KAYO MOTOR AU125 Service Manual Download

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ZHEJIANG KAYO MOTOR CO., LTD.

www.kayomoto.us

Model AU125

Service Manual

Summary of Contents for AU125

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

Page 2: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 2...

Page 3: ...for Kayo AU125 ATV maintenance adjustments disassembly installation inspection points and specifications Please read the manual carefully and follow the instructions closely when performing inspectio...

Page 4: ...tion 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...

Page 5: ...n 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 s...

Page 6: ...eyes please flush immediately with plenty clean cold water and get medical treatment as soon as possible Battery and battery solution should be kept out of reach of children Battery charging will prod...

Page 7: ...ep them from contacting volatile oils grease or liquids 10 Pack or inject recommended grease in specific places as stated in service manual 11 Use special tools when needed for disassembly and install...

Page 8: ...21 When assembling any protective caps covers or boots make sure they are seated correctly in the respective grooves Engine Break in Proper Engine break in is necessary on new engines and newly rebuil...

Page 9: ...ZHEJIANG KAYO MOTOR CO LTD WWW KAYOMOTO COM 6 1 2 VIN Number Model AU125 VIN number Engine number VIN number Nameplate Engine number 3 2...

Page 10: ...cations 1 Dimension L W H mm 1400 850 925 2 Handlebar height mm 925 3 Handlebar width mm 730 4 Rear height mm 700 5 Ground clearance of seat mm 630 6 Min terrain clearance mm 90 7 Wheelbase mm 900 8 F...

Page 11: ...ll flow filter paper filter 9 Oil trademark SAE15W 40 10 Cooling type Air cooling 11 Cooling fluid 12 Air filter type Filter with sponge filter element 13 Carburetor Horizontal plunger type JingkePZ22...

Page 12: ...city 800mL Recommended engine oil original four strokes motorcycles SAE 15W 40 For replacements it must be within following scope APIclassification SGor upper grade engine oil SAE specification refer...

Page 13: ...rake one with two disc thickness 3 5mm 3mm Brake handle stroke 5 10mm Braking force 400N m Rear brake Disc thickness 3 5mm Brake handle stroke 10 20mm Braking force 500 N m Ignition device Item Standa...

Page 14: ...crank connecting link see engine section 1 4 Fastener Torque Specifications Note When installing threads please manually attach 2 3 turns of thread first Torque Specifications chart No Item install po...

Page 15: ...ring column locking M8 8 8 18 25 17 Bolt of lower raiser M10 1 5 10 9 50 60 18 Electrical elements Battery box M8 8 8 15 20 19 Muffler installation M8 8 8 15 20 20 Voltage regulator ignition coil M6 8...

Page 16: ...heel hub 5 Installation axle for rear fork 6 Inner sleeves of rear fork 7 Rear axle liner pipe 8 Rear axle bearing and oil seal 9 Steering column clamp Note please coat inside of handlebar grip with g...

Page 17: ...ZHEJIANG KAYO MOTOR CO LTD 14 Main Harness front brake line Throttle cable rear brake line Choke cable...

Page 18: ...CO LTD 15 Battery positive Battery negative Stator ign pickup connector Gear indicator Voltage regulator Headlight Multi Function switch Key Switch Reverse indicator Neutral indicator Kill switch Brak...

Page 19: ...ZHEJIANG KAYO MOTOR CO LTD 16 CDI Ignition coil Voltage regulator rect ifier Tail light...

Page 20: ...g labels stickers and riveted tags to the new plastics 2 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 ha...

Page 21: ...the fixed bolt from brake bar by tool and remove rear brake bar 4 Remove front brake bar as the same as rear brake bar 5 Pull the damper cable as picture shows then remove it 6 Remove the bolt from a...

Page 22: ...lease then pull and lift to remove the seat Installation To install line front hook up with corresponding post then simultaneously push down and forward until latch locks into place 2 3 4 Front rack D...

Page 23: ...se 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 Remove the plastic body n...

Page 24: ...isassemble mounting bolt in order 2 Remove the front guard Installation Take it back in reverse order from disassembly note replace mounting bolts nuts and rubber washers as needed when worn 3 Regular...

Page 25: ...rs loose clothing and hair away from these parts 3 2 Maintenance period Engine maintenance is a regular periodic work due at certain time intervals for engine maintenance keeping up on standard mainte...

Page 26: ...uid lower limit Tear and damage of brake disc Replace the disc in time when front or rear brake working disc s thickness is less than 3mm Brake pad Tear and damage of brake pad The minimum brake pad f...

Page 27: ...ain wheel and chain wear severity replace it Electrical device Ignition device State of spark plug Ignition period Battery Terminal connection status Electric circuit Looseness and damage of joints Fu...

Page 28: ...steering column tighten the bottom lock nut on steering column or you can also disassemble the steering column to check bearing and clamps Keep vehicle in steady place and turn the handlebars slowly m...

Page 29: ...hoses fittings and connections If fluid is low remove top of master cylinder and add DOT4 brake liquid to limit position Note When adding brake fluid do not mix with dust or water always add fluid fro...

Page 30: ...pindles If there is still movement check the bearings ball joints a arm bushings Replace if worn or damaged Front wheel size On a level surface with handle bars straight check the front wheel toe in T...

Page 31: ...tires out of specified range will affect vehicle handling and may cause premature wear and or damage to tire tread Using adverse effects such as tire bias wear Tire tread Check Tire tread if tread is...

Page 32: ...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 3 7 Throttle check Check the free stroke of the thumb throttle lever P...

Page 33: ...eeves 1 2 Loosen lock nut 3 and barrels adjuster 4 then adjust throttle freeplay to within specification Speed limiting device adjustment Speed limit device is used to restrict throttle opening Inspec...

Page 34: ...crew If necessary the screw can be removed with pliers and replaced with a phillips head screw Suspension pre load adjustment Front shock is nonadjustable Rear shock can be adjusted from 1 to 5 This i...

Page 35: ...ed to be removed for the following operations oil pump carburetor air filter cylinder head cover start motor cylinder head cylinder block camshaft left cover AC magneto piston piston ring piston pin R...

Page 36: ...mounting bolts and tank Fuel tank pictures may differ from tanks on U S models 4 3 Air filter system Disassembly Loose the air filter clamp to remove air filter Fuel line 1 Petcock 2 Tank mounting bol...

Page 37: ...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 bo...

Page 38: ...r deformed 4 5 Disassembly and installation of engine Disassembly Note Remove floorboards pegs carburetor intake manifold and oil cooler first 1 Remove the engine front sprocket side cover then remove...

Page 39: ...shall be in the reverse order of removal 5 Engine 5 1 Maintenance information Conversion table refers Item Unit conversion Pressure 1kgf cm2 98 0665kPa 1kPa 1000Pa 1mmHg 133 322Pa 0 133322kPa Torque 1...

Page 40: ...ch 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 o...

Page 41: ...cture on the right is shown 5 3 Engine brake in Engine has a lot of relative motion components such as piston piston ring cylinder block mutually meshing transmission gear wheel etc therefore a standa...

Page 42: ...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 hours Avoid operating longer than 3 4 throttle...

Page 43: ...ming 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 R...

Page 44: ...41 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...

Page 45: ...ZHEJIANG KAYO MOTOR CO LTD 42 Remove left cover and inspect the paper pad for damage Replace if necessary Dismantle the fixing bolt of right cover...

Page 46: ...f 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...

Page 47: ...LTD 44 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 combus...

Page 48: ...emove 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 va...

Page 49: ...MOTOR CO LTD 46 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...

Page 50: ...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...

Page 51: ...dowel pin to 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 ne...

Page 52: ...O MOTOR CO LTD 49 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...

Page 53: ...nner 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 0...

Page 54: ...poor idle speed and high fuel consumption Grind cylinder end surface or replace the cylinder body The cylinder is badly worn The fitting clearance between the cylinder and position position ring is t...

Page 55: ...d 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 Right view of right crankcase half is s...

Page 56: ...ther 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 cou...

Page 57: ...MOTOR CO LTD 54 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...

Page 58: ...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...

Page 59: ...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 rem...

Page 60: ...HEJIANG KAYO MOTOR CO LTD 57 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 necessar...

Page 61: ...he 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...

Page 62: ...ere 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 th...

Page 63: ...p The engine over heats Remove the carbon deposit Carbon deposit in the ring groove The piston ring is seized in ring groove The engine starts hard or fails to start Insufficient engine output Thick b...

Page 64: ...ne starts hard or fails to start Insufficient engine output Thick blue and white fume form the exhaust muffler pipe Replace the piston ring set The piston ring is over worn The piston ring opening gap...

Page 65: ...end bearing and of the cylinder Replace the connecting rod Timing sprocket The gear is over worn of damage Abnormal sound during sprocket driving Replace the timing sprocket 5 7 Maintenance of Mechan...

Page 66: ...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 Valve spring Measure length o...

Page 67: ...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 Measure the width of...

Page 68: ...ZHEJIANG KAYO MOTOR CO LTD 65 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: ...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 Rem...

Page 70: ...g 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 s...

Page 71: ...e 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 locat...

Page 72: ...ZHEJIANG KAYO MOTOR CO LTD 69 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: ...rking surface is scratched or over worn Valve striking sound Replace the rocker arm The rocker arm shaft hole is over worn Big gap between the rocker arm and rocker arm shaft Valve striking sound Repl...

Page 74: ...ge Thick blue and white fume form the exhaust muffler pipe Replace the valve The valve stem is deformed It is impossible to close the valve completely The engine starts hard or fails to star Replace t...

Page 75: ...ean 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 agin...

Page 76: ...il 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 Take out the main jet to ch...

Page 77: ...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 Adjust mixtu...

Page 78: ...edle to the third tier If the clip rises concentration of mixture becomes dilute and if falls it becomes thick 5 9 Maintenance of Intake Exhaust System 5 9 1 Disassemble assemble and maintain intake s...

Page 79: ...an the filter element The filter core is fractured or chapped Engine air suction noise is too loud Replace the filter element 5 10 Disassemble assemble and maintain exhaust system Dismantle lock nut o...

Page 80: ...the environmental protection Maintenance of Exhaust Muffler valve Inspect the lock nut for tightness and tighten as necessary Description Damage form Trouble Cause Correction Exhaust pipe gasket The g...

Page 81: ...p 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 Remove the secondary inlet air...

Page 82: ...roken 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...

Page 83: ...unt 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 wea...

Page 84: ...ZHEJIANG KAYO MOTOR CO LTD 81 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 82 Remove rotor fixing nut Remove rotor with puller Remove rotor to check magnetism necessary replace...

Page 86: ...arter 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 transm...

Page 87: ...ZHEJIANG KAYO MOTOR CO LTD 84 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 85 Disassemble the drive sprocket and chain Dismount the fixing bolt of start motor Remove start motor...

Page 89: ...LTD 86 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...

Page 90: ...ufficient rotation force Replace carbon brush spring Armature commentator surface is fouled Starter motor has insufficient rotation force Clean the commentator surface with gasoline or alcohol Armatur...

Page 91: ...ZHEJIANG KAYO MOTOR CO LTD 88 Circuit diagram...

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KAYO MOTOR AU125, Service Manual

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