KAYO MOTOR BULL 150 User manual

1
KAYO
AU150
BULL 150
Maintenance Manual
WWW.KAYOMOTO.US
VERSION CODE:20190316
VERSION NAME:AU150 Maintenance Manual

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ZHEJIANG KAYO MOTOR CO. LTD
March of 2019
Introduction
This manual contains detailed operation for
AU150 (ATV), including maintenance and
adjustment processes, dis-assembly
and installation notes, inspection and
maintenance points, troubleshooting
methods and maintenance technical data,
and graphics.
Please read the manual carefully and follow
the instructions strictly during the inspection
period, following these instructions can
lengthen the service life of parts and enhance
the performance of the ATV.
Chapter1: introduce the normal operation
issue, tools used, basic technique and repair
data.
Chapter2: introduce how to assemble and
dis-assemble the plastics.
Chapter3: introduce the regular maintenance
and adjustment.
Chapter4: introduce how to dis-assemble the
parts in the places around engine.
Chapter5: introduce the method and notes
for dis-assembly, checking, repair and
assembly of engine parts
Chapter 6: introduce ATV chassis related
information.
Chapter7: introduce the detection and repair
of the signal and lighting system.
Appendix: Electrical schematic diagram
All contents in this manual are subject to
improve and update without notice.
Maintenance is subject to actual condition.
Zhengjiang Kayo Motor., Ltd
RD Department
March of 2019
CONTENTS
Service Information
1
Plastics
2
Regular Maintenance and
adjustment
3
Places around engine
4
Engine
5
ATV chassis
6
Signal and lighting system
7
Electrical schematic diagram
Append
ix

3

Conversion table
Danger/warning/attention
Please take the safety precautions below seriously. During maintenance, and especially during
engine service.
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, and if
you are not sure whether can finish the repair, please learn from the experienced workers firstly.
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. Maintenance information
1.1 Operation note………………………………………………………………………………1
1.2 VIN Number……………………………………………………………………………………3
1.3 Main specifications list………………………………………………………………………4
1.4 Maintenance specifications list…………………………………………………………6
1.5 Torque tightening……………………………………………………………………………9
1.6 Lubricant, sealant……………………………………………………………………………10
1.7 Cable, hose and wiring diagram………………………………………………………11
1.1 Operation notes
Safety notes
1. Wear work clothes (coveralls), hat and safety boots suitable for operation. In some conditions
safety glasses, dust masks, gloves and other safety protective supplies are needed to protect you
from injury。
2. Do not run engine in un-ventilated areas.
3. Do not touch the engine or exhaust before cooled down to avoid burns。
4. Battery solution (dilute sulfuric acid) is a strong corrosive agent, which might cause burns or
blindness when get contact with skin or eyes. Once the battery solution is accidentally touched on
clothes or skin, rinse immediately with plenty of water and go to hospital to get treatment in time
when needed. Storage battery and battery solution should be kept strictly out of reach of children.
Battery charging can produce flammable and explosive Hydrogen. There is an explosion risk if
exposed to source of fire or spark. Please charge batteries in well-ventilated places.
5. As gasoline is flammable and explosive, Pay attention to sparks as well as open flames. Vaporized
gasoline may explode or burst into flames, please choose well-ventilated areas when working with
fuel systems.
6. Attention, the rear wheel, clutch or other rotating parts and movable parts may clip hands and
clothes during maintenance. Please tie up any loose clothing or hair when performing maintenance
in these areas
7. Two or more people must constantly greet each other when operating to ensure safety.
Disassembly and installation instructions
1. All the Parts, fluids and lubricants must be Kayo brand parts or Kayo recommends.
2. When disassembling, Please sort out the parts of each system and keep separate to ensure that
all parts can be put back.
3. Clean the vehicle before inspection
4. Gaskets, O-rings, piston rings, circlips, snap-rings, cotter pins and other onetime use parts should
be replaced after disassembling.

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5. Snap rings can be deformed if opened or closed too much during disassembly. Please do not use
snap rings that have been compromised.
6. After disassembly and inspections, clean the parts and blow the cleaning agent away with
compressed air before measurements. Grease the moving surfaces before assembly.
7. During disassembly, check all the necessary parts for wear and measure. Before re-assembly
make sure all parts are within specification.
8. Bolts, nuts, screws and other fasteners shall be pre-tightened by hand, then torqued to the
specified torque value, In a diagonal sequence from large to small fasteners and from inside to out.
9. Inspect rubber parts before disassembling and replace if necessary. In addition, some rubber
parts are not resistant to gasoline, kerosene and other corrosives. Please keep these rubber parts
away from volatile oil and grease.
10. Smear or inject recommended grease in specific places as required in service manual.
11. Use the correct tools for disassembly and installation.
12. Bearings inner race or outer races can be checked by rotating with finger to confirm whether the
rotation is smooth. If the bearings are a press fit, and the removed bearing is disfigured the bearing
shall not be used again. If there are problems as bellow, please replace bearing.
Bearing axial and radial clearance is loose
The bearings if stuck or frozen, Please clean and lubricate. 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. Install snap rings with chamfered side towards force direction. Do not use the rings that have
been deformed. After assembly, rotate the rectangular ring to confirm that it is firmly installed in
the slot.
15. Please check whether all fastening parts are tightened and that function is normal after
assembling.
16. Brake fluid and coolant can damage the coating surface, plastic parts, rubber parts, etc., do not
let it adhere to these parts, in case of adhesion rinse with water immediately.
17. Make the side with manufacturer’s mark outside when install oil seal:
Pay attention not to make oil seal lips curl, do not let burrs scratch oil seal lip during assembly.
Grease the oil seal lip before assembly.
18. When installing rubber hoses, insert the rubber hose onto the fitting. If there is a hose clamp,
install the hose clamp in the hose indentation if there is one. Replace the rubber hoses that are
loose, dried or cracking.
18. Keep the inner of engine and brake hydraulic system away from dust and clay.
20. Clean gasket materials on mating surfaces before installation. Any scratches or gouges on the

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contact surface must be removed uniformly with a whetstone or resurfaced.
21. Do not bend the cables or hoses excessively. Deformed and damaged cables can cause poor
range of motion, leaks or breaks.
22 When assembling the protective cap parts, if there is a groove insert the protective cap into the
groove.
Grinding in of engine
There are many relative motion components in the engine, such as pistons, piston ring, valves
chains, sprockets, mutually meshing gears, 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 10 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.
The change of throttle should be slow, not sudden. Do not overload or drag/tow goods during the
Break-in period.
Note:
During break-in period, perform everyday maintenance.to prevent future issues
Once Break-in period is complete, schedule a service for the vehicle, then put into formal use.

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1.2 VIN number
① VIN number
② Metal plate
③ Engine number
MODEL
AU150
VIN NUMBER
ENGINE NUMBER
1
3
2

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1.3 Main Specifications
ITEM
Specification
Model
AU150
Length(mm)
1663
Width(mm)
965
Height(mm)
980
Wheelbase(mm)
1050
Engine model
156FMJ
Displacement(ml)
140
Fuel type
No. 91octane or above
Weight(kg)
141
Rider No.
1 person(Only the rider, no passenger)
Max loading quality
1 person +60kg = 120kg
Tire spec
Front tire
AT20×7-10
Rear tire
AT19×10-9
Ground clearance
135mm
Turning radius(mm)
2350mm
Engine
Start
Electric
Engine type
Single cylinder, 4-stroke, oil cooling.
Transmission
CHOHO/Chain
Bore stroke(mm)
57×57
Compression ratio
8.8:1
Lubrication mode
Splash and pressure
Oil pump type
Rotor
Lubricating oil filter type
All-flow rotating filter
Oil
SAE15W-40/SF or above
Cooling
Oil cooling

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ITEM
Specification
Air filter type
Paper filter core
Throttle Body
Type
Plunger throttle
Mix valve diameter
30mm
Fuel tank volume
7L
Transmission
Clutch
Automatic
Speed changing way
3 gears+ reverse gear
Gears
Forward gears:1 2 3 Reverse gear:R
Gear changing order
By foot/ R N 1 2 3
Drive mode
Chain driven rear axle
Engine drive rotating
direction
clockwise
Steering
equipment
Biggest steering angle
46°±1°
Brake
Front
Hydraulic disc
Rear
Hydraulic disc
buffered mode
Suspension mode
Front double A-arm independent, Rear single
shock swingarm
Frame type
MIG welded steel tube and plates

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1.4 Maintenance Specs list
Lubricating device
Item
Standard
Limits
Engine oil
capacity
Change oil
600ml(No oil filter core replaced)
-
Change oil
700ml(replace the oil filter core)
Full capacity
800ml
-
Recommended engine oil
Only use SAE 15W/40-SE oil. Don’t use
other brand of mixing use different
brand as this will cause engine
damaged and may cause accidents
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
Air intake system(see 05-engine section)
Wheel (front and rear wheels)
Item
Standard
Limits
Rim jump
Vertical
0.8mm
2.0mm
Horizontal
0.8mm
2.0mm
Tire
Residual
groove
-
3mm
Air pressure
35kPa(0.35kgf/cm2)
-
Brake system
Item
Standard
Limits
Front brake
Disc thickness
3.5mm
3.0mm
Rear brake
Brake bar stroke
10~20mm
-
Disc thickness
4.0mm
3.5mm

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Battery/charging device/Trigger coil
ITEM
STANDARD
Magneto
Type
Permanent-magnet alternator
Output
Three-phase full wave
Magneto trigger coilresistance
150
Magneto No-load voltage(engine in
cold condition)
N/A
Magneto maximum outputpower
180w
Regulated voltage
14.5 ± 0.5V
trigger coil peak voltage
≥1V,200r/min;≥8.5V,2000r/min
Rectifier type
Full wave rectification
Battery
Capacity
12V 7Ah
Voltage
Full charge
14.4V
Not full
charge
小于11.8V
Ignition device
ITEM
STANDARD
Ignition method
CDI electric ignition
Sparking plug
Type
Resistor type spark plug
Standard
D8RTC
Gap
0.6~0.7mm
Spark character
Blue and white light
Ignition coil
resistance
Primary
0.3 Ω
Secondary
3.8 kΩ
Peak voltage
Primary ignition
coil
300~450V
Pulse
20kV~30kV
Start relay coil resistor
3.5 Ω

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Light / Meter / Switch
ITEM
STANDARD
Fuse
10A
Light, bulb
Front light
12V—35W
Tail light/brake light
12V—2.8W
Valve mechanism + cylinder cover(see 05-engine section)
Cylinder + piston + piston ring + crank connecting link(see 05-engine section)
Clutch + Transmission mechanism (see 05-engine section)

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1.5 Tightening torque of fasteners
Note: When installing threads, please put antirust grease on the thread and connecting
surface.
Tightening torque at specified position-whole vehicle
No
Install position
Bolt specification
Qty
Torque(N·m)
1
Suspension lower rocker
arm bolt
GB5789 M10×1.25×70
4
45~59
2
Front shock 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
Front hub mounting
slotted nut
GB9457 M14×1.5×H18
2
126~218
6
Steering pulling rod ball pin
slotted nut
GB9457 M10×1.25
4
33~45
7
Handle bar gland screw
GB70-85 M8×30
4
22~30
8
Front brake bolt
GB5789 M8×25
4
22~30
9
Front brake bolt
M8×1.25×20
8
22~30
10
Rear brake caliper bolt
GB5789 M8×25
2
22-30
11
Rear brake disc mounting
screw
GB70-85 M8×16
4
22~30
12
Handle bar raisers mounting
bolt
GB5783 M10×1.5×30
2
45~59
13
Oil cooler mounting bolt
GB5789 M6×25
4
9~12
14
Towing ball head fix plate
mounting screw
GB70-85 M10×1.5×30
4
45~59
15
Rear hub mounting slotted
nut
GB9457 M16×1.5
2
199~311
16
Steering column mounting
slotted nut
GB9457 M10×1.25
1
110~130
17
Steering column clip plate
mounting bolt
GB5787 M8×60
2
22~30
18
Oil tank front mounting bolt
GB5789 M6×25
2
9~12
19
Oil tank rear mounting bolt
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 holder mounting
screw
GB70-85 M8×20
4
38~51
24
Plastic bottom tray mounting
screw
GB70-85 M6×45
4
13~16

10
25
Cross head tapping screw
GB845-85 ST4.2
—
—
26
Cross head machine screw
GB828-88 M5×16
2
—
27
Cross head big fat machine
screw
TM6
—
—
28
Rim mounting nut
GB6187-86 M10×1.25
16
45~59

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Tightening torque at specified position - engine(see 05-engine section)
Tightening torque for fastener in non-specified position
Spec
torque N·m
Spec
Torque N·m
5mm bolt, nut
4.5~6
5mm bolt
3.5~5
6mm bolt, nut
8~12
6mm bolt
7~11
8mm bolt, nut
18~25
6mm Convex bolt
10~14
10mm bolt, nut
30~40
8mm Convex bolt, nut
20~30
12mm bolt, nut
35~50
10mm Convex bolt, nut
30~40
Engine service tools(see 05-engine section)
Engine special tools(see 05-engine section)
1.6 lubricating grease and sealant
Position
Note point
Grease
Steeringbearing
Lightweight lithium
soap-based grease
Throttle perch connecting place
A-arm bushing
Steering column inner surface
Seatlockmovepart
Gear shift mechanism move part
Lubricating grease for Handle cable, bearding and all rotating parts
Position
Contents
Grease
Steering axle spherical surface axle
sleeve
Lubricating
Car use general
Lithium grease
GB/T5671
Rear wheel axle bracket
Front and rear shock joint place
Throttle, bar steering axle and pulling
cable connector
Left and right handle bar turning axle
place
Parking cable connect place
Engine operating materials and installation accessories (see 05-engine section)
Engine operating materialsincludes lubricatingoil (engine oil), Grease and cooling liquid. The
installation accessories contain assembly grease or lube, screw thread sealant etc.

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1.7 Wiring diagram of cable, hoses and cable
1. Reverse indicator connector(older models 2017 ) 2. Digital gear indicator connector 3.
Headlight connector 4. Neutral indicator connector (older models 2017 )5. Key switch
connector 6.Multifunction switch Connector 7. CDI connector
Note: To inspect the above parts, must remove the front rack and hood. Please refer to
02-Plastics.
1
2
3
4
5
6
3
7

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8. Brake switch (left and right) 9. Throttle cable 10. Front and Rear brake lines
1.Carburetor 2. carburetor overflow hose 3.Starter motor cable 4. Crankcase vent hose
5.Stator/ignition pickup connector 6. Gear indicator connector 7.Voltage regulator connector
Note: To inspect the above parts, must remove the shift lever, and left footrest. Please refer
to 02-Plastics.
8
9
10
1
2
3
4
7
5
6

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8. Starter Relay 9. Battery negative terminal 10. Starter cable 11. Battery positive terminal
12.Voltage regulator/rectifier
1. Tail light connector 2.Tail light
1
2
8
10
9
11
12
2

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2 Plastics
2.1 Inspection item………………………………………………………………………15
2.2 Mounting torque…………………………………………………………………15
2.3 Dis-assembly and Assembly of seat and racks
2.3.1 Seat………………………………………………………………………16
2.3.2 Front rack……………………………………………………………………16
2.3.3 Rear rack……………………………………………………………………17
2.4 Dis-assembly and Assembly of hood, gear display front cover, gear display, foot
gear rod mounting combination
2.4.1 Front number plate……………………………………………………………………17
2.4.2 Gear display front cover…………………………………………………………18
2.4.3 Gear display……….………………………………………………………18
2.4.4 Shift lever mounting combination…………………………………………18
2.5 Disassembly and Assembly of left and right footrest
2.5.1 Left footrest plate…………………………………………………………………19
2.5.2 Right footrest plate…………………………………………………………………19
2.6 Disassembly and Assembly of front ventilation plate and bumper
2.6.1 Front ventilation plate…………………………………………………………………19
2.6.2 Bumper……………………………………………………………………20
2.7 Dis-assembly and Assembly of Front and rear assy. plate
2.7.1 Front assy. plate…………………………………………………………………20
2.7.2 Rear assy. plate…………………………………………………………………21
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1
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