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KAYO MOTOR AT125-B User manual

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ZHE JIANG KAYO MOTOR CO., LTD
www.RideKayo.com
1
Model AT125-B
Service Manual
ZHE JIANG KAYO MOTOR CO., LTD
www.RideKayo.com
2
Instruction
This manual contains detailed information for Kayo AT125-B (ATV), maintenance,
adjustments, disassembly, installation, inspection points and specifications.
Please read the manual carefully and follow the instructions closely when performing
inspections and repairs, this will increase the reliability, performance and overall
lifespan of the vehicle.
ZHE JIANG KAYO MOTOR CO., LTD
www.RideKayo.com
3
Contents
Chapter 1 Maintenance information
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 CO., LTD.
All contents in this manual are subject to improve and
update without notice.
ZHE JIANG KAYO MOTOR CO., LTD
www.RideKayo.com
4
Conversion table
Item
Unit Conversion
Pressure
1kgf/cm2=98.0665kPa;1kPa=1000Pa
1PSI=0.0689kgf/cm2
1mmHg=133.322Pa=0.133322kPa
Torque
1kgf·m=9.80665N·m
Volume
1mL=1cm3=1cc
1L=1000cm3
moment
1kgf=9.80665N
Length
1in=25.4mm
Danger/warning/attention
Take the following warnings seriously, it’s important for regular maintenance,
especially important during engine maintenance.
Danger: Be on high alert for danger.
Warning: Be on alert for moderate danger.
Attention: Be on 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 should have basic mechanical knowledge before performing any service,
maintenance, or inspection.
1. Service Information
1.1 Warnings 1.5 Torque tightening
1.2 VIN Number 1.6 Lubricant, sealant
1.3 Main parameters list 1.7 Cable, hose and wiring diagram
ZHE JIANG KAYO MOTOR CO., LTD
www.RideKayo.com
5
1.4 Maintenance parameters list
1.1 Safety precautions
Safety first
1. Wearing work clothes (coveralls), hat and safety boots suitable for the operation.
In some condition’s safety glasses, dust masks, gloves and other safety protective
supplies are needed to protect you from injury.
2. Do not run the engine in unventilated places.
3. To prevent burns, do not touch the engine or exhaust until cooled.
4. Battery solution (dilute sulfuric acid) is a strong corrosive agent; contact with the
skin, contact with eyes may cause blindness. If the battery solution accidentally
touches clothes or skin, rinse immediately with clean cold water. If the battery
solution is touches 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 produce flammable and explosive gases,
if exposed to a source of fire or spark there is a risk of explosion or fire. Please charge
in well-ventilated places.
5. As 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
choose well-ventilated areas away from these hazards when refueling.
6. Attention, the rear wheel, clutch or sprockets and other rotating parts and
movable parts as hands and clothes may be caught during maintenance.
Disassembly and installation precautions
1. All Parts, lubricants oils and fluids must be Kayo brand parts or Kayo recommends.
2. During disassembly, please sort and separate out the parts and fasteners of each
system to ensure that everything is put back together properly.
3. Clean the vehicle or parts to be serviced before inspection.
4. Gaskets, o-rings, piston pin, piston ring, cotter pin and other one-time use parts
must be replaced after disassembling.
5. Snap rings can be deformed if opened too much during disassembly. DO NOT
re-use deform snap rings.
ZHE JIANG KAYO MOTOR CO., LTD
www.RideKayo.com
6
6. After disassembly and inspection, clean parts and blow the cleaning agents away
with compressed air before measuring. Grease the moving surfaces before assembly.
7. During disassembly, check all the necessary specifications and measure according
to directions in this manual. Make sure measurements and conditions are within
specification.
8. Bolts, nuts, screws and other fasteners shall be pre-tightened and then tightened in
accordance with the specified torque in a diagonal sequence. From large to small, and
from inside to outside.
9. Inspect all rubber parts during disassembly and replace if necessary. In addition, as
some rubber pieces are not resistant to corrosive materials, please keep 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 installation.
12. Ball bearings can be rotated with finger to confirm whether the rotation is flexible
and smooth.
Bearing axial and radial clearance is oversized.
Clean and grease bearings with a tight spot when rotated. If the bearings still feel
stuck after cleaning, replace. If the bearings can’t be cleaned, replace.
If the bearing is a press fit, and becomes deformed after disassembling, replace it.
13. Bearings should be lubricated or packed with grease before assembly. Take note
of the direction of installation when assembling. When installing open or double-sided
dustproof bearing, make the manufacturer's logo and dimensions outwards.
14. Let the chamfered side towards force direction when install the Snap-ring. Do not
use the rings without elasticity. After assembly, rotate the snap-ring to confirm that it
is firmly installed in the slot.
15. It’s important to check that all fastening parts are tightened and that functions are
normal after assembling.
16. Brake fluid and coolant can damage surfaces, painted parts, plastic parts, rubber
parts, etc., do not let brake fluid contact to these parts, If brake fluid contacts these
parts rinse and dilute with water immediately.
ZHE JIANG KAYO MOTOR CO., LTD
www.RideKayo.com
7
17. When installing oil seals manufacturer’s mark and sizes face outward.
Check the oil seal before using.
Grease the oil seal lip before assembly.
18. When installing rubber hose parts, insert the rubber pipe into the fitting. If there is
a hose clamp, install the hose clamp in the hose indentation. Replace rubber hoses if
dried, cracked, or deformed
19. Clean all gasket material from surfaces of before installing new parts or
reassembling.
20. Do not bend cables excessively. Kinked or damaged cables may cause poor
response and inner cables to fray and eventually break.
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 rebuilt engines
to help ensure that longevity and reliability of the engine components.
Recommended break-in time is 20 hours, as follows:
0~10 hours: Operate at no more than ½ throttle, keep gear changes and speed
variances to a minimum. Do not operate for extended amounts of time with a fixed
throttle position. Let the engine cool for 5 to 10 minutes after each hour of operation.
Avoid quick acceleration.
0~20 hours: Operate at no more than 3/4 throttle, Do not operate for extended
amounts of time with a fixed throttle position. Change gears and 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
schedule.
After Break-in period is complete schedule the unit for an inspection and service.
ZHE JIANG KAYO MOTOR CO., LTD
www.RideKayo.com
8
1.2 VIN Number
Model
HY110AT(AT125-B)
VIN number
Engine number
1 VIN number
2 Name plate
3 Engine Number
1
1.3 Specifications, Model information
No.
Item
3
2
1
ZHE JIANG KAYO MOTOR CO., LTD
www.RideKayo.com
9
1
Brand
KAYO
2
Type
AT125-B
3
Name
125cc utilityATV
4
Company
ZHEJIANG KAYO MOTOR CO., LTD.
●Dimensions, Vehicle Specifications
No.
Item
1
Starting type
Electric
1
Dimension(L*W*H)( mm)
1380*880*930
2
Handlebar height(mm)
930
3
Handlebar width(mm)
730
4
Rear fender height(mm)
700
5
Seat height (mm)
635
6
Min. ground clearance(mm)
90
7
Wheelbase(mm)
900
8
Front width outside of tires
(mm)
700
9
Rear width outside of tires (mm)
640
10
Turning radius(mm)
1650
11
Turning angle(degree)
38°±2°
12
Net weight(Kg)
97.4±2
13
curb weight(Battery+Fuel)( Kg)
102
14
Max. Speed Km/h
(Speed limitation) 40
ZHE JIANG KAYO MOTOR CO., LTD
www.RideKayo.com
10
2
Engine type
Horizontal Single cylinder, four stroke, air
cooling
3
Air distribution
SOHC/Chain drive
4
Cylinder diameter × stroke(mm)
52.4*49.5
5
Compression ratio
9.0 :1
6
Lubrication mode
Pressure + splash lubrication
7
Oil pump type
Rotor type
8
Lubricating oil filter type
Full flow filter rotary, Paper filter core
9
No. of Engine oil
SAE15W-40
10
Cooling
Air Cooling
11
Coolant
/
12
Air filter
Sponge filter cartridge
13
Carburetor
Flat suction plunger type (JINGKE
PZ22/EPA)
14
Tank volume
2L
15
Clutch type
Dry automatic clutch
16
Variable speed mode
1+1 Foot shifting, with shift protection.
17
Gear range
One forward gear, one reverse gear
18
Shift type
R~N~D
19
Deceleration
ratio
Forward Gear D
Reverse Gear R
Primary
Deceleration ratio
Clutch hub gear / primary transmission tooth
Single stage
deceleration ratio
Forward gear ratio
Forward gear ratio
Total speed ratio
●Frame
20
Driving sprocket ratio
37/13