KAYO MOTOR A180 User manual

ZHEJIANG KAYO MOTOR CO., LTD.
www.kayomoto.com
KAYO MOTO
A180
SERVICE MANUAL
ManualSERVICE
MANUALSERVICE MANUAL
www.kayomoto.com

ZHEJIANG KAYO MOTOR CO., LTD.
Preparation Instructions Catalogue
This SERVICE MANUAL introduces detailed information for A180 four-
wheeled vehicle (ATV),including the maintenance and adjustment procedures,
disassembly and assembly instructions, inspection and maintenance points,
troubleshooting methods and maintenance technical data and detailed graphical data to
guide the operation .
Please read this manual carefully and follow it
strictly during inspection and repair, this can effectively
prolong the service life of various parts, improve the
engine performance and the reliability of the whole
vehicle.
Maintenance information
1
Body cover
2
Regular inspection and
adjustment
3
Engine peripheral parts
4
Engine
5
Vehicle chassis
6
Signal and lighting system
7
Electrical schematic diagram
Appendix
The first chapter mainly introduces general
operation items, tools used, basic technologies and
maintenance parameters.
The second chapter introduces the assembly and
disassembly operation of the whole vehicle cover.
The third chapter introduces the regular inspection
and adjustment of the whole vehicle.
The fourth chapter introduces the disassembly of
engine peripheral assembly parts.
The fifth chapter introduces the methods and
precautions of disassembly, inspection, maintenance and
assembly of various parts of the engine.
The sixth chapter introduces the information about
vehicle chassis.
The seventh chapter introduces the inspection and
maintenance information of the vehicle signal and

The contents in this manual are subject to
change due to vehicle improvements and other
reasons without further notice.The actual state
of the vehicle shall prevail during maintenance.
ZHEJIANG KAYO MOTOR CO., LTD.
R & D department
August, 2021

ZHEJIANG KAYO MOTOR CO., LTD.
Unit conversion table in this book
Item
Unit conversion
Pressure
1kgf/cm2=98.0665kPa；1kPa=1000Pa
1psi=6.8948kPa
Torque
1kgf·m=9.80665N·m
Volume
1mL=1cm3=1cc
1L=1000cm3
Moment of force
1kgf=9.80665N
Length
1in=25.4mm
Danger/Warning/Caution
Please read the following explanation carefully,which emphasize the special meanings of the
words "danger", "warning" and "caution", and pay special attention to the prominent meanings when
repairing the engine.

Danger: Be alert to high danger
Warning: Be alert for moderate danger
Caution: Pay attention to minor hazards
However, please note that the “danger”and “warning”contained in this SERVICE
MANUAL cannot cover all potential risks during the use and maintenance of the engine. Therefore, in
addition to the “danger”and “warning”regulations, maintenance personnel must also have basic
mechanical safety knowledge. If you are not sure to complete the entire maintenance operation process,
please consult a more experienced senior technician.

1 Maintenance information
-1
1 Maintenance information
1.1 Operation note….……………............……………………………………………….……1-1
1.2 Vehicle identification number…………….……………....………………………….……1-3
1.3 Main parameter list…….……………………………………………......…....……………1-4
1.4 Maintenance parameter list………… ……………….....……………………….……....…1-6
1.5 Tightening torque……..……………………………………………………………...……1-8
1.6 Lubricants and sealants……………………………………………………………………1-10
1.7 Cable, hose and cable wiring diagram………..……….......………………………………1-11
1.1 Operation note
Safety Precautions
1、Work clothes (coveralls), hats and safety boots suitable for the operation must be worn, and if
necessary, safety protection such as dust-proof glasses, dust masks and gloves should be worn to
protect themselves from injury.
2、Because the exhaust gas contains harmful components, it is forbidden to run the engine for a long
time in closed places or places with poor ventilation.
3、When the engine is just stopped, the temperature of the engine and the muffler is still very high, do
not touch it before cooling to avoid burns.
4、The battery solution (dilute sulfuric acid) is a strong corrosive agent, which may cause burns and
blindness when it touches the skin and eyes. If your clothes or skin are accidentally stained with battery
solution, please rinse them with plenty of water and go to the hospital for treatment in time. The battery
and battery solution should be kept strictly and must be kept in a safe place out of the reach of children.
When the battery is charged, it will produce flammable and explosive hydrogen. Once a fire source or
electric spark approaches, there is a danger of explosion. So please charge in a well-ventilated place.
5、As gasoline is flammable, fireworks are strictly prohibited at the work site. Pay attention not only to
open flames, but also to electric sparks. In addition, the vaporized gasoline is at risk of explosion,
please choose a well-ventilated place for operation.
6. Be careful not to let the rear wheel, clutch and other rotating parts and movable parts pinch hands
and clothes during maintenance.
7. When two or more people perform operations, they must constantly greet each other to confirm

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safety.
Precautions for disassembly and assembly
1、Parts, Parts, lubricants and greases must use KAYO designated recommended products.
2、The parts of each system should be sorted and kept separately to ensure that the parts can be
installed back to their original positions.
3、Please clean the dirt and dust on the ATV before maintenance.
4、Gaskets, O-rings, piston pin retaining rings, split pins, etc. must be replaced with new ones after
disassembly.
5、The elastic collar will be deformed if the opening is too large during disassembly, and it will easily
fall off after reassembly. Please do not use elastic collar that have become loose or have lost their
elasticity.
6、After the parts are disassembled and inspected, they should be cleaned and the cleaning agent
should be blown off with compressed air before the measurement.Apply lubricating oil on the moving

1 Maintenance information
-2
7、surface before assembling.
8、When disassembling, check the necessary places and measure relevant data so that it can be
restored to the state before disassembly.
9、Fasteners such as bolts, nuts and screws should be pre-tightened first and then tightened on the
diagonal with the specified tightening torque according to the principle of from large to small and from
inside to outside.
10、During disassembly, rubber parts should be checked for aging during disassembly and replaced in
advance if necessary. In addition, since rubber parts are not resistant to gasoline, kerosene, etc., please
try not to let volatile oils and greases adhere to them.
11、Smear or inject the recommended grease in the specific places according to the requirements of the
SERVICE MANUAL.
12、The correct special tools should be used for disassembly and assembly operations.
13、The inner ring or outer ring of the ball bearing can be rotated by fingers to confirm whether the
rotation is flexible and smooth. If the disassembly method of applying force on the ball is adopted
during disassembly, the dismantled bearing should not be used again:
 If the bearing axial or radial clearance is too large, replace it.
 The bearings that feel stuck in rotation should be cleaned, and those that still feel stuck after
cleaning should be replaced, and those that cannot be cleaned should be replaced directly.
 If the bearing is originally compaction fit with vehicle or axle diameter, but it gets unsuitable
after disassembly, replace it.
14、The bearings should be coated with oil or grease before assembly.Pay attention to the
installation direction when assembling single-sided dust-proof bearings.Open type or double-sided
dust-proof bearings should be installed with the manufacturer's logo and size outward when
assembling.
15、When installing the rectangular retaining ring, the chamfered side should face the direction of
force. Do not use the retaining ring that has been slackened and lost its elasticity. After assembling,
turn the rectangular retaining ring to confirm that it is firmly installed in the groove.
16、After assembly, it is necessary to check whether each fastening part is tightened and whether it
is working properly.
17、Brake fluid and coolant will damage the painted surface, plastic parts, rubber parts, etc., do not
allow them to adhere to such parts, in case of adhesion, immediately rinse with water.
18、The oil seal should be installed with the side marked by the manufacturer facing outward (the
direction without oil):
 When assembling, be careful not to curl the oil seal lip and prevent burrs from scratching the oil
seal lip.

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 Apply grease to the oil seal lip before assembling .
19、When installing hose parts, insert the hose into the root of the joint. If there is a pipe clamp,
install the pipe clamp in the dent of the pipe. Replace the hoses that are not tight during installation.
20、Do not get dust, dirt, etc. into the engine and brake hydraulic system.
21、The gasket material attached to the joint surface of each engine box must be cleaned up before
assembly. Touch marks on the contact surface must be grind evenly with oilstone to remove them.
22、Do not twist or bend the cable excessively. Deformed and damaged cables will cause
malfunction or breakage.
23、When assembling protective cap parts, if there is a groove, the protective cap must be inserted
into the groove.
Engine running-in
The engine has many parts for relative movement, such as pistons, piston rings, cylinder blocks,
intermeshing transmission gears. Therefore, in the initial stage of using,it is necessary to perform
standardized running-in, which can make the moving parts adapt to each other,correct the working
clearance, and form a good smooth friction surface that can withstand heavy loads. Only the
engine that has been run-in standardized can have excellent performance and reliability.
The recommended running-in time is 10 hours, and the specifications are as follows:
0～10 hours: Avoid continuous operation at a throttle greater than 1/2. , while changing vehicle
speed. It is not recommended to run for a long time at a fixed throttle position.After every 1 hour
of work, stop and turn off the engine to cool down for 5-10 minutes to avoid sudden
acceleration.Throttle change should be slow, not sudden big sudden small,do not drag goods
during running-in.

1 Maintenance information
3
Note ：
 During the running-in period, carry out daily maintenance according to the
specification, and promptly remove any fault；
 After the running-in is over, the whole machine can be maintained before entering
the normal driving stage.
1.2 Vehicle identification number
①VIN number
②Vehicle nameplate
③Engine number
Model
A180
VIN number
Engine number

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4
1
2
3

1 Maintenance information
1.3 Main parameter list
Item
Parameter
Model
A180
Length（mm）
1560
Width（mm）
1020
Height（mm
1000
Wheelbase（mm）
1085
Engine mode
1P63QML
Displacement（ml）
177
Fuel type
No. 92 gasoline and above
Dry Weight(kg)
155
Number of passengers
1 person（only rider）
Max. Loading weight
1 person ＋80kg = 140kg
Tire size
Front
AT23×7-10
Rear
AT22×10-10
Ground Clearance
160mm
Turning radius (minimum turning radius
of the closest point)
2400mm
Engine
Starting method
Electric start、Hand pull start
Engine type
Single cylinder, four-stroke, air-cooled
Air distribution
CHOHO/Chain drive
Cylinder diameter x stroke（
mm）
62.5×57.8
Compression ratio
10.0:1
Lubrication method
Pressure + splash lubrication
Oil pump type
Rotor type
Lubricating oil filter type
Full flow filter rotary
Engine oil grade
SF MA 15W-40
Cooling type
Air Cooling

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Item
Parameter
Air filter type
Sponge filter element filtering type
Throttle body
\
\
\
\
Fuel capacity
5.6L
Transmission
system
Clutch type
Automatic clutch
Variable speed method
CVT
Shift gear
F-N-R
Shift mode/sequence
Manual/F-N-R
Output type
Rear axle output
Rotation direction of
engine output
In the forward gear, viewed from the rear of the
vehicle, the front is clockwise.
Steering device
Maximum steering
angle
45°±1°
Braking device type
front
Hydraulic disc
rear
Hydraulic disc
Buffer mode
Suspension method
Front wheel double rocker independent
suspension, rear wheel non-independent
suspension
Frame type
Steel pipe and steel plate welded type

1 Maintenance information
1.4 Maintenance parameter list
Lubricating device
Item
Standard
Limitation
Engine oil
capacity
Change oil
800ml(No oil filter replaced）
－
Change oil
850ml（Replace the oil filter）
Full capacity
900ml
－
Recommended engine oil
Only use SF MA 15W-40 or equivalent
engine oil, do not substitute or mix
different brands of engine oil, which
will cause engine damage and cause
accidents.
Oil
pump
rotor
Radial clearance of inner
and outer rotor
－
0.12mm
Radial clearance between
outer rotor and pump body
－
0.12mm
Axial clearance between
rotor surface and pump
body
0.05~0.1
0.2mm
Intake system（For details, please see 05-Engine section)
Wheels (front and rear wheels are the same)
Item
Standard
Limitation
Rim jump
Vertical
0.8mm
2.0mm
Horizontal
0.8mm
2.0mm
Tyre
Residual groove
－
3mm
Air pressure
35kPa（0.35kgf/cm2）
－
Brake system
Item
Standard
Limitation
Front brake
Brake disc thickness
3.5mm
3.0mm
Rear brake
Brake handle stroke
10~20mm
－
Brake disc thickness
4.0mm
3.5mm

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Battery / charging device / trigger coil
Ignition device
Item
Standard
Ignition method
CDI electronic ignition
Spark plug
Type
Resistance spark plug
Standard
A7RTC
Spark plug gap
0.6~0.7mm
Spark characteristics
Blue and white light
Ignitioncoil
resistance
primary
0.3 Ω
Secondary
3.8 kΩ
Peakvoltage
Ignition coil primary
300~450V
Pulse generator
20kV~30kV
Coil resistance of starting relay
3.5Ω
Item
Standard
Magneto
Type
Permanent magnet alternator
Output
Three-phase full wave
Magneto trigger coil resistance
150
Magneto no-load voltage (engine in
cold state)
No
Maximum output power of magneto
180w
Regulatedvoltage
14.5 ± 0.5V
Trigger coil peak voltage
≥1V，200r/min；≥8.5V，2000r/min
Rectifier type
Full wave rectification
Battery
Capacitance
12V7Ah
Voltage between
terminals
Fully charged
14.4V
Insufficient charging
Less than11.8V

1 Maintenance information
Lighting / Meter / Switch
Item
Standard
Fuse
10A
Light, bulb
Headlamp
12V—35W
Tail light/brake light
12V—2.8W
Valve train + cylinder head (see 05- Engine section for details)
Cylinder + Piston + Piston Ring + Crank Connecting Rod (see 05-Engine section for
details)
Clutch + transmission mechanism (see 05-engine section for details)

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1.5 Tightening torque
Note: Before installing the thread, apply anti-rust grease on the threaded part and
the joint surface.
Tightening torque of the designated part-Whole vehicle
No.
Item
Fastener code
Quantity
Tightening torque
（N·m）
1
Suspension lower rocker bolt
GB5789 M10×1.25×70
4
45~59
2
Front shock-absorbing bolt
GB5787 M10×1.25×40
4
45~59
3
Rear shock bolt
GB5787 M10×1.25×50
1
45~59
4
Rear shock bolt
GB5787 M10×1.25×45
1
45~59
5
Slotted nut for front wheel hub installation
GB9457 M14×1.5×H18
2
126~218
6
Steering rod ball pin slot nuts
GB9457 M10×1.25
4
33~45
7
Direction handlebar gland screw
GB70-85 M8×30
4
22~30
8
Front brake caliper bolt
GB5789 M8×25
4
22~30
9
Front brake disc bolt
M8×1.25×20
8
22~30
10
Rear brake caliper body bolt
GB5789 M8×25
2
22-30
11
Rear brake disc mounting screw
GB70-85 M8×16
4
22~30
12
Mounting bolt of direction handlebar
pressure block
GB5783 M10×1.5×30
2
45~59
13
Oil cooler mounting bolt
GB5789 M6×25
4
9~12
14
Trailer ball fixing plate mounting screw
GB70-85 M10×1.5×30
4
45~59
15
Slotted nut for rear wheel hub installation
GB9457 M16×1.5
2
199~311
16
Slotted nut for steering column installation
GB9457 M10×1.25
1
110~130
17
Steering column clamp mounting bolt
GB5787 M8×60
2
22~30
18
Mounting bolts in front of fuel tank
GB5789 M6×25
2
9~12
19
Mounting bolts behind the fuel tank
GB5789 M6×30
2
9~12
20
Horn mounting bolt
GB5787 M6×16
1
9~12
21
Negative pressure switch bolt
GB5787 M6×16
1
9~12
22
Engine mounting bolt
GB5787 M10×1.25×160
1
45~59
23
Sprocket base mounting screws
GB70-85 M8×20
4
38~51
24
Plastic bottom bracket mounting screws
GB70-85 M6×45
4
13~16
25
Cross pan head tapping screw
GB845-85 ST4.2
—
—
26
Cross pan head machine screw
GB828-88 M5×16
2
—
27
Cross large flat head machine screw
TM6
—
—
28
Rim mounting nut
GB6187-86 M10×1.25
16
45~59

1 Maintenance information
Tightening torque of the specified part - engine part (see 05-engine part for details)
Tightening torque of fasteners at unspecified positions
Type
Torque（N·m）
Type
Torque（N·m）
5mm bolt and nut
4.5~6
5mm screw
3.5~5
6mm bolt and nut
8~12
6mm screw
7~11
8mm bolt and nut
18~25
6mm convex bolt
10~14
10mm bolt and nut
30~40
8mm convex bolt and nut
20~30
12mm bolt and nut
35~50
10mm convex bolt and nut
30~40
Engine maintenance tools (see 05- Engine section for details)
Engine special tools (see 05- Engine section for details)
1.6 Lubricants and sealants
Coating place
Note
Grease
Steering bearing
Lightweight lithium
soap grease
Throttle cable connection
Active part of the rocker arm
Inner peripheral surface of steering column
Cushion lock movable part
Active part of shift mechanism
Lubrication of operating cables, bearings and rotating parts
Position
Content
Grease
Spherical shaft sleeve of steering shaft
General Lithium
Grease for
Automobile
Rear axle support
Front and rear shock absorber joints
Throttle handle shaft and cable connector
Left and right brake lever shaft

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Parking cable connection
Lubricate
GB/T5671
Engine operating materials and installation accessories (see 05-Engine
section for details)
Engine operating materials include lubricating oil (oil), grease (butter) and
coolant, etc.
Installation accessories include plane sealant, thread locking glue, etc.