KAYO MOTOR AU125 User manual

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

ZHEJIANG KAYO MOTOR CO., LTD.
www.kayomoto.us
2

ZHEJIANG KAYO MOTOR CO., LTD.
WWW.KAYOMOTO.COM
Instruction
This manual contains detailed information for Kayo AU125(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.

ZHEJIANG KAYO MOTOR CO., LTD.
WWW.KAYOMOTO.COM
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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.

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WWW.KAYOMOTO.COM
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Conversion table
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.
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 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
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.

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4. Gaskets, o-rings, piston pin, piston ring, cotter pin and other onetime 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.
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.

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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.
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.
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 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.

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1.2 VIN Number
Model
AU125
VIN number
Engine number
①VIN number
②Nameplate
③Engine number
3
2

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1.3 Specifications, Model information
No.
Item
1
Brand
KAYO
2
Type
AU125
3
Name
110cc utilityATV
4
Company
ZHEJIANG KAYO MOTOR CO., LTD.
●Dimensions, Vehicle Specifications
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
Front track（mm）
700
9
Rear track（mm）
640
10
Turning radius（mm）
1650
11
Turning angle（degree）
38°±2°
12
Net weight（Kg）
105±2
13
curb weight（battery+fuel）（Kg）
110
14
Max. Speed Km/h
40（limited speed）
2