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KAYO MOTOR AT125-B - User Manual

KAYO MOTOR AT125-B
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ZHE JIANG KAYO MOTOR CO., LTD
www.RideKayo.com
1
Model AT125-B
Service Manual
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Summary

Instruction

Service Information

1.1 Warnings

General warnings and safety alerts for operation.

1.2 VIN Number

Information on identifying the vehicle's VIN and engine number.

1.3 Main parameters list

Key specifications and parameters of the vehicle.

1.4 Maintenance parameters list

Detailed maintenance parameters for the vehicle.

1.1 Safety precautions

Essential safety measures to follow during maintenance and operation.

Disassembly and installation precautions

Precautions to take during vehicle disassembly and reassembly procedures.

1.5 Torque tightening

Guidelines for proper torque application during assembly.

1.6 Lubricant, sealant

Recommended lubricants and sealants for maintenance.

1.7 Cable, hose and wiring diagram

Diagrams illustrating cable, hose, and wiring routing.

Engine Break-in

Specifications and Model Information

Vehicle Specifications

Engine Specifications

Lubrication system

Information on the engine's lubrication system, including oil type and capacity.

Air intake system

Details about the engine's air intake system.

Oil cooling device

Details about the mesh oil cooler used for engine cooling.

Wheel (front and rear wheels)

Specifications and maintenance for the front and rear wheels.

Brake system

Specifications and maintenance for the front and rear brake systems.

Ignition device

Information about the ignition system, spark plug, and ignition coil.

Light; Instrument; Switch

Details on lights, instruments, and switch functions.

Fastener Torque Specifications

Lubricating Grease and Sealant

Wiring and Cable Routing Diagrams

Plastic Body

2.1 Maintenance cautions

Cautions to be observed during plastic body maintenance.

2.2 Installation torque

Specific torque values for installing plastic body components.

2.3.1 Hood

Procedure for disassembling and installing the hood.

2.3.2 Handlebar

Procedure for disassembling and installing the handlebar assembly.

2.3.3 Seat

Procedure for disassembling and installing the seat.

2.3.4 Front Bumper

Procedure for disassembling and installing the front bumper.

2.3.5 Plastic Body

Procedures for disassembling and installing the main plastic body panels.

2.3.6 Middle guard

Procedure for disassembling and installing the middle guard.

Dismantling of left & right rear fender

Procedure for removing the left and right rear fenders.

2.3.7 Rear body

Procedure for disassembling and installing the rear body section.

2.3.8 Left & Right Guard

Procedure for disassembling and installing the left and right guards.

2.3.9 Front body

Procedure for disassembling and installing the front body section.

2.3.10 Foot peg guards

Procedure for disassembling and installing the foot peg guards.

2.3.11 Pedal

Procedure for disassembling and installing the floorboard/foot peg.

Regular Maintenance and Adjustment

3.1 Maintenance information

General information regarding maintenance procedures.

3.2 Maintenance period

Recommended intervals for routine maintenance tasks.

3.3 Steering column and brake system

Maintenance and adjustment of the steering column and brake system.

3.4 Wheel

Maintenance and checks for the vehicle's wheels.

3.5 Suspension system

Procedures for inspecting and checking the suspension system.

3.6 Gear box and fuel system

Maintenance for the gearbox and fuel system.

3.7 Throttle check

Procedure for checking and adjusting the throttle.

Steering system freeplay

Checking and adjusting the steering system's freeplay.

Brake pump assembly

Inspection and maintenance of the brake pump assembly.

Front brake disc and brake pads

Procedures for checking and replacing front brake discs and pads.

3.4 Wheel

Procedures for inspecting and maintaining the vehicle's wheels.

Front wheel size

Checking and adjusting the front wheel toe-in alignment.

Tire pressure

Checking and adjusting tire pressure for optimal performance and safety.

Tire tread

Inspecting tire tread depth and replacing worn tires.

3.5 Suspension system

Procedures for inspecting and checking the suspension system.

3.6 Gear shifter and fuel system

Maintenance and checks for the gear shifter and fuel system components.

Fuel device

Inspection of fuel lines and components for aging or damage.

3.7 Throttle check

Procedure for checking throttle operation, freeplay, and return.

Speed limiting device adjustment

Adjusting the speed limiting device for throttle control.

Engine Systems

4.1 Maintenance information

General information and precautions for engine maintenance.

4.2 Fuel system

Procedures for maintaining the fuel system.

4.3 Air intake system

Procedures for maintaining the air intake system.

4.4 Exhaust system

Procedures for maintaining the exhaust system.

4.5 Disassembly and installation of engine

Detailed steps for engine removal and installation.

Fuel tank removal

Steps for removing the fuel tank from the vehicle.

Air filter system disassembly

Steps for disassembling the air filter system.

Air filter system installation

Steps for installing the air filter system.

Exhaust system disassembly

Steps for disassembling the exhaust system.

Exhaust system assembly

Steps for assembling the exhaust system.

Engine Maintenance

5.1 Maintenance information

General information and precautions for engine maintenance.

General precautions

Important general safety precautions for engine maintenance.

Engine Oil and Fuel

Fuel

Recommended type of fuel for the vehicle.

Engine oil

Recommended engine oil type, grade, and viscosity chart.

Engine Brake-in

Maintenance Schedule

Subsidiary

Maintenance schedule based on odometer readings.

Cylinder Head Maintenance

Cylinder Head Troubleshooting

Cylinder head

Troubleshooting common problems related to the cylinder head.

Spark plug

Troubleshooting common problems related to the spark plug.

Cylinder Maintenance

Cylinder Body Troubleshooting

Cylinder body

Troubleshooting specific issues with the cylinder body.

Crankcase Maintenance

Crankcase Troubleshooting

Right crankcase cover

Troubleshooting issues with the right crankcase cover.

Left crankcase

Troubleshooting issues with the left crankcase.

Crankshaft Connecting Rod Maintenance

Crankshaft Connecting Rod Troubleshooting

Piston

Troubleshooting common problems related to the piston.

Crank pin

Troubleshooting common problems related to the crank pin.

Bearing

Troubleshooting common problems related to bearings.

Piston ring set

Troubleshooting common problems related to piston ring sets.

Piston pin

Troubleshooting common problems related to the piston pin.

Connecting rod

Troubleshooting common problems related to the connecting rod.

Timing sprocket

Troubleshooting common problems related to the timing sprocket.

Valve Mechanism Maintenance

Distribution Mechanism Maintenance

Valve oil seal

Troubleshooting problems related to valve oil seals.

Camshaft

Troubleshooting common problems related to the camshaft.

Rocker arm

Troubleshooting common problems related to the rocker arm.

Valve

Troubleshooting common problems related to the valve clearance.

Valve spring

Troubleshooting common problems related to the valve spring.

Carburetor Maintenance

Intake;Exhaust System Maintenance

5.7.1 Disassemble, assemble and maintain intake system

Detailed steps for intake system disassembly, assembly, and maintenance.

Air filter

Troubleshooting common problems related to the air filter.

Exhaust System Maintenance

Environmental Protection System Maintenance

Valve

Inspection of exhaust pipe gasket and muffler enclosure for proper function.

Maintenance of environment protection valve

Troubleshooting common issues with the environmental protection valve.

air pump

Troubleshooting defective air pump issues.

air cleaner

Troubleshooting defective air cleaner issues.

connecting hose

Troubleshooting issues with loose connecting hoses.

Gasket

Troubleshooting issues with secondary air leaks from gaskets.

muffler exhaust

Troubleshooting poor combustion due to muffler exhaust carbon deposit.

Electric Starter Maintenance

Electric Starter Troubleshooting

Starter motor

Troubleshooting issues with the starter motor's rotation force and components.

Wiring Diagram

KAYO MOTOR AT125-B Specifications

General IconGeneral
BrandKAYO MOTOR
ModelAT125-B
CategoryOffroad Vehicle
LanguageEnglish

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