Kayo Bull AU Series User manual

Zhejiang Kayo Motor Co., Ltd.
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Zhejiang Kayo Motor Co., Ltd.
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Important Information
Before riding, please read this user’s manual carefully and take related training courses. Please
follow tips for lowest age for the model. The manual contains plenty of important safety
information and tips necessary for riding and maintenance. For your personal interests, please pay
attention to the following notations:
WARNING
—
—— —f fa ai il lu ur re e t to o f fo ol ll lo ow w t th he e w wa ar rn ni in ng g, , y yo ou u w wi il ll l r re es su ul lt t i in n s se er ri io ou us s i in nj ju ur ry y o or r d de ea at th h. .
CAUTION
—
—— —f fa ai il lu ur re e t to o f fo ol ll lo ow w t th he e c ca au ut ti io on n, ,y yo ou u a an nd d y yo ou ur r v ve eh hi ic cl le e c ca an n r re es su ul lt t i in n i in nj ju ur ry y. .
P
Pl le ea as se e f fi il ll l i in n y yo ou ur r A AT TV V i in nf fo or rm ma at ti io on n i in n t th he e b bo ox x b be el lo ow w: :
VIN
：
：
Engine No.
：
：
Dealer name：

Zhejiang Kayo Motor Co., Ltd.
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Kayo has been dedicated to develop best products with advanced design and research methods, to
help our customers enjoy the pleasure of outdoor sports physically and mentally.
Kayo persistently pursues good quality of products and reasonable cost control to realize Thank
you for choosing and supporting Kayo. Kayo will spare no efforts to offer what fits your best.
Wish you a pleasant ride!

Zhejiang Kayo Motor Co., Ltd.
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This manual should be considered as a permanent part of the ATV and should remain with the
ATV when it is resold.
This manual includes the latest production information available. Zhejiang Kayo Motor Co., Ltd.
reserves the right to make changes at any time without notice and without incurring any
obligation.
No part of this publication should be reproduced without permission of Zhejiang Kayo Motor Co.,
Ltd..
This vehicle pictured in this book may not match your actual vehicle due to product update.
Preface
Thank you for choosing our sports seriesATV. We will do our uttermost to serve you and our
products will bring you enjoyment.
Now you own a technically advanced utility typeATV from Kayo which is specially designed for
riders above 16. Before riding, please read the user’s manual carefully, especially the safety tips.
The information is intended to help you to avoid the damage to your vehicle, other property or the
environment.As long as you maintain and use the vehicle as required by the manual book, the
ATV will bring you lots of fun and enjoyment instead of unnecessary hurt.
We treat every customer seriously and appreciate each advice you put forward. For differences of
demands from customers in different areas under various cultures, our products may have some
disadvantages. Your suggestions for improvements and developing are welcome.
We treat every customer seriously and appreciate each advice you put forward. For differences of
demands from customers in different areas under various cultures, our products may have some
disadvantages. Your suggestions for improvements and developing are welcome.

Zhejiang Kayo Motor Co., Ltd.
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Warranty Declaration
In the design and production of Kayo AU series ATV, the general and various complicated
conditions are taken into consideration.It’s crucial to maintain the the vehicle especially the early
use of engine and frame, to reduce wear and prolong service life based on the manual
book.Improper adjustment to the vehicle may damage the parts, reduce safety and service life.
Warranty shall not cover the bikes which are modified without Kayo authorization or
attached with spare parts which are not officially certified or don’t fit the model. Warranty
shall not cover the bikes which are not maintained based on the manual book or when no
proper maintenance record cannot be provided.Warranty shall not cover the bikes which are
broken due to improper operation or irregular use.
Notice: Above is general declaration. Please check with the local authorized distributor for
detailed warranty period and information.
Age Recommendation
Lowest age for this ATV is 16 years old. Young children under 16 should not operate the vehicle.

Zhejiang Kayo Motor Co., Ltd.
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Rider Training
All riders of this ATV should be guided properly.
KAYO utility type ATV —AU180

Zhejiang Kayo Motor Co., Ltd.
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WARNING
Kayo AU series models are utility vehicles, not suitable for high intensity professional racing.
Our company shall not incur the obligation when the rider uses the vehicle out of the range of
application and cause breakdown and accident.
The rider should wear necessary defensive gears before riding.
The rider should inspect the vehicle to make sure its systems and components are in good
condition before riding.
The rider is forbidden to ride after drinking alcohol or taking drug or narcotics.

Zhejiang Kayo Motor Co., Ltd.
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Zhejiang Kayo Motor Co., Ltd.
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CONTENTS
Vehicle Component Locations …………...…………………………………………....… 2
Vehicle Parameter ……………………………………………………………………. 3
Vehicle Mark Description ………………………………………………………………. 4
Control Functions …………………………………………………………………....7
Loading Functions ……………………………………………………………………. 9
ATV Riding Knowledge …………………………………………………………..……10
ATV Safety Matters …………………………………………………………………….12
Inspection and Maintenance ……………………………………………………………. 16
Troubleshooting …………………………………………………………….......………. 21
Unpacking and Dissemble …………………………................................................24
AU180 Electrical Circuit Diagram………………… .........................................................25

Zhejiang Kayo Motor Co., Ltd.
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AU180 Vehicle Component Locations

Zhejiang Kayo Motor Co., Ltd.
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Vehicle Parameter
M
Mo od de el l P Pa ar ra am me et te er r
Vehicle size and weight
MODEL
AU180
Vehicle length
1680mm(66.1in)
Vehicle width
960mm(37.8 in)
Vehicle height
980mm(38.6 in)
Seat height
730mm(28.7 in)
Wheelbase
1050mm(41.3in)
Ground clearance
150mm(5.9 in)
Front wheel track
730mm(28.7 in)
Rear wheel track
735mm(28.9 in)
Vehicle weight
155kg
E
En ng gi in ne e P Pa ar ra am me et te er r
Engine parameter
Engine model
R02-GY200-ATV
Engine type
Single cylinder, 4 stroke, air cooler
Displacement
177.3ml
Bore ×Stroke
62.5X57.8mm
Compression ratio
10:1
Max Power
9.1KW/7500±500r/min
Max Torque
10.0N.m/5500±500r/min
Ignition
C.D.I
Starting
electric

Zhejiang Kayo Motor Co., Ltd.
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Vehicle Mark Description
Vehicle Information Coding
AU180
(1)VIN NO. (2) ENGINE NO.

Zhejiang Kayo Motor Co., Ltd.
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Warning Stickers and Position
General Warning Sticker Age Warning Sticker
This warning sticker is put on the left front plastic, same as below picture.

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Tyre Pressure and Overload Combined Warning Sticker Passengers Warning Sticker
The above two warning stickers are put on the left rear fender, same as below picture.
Please observe the prompt content of warning labels, otherwise, it may cause property loss and even
casualties. Please keep warning labels clear and complete. If warning labels are blurred or damaged, please
contact the local distributor for new ones, and paste in the original position.

Zhejiang Kayo Motor Co., Ltd.
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Control Functions
Handlebar&Switches
LEFT HANDLEBAR
Engine stop switch :
With the Engine stop switch on the left of handlebar in the “Stop”position, the engine cannot be started. With the
Engine stop with in the 'RUN" position, the engine can be started.
Electric starting button:
With the key switch in the 'ON' position, pressing this button will automatically start the engine.
Parking brake:
Set the parking brake: grip the brake lever, press the parking brake pin, then set the parking brake.
RIGHT HANDLEBAR

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Throttle Lever
The throttle lever is used for controlling the engine and ATV speed. Operate this Iever with your thumb. Push it
forward to increase engine and ATV speed. Release it to decrease engine and ATV speed.
Parking Brake
To set parking brake, squeeze front brake lever, press parking brake pin, set the parking brake lever.
Throttle Limiter Screw
When controlling the throttle, you should screw in the adjusting screw.
Using the throttle limiter screw to restrict maximum speed of the ATV. Adjusting this limiter according to the
rider’s skill and experience.
Adjusting procedures:
1. Loosen the Lock nut.
2. Turn the throttle limiter screw clockwise to restrict maximum speed of the ATV.
3. Turn the throttle adjusting screw counterclockwise to increase the maximum speed of the ATV.
4. After adjusting, tighten the lock nut.
Fuel Tank Switch
There are two positions: “ON","OFF".
“ON” position - In this position, fuel will flow into the carburetor when the engine is running or being started.
“OFF” position-Fuel will not flow into the carburetor.
Fuel Tank Cap
To open the fuel tank cap，take the end of the vent tube out from the vehicle body, needing to turn the fuel tank cap
counterclockwise．To close the fuel tank cap，turn in it clockwise and tighten it firmly. Be sure that the vent tube
securely connects to the cap.

Zhejiang Kayo Motor Co., Ltd.
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Loading Functions
As originally equipped, this ATV can carry cargo or tow a trailer, but please be sure to be accordance with
your common sense and good judgment. Please note the following：
● Do not exceed the weight limit. An overloaded ATV can be unstable.
Maximum load (AU180):
Rear rack: 20 kg (44 lbs) front rack: 15 kg (33 lbs)
● When loading the cargo on the rack, it’s better to be close to the vehicle center, that is, near the front of rear rack
and the rear of front rack. Both sides of the rack should be best possible to share the goods. Goods should be fixed
firmly to ensure not to damage to the carrier and not to move during riding.
● Overload moving could cause an accident.
● Ensure that the load would not interfere with your control of theATV, and will not affect your sight.
● Control riding speed to be slower than the no-load speed. The heavier the loading is, the slower the speed will
be.
● It needs a longer braking distance when loading, because the heavier vehicle takes longer time to stop.
● Avoid sharp turns, except in very slow speed.
● Avoid riding on hills and rough terrain. Please choose the terrain very carefully. ATV increased weight will affect
the stability and handling.
● The cargo rack must not carry passengers.

Zhejiang Kayo Motor Co., Ltd.
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ATV Riding Knowledge
What You Should Know Before Riding
1. Before riding, you should read all the following information carefully. Operating this ATV without reading
instruction could be dangerous.
2. Beginners and inexperienced riders should take the complete training course .You should be well acquainted
with skills learned in the course and practice the operating techniques described in this user's manual.
3. Before riding, you should find a good place to practice the skills, find a flat, open area with enough space to
practice the new skills, make sure that it is legal to ride in the area you select, review the local laws and make
sure you are not trespassing. When you are riding, please keep the terrain in good condition, do not destroy
plants, trees or other vegetation, do not litter and affect the local animals.Only in this way, your riding area
can remain for future use.
4. After you find a good place to practice, please review the control system on your ATV before riding, learn to
find these controls without looking for switches, because you will not have time to look for them when you
are riding. The risk of riding could increase greatly if you do not know how to operate the ATV properly
under different situations and in different types of terrain.
If you are properly prepared, you will have a more enjoyable riding.

Zhejiang Kayo Motor Co., Ltd.
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Inspect the ATV Before Riding：
Failure to inspect the ATV before operating could be hazardous. Failing to perform proper maintenance could also
be hazardous. Failing to inspect and maintain your ATV could increase the chances of an accident or equipment
damage. Always inspect your ATV each time before riding, and make sure it is in a safe operating condition.
ITEM TO CHECK
CONTENT
Steering
Smoothness; No restriction of movement; No play or looseness
Brakes
Proper damping return; Enough braking force; Effective braking performance
Tires
Proper air pressure; Enough tire pressure; No cracks and breaks or other
damages
Fuel
Enough fuel for the expected trip; Fuel hose connected securely; No damage
to fuel tank or cap; Fuel tank cap closed securely
Engine stop
Proper operation
Engine oil
Proper level - Check the oil by inspecting the Engine Oil Indicator located at
the bottom of the engine. The engine oil should completely fill the view
window. Add oil if the window is not completely filled.
Throttle
Proper and smooth throttle return; Smooth return on the idle position
Chain drive system
Proper tension; Adequate lubrication; No excessive wear or damage
General condition
Bolts and nuts are tight; No ‘quack-quack’ from any parts of the engine when
running; No visible damage
WARNNING！
1. Overloading could be hazardous! Overloading could cause changes in vehicle handling and could lead to an
accident. It must not exceed theATV rated loading.
2. Do not make any unnecessary changes on the ATV! Improper installation of accessories or modifications to
this vehicle may cause changes in handling, which could lead to an accident.
3. Please do not use improper tires or improper tire air pressure. If you use improper tires or improper air
pressure, you may lose control of the ATV, which will cause an accident.
Using the wedge to chock the ATV to avoid the mechanical problems, or the wedge can be used for ATV
temporary stay during the riding. Before riding the ATV, be sure to check the above items. Be sure your ATV is in
good condition of safe riding.

Zhejiang Kayo Motor Co., Ltd.
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ATV Safety
Safety Gear
An approved motorcycle helmet is the most important part of your safety gear. An approved motorcycle helmet
can help prevent a serious head injury. Choose a helmet that fits snugly. Motorcycle dealers can help in selecting a
good quality helmet which fits properly.
You should wear eye protection when you ride. If a rock or a branch hits your eyes, the eye protection would
protect you from injury. Remember to wear goggles or a face shield.
Wear proper clothing when you ride. The proper clothes can protect you from injury. Wear a good pair of gloves,
strong boots that are over the ankle, and a long sleeve shirt
WARNING！
1. Checking maintenance items when the engine is running could be hazardous.
You could be severely injured if your hands or clothing get caught in moving ATV parts. Shut the engine off when
performing maintenance checks, except checking the engine stop switch and throttle.
2. Operating this ATV without wearing an approved motorcycle helmet, eye protection, and protective clothing
could be hazardous. Operating without an approved motorcycle helmet or eye protection would increase your
chances of a severe head injury or death in an accident. Operating without protective clothing also increases your
chances of severe injury in an accident. Always wear an approved motorcycle helmet which fits properly. Always
wear eye protection (goggles or face shield). You should also wear gloves, boots, long sleeve shirt or jacket.
Break-In Period
The first month is the most important in the life of your riding. Proper operation during this Break-In period will
be helpful for assuring maximum life and performance of your new vehicle. The following guidelines explain
proper Break-In procedures.
Maximum Throttle Percentage Recommendation:
During the first 10 hours of operation, you should always use less than 1/2 throttle percentage.
Change the Engine Rotating Speed:
Change the engine rotating speed during the Break-In period, which make parts ‘run’, then ‘unload’ (permit parts
to be cooling). Although it is just during the procedure of adding some pressure into engine parts Break-In period,
please be careful that it would not be loaded too much to damage the engine.
Avoid Constant Low Rotating Speed: