KAYO MOTOR AU110 User manual

ZHEJIANG KAYO MOTOR CO., LTD.
WWW.KAYOMOTO.COM
AU110 model
Maintenance Manual

ZHEJIANG KAYO MOTOR CO., LTD.
WWW.KAYOMOTO.COM
Instruction
This manual contains detailed operation for AU110 (ATV), maintenance and
adjustment process, disassembly and installation notes, inspection and maintenance
points, trouble shooting methods and maintenance technical data, also with graphical
data.
Please read the manual carefully and follow the instructions strictly among inspection
period, that would enhance the reliability of motor and all parts.

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Content
Chapter 1 Service Information
Chapter 2 Seat and Rack
Chapter 3 Body and Covering
Chapter 4 Regular Maintenance and adjustment
Chapter 5 Places around engine
Chapter 6 Engine
Appendix Electrical schematic diagram
ZHEJIANG KAYO MOTOR CO., LTD.
All contents in this manual are subject to improve and
update without notice. Maintenance is subject to actual condition.

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1
Conversion table
Danger/warning/attention
Take the below explanations seriously, it’s important for maintenance, especially for
engine.
Danger: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, so besides the above explanations, the service operator should also
have basic mechanical knowledge. If the operator is unsure of completing the entire
maintenance operation, consult a more experienced senior technician.
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

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1. Service Information
1.1 Operation note 1.2 VIN Number 1.3 Main parameters list
1.4 Maintenance parameters list 1.5 Torque tightening
1.6 Lubricant, sealant 1.7 Cable, hose and wiring diagram
1.1 Operation note
Security
1. Wearing work clothes (coveralls), hat and safety boots suitable for the operation.
In some conditions dust glasses, dust masks, gloves and other safety protective
supplies are needed to protect you from injury.
2. Do not let the engine long running in airtight spots or unventilated places.
3. In case of scald, don’t touch the engine when the engine just stops working.
4. Battery solution (dilute sulfuric acid) is a strong corrosive agent; contact with the
skin, splash into the eye burns may lead blindness. Once the battery solution is
accidentally touched on clothes or skin, rinse immediately with plenty of water. If the
battery solution is touched on eyes, please flush immediately with plenty of water and
get treatment in time. Storage battery and battery solution should be kept strictly,
keep out of reach of children. Battery charging will produce flammable and explosive
hydrogen, once there is a source of fire or spark close, there is an explosion risk.
Please charge it in well-ventilated places.
5. As gasoline is flammable and explosive, it is strictly prohibited to set off fireworks
in the work site. Pay attention to sparks as well as open flames. Besides, the
vaporized gasoline may explode, please choose well-ventilated sites.
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 must constantly greet each other when operating to ensure
safety.
Disassembly and installation instructions
1. All the Parts, lubricants and lipids must be Kayo brand parts or Kayo recommends.
2. When disassemble, Please sort out the parts of each system and kept separately
to ensure that all parts can be put back.
3. Keep the vehicle clean before inspection.
4. The Gasket, o-ring, piston pin baffle ring, cotter pin and other parts must be
replaced after disassembling.
5. Snap ring will be deformed if the opening is too big during disassembly and easy to
fall off after reassemble. Please do not use snap ring which was inelastic.
6. After disassembly and inspection, clean the parts and blow the cleaning agent
away with compressed air before measurement. Grease the moving surface before
assembly.
7. During disassembly, check all the necessary sites and measure relevant data,
make sure the reassembly condition as same as previous state.
8. Bolts, nuts, screws and other fasteners shall be pre-tightened and then tightened
in accordance with the specified tightening torque on the diagonal in accordance with
the principle of from large to small and from inside to outside.

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9. Inspect the rubber parts before disassembling and replaced in advance if
necessary. In addition, as the rubber pieces are not resistant to gasoline, kerosene
and other erosion, do keep them from volatile oil and grease.
10. Smear or inject recommended grease in specific places as service manual
request.
11. Use special tools for disassembly and installation.
12. The ball bearing can be rotated in inner ring or outer ring with finger to confirm
whether the rotation is flexible and smooth. If the disassembly method is on the ball,
the removed bearing shall not be used again. If there are problems as bellow, please
replace bearing.
Bearing axial and radial clearance is oversized.
The bearings with a sense of stuck when rotate, clean it. If the bearings still feel
stuck after cleaning, replace it. If it can’t be cleaned, replace it.
If the bearing is originally compaction fit with vehicle or axle diameter, but it gets
unsuitable after disassembly, replace it.
13. The bearings should be lubricated with oil or grease before assembly. Notice the
direction of installation when assemble one-side dustproof bearing. When assemble
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 rectangular ring.
Do not use the ring without elasticity. After assembly, rotate the rectangular ring to
confirm that it is firmly installed in the slot.
15. It’s important to check whether all fastening parts are tightened and whether the
work is normal after assembling.
16. Brake fluid，gas and oil can damage the coating surface, plastic parts, rubber
parts, etc., do not let it adhere to these parts.
17. Make the side with manufacturer’s mark outside when install oil seal.
Check the oil seal before using.
Pay attention not to make oil seal lip curly, do not let burr scratch oil seal lip during
assembly.
Grease the oil seal lip before assembly.
18. When installing rubber pipe parts, insert the rubber pipe into the root of the joint. If
there is a pipe clamp, install the pipe clamp in the pipe indentation. Replace the
rubber pipe which without tightness.
19. Keep the inner of engine，fuel tank and brake hydraulic system away from dust
and clay.
20. Clean the gasket material which attached on the bonding surface of engine
before installation. The scratches on the contact surface must be removed uniformly
with a whetstone.
21. Do not bend the cable excessively. Deformed and damaged cables may cause
poor movement or breakage.
22. When assembling the protective cap parts, if there is a groove insert the
protective cap into the groove.
Break-in of engine

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There is a lot of relative motion components in engine, such as piston, piston ring,
cylinder, mutually meshing gear, etc., it’s very important to have a standard break-in
at the beginning of using. Break-in can help the moving parts adapt to each other,
correction work, form a smooth friction surface which can bear heavy load, by this
way the engine will have excellent performance and reliability.
Recommended break-in time is 20 hours, as follows:
0~10 hours: To avoid continuous operation under the condition of 1/2 throttle, the
speed should be changed frequently, and it is not recommended to operate for a long
time with a fixed throttle position; Cool the engine for 5 to 10 minutes after each hour
of operation. Avoid quick acceleration.
10~20 hours: To avoid continuous operation under the condition of 3/4 throttle, the
speed can be changed freely except full throttle.
Note:
During break-in period, do everyday maintaining, and eliminate hidden trouble in
time.
Break-in period ended, make a maintenance for the vehicle, then putted into
formal use.
1.2 VIN Number
Model
AU110
VIN number
Engine number
See the attached figure for the position of engraving
①VIN number
②Nameplate
③Engine number
3
1

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1.3 Main parameters list
No.
Item
1
Brand
KAYO
2
Type
AU110
3
Name
110cc utility ATV
4
Company
ZHEJIANG KAYO MOTOR CO., LTD.
●Main parameters
1
Dimension（L*W*H）（mm）
1430*860*890
2
Handlebar height（mm）
855
3
Handlebar width（mm）
675
4
Rear height（mm）
740
5
Ground clearance of seat（mm）
665
6
Min. terrain clearance（mm）
115
7
Wheelbase（mm）
910
8
Front track（mm）
840
9
Rear track（mm）
870
10
Turning radius（mm）
1650
11
Turning angle（degree）
38°±2°
12
Net weight（Kg）
98
13
Max. Speed Km/h
40（limited speed）
●Engine parameters
No.
Item
1
Starting type
Electric
2
Type
horizontal ，Single cylinder, four stroke, air
cooling
2

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3
Distribution way
SOHC/chain drive
4
Cylinder diameter ×
mileage（mm）
52.4*49.5
5
Compression ratio
9.0:1
6
Lubrication mode
Combination splash and pressure feed
7
Oil pump type
Rotor
8
Lubricating oil filter
type
All-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/EPA
state）
14
Tank volume
2L
15
Clutch type
Dry automatic clutch
16
Gearshift method
1+1shiftear with foot、with reverse gear
17
Gear range
1 forward gear, 1 reverse gear
18
Shift type
R~N~D
19
Reduction
ratio
Forward gear D
Reverse gear R
Primary
Gear hub of clutch/primary gear
Single-
stage
Gear ratio of forward gear
Gear ratio of
forward gear
Overall
● Frame
20
Drive sprocket ratio
37/13
21
Output type
Chain drive,rear wheel drive
22
Brake type
Front and rear disc
23
Suspension type
Freestanding double rocker
24
Frame type
Steel tube and steel plate welded type
●Lubricating device
Item
Standard
Limitation
Engine oil
capacity
Change oil
800mL （No oil filter element replaced
）
－
Change oil
800mL （replace the oil filter element
）
Full capacity
800mL
－

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Recommended engine oil （ original ）
·four-strokes motorcycles SAE-15W-40
For replacements, it must be within
following scope:
·API classification ： SG or upper grade
engine oil
·SAE specification ： refer to left table
Oil pump
rotor
Radial clearance of inner
and outer rotors
0.07 mm～0.15mm
0.2mm
Radial clearance between
outer rotor and pump body
0.03 mm～0.10mm
0.12mm
Axial clearance between
rotor surface and pump
body
0.023 mm ～ 0.055 mm
0.12 mm
Oil pressure
1500r/min ， 90 ℃ : 200 kPa ~400kPa ，
General 240 kPa
6000r/min ， 90 ℃ :600 kPa ~700kPa ，
general 600 kPa
●Air intake system（see engine section）
●Cooling device (without)
●Wheel (front and rear wheels)
Item
Standard
Limitation
Rim jump
Vertical
1.0mm
2.0mm
Horizontal
1.0mm
1.8mm
Tyre
Residual groove
~
3.0mm
Air pressure
4.0 PSI
~
●Brake system
Item
Standard
Limitation
Front brake（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
Standard
Ignition method
CDI electric ignition
temperature
Viscosity
grade

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Sparking plug
Type
Resistor type spark plug
Standard
A7RTC/（torch）
Gap
0.6~0.7mm
Spark character
>8mm, one bar
Spark advance angle
Ignition coil
resistance
Primary
0.43~0.57Ω
Secondary
10.1~11KΩ
Peak voltage
Primary ignition coil
>150V
Pulse
2V
●Light / Instrument / Switch
Item
Standard
Relay insert fuse
15A
Light
Headlight left and right
LED
Taillight/brake light
LED
Gear indicator
LED
●Valve mechanism + cylinder cover（see engine section）
●Cylinder + piston + piston ring + crank connecting link（see engine
section）
1.5 Tightening moment of fastener
Note: When installing threads, please manually attach 2~3 turns of thread
first.
Tightening moment at specified position-whole vehicle
No.
Item
install position
Bolt
specificatio
n
Clas
s
Moment N*m
1
Engine
Rear power bolt
M8
10.9
37~50
2
Up power bolt
M8
10.9
37~50
3
Down power bolt
M8
8.8
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
18~25（with
blue thread
sealants）
9
Front disc
M6
10.9
15~20
10
Disc pump
M8
10.9
29~35
11
Front brake tee
M8
8.8
18~25

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12
Rear axle
Rear axle
M12*1.25
8.8
55~65
13
Nut
M27*1.5
80~90
14
Chain bolt
M6
8.8
8~12
15
Turning
Clamp locking bolt
（hexagon）
M8
10.9
18~25
16
Steering 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
8.8
7~11
21
Oil tank,
body parts,
plastic
Oil tank
M6
8.8
7~11
22
Oil tank switch
M6
8.8
7~11
23
Plastic screw
TM6
7~11
24
Screw for headlight
and plastic
ST4.2
3~5
●Tightening moment at specified position - engine（see engine section）
●Engine service tool（see engine section）
●Engine special tool（see engine section）
1.6 lubricating grease and sealant
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
Inner sleeves of rear fork
7
Rear axle liner pipe
8
Rear axle bearing and oil seal
9
Steering column clamp
Note: please coat glue for handlebar grip before installing.
Engine operating materials and installation accessories (see
engine section) Engine operating materials includes lubricating oil (engine oil),
Grease (butter) and cooling liquid. The installation accessories contains flat coating
glue, screw thread sealant etc.
1.7 Wiring diagram of cable, hosepipe and inhaul cable

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Main cable
Oil tube for front brake
Throttle cable
Oil tube for rear brake
Damper cable

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Positive
pole
Negative
pole
Magneto
connector
Gear indicator
Voltage regulator
Headlight
Functional switch
Electrical lock
Reverse gear
display
Neutral display
Stop switch
Brake cable

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CDI
Ignition
coil
Voltage
stabilizer
Rear
light

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2. Seat and rack
2.1 Seat
Disassembly
Lift up the seat hook 1
Lift up the rear of seat, and then pull it backward. 2
Remove the seat.
Installation
Take it back in reverse order from disassembly.
Check if the seat is installed in place and firm.
2.3.2 Front rack
Disassembly
Disassemble the mounting bolts from rack 1
(left and right each one）
Disassemble front rack 2
Installation
Take it back in reverse order from disassembly.
2.3.3 Rear rack
Disassembly
Disassemble mounting bolt from rear rack 1
(left and right each one）
Disassemble rear rack 2
Installation
Take it back in reverse order from disassembly.
2
1
2
1
2
1

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3 Body covering
3.1 Maintenance cautions
3.2 Installation torque
3.3 Seat, front guard, clay, hood, rear body, left and right guard,front
body，plastic pedal, dismounting left and right pedal
3.1 Maintenance cautions
Operation cautions
When replacing the covering parts, please stick the tags and riveting warning
labels to the new covering.
This chapter is about the dismounting sequence of covering.When related
coverings need to be disassembled to overhaul the internal parts of the vehicle,
it can be carried out by referring to this chapter.
Pipe, inhaul cable should be equipped according to wiring diagram of cable,
hosepipe and inhaul cable.
3.2 Installation torque
M8 bolt：18~25N*m
TM6 bolt：7~11 N*m
M6* bolt：8~12 N*m
3.3 Hood, handlebar, seat, plastic parts (clay, rear body, left
and right guard, front body), front guard, plastic pedal,
dismounting left and right pedal
3.3.1 Hood
Disassembly
①Remove the front display
lampshade retaining bolts 1
Remove the front display lampshade
2
②Remove hood retaining bolts 3
Pull the hood in the direction shown
in the picture, and remove the hood
after the buckle is loosened (Note:
the buckle on the hood is easy to
break with caution)
Installation
Take it back in reverse order from disassembly.
1
2
3

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After installation, pay attention to check whether the seat cushion is installed in
place and firmly.
(Note: if the buckle is broken, replace it in time)
3.3.2 Handlebar
Disassembly
1. Cut off power first.
2. Cut plastic ties first, then pluck
functional switch, stop switch and
brake cable plug in sequence.
3. Loose 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 accelerator
cap to remove the throttle cable.
7. Dismounting fixed bolt, then the
lower raiser, remove handlebar at
last.
Installation
Take it back in reverse order from disassembly, then check if it installed well.
(note:1. after installation, check the flame-out switch connector, function switch
connector, brake connector etc., in case of misconnection or looseness.
2.Check if the dumper cable and throttle cable in right position.
3. Front and rear brake in right position, the wiring way refers to the vehicle
wiring diagram.
3.3.3 front guard
Disassembly
1. Disassemble mounting bolt in
order.
2. Remove the front guard.
Function switch
Rear brake
Front brake
Throttle seat
Damper switch
Flame-out switch
Front display lampshade bracket

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Installation
Take it back in reverse order from disassembly
(note: if the mounting bolt or nut is broken, replace it to same specification in
time)
3.3.4 Plastic parts
Disassembly
1. Disconnect electric plug, neutral indicator plug, reverse indicator plug and
headlight plug.
2. Disassemble plastic parts fixing bolts 1/1，2/2，3/3，4/4，5/5，6/6，7/7，
8
3. Twist the oil cap, remove the plastic parts.
(note: remove the handlebar and hood first before dismount plastic parts.)
Take it back in reverse order from disassembly
Mounting bolt
1
2
3
4
5
6
7
8
2
1
3
4
5
6
7
the oil cap

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（note: if the mounting bolt or nut is broken, replace it to same specification in
time. After installation, check headlight connector, electric connector, reverse
indicator connector etc., in case of looseness or misconnect.
4. Regular maintenance and adjustment
4.1 Maintenance information
4.2 Maintenance period
4.3 Inspection ways
4.4 Steering column and brake
system
4.5 Wheel
4.6 Suspension system
4.7 Gear box and fuel system
4.8 Throttle check
4.9 Light device
4.10 Shock absorber selection
4.1 Maintenance information
Operation cautions
Note:
Do not let the engine long running in airtight spots and unventilated places,
because the exhaust contains carbon monoxide (CO) and other toxic
components.
In case of scald, don’t touch the engine when the engine just stops working.
If it must be, please wear long sleeves work clothes and gloves.
As gasoline is flammable and explosive, it is strictly prohibited to set off
fireworks in the work site. Pay attention to sparks as well as open flames.
Vaporized gasoline may explode, please choose well-ventilated sites.
Being careful of drive system and rotary parts, don’t let them pinch your
hands and clothes.
Note:
Keep the vehicle in a flat and stable place.
4.2 Maintenance period
Engine maintenance is a regular periodic work, according to a certain time
interval for engine maintenance is very important, standard maintenance is
helpful for well engine performance, reliable work, economic and durable, the
following is the A125 engine maintenance period table.
Note: the contents in the table is based on normal condition, if in bad
condition, the period should be shorter.
A：adjustment
C：clean
I：inspection
10 hours or300km
20 hours or750km