KAYO MOTOR AU180 User manual

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Model AU180
Service Manual

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Instruction
This manual contains detailed information for Kayo BULL180 /AU180 (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.
All contents in this manual are subject to improvements and
update without notice.

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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
Chapter 6 Chassis
Chapter 7 Signal and Lighting Systems
Electrical Schematic Diagram
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Conversion table
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
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

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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 areas.
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.

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5. Snap rings can be deformed if opened too much during disassembly. DO NOT
re-use deformed 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.
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.

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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
1.2 VIN Number

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Model
AU180
VIN number
Engine number
1VIN number frame stamp
2 VIN plate
3 Engine number
1.3 Main parameters list
1
2
3

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Item
Parameters
Model
AU180
L（mm）
1710
W（mm）
975
H（mm）
1030
Wheelbase（mm）
1100
Engine model
1P63QML
Displacement（ml）
177
Fuel type
No.92 gasoline and higher grade
Kerb weight（kg）
160
passengers
1 person（Driver）
Max. Loading weight
1 person＋80kg = 140kg
Tire size
Front wheel
AT23×7-10
Rear wheel
AT22×10-10
Min. Ground clearance
160mm
Turning radius (min. Turning radius of
the closest point)
2400mm
Engine
Starting mode
Electric
Type
Single cylinder, four stroke, oil cooling
Distribution way
CHOHO/chain transmission
Cylinder diameter × mileage
（mm）
62.5×57.8
Compression ratio
10.0:1
Lubrication mode
Combination splash and pressure feed
Oil pump type
Rotor
Lubricating oil filter type
Full flow filter rotary type
Oil trademark
SF MA 15W-40
Cooling type
Oil cooling
Item
Parameters
Air filter type
sponger filtering core

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Throttle body
\
\
\
\
Tank volume
5.6L
Drive system
Clutch type
Automatic clutch
Gearshift method
CVT
Gear range
F-N-R
Shift type
Manual/F-N-R
Output mode
Rear axle output
Rotate direction of
engine output shaft
Forward gear, viewed from the rear of the
vehicle, the front is clockwise.
Steering gear
Maximum steering Angle
45°±1°
Brake type
Front
Hydraulic disc
Rear
Hydraulic disc
Buffering
mode
Suspension mode
Front wheel double rocker arm independent
suspension, rear wheel independent
suspension
Frame type
Steel tube and steel plate welded type
1.4 Maintenance parameters list

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●Lubrication system
●Air intake system（see engine section）
●Brake system
Item
Standard
Limitation
Front brake
disc thickness
3.5mm
3.0mm
Rear brake
Brake handle stroke
10~20mm
－
disc thickness
4.0mm
3.5mm
●Storage battery / Charging device / Trigger coil
Item
Standard
Limitation
Engine oil
capacity
Change oil
800ml（No oil filter element
replaced）
－
Change oil
850ml（replace the oil filter
element）
Full capacity
900ml
－
Recommended engine oil
Please choose SF MA 15W-40,
or it may cause engine damage
and accident
Oil pump
rotor
Radial clearance of inner
and outer rotors
－
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
Item
Standard
Limitation
Rim jump
Vertical
0.8mm
2.0mm
Horizontal
0.8mm
2.0mm
Tire
Residual groove
－
3mm
Air pressure
35kPa（0.35kgf/cm2）
－

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Item
Standard
Magneto
Type
permanent magnet alternator
Output
three-phase full-wave
Magnetotrigger coil resistance
150
Magneto no-load voltage (engine in
coldstate)
None
Maximum output
180w
Stable voltage
14.5 ± 0.5V
Peak voltage of trigger coil
≥1V，200r/min；≥8.5V，2000r/min
Rectifier type
Full-wave rectification
Storage
battery
Ca
pacity
12V7Ah
Voltage between ter
minals
Fullcharge
14.4V
Insufficient
Less than 11.8V
●Ignition device
Item
Standard
Ignition method
CDI electric ignition
Item
Item
Resistor type spark plug
Ignition method
Ignition method
A7TC
Sparking
plug
Type
Sparking
plug
Type
0.6~0.7mm
Standard
Standard
Blue-white light
Gap
Gap
0.3 Ω
Spark
character
Spark character
3.8 kΩ
Peak voltage
Primary ignition coil
300~450V
Pulser
20kV~30kV
Starter relay coil resistance
3.5 Ω
●Light / Instrument / Switch

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Item
Standard
Accessory inline fuse
10A
Light
Headlight
12V—35W
Taillight/brake light
12V—2.8W
●Valve mechanism + cylinder cover（see engine section）
●Cylinder + piston + piston ring + crank connecting link（see engine section）
1.5 Fastener Torque Specifications
Note: Apply anti-rust grease to the thread and joint surface before installation.
Torque Specifications chart
No.
Item
Fastener code
Qty.
Moment（N·m
）
1
Lower rocker bolts of
suspension
GB5789 M10×1.25×70
4
45~59
2
Front brake bolts
GB5787 M10×1.25×40
4
45~59
3
Rear brake bolts
GB5787 M10×1.25×50
1
45~59
4
Rear brake bolts
GB5787 M10×1.25×45
1
45~59
5
Slotted nut for front hub
installation
GB9457 M14×1.5×H18
2
126~218
6
Slotted nut steering link
ball pin
GB9457 M10×1.25
4
33~45
7
Cover screw of handlebar
GB70-85 M8×30
4
22~30
8
Front brake clamp bolt
GB5789 M8×25
4
22~30
9
Front brake disc bolt
M8×1.25×20
8
22~30
10
Rear brake clamp bolt
GB5789 M8×25
2
22-30
11
Rear brake disc bolt
GB70-85 M8×16
4
22~30
12
Pressing erection bolt of
handlebar
GB5783 M10×1.5×30
2
45~59
13
Oil cooler mounting bolts
GB5789 M6×25
4
9~12
14
Mounting screw of trailer
ball fixing plate
GB70-85 M10×1.5×30
4
45~59
15
Slotted nut of rear hub
GB9457 M16×1.5
2
199~311
16
Slotted nut of steering
column
GB9457 M10×1.25
1
110~130
17
Bolt for steering column
clamp
GB5787 M8×60
2
22~30

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18
Mounting bolt in front of
tank
GB5789 M6×25
2
9~12
19
Mounting bolt behind tank
GB5789 M6×30
2
9~12
20
Mounting bolt of
horns
GB5787 M6×16
1
9~12
21
Bolt of negative
pressure switch
GB5787 M6×16
1
9~12
22
Mounting bolt of engine
GB5787 M10×1.25×160
1
45~59
23
Mounting screw of chain
wheel seat
GB70-85 M8×20
4
38~51
24
Mounting screw of plastic
collets
GB70-85 M6×45
4
13~16
25
self-tapping screw Pan
Head
GB845-85 ST4.2
—
—
26
Cross recessed pan head
screws
GB828-88 M5×16
2
—
27
Cross recessed flat head
screw
TM6
—
—
28
Mounting nut of wheel rim
GB6187-86 M10×1.25
16
45~59
●Tightening moment at specified position - engine（see engine section）
●Tightening moment at unspecified position
Type
Torque N·m
Type
Torque N·m
5mm bolt, nut
4.5~6
5mm screw
3.5~5
6mm bolt, nut
8~12
6mm screw
7~11
8mm bolt, nut
18~25
6mm flange bolt
10~14
10mm bolt, nut
30~40
8mm flange bolt, nut
20~30
12mm bolt, nut
35~50
10mm flange bolt, nut
30~40
●Engine service tool（see engine section）
●Engine special tool（see engine section）
1.6 lubricating grease and sealant

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Position
Note
Grease
Steeringbearing
Light lithium base grease
Connectionofthrottleandcable
Movable part of rocker arm
Inner of steering column
Movablepartsofseatlock
Movable parts of gearshift
●Lubrication of control cable, bearing and other movable parts
Position
Content
Grease
Spherical bushing for steering
shaft
lubrication
General Purpose Lithium
Lubricating Grease for
Automobile
GB/T5671
Rear axle support
Joints of front and rear brake
Throttle handle shaft and cable
connector
Left and right brake handle rotors
Parking cable connection
Engine operating materials and installation accessories (see engine
section) Engine operating materials include lubricating oil (engine oil), Grease and
may require thread sealant or thread lock.
1.7 Wiring and Cable Routing Diagrams

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1. Alternate reverse gear display connector 2. Instrument connector
3. Headlight connector 4. Alternate neutral display connector
5. Electric door lock switch connector
6. Multifunctional switch connector of left handlebar 7. Igniteconnector
Note: Removing the front panel before inspection and repair for above parts. For
details, please refer to chapter 2, plastic cover.
2
1
3
4
5
6
3
7

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8.Brake sensor (left, right) 9. Throttle cable 10. Brake lines
1. Carburetor 2. outlet pipe for carburetor 3. Starter motor cable
4. Engine exhaust pipe 5. Magneto trigger connector
6. Gear display connector 7. Regulated rectifier connector
Note: please disassemble the gear lever and pedal before inspection and repair for
above parts. For details, please refer to chapter 2, plastic cover.
8
9
10
1
2
3
4
5
6
7

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8. Starter Relay 9. Battery negative wire 10. Starting motor wire
11. Battery positive wire 12. Voltage regulator rectifier
1.
1. Tail light connector 2. rear light
8
9
10
11
12
1
2

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2 Plastics and Body parts
2.1 Maintenance warnings
2.2 Installation torques
2.3 Seat and carrier
2.4 Front guard of gear indicator, gear display and gear lever
2.5 Dismounting left and right footpegs
2.6 Dismounting of front ventilating boardand bumper
2.7 Dismounting of front assembly plate and rear assembly plate
2.1 Maintenance warnings
Operation cautions
1. When replacing plastics parts, please install new warning labels, stickers and riveted tags to
the new plastics.
2. This chapter is about the dismounting the body plastics.
2.2 Installation torques
M8 bolt
21（2.1）
Torque N·m (kgf·m)
M6 bolt
10（1.0）
Torque N·m (kgf·m)
M5 bolt
5（0.5）
Torque N·m (kgf·m)
Self-threading pin
4（0.4）
Torque N·m (kgf·m)
2.3 Seat and carrier
2.3.1 Seat
Locate the seat latch under the seat
Pull the latch to release, then pull and lift to
remove the seat.
Installation
To install line the front hook up with the
corresponding post. then simultaneously push
down and forward until the latch locks into place.
2
1

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2.3.2 Front rack
Disassembly
Disassemble the mounting screw from front
rack 3(left and right）
Remove mounting bolts 1
Remove front rack 2
Installation
in reverse order of disassembly.
2.3.3 Rear rack
Disassembly
Disassemble the mounting bolts from rear
rack 1（left, right）
Remove rear rack 2
Installation
in reverse order of disassembly.