert for danger Warning Be on alert for moderate danger Attention Be on alert for minor danger This manual may contain some potential risks when performing engine work and maintenance please pay close attention to the above explanations Service technician or mechanics should have basic mechanical knowledge before performing any service m...

Page 5: ...arging will produce flammable and explosive gases if exposed to a source of fire or spark there is a risk of explosion or fire Please charge in well ventilated places 5 As gasoline is flammable and explosive Pay attention to sparks as well as open flames Vaporized gasoline may explode if exposed to open flame or sparks please choose well ventilated areas away from these hazards when refueling 6 At...

Page 6: ... bearings can be rotated with finger to confirm whether the rotation is flexible and smooth Bearing axial and radial clearance is oversized Clean and grease bearings with a tight spot when rotated If the bearings still feel stuck after cleaning replace If the bearings can t be cleaned replace If the bearing is a press fit and becomes deformed after disassembling replace it 13 Bearings should be lu...

Page 7: ...e grooves Engine Break in Proper Engine break in is necessary on new engines and newly rebuilt engines to help ensure that longevity and reliability of the engine components Recommended break in time is 20 hours as follows 0 10 hours Operate at no more than throttle keep gear changes and speed variances to a minimum Do not operate for extended amounts of time with a fixed throttle position Let the...

Page 8: ...HE JIANG KAYO MOTOR CO LTD www RideKayo com 8 1 2 VIN Number Model HY110AT AT125 B VIN number Engine number 1 VIN number 2 Name plate 3 Engine Number 1 1 3 Specifications Model information No Item 3 2 1 ...

Page 9: ... Dimension L W H mm 1380 880 930 2 Handlebar height mm 930 3 Handlebar width mm 730 4 Rear fender height mm 700 5 Seat height mm 635 6 Min ground clearance mm 90 7 Wheelbase mm 900 8 Front width outside of tires mm 700 9 Rear width outside of tires mm 640 10 Turning radius mm 1650 11 Turning angle degree 38 2 12 Net weight Kg 97 4 2 13 curb weight Battery Fuel Kg 102 14 Max Speed Km h Speed limita...

Page 10: ...e oil SAE15W 40 10 Cooling Air Cooling 11 Coolant 12 Air filter Sponge filter cartridge 13 Carburetor Flat suction plunger type JINGKE PZ22 EPA 14 Tank volume 2L 15 Clutch type Dry automatic clutch 16 Variable speed mode 1 1 Foot shifting with shift protection 17 Gear range One forward gear one reverse gear 18 Shift type R N D 19 Deceleration ratio Forward Gear D Reverse Gear R Primary Deceleratio...

Page 11: ... Original four strokes motorcycles SAE 15W 40 For replacements it must be within following scope API classification SG or upper grade engine oil SAE specification refer to left table Oil pump rotor Internal and external rotor clearance 0 07 mm 0 15mm 0 2mm Clearance between outer rotor and box 0 03 mm 0 10mm 0 12mm Oil pump rotor end clearance 0 023 mm 0 055mm 0 12mm Oil pressure 1500r min 90 时 20...

Page 12: ...lever stroke 5 10mm Braking force 400N m Rear brake disc thickness 3 5mm Brake lever stroke 10 20mm Braking force 500 N m Ignition device Item Standard Ignition method CDI electric ignition Sparking plug Type Resistor type spark plug Standard ATR7C torch Gap 0 6 0 7mm Spark character 8mm 1 bar Spark advance angle Ignition coil resistance Primary 0 43 0 57Ω Secondary 10 1 11KΩ Peak voltage Primary ...

Page 13: ...n 1 4 Fastener Torque Specifications Note When installing threads please manually attach 2 3 turns of thread first Torque Specifications chart No Item Install position Bolt specification Grade Torque N m 1 Engine Lower mounting bolt M8 10 9 Grade 37 50 2 Upper mounting bolt M8 10 9 Grade 37 50 3 Bottom mounting bolt M8 8 8 Grade 18 25 4 Suspension Brake bolts M10 1 25 8 8 Grade 35 45 5 A arm bolts...

Page 14: ... bolt M6 8 8 8 12 15 Turning Handlebar clamps M8 10 9 18 25 16 Steering column bolts M8 8 8 18 25 17 Handlebar riser bolt M10 1 5 10 9 50 60 18 Electrical components Battery Box M8 8 8 15 20 19 Muffler M8 8 8 15 20 20 Voltage regulator ignition coil M6 8 8 7 11 21 Fuel tank body parts plastic Fuel Tank M6 8 8 7 11 22 Fuel Tank Switch M6 8 8 7 11 23 Pegs floorboards M8 8 8 18 25 24 Brush guards M6 ...

Page 15: ...222 2 Ball joints of rocker arms 3 Steering column bottom 4 steering knuckle spindle and wheel hubs 5 Pivot bolts swing arm a arms 6 Bushings Bearings 7 Rear axle liner bushings tubes 8 Rear axle bearing and oil seal 9 Steering column clamp Note please coat inside of handlebar grip with grip glue before installing Engine operating materials and installation accessories see engine section Engine op...

Page 16: ...ZHE JIANG KAYO MOTOR CO LTD www RideKayo com 16 1 6 Wiring and cable Routing diagrams Main Harness Front brake line Throttle Cable Rear brake line Choke cable ...

Page 17: ...nector Combination switch connector Key switch Reverse indicator connector Neutral indicator connector Kill switch connector Brake cable connector Positive battery cable Negative battery cable Stator connector Gear display connector Rectifier regulator connector ...

Page 18: ...ZHE JIANG KAYO MOTOR CO LTD www RideKayo com 18 Ignition Coil CDI Rectifier Regulator Tail light ...

Page 19: ...tickers and riveted tags to the new plastics This chapter is about the dismounting the body plastics 2 2 Installation torque M8 bolt 18 25N m TM6 bolt 7 11 N m M6 bolt 8 12 N m 2 3 Hood handlebar seat plastic parts rear body front body and middle guard front guard plastic pedals 2 3 1 Hood Disassembly 1 Remove the bolts 1 and 2 2 Push down and gently pull the hood forward to remove Be careful as t...

Page 20: ...nd remove right grip 3 Release the handle bolt of the disc brake with the tool and remove the brake handle 4 dismantling the front brake and rear brake 5 Pull out the air door line according to the graphic direction then remove the choke cable 6 Screw the accelerator cap bolts with tools and remove the throttle cable 7 Remove the pressing bolts remove the upper block and remove the handle bar 1 2 ...

Page 21: ... and hose routing 2 3 3 Seat Disassembly Locate the seat latch under the seat Pull the latch to release then pull and lift to remove the seat Installation To install line the front hook up with the corresponding post Then simultaneously push down and forward until the latch locks into place 2 3 4 Front Bumper Disassembly 1 The mounting bolts in order 2 Then remove the front bumper Seat latch ...

Page 22: ...ly Then adjust bumper into position and tighten bolts 2 3 5 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 Remove the plastic body note remove the handlebar and hood before removing plastic body 安装 Oil tank Cap 1 2 3 4 5 Mounting bolt ...

Page 23: ... 3 6 Middle guard Disassembly 1 Remove the mounting bolts of the left fender in turn 2 Remove the middle guard Installation Install in reverse order from disassembly Note replace mounting bolts nuts and rubber washers if damaged or worn Dismantling of left right rear fender 1 Remove the mounting bolts of the left fender in turn 2 Remove the left rear fender Installation Install in reverse order ...

Page 24: ...isassembly 1 Remove the mounting bolt 1 2 3 4 5 6 7 8 and corresponding bolts on opposite side 2 Take the rear body off Installation Install in reverse order from disassembly Note replace locking nuts and rubber washers as needed 2 3 8 Left Right Guard Disassembly 1 Remove the mounting bolts 1 2 3 and 4 of the left guard 5 6 7 8 1 2 3 4 ...

Page 25: ... plate according to the direction showed on the picture loosen the buckle on the plastic part and remove the left guard plate Installation Installation is done in reverse order Note replace locking nuts and rubber washers as needed 2 3 9 Front body Disassembly 1 2 3 4 ...

Page 26: ...1 2 3 4 and oil tank cap 2 Remove the key switch headlight connector then remove the front body Installation 1 Install in reverse order from disassembly replace mounting bolts nuts and rubber washers as needed when worn check all electrical connectors cable and hose routing after installation 1 2 fuel tank cap 3 4 ...

Page 27: ...ing bolts 1 2 and 3 2 Remove the foot guard Installation Install in reverse order of disassembly Note replace mounting bolts nuts and rubber washers in time once they worn 2 3 11 Pedal Disassembly floorboard foot peg 1 Remove the mounting bolts 1 2 3 4 and 5 2 Remove peg bracket and foot peg 1 2 3 ...

Page 28: ... 3 Regular maintenance and adjustment 3 1 Maintenance information 3 2 Maintenance period 3 3 Steering column and brake system 3 4 Wheel 3 5 Suspension system 3 6 Gear box and fuel system 3 7 Throttle check 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 3 1 2 4 5 ...

Page 29: ... time intervals for engine maintenance keeping up on standard maintenance will increase the lifespan and reliability of the components the following is the A125 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 A Adjustment C Clean I Inspection L Lubrica...

Page 30: ...on plate thickness 1 5mm when less than 1 5mm please replace it Running Device Vehicle Wheels Tire Pressure Front Tyre 45kPa 0 45kgf cm2 4 0PSI Rear Tyre 45kPa 0 45kgf cm2 4 0PSI Tyre cracking and damage Tire groove depth and abnormal wear If there is no appearance on the tire surface Wear indication residual groove depth should be not less than 3mm Loosening of wheel nuts and wheel shafts Sway of...

Page 31: ...tening hardware then repair Battery Terminal connection status Electric circuit Loosening and damage at joints Fuel System Fuel leaking Throttle Condition Throttle turn handle with clearance 3 5mm Light Indicators Function Exhaust Pipe Muffler loose or damage during Installation Performance of the Muffler Vehicle Frame loose or damage Others Grease status of various parts of frame Abnormal part th...

Page 32: ...m check steering rods and connecting points for damage 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 If brake is below the lower limit stop using the vehicl...

Page 33: ...eck the surface of brake disc if it is worn damaged bent or grooved replace If the disc thickness is less than 3 0mm replace Check or replace brake pads 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 3 4 Wheel With the atv on a jack of atv lift Lift the front wheels off the ground Pus...

Page 34: ...heel toe in to within 4 10mm and lock into place Note after the adjustment of front toe in drive the vehicle slowly and make sure vehicle tracks straight and true After test ride check measurement again to 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...

Page 35: ...it 3 5 Suspension system Keep vehicle in a horizontal position and compress up and down several times according to the pictures If there is shaking or abnormal sounds check whether there is oil leakage in the shock absorber or check for damage or loosening in the fastening parts 3 6 Gear shifter and fuel system ...

Page 36: ...d damage Replace if any damages are found or if more than 2 years old 3 7 Throttle check Check the free stroke of the thumb throttle lever Press the accelerator several times as shown in the diagram check the freeplay of the thumb throttle Check for any sticking or slow return of the lever Thumb throttle should be easy and smooth to push and should snap back quickly when released Freeplay 3 5mm Ad...

Page 37: ...ength limit of speed limit screw Thread length a 25mm Adjustment Loosen the lock nut then adjust it with a phillips screwdriver 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 ...

Page 38: ...y and installation of engine 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 Please dispose of liquid such as...

Page 39: ... 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 Fuel tank removal Remove the plastic body parts remove fuel lines from tank and fuel valve then remove tank mo...

Page 40: ...ied or cracked hoses replace before installing when necessary 4 3 Air filter system Disassembly Loose the air filter clamp to 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 mounting bolt of fuel tank air filter clamp ...

Page 41: ...h is connected to the exhaust pipe and the exhaust vent of the engine and then remove the exhaust pipe 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 Disassembly Note Remove floorboards pegs carburetor intake mani...

Page 42: ...t sprocket side cover then remove chain 2 Remove the ground lead and all electrical connectors exhaust pipe and gear shifter 3 Remove the 3 engine mounting bolts Crankcase breather hose starter motor cable ground lead Stator wires gear indicator wire Spark plug cap Shift lever Engine Mounts ...

Page 43: ...hall be in the reverse order of removal 5 Engine 5 1 Maintenance information Conversion table refers item Unit conversion pressure 1kgf cm 2 98 0665kPa 1kPa 1000Pa 1mmHg 133 322Pa 0 133322kPa torque 1kgf m 9 80665N m volume 1mL 1cm3 1cc 1L 1000cm3 torque 1kgf 9 80665N Danger warning attention Danger Be on high alert for danger ...

Page 44: ...tilated Don t use gasoline as a cleaning fluid To avoid burns do not touch uncooled engine oil exhaust system parts If the fuel lubrication and exhaust systems are serviced please check for leaks In order to protect the environment Dispose of used oil coolants acids and other toxic chemicals properly Warning If parts need to be replaced during maintenance please use parts recommended or provided b...

Page 45: ...torcycle quality grade according to the classification of the API SG level or by the superior if no SAE15W 40 oil according to the engine using the environment temperature as the picture on the below is shown 5 3 Engine brake in Engine has a lot of relative motion components such as piston piston ring cylinder Warning Avoid mixing different oil brands and grades ...

Page 46: ...this process the engine will has excellent performance and reliability Recommended break in time 20 hours details as follows 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 10 20 hou...

Page 47: ...ubrication Replace 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 Battery Charge Charge Charge Charge Brake disc Check Adjust Adjust Replace Brake system Adjust Adjust Clean Clean Brake light switch Adjust Adjust Adjust Adjust Illuminating system Check...

Page 48: ...n cylinder head Right view of the 125 engine is shown in the figure Left view of the 125 engine is shown in the figure Remove the acorn nuts of cylinder head from cylinder studs Dismantle the fixing bolt of left cover Remove cylinder head Check the state of paper pad Replace if necessary ...

Page 49: ...RideKayo com 49 Remove left cover and inspect the paper pad gasket for damage Replace if necessary Dismantle the fixing bolt of right cover Remove the right cover of cylinder head Inspect the gasket for damage and replace if necessary ...

Page 50: ...or damage and replace if necessary Remove inlet exhaust valve cap Check the state of seal ring of valve cap and replace if worn or if reuse is questionable Remove the fixing bolts of cam sprocket Remove the connecting bolt of cylinder head Remove cylinder head assembly ...

Page 51: ...r 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 Grind the valve and valve seat if there is gasoline leak into the combustion chamber ...

Page 52: ... exhaust valve spring and check the state Replace if necessary Inspect the oil seal of inlet exhaust valve for damage Replace if necessary Remove the spark plug to clean the carbon deposits and dirt Check the spark plug gap and set it to 0 6 to 0 7 if necessary ...

Page 53: ...st muffler pipe Replace the valve guide The cylinder gasket is broken Air leakage between the cylinder head and cylinder The engine starts hard or fails to start Insufficient engine output Engine speed changes during idle run Replace the cylinder head gasket The fixing nut is not properly tightened Air leakage between the cylinder head and cylinder The engine starts hard or fails to start Insuffic...

Page 54: ...asket and dowel pin to check Dismantle fixing bolt of timing chain of guide for wear and damage Replace if necessary wheel Remove the guide wheel of timing chain to Dismantle connecting bolt of cylinder block inspect for wear and damage Replace if necessary Remove the cylinder block Remove the circlip of piston pin ...

Page 55: ...ZHE JIANG KAYO MOTOR CO LTD www RideKayo com 55 ...

Page 56: ...yo com 56 Remove the piston of piston pin to check whether it is damaged Replace if necessary Inspect the paper pad for worn or damage Replace if necessary Check whether there is residual gasket on cylinder Clean with gasoline if necessary ...

Page 57: ...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 05mm Replace the cylinder block if it has beyond this value ...

Page 58: ...sumption Grind the cylinder end surface or replace the cylinder body The cylinder is badly worn The fitting clearance between the cylinder and position position ring is too wide The engine starts hard or fails to start Insufficient engine output Poor engine idle speed Thick blue and white fume form the exhaust muffler pipe Repair with boring machine or replace the cylinder body The cylinder gasket...

Page 59: ...ain shaft and countershaft are worn Replace if necessary Right view of right crankcase half is shown in fig and check the state of right crankcase half Replace if necessary Left view of left crankcase is shown below and check whether the oil seal of countershaft and oil seal edge of gearshift lever are worn Replace if necessary ...

Page 60: ...ght view of right crankcase half is shown in fig and check whether bearing of main shaft and countershaft are worn Replace if necessary Dismantle fixing bolt of left crankcase cover Remove the neutral indicator and check the state Replace if necessary ...

Page 61: ...ZHE JIANG KAYO MOTOR CO LTD www RideKayo com 61 Dismantle the fixing bolt of magneto stator and remove the stator Check the condition of left crankcase cover and replace if necessary ...

Page 62: ...y resulting in air leakage between the cylinder head and cylinder The engine starts hard or fails to start Insufficient engine output Engine speed changes during idle run Repair the threaded or replace the crankcase The bolt of the cylinder is broken The same as front The same as front Replace the cylinder bolt The oil seal is damaged or the oil seal edge is damage worn aged Oil leakage is ineffec...

Page 63: ...ver and the case Replace the gasket 5 4 4 Maintenance of Crankshaft Connecting Rod Disassemble assemble and maintain crankshaft connecting rod Remove the fixing bolt of crankcase from its holding place Remove left crankcase half Take care not to forget the washer of mainshaft and countershaft when removing the left crankcase ...

Page 64: ...4 Remove the paper pad to inspect for wear and damage Replace if necessary Remove the connecting rod assembly Inspect connecting rod bearing for wear and damage Replace if necessary Check gap of big end of connecting rod Reset the gap if necessary ...

Page 65: ...in 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 Check the side gap between piston ring and piston groove using a feeler gauge ...

Page 66: ...ap is too wide Check whether there is excessive carbon deposit on piston top and groove Remove if necessary Check the state of piston and replace if worn or if reuse is questionable Measure diameter of piston skirt Replace it if the value is beyond the maintenance limit value ...

Page 67: ...to start Insufficient engine output Thick blue and white fume form the exhaust muffler pipe Scuffing or scratches on the surface of piston skirt Scuffing or scratches on the surface of piston skirt The piston 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 for...

Page 68: ...r properly Improper fixing The piston ring gap is not staggered Thick blue and white fume form the exhaust muffler pipe Refining 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 Striking sound of the piston pin and of the cylinder Replace the piston pin Connecting rod The connecting rod small end hole is over worn The ...

Page 69: ... 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 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 70: ...70 Measure length of valve spring to check whether the spring is damaged or worn Replace if necessary Remove the spring of inlet and exhaust valve to inspect for wear and damage Note when assemble the valve spring make sure its dense end downward ...

Page 71: ...he 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 large than 1 5mm Check whether the valve stem is distorted Replace if necessary Inspect the timing camshaft bearing for wear and check the state of camshaft ...

Page 72: ...t 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 Remove the guide wheel of timing chain to inspect for wear and damage Replace if ...

Page 73: ... LTD www RideKayo com 73 necessary Remove the fixing bolt of timing tensioner and check the state Replace if worn or if reuse is questionable Remove the timing tensioner arm to inspect for wear and damage Replace if necessary ...

Page 74: ...ssary 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 ...

Page 75: ...KAYO MOTOR CO LTD www RideKayo com 75 crankcase cover Check whether the O mark on cam sprocket is aimed to the gap of cylinder head Readjust if necessary Set the valve clearance of rear cylinder to 0 05mm 0 06mm ...

Page 76: ... the exhaust muffler pipe Replace the complete set of valve oil seal Camshaft The cam is cover worn Insufficient engine output Replace the camshaft 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 轴承的轴向或径向间隙太宽旋转时轴承旋转不正常或声音异常 Abnormal sound heard during camshaft transmissi...

Page 77: ...ghtly 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 marks ablation or damage It is impossible to fit the valve and the valve seat tightly The engine starts hard or fails to start Insufficient engine output Engine speed changes during idle run Replace the valve The ...

Page 78: ...r and circlip of air cleaner Remove the carburetor Remove and clean throttle cap Clean the carburetor as follows Remove the dirt and clean inner oil way Dismantle the fixing bolt of float chamber cap Remove the float chamber cap Remove the water and debris in the cap if necessary Check the state of seal ring and replace if it is aging ...

Page 79: ...t needle valve to inspect for wear and damage Replace if necessary Remove the throttle and oil needle and check the condition replace if necessary Check the state of float case and replace as necessary Adjust the height of float case by moving the float up or down ...

Page 80: ... MOTOR CO LTD www RideKayo com 80 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 ...

Page 81: ...justment screw and inspect for worn Replace if necessary Adjust mixture screw of carburetor 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 incorrect which indicates carburetor leaks or the oil supply is insufficient ...

Page 82: ...lter to remove dust from the casing and remove the air filter to clean For the troubleshooting of the air cleaner please 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 performance of engine during idle run Excessive fuel consumption The exhaust muffler ...

Page 83: ...d maintain exhaust system Remove the fixing bolt from left crankcase cover Dismantle suspension bolt of muffler to check whether the suspension support is damaged Repair or replace if necessary Remove the muffler to inspect for broken and damage Replace or repair if necessary ...

Page 84: ...ZHE JIANG KAYO MOTOR CO LTD www RideKayo com 84 Remove the washer of muffler to inspect for damage Replace if necessary ...

Page 85: ...n 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 Description Damage form Trouble Cause Correction Exhaust pipe gasket The gasket is broken Exhaust pipe leakage Engine exhaust noise is too loud Replace exhaust pipe gasket Exhaust muffler enclosure broken The muffler enclosure is broken Engine exhaust ...

Page 86: ...r pump broken or plugged defective air pump Emission fails to meet the standard Replace air cleaner air cleaner damaged or plugged defective air cleaner Emission fails to meet the standard Replace connecting 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 st...

Page 87: ...embly maintenance and management of electric starter Remove the fixing bolts on the cover of left crankcase Remove the fixing bolts of file display Then remove the file display and check for wear and damage Replace them when necessary Remove the cover of left crankcase ...

Page 88: ...k the condition If it is worn please replace it Remove the fixing bolt of magnetic stator and bolt of trigger Check the status of stator with a multimeter If it is worn please replace with the new one Disassemble the fixing nut of rotor and remove the rotor with special tools ...

Page 89: ...r is demagnetized Replace it when necessary Remove the fixing bolt of overrunning clutch Remove the clutch Check for wear and damage to the clutch seats rollers and springs Replace it when necessary Check the wear and damage of the drive sprocket and drive gear replace it when necessary ...

Page 90: ... MOTOR CO LTD www RideKayo com 90 Disassemble the pressing plate of start sprocket Remove the tension strip of the clutch and check its condition If the tension strip is found to be worn or problems in use replace it ...

Page 91: ...ZHE JIANG KAYO MOTOR CO LTD www RideKayo com 91 Remove the snap ring from start motor sprocket Remove the drive sprocket and chains Remove the fixing bolt of electric starter ...

Page 92: ...AYO MOTOR CO LTD www RideKayo com 92 Remove the electric starter Check the electric starter for damage Replace it when necessary Remove the disc of oil separation and check the condition Replace it when necessary ...

Page 93: ...ZHE JIANG KAYO MOTOR CO LTD www RideKayo com 93 Check the edges of the oil seal for wear Replace it when necessary Remove the seal ring Check the status of oil seal ring and replace it when necessary ...

Page 94: ...ZHE JIANG KAYO MOTOR CO LTD www RideKayo com 94 ...

Page 95: ...ce Replace carbon brush spring Armature commentator surface is fouled Starter motor has insufficient rotation force Clean the commentator surface With gasoline or alcohol Armature commentator surface is spotted burnt or damaged Starter motor has insufficient rotation force Polish the surface against the Commentator with fine abrasive Paper Make the cut on the mica Plate between each commentator Pi...

Page 96: ...ZHE JIANG KAYO MOTOR CO LTD www RideKayo com 96 ...

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