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KAYO MOTOR AU125, Руководство по обслуживанию

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ZHEJIANG KAYO MOTOR CO., LTD.

 

www.kayomoto.us

 

1 

 

 

 

 

 

Model AU125 

Service Manual 

 

 

 

Содержание AU125

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 85: ...ZHEJIANG KAYO MOTOR CO LTD 82 Remove rotor fixing nut Remove rotor with puller Remove rotor to check magnetism necessary replace...

Страница 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...

Страница 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...

Страница 88: ...ZHEJIANG KAYO MOTOR CO LTD 85 Disassemble the drive sprocket and chain Dismount the fixing bolt of start motor Remove start motor...

Страница 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...

Страница 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...

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

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