KAYO MOTOR STORM 150 Service Manual
  1. Manuals
  2. Brands
  3. KAYO MOTOR Manuals
  4. Offroad Vehicle
  5. STORM 150
  6. Service manual

KAYO MOTOR STORM 150 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

ZHEJIANG KAYO MOTOR CO., LTD.
Model A150
STORM 150
Service Manual
WWW.RIDEKAYO.COM

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the STORM 150 and is the answer not in the manual?

Questions and answers

Related Manuals for KAYO MOTOR STORM 150

Summary of Contents for KAYO MOTOR STORM 150

  • Page 1 ZHEJIANG KAYO MOTOR CO., LTD. Model A150 STORM 150 Service Manual WWW.RIDEKAYO.COM...
  • Page 2 ZHEJIANG KAYO MOTOR CO., LTD. Introduction This manual contains detailed information for Kayo A125 (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.
  • Page 3 ZHEJIANG KAYO MOTOR CO., LTD. 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.

  • Page 4: Conversion Table

    ZHEJIANG KAYO MOTOR CO., LTD. Conversion table Unit conversion Item 1kgf/cm 2 =98.0665kPa；1kPa=1000Pa pressure 1PSI=0.0689kgf/cm 1mmHg=133.322Pa=0.133322kPa 1kgf·m=9.80665N·m Torque 1mL=1cm 3 =1cc volume 1L=1000cm 3 Moment 1kgf=9.80665N 1in=25.4mm Length Danger/warning/attention Take the following warnings seriously, it’s important for regular maintenance, especially important during engine maintenance.

  • Page 5: Service Information

    ZHEJIANG KAYO MOTOR CO., LTD. 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.
  • Page 6 ZHEJIANG KAYO MOTOR CO., LTD. 3. Clean the vehicle or parts to be serviced before inspection. 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 deformed snap rings.
  • Page 7 ZHEJIANG KAYO MOTOR CO., LTD. 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.

  • Page 8: Vin Number

    ZHEJIANG KAYO MOTOR CO., LTD. schedule. After Break-in period is complete schedule the unit for an inspection and service 1.2 VIN Number STORM 150（A150） Model VIN number Engine number 1 VIN number 2Engine number WWW.RIDEKAYO.COM...
  • Page 9 ZHEJIANG KAYO MOTOR CO., LTD. 1.3 Specifications, Model information Item Brand KAYO A150 Type Name 150cc utility ATV Company ZHEJIANG KAYO MOTOR CO., LTD. ● Dimensions, Vehicle Specifications Dimension（L*W*H） （mm） 1535*920*950 Handlebar height（mm） Handlebar width（mm） Rear fender height（mm） Seat height （mm）...

  • Page 10: Engine Specifications

    ZHEJIANG KAYO MOTOR CO., LTD. curb weight（battery+fuel） （Kg） Max. Speed Km/h 60（limited speed） ● Engine Specifications No. Item 156FMI Engine model Type horizontal，Single cylinder, four stroke, oil cooling 140CC displacement（ml） 57*56 Cylinder diameter × mileage（mm*mm） 9.2:1 Compression ratio engine weight (kg) 8.2/8000...
  • Page 11 ZHEJIANG KAYO MOTOR CO., LTD. ● Frame Drive sprocket ratio 45/14 Output type Chain drive,rear wheel drive Brake type Front and rear disc Double A-arm/coilover front Suspension type Swingarm /single shock rear Frame type Steel tube and steel plate ●...
  • Page 12 ZHEJIANG KAYO MOTOR CO., LTD. ●Oil cooling device ●Wheel (front and rear wheels) Item Standard Limitation Vertical 1.0mm 2.0mm Rim jump Horizontal 1.0mm 1.8mm Tread 3.0mm Tire Air pressure 4.0 PSI ●Brake system Item Standard Limitation disc thickness Front brake 3.5mm...

  • Page 13: Fastener Torque Specifications

    ZHEJIANG KAYO MOTOR CO., LTD. Spark advance angle 15 btdc 0.43~0.57Ω Ignition coil Primary resistance 10.1~11KΩ Secondary Peak Primary ignition >150Vac voltage coil Pulse 2Vac ●Light / Instrument / Switch Item Standard Accesory inline fuse Light Headlight E4 35W Taillight/brake...
  • Page 14 ZHEJIANG KAYO MOTOR CO., LTD. 10.9 37~50 Engine Upper mounting bolt 18~25 Bottom mounting bolt 15~20 Muffler M10*1.25 35~45 Brake bolts M10*1.25 35~45 Suspension A-arm bolts M10*1.25 10.9 58~71 Rear swing arm bolt M12*1.25 50~60 Shock bolts 18~25 （with Rear disc blue thread sealants）...
  • Page 15 ZHEJIANG KAYO MOTOR CO., LTD. 18~25 Turning Steering column （with blue bolts thread sealants） M10*1.5 10.9 50~60 Handlebar riser bolt 15~20 Electrical Battery box components 7~11 Voltage regulator ignition coil 7~11 Fuel tank, fuel tank body parts, 7~11 fuel tank switch plastic 18~25 （with...
  • Page 16 ZHEJIANG KAYO MOTOR CO., LTD. Position Effect Grease Dust cap for rocker arms lubrication XHP222 High temp grease Ball joints of rocker arms Steering column bottom steering knuckle/spindle and wheel hubs Pivot bolts (swing arm, a-arms) Bushings, Bearings Rear axle liner bushings, tubes...
  • Page 17 ZHEJIANG KAYO MOTOR CO., LTD. Main Harness Brake light Combination switch wires switch wires Choke cable Throttle cable front brake line WWW.RIDEKAYO.COM...
  • Page 18 ZHEJIANG KAYO MOTOR CO., LTD. Gear indicator connector (Digital indicator models) Neutral gear connector (analog models) Reverse gear indicator (analog models) combination switch connector Stop switch headlight Electric lock/ Key switch Starter Battery Battery Relay positive negative WWW.RIDEKAYO.COM...
  • Page 19 ZHEJIANG KAYO MOTOR CO., LTD. Rear light Ignition coil Voltage regulator Brake light switch WWW.RIDEKAYO.COM connector...
  • Page 20 ZHEJIANG KAYO MOTOR CO., LTD. Ground cable Stator/ignition pickup, gear indicator connector WWW.RIDEKAYO.COM...

  • Page 21: Maintenance Cautions

    ZHEJIANG KAYO MOTOR CO., LTD. 2 Plastic body 2.1 Maintenance warnings 2.2 Installation torques 2.3Seat, front guard, hood, rear body, left and right guard, plastics foot guards, dismounting left and right footpegs 2.1 Maintenance cautions Operation cautions 1. When replacing plastics parts, please install new warning labels, stickers and riveted tags to the new plastics.
  • Page 22 ZHEJIANG KAYO MOTOR CO., LTD. 2. Push down and gently pull the hood forward to remove. (Be careful as the tabs are easy to break) 3. Installation: In reverse order of disassembly. Locate tabs into slots and push to lock into place then install bolts...
  • Page 23 ZHEJIANG KAYO MOTOR CO., LTD. Combination switch Choke cable switch Front brake Throttle seat Handle bar riser Indicator panel Installation In reverse order from disassembly, follow steps 5. Through 1. *after install, make sure to double check electrical connections, wire, cable and hose routing) 2.3.3 Seat...

  • Page 24: Front Bumper

    ZHEJIANG KAYO MOTOR CO., LTD. Seat latch Installation To install line the front hook up with the corresponding post. Then simultaneously push down and forward until the latch locks into place. 2.3.4 Front Bumper Disassembly 1. The mounting bolts in order.
  • Page 25 ZHEJIANG KAYO MOTOR CO., LTD. 2.3.5 Plastic Body Disassembly 1. Disconnect all necessary electrical connectors. 2. Disassemble plastic parts fixing bolts1,2， 3,4， 5,6， 7, 8,9, 10 in order on both sides 3. Remove the plastic body. (note: remove the handlebar and hood before removing plastic body.) 1, 2 WWW.RIDEKAYO.COM...
  • Page 26 ZHEJIANG KAYO MOTOR CO., LTD. Installation Install the plastic body in reverse order from disassembly. *check all electrical connectors, cable, and hose routing after installation. 2.3.6 Middle guard Disassembly 1. Remove the mounting bolt 1 and 2 2. Remove the middle guard...

  • Page 27: Front Body

    ZHEJIANG KAYO MOTOR CO., LTD. Disassembly 1. Remove the mounting bolts1/2，3/4,5/6 (and corresponding bolts on opposite side） 2. Take the rear body off. Installation Install in reverse order from disassembly. （Note: replace locking nuts and rubber washers as needed.) 2.3.8 Front body Disassembly （Note: remove the handlebar, hood, and middle guard)
  • Page 28 ZHEJIANG KAYO MOTOR CO., LTD. Installation 1. Install in reverse order from disassembly. Replace mounting bolts, nuts and rubber washers as needed when worn.) *check all electrical connectors, cable, and hose routing after installation 2.3.9 Foot peg guards WWW.RIDEKAYO.COM...
  • Page 29 ZHEJIANG KAYO MOTOR CO., LTD. Disassembly 1. Remove mounting bolts 1、2、3、4， 2. Remove the foot guard. Installation Install in reverse order of disassembly. （Note: replace mounting bolts, nuts and rubber washers in time, once they worn.) 2.3.10 Pedal Disassembly floorboard/ foot peg 1.

  • Page 30: Maintenance Information

    ZHEJIANG KAYO MOTOR CO., LTD. Installation Install in reverse order of disassembly. （Note: replace mounting bolts, nuts and rubber washers in time, once they worn.) Regular maintenance and adjustment 3.1 Maintenance information 3.6 Suspension system 3.2 Maintenance period 3.7 Gear box and fuel system 3.3 Inspection ways...

  • Page 31: Maintenance Period

    ZHEJIANG KAYO MOTOR CO., LTD. Note:  Do not run the engine in unventilated places, because the exhaust contains carbon monoxide (CO) and other toxic components.  To prevent burns, don’t touch the engine or exhaust until it has cooled down.
  • Page 32 ZHEJIANG KAYO MOTOR CO., LTD. clutch Item Period Criterion Parts Item ○ Steering Operating flexibility wheel Steering ○ Damage system ○ Steering linkages and Steering movements ○ Ball joint shaking system ○ ○ Pedal, lever travel Brake pedal, ○ ○...
  • Page 33 ZHEJIANG KAYO MOTOR CO., LTD. ○ ○ Damper Leakage and damage ○ Function ○ ○ Chain deflection>20mm Transmission and lubrication, Chain tightness Transmissi ○ ○ If chain wheel and chain Transmission and lubrication, Flywheel, wear severity, replace it. tightness of fixing bolt...
  • Page 34 ZHEJIANG KAYO MOTOR CO., LTD. If there is a shaking, check it’s caused by steering column, linkages, ball joints, or fastening hardware then repair. If it’s caused by steering column, tighten the bottom lock nut on steering column, or you can also disassemble the steering column to check bearing and clamps.
  • Page 35 ZHEJIANG KAYO MOTOR CO., LTD. If it is hard to turn, check cable, hose and wire routing, if there is no problem, check steering rods and connecting points for damage. Note: the steering must be smooth, and move freely between left locked position to right locked position .
  • Page 36 ZHEJIANG KAYO MOTOR CO., LTD. The brake pads, caliper and disc are normal wear and tear items Check or replace the brake disc ● Check the surface of brake disc, if it is worn, damaged, bent, or grooved replace. ● If the disc thickness is less than 3.0mm, replace.
  • Page 37 ZHEJIANG KAYO MOTOR CO., LTD. On a level surface with handle bars straight check the front wheel toe-in. The front wheel relative to the forward direction of the vehicle is: A in front and B behind the wheel Toe-in specification：B-A=4 ~ 10mm If not in this range, adjust steering rods, adjust the wheel toe-in to within 4~10mm, and lock into place.

  • Page 38: Suspension System

    ZHEJIANG KAYO MOTOR CO., LTD. Tire tread Check Tire tread, if tread is less than 3mm, replace it. Suspension system Keep vehicle in a horizontal position and compress up and down several times according to the pictures. If there is shaking or abnormal sounds, check whether there is oil leakage in the shock absorber, or check for damage or loosening in the fastening parts.

  • Page 39: Throttle Check

    ZHEJIANG KAYO MOTOR CO., LTD. Changing gears, with the shift lever should be smooth and gear changes should have a positive firm feeling. Shift lever Fuel device Remove the plastic parts first. Check fuel vacuum and vent lines for aging, dry rot cracks and damage. Replace if any damages are found or if more than 2 years old.
  • Page 40 ZHEJIANG KAYO MOTOR CO., LTD. Freeplay : 3~5mm Adjust throttle free play if out of specification. Pull back rubber sleeves 1-2. Loosen lock nut 3 and barrell adjuster 4 then adjust throttle free-play to within specification. Speed limiting device adjustment...
  • Page 41 ZHEJIANG KAYO MOTOR CO., LTD. Speed limit device is used to restrict throttle opening. Inspect the thread length limit of speed limit screw. Thread length a=25mm Adjustment: Loosen the lock nut, then adjust it with a phillips screwdriver. a=25mm For beginners, Throttle limiter should be adjusted inward to limit throttle as much as possible for safety.

  • Page 42: Engine Systems

    ZHEJIANG KAYO MOTOR CO., LTD. Spanner wrench Spanner wrench slots Engine systems 4.1 Maintenance information 4.3 Air intake system 4.2 Fuel system 4.4 Exhaust system 4.5 Disassembly and installation of engine Maintenance information Precautions ● Before performing maintenance, please make sure that the engine is not running, battery is disconnected and that the heated parts have cooled, to avoid injury.

  • Page 43: Installation

    ZHEJIANG KAYO MOTOR CO., LTD. Tightening torque See 1.5 4.2 Fuel system Gasoline is flammable and explosive. Pay attention to sparks and open flame. Vaporized gasoline may explode if exposed to open flame or sparks , please choose well-ventilated areas away form these hazards when refueling or working on the fuel system and its related components.

  • Page 44: Exhaust System

    ZHEJIANG KAYO MOTOR CO., LTD. Disassembly Loose the air filter clamp to remove air filter. Air filter clamp Installation Installation shall be in the reverse order of removal. Make hose clamp is in the groove and any vacuum lines are hooked up correctly.
  • Page 45 ZHEJIANG KAYO MOTOR CO., LTD. Mounting bolt clamp Remove exhaust flange nuts. then remove exhaust pipe. Assembly Installation shall be in the reverse order of removal. *do not reuse exhaust head pipe gasket always replace, replace muffler gasket and any hardware for exhaust if damaged or deformed.
  • Page 46 ZHEJIANG KAYO MOTOR CO., LTD. Disassembly and installation of engine Disassembly (Note: Remove floorboards/ pegs, carburetor, intake manifold and oil cooler first) 1. Remove the engine front sprocket side cover, then remove chain. Remove the ground lead, and all electrical connectors, exhaust pipe, and gearshifter.
  • Page 47 ZHEJIANG KAYO MOTOR CO., LTD. Ignition Gear shift coil cap lever Remove the 3 engine mounting bolts Bottom engine Engine mounting bolt mounting bolt 2. Remove the engine from the right side of vehicle. Installation www.kayomoto.us...
  • Page 48 ZHEJIANG KAYO MOTOR CO., LTD. Installation shall be in the reverse order of removal. Engine Maintenance information Conversion table refers Item Unit conversion 1kgf/cm =98.0665kPa 1kPa=1000Pa Pressure 1mmHg=133.322Pa=0.133322kPa Torque 1kgf · m = 9 . 8 0 6 6 5 N ·m...
  • Page 49 ZHEJIANG KAYO MOTOR CO., LTD. ● If toxic or flammable substances are used, handle that in accordance with the manufacturer's instructions strictly and make sure workplace must be well ventilated. ● Don't use gasoline as a cleaning fluid. ● To avoid burns, do not touch uncooled engine oil, exhaust system parts ●...

  • Page 50: Engine Oil And Fuel

    ZHEJIANG KAYO MOTOR CO., LTD. 5.2 Engine oil and fuel Warning: Avoid mixing different oil brands and grades Fuel: Use octane 93# or higher unleaded gasoline. Engine oil： Use sae15w-40 oil for 4 stroke motorcycle, quality grade according to the...

  • Page 51: Engine Number

    ZHEJIANG KAYO MOTOR CO., LTD. 5.4 Engine number Engine Number Engine head displacement label label 5.4 Maintenance Subsidiary maintain times Odometer reading 1000km 4000km 8000km 12000km Items Clean Clean Clean Fuel system Clean Clean Clean Clean Oil filter Clean www.kayomoto.us...
  • Page 52 ZHEJIANG KAYO MOTOR CO., LTD. Adjust, clean Adjust, clean Control Adjust Adjust, clean Clean Clean Clean Clean Carburetor Clean Clean Clean Clean Air cleaner Adjust Adjust, clean Adjust, clean Adjust, clean Spark plug gap Adjust Adjust Adjust Adjust Valve clearance...
  • Page 53 ZHEJIANG KAYO MOTOR CO., LTD. Left view of the 150 engine is shown in the figure Remove the acorn nuts of cylinder head from cylinder studs Remove cylinder head. Check the state of paper pad/ gasket. Replace if necessary. Dismantle the fixing bolt of left cover.
  • Page 54 ZHEJIANG KAYO MOTOR CO., LTD. Remove left cover and inspect the paper pad/gasket for damage. Replace if necessary. Dismantle the fixing bolt of right cover. www.kayomoto.us...
  • Page 55 ZHEJIANG KAYO MOTOR CO., LTD. Remove the right cover of cylinder head. Inspect the gasket for damage and replace if necessary. o-rings and replace if worn or if reuse is questionable. Remove intake and exhaust valve caps .Check Remove the fixing bolts of cam sprocket.
  • Page 56 ZHEJIANG KAYO MOTOR CO., LTD. Remove the connecting bolt of cylinder head. Remove cylinder head assembly. Remove timing driven sprocket. Inspect the timing driven sprocket for wear and damage. Replace if necessary. www.kayomoto.us...
  • Page 57 ZHEJIANG KAYO MOTOR CO., LTD. Check whether there is excessive carbon deposit in combustion chamber. Clean and replace if necessary. Remove the cylinder head. Pour gasoline into inlet/exhaust pipe to inspect the seal condition. Grind the valve and valve seat if there is gasoline leak into the combustion chamber.
  • Page 58 ZHEJIANG KAYO MOTOR CO., LTD. Inspect the oil seal intake and exhaust valves for damage. Replace if necessary. Remove the spark plug to clean the carbon deposits and dirt .Check the spark plug gap and set it to 0.6 to 0.7 if necessary.
  • Page 59 ZHEJIANG KAYO MOTOR CO., LTD. For the troubleshooting of cylinder head ,please refer to the following table Description Damage Form Problem Cause Correction Too much oil dirt or sand Poor heat The engine overheats. Remove the oil dirt or on the cooling fins.
  • Page 60 ZHEJIANG KAYO MOTOR CO., LTD. 5.4.2 Disassemble, assemble and maintain cylinder Remove cylinder gasket and dowel pins check for wear and damage. Replace if necessary. Remove the cylinder block. Dismantle the fixing bolt of timing chain of guide wheel. Remove the circlip of piston pin.
  • Page 61 ZHEJIANG KAYO MOTOR CO., LTD. Remove the piston of piston pin to check whether it is damaged. Replace if necessary. Remove and replace gaskets. Check whether there is residual gasket on cylinder. Clean and scrape if necessary. www.kayomoto.us...
  • Page 62 ZHEJIANG KAYO MOTOR CO., LTD. Check condition cylinder walls .Replace if worn or if reuse is questionable. Check whether the internal diameter has exceed the limit value. Measure the diameter at top, middle and bottom of cylinder. The limit value is 52.05 mm.
  • Page 63 ZHEJIANG KAYO MOTOR CO., LTD. Troubleshooting of the cylinder body, please refer to the following table Maintenance of Cylinder Body Description Damage form Trouble Cause Correction Excessive oil Poor heat The engine overheats Remove the oil dirt or sand on...
  • Page 64 ZHEJIANG KAYO MOTOR CO., LTD. Check the conditon of right crankcase cover and replace if necessary. Left view of right crankcase half is shown in fig and check whether bearing of main shaft and countershaft are worn. Replace if necessary.
  • Page 65 ZHEJIANG KAYO MOTOR CO., LTD. Right view of right crankcase half is shown in fig and check the state of right crankcase half. Replace if necessary. Left view of left crankcase is shown below and check whether the oil seal of countershaft and oil seal edge of gearshift lever are worn .Replace if necessary.
  • Page 66 ZHEJIANG KAYO MOTOR CO., LTD. Remove the neutral indicator and check the state. Replace if necessary. Dismantle the fixing bolt of magneto stator and remove the stator. www.kayomoto.us...
  • Page 67 ZHEJIANG KAYO MOTOR CO., LTD. Check the condition of left crankcase cover and replace if necessary. www.kayomoto.us...
  • Page 68 ZHEJIANG KAYO MOTOR CO., LTD. Troubleshooting of crankcase, please refer to the following table. Trouble Description Problem Compucation Correction Crack in the crank case Oil leakage from the Repair or replace the crankcase crankcase Replace the gasket Oil leakage from the...
  • Page 69 ZHEJIANG KAYO MOTOR CO., LTD. 5.4.4 Maintenance of Crankshaft Connecting Rod Disassemble, assemble and maintain crankshaft connecting rod Remove the fixing bolt of crankcase from its holding place. Remove left crankcase half. Take care not to forget the washer of mainshaft and countershaft when removing the left crankcase.
  • Page 70 ZHEJIANG KAYO MOTOR CO., LTD. Remove the connecting rod assembly. Check gap of big-end of connecting rod. Reset the gap if necessary. Inspect connecting rod bearing for wear and damage. Replace if necessary. value is over the maintenance limit value.
  • Page 71 ZHEJIANG KAYO MOTOR CO., LTD. Check the axial and radial jumping of connecting rod bearing. Replace the conrod if the jumping is large. Check the side gap between piston ring and piston groove using a feeler gauge. Replace the piston if the gap is too wide.
  • Page 72 ZHEJIANG KAYO MOTOR CO., LTD. Check the state of piston and replace if worn or if reuse is questionable. Measure diameter of piston skirt. Replace it if the value is beyond the maintenance limit value. Assemble the piston ring according to the size and check whether piston ring is damaged or the elasticity is weaken.
  • Page 73 ZHEJIANG KAYO MOTOR CO., LTD. deposit Carbon deposit in the ring The piston ring is seized in ring The engine starts hard or fails to groove groove start. Insufficient engine output; Thick blue and white fume form Scuffing or scratches on Scuffing or scratches on the surface 环槽中积碳...
  • Page 74 ZHEJIANG KAYO MOTOR CO., LTD. connecting The fitting clearance between the Striking sound of the piston and Replace the small-end hole is over piston pin and the small-end is too of the cylinder connecting rod worn wide Striking sound of the cylinder...
  • Page 75 ZHEJIANG KAYO MOTOR CO., LTD. Remove the timing cam, rocker arm , rocker arm shaft to inspect for worn.Replace if necessary. Remove the circlip of inlet and exhaust valve. Remove inlet vale stem and exhaust valve stem take care and don`t miss the valve clip.
  • Page 76 ZHEJIANG KAYO MOTOR CO., LTD. Check the external diameter of valve stem using a verier clipper. Replace the valve stem if the valve is beyond the maintenance limit valve. Measure the width of valve contact surface to check whether the contact surface is rough or abnormal.
  • Page 77 ZHEJIANG KAYO MOTOR CO., LTD. Inspect the timing camshaft bearing for wear and check the state of camshaft. Replace if necessary. Check the gap of rocker arm shaft and rocker arm. Replace the rocker arm shaft and rocker arm if the gap is large.
  • Page 78 ZHEJIANG KAYO MOTOR CO., LTD. Remove the guide wheel of timing chain to inspect for wear and damage. Replace if necessary. Remove the fixing bolt of timing tensioner and check the state. Replace if worn or if reuse is questionable Remove the timing tensioner arm to inspect for wear and damage.
  • Page 79 ZHEJIANG KAYO MOTOR CO., LTD. Remove the oil tube and spring and check the state. Replace if necessary. Remove the small timing chain and check the state. Replace if necessary. the valve cap and check the condition. Adjust valve clearance as follows; Remove...
  • Page 80 ZHEJIANG KAYO MOTOR CO., LTD. Adjust valve clearance of front cylinder. Turn magnetic rotor counterclockwise to make piston locate at top dead center and make T mark aimed to the mark of left crankcase cover. Check whether the O-mark on cam sprocket is aimed to the gap of cylinder head.
  • Page 81 ZHEJIANG KAYO MOTOR CO., LTD. For the troubleshooting of engine distribution mechanism, please refer to the following table Maintenance of Distribution Mechanism Descriptions Damage form Trouble Cause Correction www.kayomoto.us...
  • Page 82 ZHEJIANG KAYO MOTOR CO., LTD. The edge of valve oil seal is Thick blue and white fume form Replace the Valve oil seal worn, age or damage. the exhaust muffler pipe. complete set of valve oil seal The cam is cover worn...
  • Page 83 ZHEJIANG KAYO MOTOR CO., LTD. Replace the valve The valve stem is over worn fitting clearance Sound of valve leakage, Thick between the valve stem and blue and white fume form the the valve guide is too wide exhaust muffler pipe...
  • Page 84 ZHEJIANG KAYO MOTOR CO., LTD. Clean the carburetor as follows: 。 Remove the dirt and clean inner oil way.Dismantle the fixing bolt of float chamber cap. Remove the float chamber cap. Remove the water and debris in the cap if necessary.
  • Page 85 ZHEJIANG KAYO MOTOR CO., LTD. Check the state of float case and replace as necessary. Adjust the height of float case by moving the float up or down. Take out the main jet to check whether the jet hole is clogged. Clean if necessary.
  • Page 86 ZHEJIANG KAYO MOTOR CO., LTD. Dismantle the mixture adjustment screw and inspect for worn. Replace if necessary.Adjust mixture screw of carburetor as the following. Standard: Tighten mixture screw, and turn it one And a half turns clockwise. Measure height of float case to check whether it is distorted or there is fuel inside.
  • Page 87 ZHEJIANG KAYO MOTOR CO., LTD. 5.7 Maintenance of Intake/Exhaust System 5.7.1 Disassemble, assemble and maintain intake system Remove the clamp from air filter to take off the air filter Clean the cover of air filter, then dispatch it for cleaning. The filter element is paper filter, it can’t clean, please replace directly.
  • Page 88 ZHEJIANG KAYO MOTOR CO., LTD. 5.8 Disassemble, assemble, maintain and manage motor starter Remove the fixing bolt from left crankcase cover. Dismount gear indicator switch fixing bolt, remove gear indicator to check the wear or damage condition, replace it if necessary.
  • Page 89 ZHEJIANG KAYO MOTOR CO., LTD. Remove gasket to check it’s condition. If the gasket is worn or reusable, please replace. Remove fixing bolts of stator and trigger . www.kayomoto.us...
  • Page 90 ZHEJIANG KAYO MOTOR CO., LTD. Check stator status with multimeter.If wear and tear or re-use problems, please replace the new accessories Remove rotor fixing nut Remove rotor with puller www.kayomoto.us...
  • Page 91 ZHEJIANG KAYO MOTOR CO., LTD. Remove rotor to check magnets, if necessary replace. Remove starter clutch fixing bolt. Remove clutch to check for wear and damage. condition of clutch seat,pulley and spring. If it necessary replace it. Check the condition of drive sprocket and transmission gear.
  • Page 92 ZHEJIANG KAYO MOTOR CO., LTD. Disassemble start sprocket press board Dismount starter chain tensioner check the condition. If worn or damaged, replace it. Remove the snap ring from start motor sprocket. www.kayomoto.us...
  • Page 93 ZHEJIANG KAYO MOTOR CO., LTD. Disassemble the drive sprocket and chain. Dismount the fixing bolt of start motor. Remove starter motor. www.kayomoto.us...
  • Page 94 ZHEJIANG KAYO MOTOR CO., LTD. Check the starter motor wiring and spline condition if necessary replace it. Disassemble the oil separation disc and check the condition, if it necessary replace it. Check oil seal edges for wear. Replace as necessary.
  • Page 95 ZHEJIANG KAYO MOTOR CO., LTD. For the troubleshooting of engine electric starter, please refer to the following table. Maintenance of Electric Starter Description Damage form Trouble Cause Correction Carbon brush is over worn. Starter motor has insufficient The carbon brush spring is rotation force or it is out of work.
  • Page 96 ZHEJIANG KAYO MOTOR CO., LTD. Circuit diagram www.kayomoto.us...

This manual is also suitable for:

A150

Table of Contents

Save PDF