KAYO MOTO AU180 User manual

KAYO MOTO
AU180
Assembly Manual
WWW.KAYOMOTO.COM

1.The above picture shows the tools needed to
unpack and install the vehicle
① Phillips screwdriver
② Needle nose pliers
③ No. 8 T-socket
④ No. 10-12 wrench
⑤ No. 13 wrench
⑥ 6mm hexagon socket
⑦ 8mm hexagon socket
⑧ 12mm socket
⑨ 14mm socket
⑩ 27mm socket
⑪ Socket extension rod
⑫ Torque wrench
⑬ No. 10 T-socket
2.Remove the straps and cardboard cover.
3.Take out the parts attached on the vehicle and
the packaging iron frame, remove the iron frame
screws, wait for subsequent installation.
4.The parts shown above need to be
subsequently installed on the vehicle.
5.Above photo shows the accessories in the
carton. Please read the user’s manual(A) before
assembling.

Name Quantity
A User’s manual 1
B Cable tie 2
C Nut 8
D Rear reflector 1
E Bracket for gear indicator
cover
1
F Front/Rear L&R reflector 4
G Nut 2
cotter pin 2
washer 2
Spring washer 2
H Linkage ball head components 1
I Dust cover 4
J Air pressure gauge 1
K Spark plug socket 1
L Bolt 4
Nut 4
M Front shock 2
6. The picture shows the details of the standard
parts in the accessory box.
Name Quantity
N Rear Right/left
band
bolt 10
washer 10
nut 10
O Front rack and
cover
Bolt M6*16 6
Bolt M8*25 2
Bolt M8*16 2
P Rear rack and
cover
Bolt M8*16 4
Bolt M6*16 10
Q Subframe Bolt M8*16 3
R gear indicator
cover
Bolt M5*16 2
S front fence and
cover
Bolt M8*16 4
Bolt M6*16 4
7.Install E, use tool ⑥ ⑫ to tighten clamps, the
distance between the two ends of the mark is
close, tighten evenly, first start by hand tightening
all four clamp bolts. (The handlebar is tilted 3-5°
vertically to the rear after installation, and the
torque is required to be 25-30N·m).
8.Use tool ① to tighten the gear indicator cover
bolts.
9.Use tool ① to install the multi-functional switch.

10.Put the vehicle on the stand for easy
installation of other accessories.
11.Use tool ⑤⑨⑫ to tighten L as above. (the torque
is required to be 49-59N·m)
12.Use tool ⑧⑫ to install front rack and front
fence tighten O & S (he torque is required to be
25-30N·m)
13.Use tool ③ to tighten O & S for front rack cover
and front fence cover.
14.Install subframe as above, use tool ⑧ ⑫ to
tighten Q (torque is required to be 25-30N·m).
15.Install rear rack as above use tool⑧ ⑫ to tighten
P (torque is required to be 25-30N·m). Then
use ③ to tighten P for the rear rack cover.

16.First use tool ① to remove the fixing screws
for the plastic foot peg, then install the right/left
band and tighten N.
17.Please refer to user’s manual (A) for air
pressure requirements. Use compressed air to
inflate the tires and use the air pressure gauge (J)
to inflate to the standard value of 5psi.
18.Install front wheel on the front hub as above,
then use tool ⑨⑫ to tighten C (torque
requirement 60-68 N m).
119.Align the rear wheel with the splines and push
on the rear axle, with the air nozzle cap facing
outward. Use tool ⑩ ⑫ to lock the nut and washer,
then insert the cotter pin, keep the bending angle
greater than 180°
Note: Torque requirement 77-92N.m
20.Insert the dust cover(I) into the positions
shown above.
21.Use tool ⑦⑫ to tighten bolts for H（the torque is
required to be 25-30N·m）

22.Take out the battery, according to the user’s
manual (A), first tear off the seal on the battery,
add electrolyte, then install the battery cover
and wait for the subsequent installation into the
battery box.
23.Pull the latch as above shown and remove the
seat cushion, waiting for the subsequent
installation of the battery.
24.Use tool ④⑬ to remove the battery holder. 25.Install the battery and fix the battery holder,
connect the positive and negative poles as shown
above, use tool ① to tighten the screws, then
install the seat back. (Red is positive, black is
negative)
26.Unscrew the fuel tank cap, add gasoline,
and tighten the fuel tank cap clockwise.
27.Please read the user’s manual (A) carefully
before riding to better understand the performance
of the vehicle.