KAYO MOTOR AY70-2 Service Manual Download

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ZHEJIANG KAYO MOTOR CO., LTD.

WWW.KAYOMOTO.COM

Model AY70-2

Service Manual

Summary of Contents for AY70-2

Page 1: ...ZHEJIANG KAYO MOTOR CO LTD WWW KAYOMOTO COM 1 Model AY70 2 Service Manual...

Page 2: ...ion for AY70 2 ATV maintenance adjustments disassembly installation inspection points and specifications Please read the manual carefully and follow the instructions closely when performing inspection...

Page 3: ...ion 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 4: ...ert 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 shoul...

Page 5: ...ventilated areas away form these hazards when refueling 6 Attention the rear wheel clutch or other rotating parts and movable parts may clip hands and clothes during maintenance 7 Two or more people...

Page 6: ...17 When installing oil seals manufacturer s mark and sizes face outward Check the oil seal before using Pay attention not to make oil seal lip curly do not let burr scratch oil seal lip during assembl...

Page 7: ...d vary speeds as necessary Let the engine cool for 5 to 10 minutes after each hour of operation Avoid quick acceleration Note During break in period inspect for noises and wear and follow maintenance...

Page 8: ...Front track mm 640 9 Rear track mm 550 10 Turning radius mm 1650 11 Turning angle degree 38 2 12 Net weight Kg 76 2 13 Kerb weight battery fuel Kg 81 14 Max Speed Km h 40 limited speed Engine paramet...

Page 9: ...rocker 24 Frame type Steel tube and steel plate welded type Lubrication system Item Standard Limitatio n Engine oil capacity Change oil 800mL No oil filter element replaced Change oil 800mL replace t...

Page 10: ...disc thickness 3 5mm Brake handle 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 to...

Page 11: ...8 18 25 4 Suspensio n Brake bolts M10 1 25 8 8 35 45 5 Axle of upper rocker arm M10 1 25 8 8 35 45 6 Rear rocker arm bolt M10 1 25 10 9 58 71 7 Fork axle M12 1 25 8 8 50 60 8 Brake Rear disc M8 8 8 18...

Page 12: ...No Position Effect Grease 1 Dust cap for rocker arms lubrication XHP222 2 Ball joint of rocker arms 3 Steering column bottom 4 Joints of knuckle and wheel hub 5 Installation axle for rear fork 6 Inne...

Page 13: ...ZHEJIANG KAYO MOTOR CO LTD WWW KAYOMOTO COM 13 Main cable Oil tube for front brake Throttle cable Oil tube for rear brake Damper cable...

Page 14: ...OTOR CO LTD WWW KAYOMOTO COM 14 Headlight Functional switch Electrical lock Reverse gear display Neutral display Stop switch Brake cable Positive pole Negative pole Magneto connector Gear indicator Vo...

Page 15: ...ZHEJIANG KAYO MOTOR CO LTD WWW KAYOMOTO COM 15 Voltage stabilizer Rear light CDI Ignition coil...

Page 16: ...Pipe inhaul cable should be equipped according to wiring diagram of cable hosepipe and inhaul cable 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...

Page 17: ...ove the bolt from accelerator cap to remove the throttle cable 7 Dismounting fixed bolt then the lower raiser remove handlebar at last Installation In reverse order from disassembly then check if it i...

Page 18: ...ly Check if the seat is installed in place and firm Note the seat cushion front hook must be installed in the frame limit and the seat cushion limit column must be installed in the frame limit 2 3 4 F...

Page 19: ...Disconnect all necessary electrical connectors 2 Disassemble plastic parts fixing bolts1 2 3 4 5 6 7 8 9 10 in order note 2 4 6 8 10 on the other side 3 Twist the oil cap remove the plastic parts note...

Page 20: ...tor electric connector reverse indicator connector etc in case of looseness or misconnect 2 3 6 Left and right plastic pedal Disassembly of right plastic part pedal 1 Remove the foot mounting bolt 1 a...

Page 21: ...and gloves 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 refuel in well ventilated areas B...

Page 22: ...I C clutch I Item Period Criterion Parts Item Daily Half year One year Steering device Steering wheel Operating flexibility Steering system Damage Installation status of steering system Ball pin shaki...

Page 23: ...Function Transmissi on Chain Transmission and lubrication tightness Chain flapping 20mm Flywheel chain wheel Transmission and lubrication tightness of fixing bolt If chain wheel and chain wear severi...

Page 24: ...tening the lock nut on steering column or you can also disassemble the steering column Keep vehicle in steady place and turn the handlebar slowly to check if the movement is smooth If it is hard to tu...

Page 25: ...e 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 Front brake disc and brake pads wear of brake block The brak...

Page 26: ...ative to the forward direction of the vehicle is A in front and B behind the wheel Toe in specification B A 4 10mm If not in this range adjust steering rod adjust the wheel toe in to 4 10mm and lock i...

Page 27: ...f rear wheel is the same as front wheel 3 6 Suspension system Keep vehicle in a horizontal position and compress up and down for several times according to the pictures If there is shaking or abnormal...

Page 28: ...rator several times as shown in the diagram and check the freeplay of the thumb throttle Under normal circumstances there is no sticky phenomenon of the accelerator naturally Freeplay 3 5mm Adjust thr...

Page 29: ...with a phillips screwdriver Note For beginners the speed limiter should be in a tight position and until the technology has reached a certain level it can be changed Besides the thread length limit i...

Page 30: ...s during maintenance In order to protect the engine frame please wrap the engine before operating When the engine is removed the corresponding containers should be prepared to receive coolant oil and...

Page 31: ...ase choose well ventilated areas away form 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...

Page 32: ...muffler and exhaust head pipe then remove the muffler mounting bolt to remove muffler Remove the self locking nut 3 between exhaust mouth and exhaust pipe then remove exhaust pipe Installation Instal...

Page 33: ...the ground lead gear indicator cable magneto cable start motor cable exhaust pipe ignition coil cap and gearshift 3 Remove the power bolts lug and bolt of engine bottom Magneto cable Gear indicato r c...

Page 34: ...er Be on high alert for danger Warn to be alert to moderate danger Attention to be alert to minor danger This manual may doesn t contain some potential risks in engine work and maintenance the service...

Page 35: ...be reused should be arranged in order it s helpful to assembly Choose special tools as specified in the maintenance manual Ensure that parts used in assembly are clean and must be lubricated where req...

Page 36: ...e 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 excellent performance and...

Page 37: ...djust Adjust Engine lubrication 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 cha...

Page 38: ...5 4 Maintenance of Engine Body 5 4 1 Disassemble assemble and maintain 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 l...

Page 39: ...OR CO LTD WWW KAYOMOTO COM 39 Remove cylinder head Check the state of paper pad Replace if necessary Dismantle the fixing bolt of left cover Remove left cover and inspect the paper pad for damage Repl...

Page 40: ...ntle the fixing bolt of right cover Remove the right cover of cylinder head Inspect the gasket for damage and replace if necessary Remove inlet exhaust valve cap Check the state of seal ring of valve...

Page 41: ...ZHEJIANG KAYO MOTOR CO LTD WWW KAYOMOTO COM 41 Remove the fixing bolt of timing driven sprocket Remove the connecting bolt of cylinder head Remove cylinder head assembly...

Page 42: ...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...

Page 43: ...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 Deposit and dust Che...

Page 44: ...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...

Page 45: ...sket and 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 Repl...

Page 46: ...O COM 46 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 cyl...

Page 47: ...cylinder inner wall Replace 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...

Page 48: ...he cylinder and cylinder 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...

Page 49: ...ankcase half Check whether 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...

Page 50: ...ankcase 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 Right vie...

Page 51: ...smantle 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 Check the condition...

Page 52: ...ine starts hard or fails to start Insufficient engine output Engine speed changes during Repair the threaded or replace the crankcase The bolt of the cylinder is broken The same as front The same as f...

Page 53: ...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 w...

Page 54: ...AYO MOTOR CO LTD WWW KAYOMOTO COM 54 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...

Page 55: ...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 betwe...

Page 56: ...ve 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 Assemble the pi...

Page 57: ...nt engine output Thick blue and white fume form the exhaust muffler pipe Replace the piston The piston pin hole is over worn Excessive fitting clearance between the piston ring and the hole Striking s...

Page 58: ...pin Connecting rod The connecting rod small end hole is over worn The fitting clearance between the piston pin and the small end is too wide Striking sound of the piston and of the cylinder Replace th...

Page 59: ...e 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 mi...

Page 60: ...e valve spring make sure its dense end downward Check the external diameter of valve stem using a verier clipper Replace the valve stem if the valve is beyond the maintenance limit valve Measure the w...

Page 61: ...the valve stem is distored Replace if necessary Inspect the timing camshaft bearing for wear and check the state of camshaft Replace if necessary Check the gap of rocker arm shaft and rocker arm Repl...

Page 62: ...g 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 necessary Remove the fix...

Page 63: ...rm to inspect for wear and damage Replace if necessary Remove the oil tube and spring and check the state Replace if necessary Remove the small timing chain and check the state Replace if necessary Ad...

Page 64: ...n 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 to the gap of cyl...

Page 65: ...g or abnormal sound during swiveling Abnormal sound heard during camshaft transmission Replace he camshaft Rocker arm The working surface is scratched or over worn Valve striking sound Replace the roc...

Page 66: ...fails to start Insufficient engine output Engine speed changes during idle run Replace the valve The valve stem is over worn The fitting clearance between the valve stem and the valve guide is too wid...

Page 67: ...er 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 c...

Page 68: ...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 check whether the jet hole is clogged Clean...

Page 69: ...ixture 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 t...

Page 70: ...fer 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 performa...

Page 71: ...mantle locknut of muffler Dismantle suspension bolt of muffler to check whether the suspension support is damaged Repair or or replace if necessary Remove the muffler to inspect for broken and damage...

Page 72: ...nspect the locknut for 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 ga...

Page 73: ...e refer to the following table Maintenance of environment protection valve Parts Damage form Trouble Cause Correction air pump air pump broken or plugged defective air pump Emission fails to meet the...

Page 74: ...Remove the retaining bolt from the left crankcase cover Remove the mounting bolt Remove the indicator and check for wear and damage Replace if necessary Remove the left crankcase cover muffler exhaus...

Page 75: ...TD WWW KAYOMOTO COM 75 Remove washer and check condition Replace if worn or reused Remove the magnetic stator fixing bolt and trigger bolt Check stator state with multimeter if worn or reused replace...

Page 76: ...KAYO MOTOR CO LTD WWW KAYOMOTO COM 76 Remove rotor retaining nut Remove the rotor with a special tool Remove the rotor and check for demagnetization Replace if necessary Remove the overclutch retaini...

Page 77: ...r and damage Replace if necessary Check for wear and damage of drive sprocket and drive gear and replace if necessary Remove the sprocket wheel press board Remove the tension band of the clutch and ch...

Page 78: ...ZHEJIANG KAYO MOTOR CO LTD WWW KAYOMOTO COM 78 Remove the snap ring of the starting motor sprocket Remove the drive sprocket and chain Remove starter motor retaining bolts Remove the starting motor...

Page 79: ...he starter windings are damaged Replace if necessary Remove oil separation disc and check condition Replace if necessary Check whether the oil seal is worn Replace if necessary Remove the seal ring Ch...

Page 80: ...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...

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