KAYO MOTOR TD125 Service Manual
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KAYO MOTOR TD125 Service Manual

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KAYO MOTO
TD125
SERVICE MANUAL
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Summary of Contents for KAYO MOTOR TD125

  • Page 1 KAYO MOTO TD125 SERVICE MANUAL www.kayomoto.com...
  • Page 2 The model in the image may be different from the real model. PREFACE Thank you for choosing the 21 TD125 of KAYO MOTO as your choice for off-road recreation. I believe you will not be disappointed with this choice. This manual is designed to help you better use our products. This manual describes in detail the maintenance and adjustment procedures, disassembly and assembly essentials, inspection and maintenance points, troubleshooting methods and maintenance technical data of TD125, with detailed graphic data to guide the operation.

  • Page 3: Table Of Contents

    Suggestions for Daily Use……………………………………………………………....………………9 Appearance………………… ……10 21 TD125 Parts and Position..……………………………………………………………..…………………10 VIN and Engine Number……………………………………………..………………………....………12 VIN Number…………………...……………………………………………………………………….………12 Engine number………………………………………………………………………………………….………12 Specification…………………………………………………………………………………....………13 21 TD125 Size and Weight Specification …………………………………..…………………………..………13 Manipulation………………………………………………………....…………………………………14 Front disc brake……....…......………………………………...………………………………14 Throttle…… ..……………………………………………………………………...……………………………14 Ignition………….…………………………………………………………………..…………………………14 Stall………………………..……………………….…………………………………...………………………15 Fuel tank switch…………………………….…….………………………………………..…………………15 Gear shifting…………………………...….……….……………………………………..………………15 Rear disc brake….…………..………………….………..…………………………………………………16...
  • Page 4 Notes before Use………………………………….………......……………………………………17 Suggestions for first-time users…...….………….......………………….……………………………17 Running-in process………..…………………….……………..……………………………………………17 Riding Guide…...……………………………….…………………....…………………………………18 Checking items before riding………..……………………………………..……………………………18 Notes when ignition………………………………………..……………………..………………………18 Notes when starting……………..………...……………………………………………..…………………18 Notes when cornering………....……………………………………………………..……………19 Notes when acceleration…………….......………………………………………………..………19 Notes when gear shifting……..…..……………………………………………………………………19 Notes when braking…………....…..………………………………………………………………19 Notes when parking…………….......…..…………………………………………………………19 Maintenance Periodic Table..............……………………………………………20 Suspension system setup…………….........…....…………………………………21 Check the compression and rebound of the motorcycle when riding……..........…………21 Measure distance from center of rear wheel to rear fender in suspension...…......…………………21...
  • Page 5 Check the rear brake friction plate…………………………………………………..…………………………33 Tire inspection and maintenance…………………………………………………………..……………………33 Removal and installation of front wheel………………………………………………………..………………33 Removal and installation of rear wheel……………………………………………………………..………………33 Check the outside surface of the tire…………………………………………………………………..………34 Check tire pressure………………………………………..………………………………………………………34 Check the wheel spokes……………………………………..…………………………………………………34 Engine installation………………………………………………..…………………………………………………35 Engine maintenance and adjustment………………………………..…………………………………………35 Inspection of bolts and nuts of cylinder and cylinder body………………..……………………………………35 Check valve clearance…………………………………………………………..…………………………………35 Inspection of compression pressure………………………………………………..……………………………35...
  • Page 6 Installation of cylinder block……………………………………………………………………...………………50 Clutch, driving gear, driven gear, oil pump, shifting mechanism……………………………...…………………51 Matters needing attention…………………………………………………………………………………………51 Main parameters and maintenance standards……………………………………………………….……………51 Fault symptom and cause analysis………………………………………………………………..……………52 Removal of right trim cover……………………………………………………………………..………………52 Adjustment of clutch stroke……………………………………………………………………..………………52 Removal of right crankcase cover……………………………………………………………..………………53 Clutch disassembly……………………………………………………………………..………………………53 Disassembly of driving and driven gears…………………………………………………...……………………53 Removal of engine oil pump…………………………………………………………………..…………………54...

  • Page 7: Meaning Of Symbols And Technical Terms

    Check the combination of main and auxiliary shafts………………………………..……………………………69 Inspection of starting shaft………………………………………………………….…………………..………69 Assembly of variable speed drum………………………………………………….………………....………69 Installation of variable speed drum, main and auxiliary shaft, crankshaft and starting shaft…..………………70 Installation of crankcase……………………………………………………………..……………………………70 Engine troubleshooting…………………………………………………………...…………………………………71 Motorcycle cleaning…………………………………………………………..…………………………………74 Storage of motorcycle………………………………………………………………………… ……………………74 The main points of maintenance………………………………………………………………...

  • Page 8: Suggestions For Daily Use

    Suggestions for Daily Use The vast majority of off-road motorcycle fatalities are caused by head injuries. Without helmets, the chances of serious injury or death from a head-hit will be much higher. Therefore, we strongly recommend that you wear a full set of safety equipment such as helmet, goggles, gloves and boots when driving, which will save your life at the critical moment.
  • Page 9 Vehicle Component and Position 21 TD125 Vehicle Component and Position 10 11 12 13 15 16 Name Name Front fender Front fork Headlight Fuel tank Handlebar Carburetor Vent pipe Gear shift lever Fuel tank cap Pedal Fuel tank petcock Side stand...

  • Page 10: Vin And Engine Number

    26 27 28 29 Name Name Rear fender Rear brake caliper Muffler Swing arm Seat Rear brake oil cup Rear shock Brake pedal Upper clamp Steel chassis Lower clamp Muffler pipe Rear brake disc VIN and Engine Number VIN Number...

  • Page 11: Engine Number

    VIN Number of 21 TD125 is carved on the frame of head pipe. Engine Number Engine Number of 21 TD125 is carved on the engine crankcase body behind gear lever. Specification TD125 size and quality parameters Length*Width*Height (mm) 1600*750*990 Wheelbase (mm)

  • Page 12: Front Disc Brake

    Engine parameter Engine type Single cylinder, four stroke, air - cooled, manual clutch Displacement 119.6cc Max power (kw/r/min) 5.6/8000 Max torque (N•m/r/min) 8.5/5000 Compression ratio 9.3:1 Gear shift type Constant mesh 4 speed gears Start method Kick Ignition system Chain #428；15T/41T Frame/shock/Braking/Wheel parameters Frame type...

  • Page 13: Throttle

    Front brake caliper Throttle The throttle is located on the right side of the handlebar and is controlled by right hand rotation. Turn the throttle up when turning the handle counterclockwise, then turn the handle back to the position after releasing the handle. Throttle Ignition The vehicle starting lever is located on the right side of the...

  • Page 14: Fuel Tank Switch

    Gear Shifting The shift lever is located on the left side of the engine, which is operated by stepping on and lifting the shift lever. The 21 TD125 engines are in four-gear gear with constant meshing. Gearshift lever Rear disc brake The foot brake pedal is located on the right side of the engine and is operated by stepping.

  • Page 15: Parking Stand

    Parking stand The 21 TD125 uses a single stand for parking. The single stand is on the left side of the motorcycle. When in use, straighten the motorcycle, kick the single stand to expand it, and tilt the motorcycle to the left so that the single stand touches the ground and supports the motorcycle.

  • Page 16: Riding Guide

    DANGER: When driving a motorcycle, please do not accelerate at all costs. This behavior can easily lead to engine damage and safety accidents. Therefore, please pay attention to certain driving skills when using a motorcycle. Riding guide Checking items before riding 1.Check the fuel level in the tank 2.Check the oil level in the oil cup of hand brake 3.Check the oil level in the oil cup of foot brake...

  • Page 17: Notes When Starting

    1.Turn the oil tank switch to the "ON" position; 2.Pinch the brake handle with the right hand; 3.Step the right foot on the starting lever vigorously; 4.The engine starts and process ends. Notes when starting 1.Before starting, inspection should be carried out first, including the state of the vehicle and the driver's clothing. 2.When starting the vehicle speed should not be too fast.
  • Page 18 Every 30 hours Every 20 hours Every 10 hours/after racing Once after 1 hour riding ○ Check and charge the battery ● ● ● ● ● ● ● ● ● ● ● ●...
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  • Page 22 ● suspension components must match the rider's weight. ● The standard weight of rider for 21 TD125 off-road motorcycles is ● shown in the table below. ○ 21 TD125 25～65kg...
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  • Page 41: Measure Distance From Center Of Rear Wheel To Rear Fender In Suspension

    Measure distance from center of rear wheel to rear fender in suspension...

  • Page 42: Measure Distance From Center Of Rear Wheel To Rear Fender Under No Load

    3.Use side stand to support the whole motorcycle 4.Calculate the difference between "A1" and "A2" and denote it as "D1". The D1 value of 21 TD125 is shown as follows, TD125 10～34mm Measure distance from center of rear wheel to rear fender in riding condition The measurement procedure is as follows: 1.The rider rides the motorcycle (engine does not start)

  • Page 43: Check The Setup Of The Front Shock

    Adjust the lock plate The spring preload of the rear shock can be controlled by adjusting the lock plate. Adjust the lock plate downward, the spring preload increases; Adjust the lock plate upward, the spring preload is reduced. Check the setup of the front shock The measurement procedure is as follows: 1.Place the whole motorcycle on the ground.

  • Page 44: Motorcycle Maintenance

    Motorcycle maintenance Placement of motorcycle When carrying out the related maintenance of the motorcycle, it is necessary to suspend the motorcycle to facilitate the disassembly and assembly of the parts. Disassembly and assembly of front shock protector Steps of disassembly and assembly of front shock protector are as follows: 1.Disassemble the fixing screws of front shock protector.

  • Page 45: Disassembly And Assembly Of Clamp

    Steps of disassembly and assembly of front shock are as follows: 1.Disassemble the front disc brake. 2.Disassemble the front wheel. 3.Loosen the fixing bolt on the clamp. 4.Remove the front shock. 5.Assembly shall be carried out in the reverse order of disassembly.

  • Page 46: Disassembly And Assembly Of Front Fender

    Disassembly and assembly of front fender Steps of disassembly and assembly of front fender are as follows: 1.Remove the bolts. 2.Remove the front fender 3.Assembly shall be carried out in the reverse order of disassembly. Disassembly and assembly of rear shock...

  • Page 47: Disassembly And Assembly Of Seat

    Check the rear shock and observe whether the spring has cracks. Replace rear shock if necessary. Steps of disassembly and assembly of rear shock are as follows: 1.Remove the bolts of the rear shock and the frame; 2.Remove the bolt connecting the rear shock and the swing arm;...

  • Page 48: Disassembly And Assembly Of Exhaust Pipe

    2.Clean up the dust attached to the air filter sponge and soak the surface with the air filter oil. If the dust on the sponge is really difficult to deal with, you can also replace a new air filter sponge. 3.Use gasoline to clean the fire net and allow it to air dry naturally.

  • Page 49: Disassembly And Assembly Of The Chain

    The checking of the chain is carried out from the following aspects: 1.Inspect the chain from the back of motorcycle to see if the chain is skewed. 2.Turn the rear wheel by hand to see if the rear wheel turns smoothly.

  • Page 50: Inspect Rear Sprocket, Engine Sprocket And Chain Guide Structure

    Note: alternately wet and dry working conditions will greatly shorten the service life of the chain and its surrounding parts. Therefore, please choose the appropriate lubricant according to the correct lubrication method. Note: if the chain needs to be frequently tension, or you find any signs of wear on the front sprocket, rear sprocket and chain, please contact KAYO dealer for a comprehensive inspection to avoid safety problems.

  • Page 51: Inspection Of The Handle Bar

    Disc brake limit thickness table is as follows: Front limit thickness Rear limit thickness TD125 3.0mm 3.0mm Check the fluid level of front brake disc 21 TD125 uses hydraulic disc brake, and its disc brake fluid level can be checked through the observation hole.

  • Page 52: Refill The Front Brake Disc Fluid Oil

    Check the brake lever and make sure the movement is correct. Model Brake pedal free movement TD125 20～45mm Check the rear disc brake fluid level Observe the fluid level hole and check the level of the brake fluid.

  • Page 53: Refill Rear Disc Brake Fluid

    Note: do not let the brake fluid splash on the paint surface, easy to cause corrosion. Danger: please pay attention to check whether the brake fluid leakage, brake fluid tube is damaged. If there is leakage problem, please contact KAYO dealer. Refill rear disc brake fluid The steps to refill brake fluid are as follows: 1.Remove lid screw.
  • Page 54 KAYO dealer. Recommended pressure： Air pressure of Air pressure of front wheel rear wheel TD125 250kPa 250kPa Note: The tire pressure should be checked under cooling condition. Check the wheel spokes Pull the adjacent spokes with your fingers to check whether the spokes lack tension.
  • Page 55 ⑹ Install exhaust muffler. The M8 nut and the exhaust pipe sealing ring should be firmly installed, and the tightening torque should be 25 ~ 30N•m. The exhaust port should not leak during the installation. Engine maintenance and adjustment Inspection of bolts and nuts of cylinder and cylinder body Check at initial 1000km and every 5000km.
  • Page 56 according to the specified torque and the valve clearance is adjusted correctly. Adjustment of clutch control system In order to ensure the correct use of the clutch and the portable operation, the user should ensure that the clutch is in the normal state of engagement, not allowed to be in a semi-clutch state. Adjustment around the engine Idle speed adjustment of carburetor Throttle screw...
  • Page 57 Adjust the position of the shift lever Adjust the shift lever in the following order: Shift lever fixing bolt 1.Loosen the fixing bolt of the shift lever 2.Remove the shift lever 3.Turn the shift lever to the appropriate position and load the spline 4.Tighten the shift lever fixing bolt Check and replace spark plug...
  • Page 58 If the engine is running, turn off and wait a few minutes for the oil to reach the bottom of the crankcase. Remove the oil gauge Oil level gauge and observe through the oil gauge that the oil level should be between the upper and lower scales of the oil gauge.
  • Page 59 Intake valve 0.013~0.04 0.07 Clearance between valve rod and valve guide Exhaust valve 0.025~0.052 0.08 Width of valve sealing tape Flatness of cylinder head 0.04 0.05 Width of cylinder head valve seat face Fault symptom and cause analysis Fault symptom Cause analysis Remarks Valve clearance is too small...
  • Page 60 Timing check Timing mark of driven sprocket 1.Use special tools to rotate C100 six level magneto locking nut, at the same time through the small inspect hole on the left front cover to observe the magneto rotor Timing mark of cylinder head on the timing scale line and the left front cover on the Magneto rotor timing scale timing mark is correct;...
  • Page 61 clearance up and down. 3.Valve clearance should be in the range 0.01-0.03mm. Removal of cylinder head Cap nut Cover of cylinder head The removal steps of cylinder head are as follows: 1.Remove the 4 GB/T 923/M6 cap nuts securing the Connecting bolts for cylinder head and cylinder block cylinder head cover;...
  • Page 62 valve stem and measure the outside diameter of the valve stem. Maintenance limit value: Intake：φ4.96mm Exhaust：φ4.94mm 2.Maintenance limit value contact surface width:1.5mm 3.Check the valve spring for abnormal wear and measure the free length of the spring: standard values: outer valve spring 35.55mm Inner valve spring 32.78 mm Maintenance limit value:outer valve spring 34.80mm Inner valve spring 32.03mm...
  • Page 63 3.Check whether the cylinder head is deformed, and check the flatness of the cylinder head with knife edge ruler and feeler ruler; 4.Check whether the oil cap is damaged. Check and grind valve seats Check and grind the valve seat as follows: The carbon deposit in the combustion chamber is completely clean, evenly smear a thin layer of red oil on the valve seat, put the valve on the valve seat gently tap...
  • Page 64 3.When grinding the valve, use the electric gun sleeve on the rubber hose (with a tight fit), and then the valve rod sleeve on the rubber hose, the grinding graphite paste coated on the valve sealing belt, and then attached to the valve seat sealing line, start the electric gun, turn the valve, the valve and the seat ring with grinding.
  • Page 65 2. Pull the trap to TDC, then attach the timing driven sprocket to the timing chain. Timing sprocket O stamped upward. 3. Install the cylinder head on the bolt A and B, then load the cylinder head gasket, and then load the cylinder head cover.
  • Page 66 8. Put the O-ring into the groove of the valve cover, and then install the valve cover on the cylinder head and tighten, fastening torque: 8 ~ 12N·m. 9. Put the spark plug into the spark plug thread of the cylinder head and tighten it.
  • Page 67 ring0.1 ~0.250 50.4 Outside diameter of piston pin φ12.994~φ13 φ12.985 Inner diameter of tip of connecting φ13.016~φ13.027 Φ13.035 Clearance between connecting rod tip 0.016~0.033 0.05 and piston pin Fault symptom and cause analysis Fault symptom cause analysis Remark pressure Abnormal wear of cylinder block or piston ring cylinder Abnormal wear of cylinder block, piston or piston ring...
  • Page 68 1. Check whether the cylinder block is worn or damaged; 2. Measure the inner diameter of the cylinder block, take three positions, namely the top, middle and bottom of the piston stroke, and measure the two directions which are at right angles to each other. Maintenance limit value: φ52.418mm.
  • Page 69 Piston ring installation steps are as follows: 1. Clean the piston ring groove; 2. Install the piston ring; Note: (1) During installation, the piston and piston ring should be prevented from being damaged; (2) when installing the piston ring, one ring and two rings are literally facing the top of the piston, and the opening is staggered 180°, and the opening direction is toward the piston skirt direction;...
  • Page 70 gasket in place. Then load the chain guide roller into the cylinder body. The guide roller pin shaft passes through the cylinder body and the chain guide roller. Tighten the guide wheel pin shaft. Tightening torque: 10-14n ·m; 5. Tighten the bolts connecting the cylinder body and the crankshaft box body.
  • Page 71 cover Gear shifting arm bending The position of clutch cable is not adjusted Shift difficult correctly Variable speed drum positioning plate spring broken or elastic not enough Removal of right trim cover The steps to remove the right trim cover are as follows: 1.Remove T820-M6x22 cross-reckled...
  • Page 72 butterfly washer, clutch stop washer; 5. Take out the clutch; 6. Remove the clutch driving gear jacket; 7. Remove the elastic retainer below the clutch, and take out the clutch upper plate, friction plate, friction plate, clutch driving plate, outer cover, shock absorption spring, spring in turn.
  • Page 73 1. Check whether the oil seal of starting shaft and clutch push rod on the right crankcase cover is damaged. If the oil seal is found to be broken, a new oil seal should be replaced; Attention when replacing oil seal: (1) Confirm whether the state of oil seal is correct, starting shaft oil seal 13.7×24×5, clutch push rod oil seal 12×21×4;...
  • Page 74 the right oil pump. Check shift mechanism Check steps of the gear change mechanism are as follows: 1. Check whether the roller of the variable speed drum positioning plate rotates flexibly, whether positioning plate is bent, and whether the spring is deformed;...
  • Page 75 Assembly of oil pump The assembly steps of the oil pump are as follows: 1. First pass the oil pump shaft through the oil pump gear, and then load the oil pump pin into the pin hole combining the oil pump and the oil pump gear; 2.
  • Page 76 cover gasket and the clutch end cover. Take 4 pieces of cross countersunk screw M5x10 to lock the end cover. When locking the screw, pre-tighten it and then tighten it diagonally and in place. After assembly in place, the inner ring of the rotating bearing should rotate flexibly without clamping phenomenon.
  • Page 77 Magneto, timing chain Matters needing attention ◆The removal and installation of the magneto, left cover and double teeth introduced in this section, as long as the left crankcase cover is removed, without removing the engine can be completed; ◆ For the inspection of magneto, refer to the methods in the section of battery charging system. Removal of left rear cover The steps for removing the left rear cover are as follows: 1.
  • Page 78 Removal of starting motor and starting sprocket The removal steps of starting motor and starting sprocket are as follows: 1. Remove the two GB/T 5787/ M6x25 bolts fastening the starting motor; 2. Remove the starting motor; 3. Remove 1 hexagon head bolt GB/T 5783-M6×10 for fastening the starting sprocket press plate;...
  • Page 79 Transition plate, starting motor, starting sprocket inspection Transition plate, starting motor, starting sprocket check steps are as follows: 1. Check whether the starting sprocket is damaged, whether the transition plate is damaged, whether the transition suet seal is damaged, and whether the transition plate O-ring is damaged.
  • Page 80 4. Tension arm and tension bar have flexible action without clamping. Transition plate installation Transition plate installation steps are as follows; 1. Mount two sealing rings 6.8×1.9 on the left crankshaft box; 2. Put the O-ring into the positioning pin, and then into the left body; 3.
  • Page 81 rotor convex hull is qualified; Tightening torque: 10-14n ·m. 6. Combine the O-ring with the large and small viewhole covers, put the o-ring into the left front cover and tighten it. Note: The trigger locator plate should not press the wire harness.
  • Page 82 Radial backlash at big 0.004~0.012 0.015 end of connecting rod Fault symptom and cause analysis Fault symptom Cause analysis Remark The shift fork is bent and deformed Shift difficulty Gaskets and bolts of speed drum loose and loose The pawl of the shift gear is worn G roove-skipping The shift fork is bent or worn The needle roller bearing at the big end of the...
  • Page 83 The decomposition steps of the variable speed drum are as follows: 1. Remove the spring clip. 2. Pull out the fork pin. 3. Take out the fork Inspection of crankshaft Check the crankshaft as follows: 1. Put the crankshaft on the V-shaped iron, and measure the large side clearance of the connecting rod with the thickness gauge.
  • Page 84 Check shift fork, fork shaft and shift drum Check the shift fork, fork shaft and speed drum as follows: 1. Check whether the shift fork is worn, bent or any other fault, and measure the inside diameter of the shift fork;...
  • Page 85 Note: 1. The shift fork of the speed drum is installed in the main and auxiliary shaft positions. 2. Do not install gaskets of starting shaft and auxiliary shaft. Installation of crankcase The installation steps of crankcase are as follows: 1.
  • Page 86 Engine failure, can focus on the above four aspects, check, analyze the cause of the failure, and to eliminate. Fault performance Inspection method Inspection result Possible cause No fuel in the tank No fuel flow into the The fuel line from tank to carburetor carburetor is blocked Check for fuel flow into...
  • Page 87 correct Carburetor seal ring leak deteriorates Check carburetor gasket for leaks The carburetor is loose Not leak Carburetor gasket damaged Faulty spark plug charcoal accumulation The spark is weak or The electronic igniter is intermittent Remove spark plug and faulty perform spark test The magneto is out of order The spark plug cap is faulty...
  • Page 88 worn he fit clearance between the main and driven gears is too small or too large Motorcycle cleaning Vehicle cleaning is also an important part of the daily use and maintenance of motorcycles, often clean your motorcycle, can make your car to maintain a good state of motion, prolong its service life. You can clean your motorcycle by following the steps: 1.
  • Page 89 4. Install batteries; 5. Check the items to be checked before daily driving; 6. Regular lubrication of the motorcycle. The main points of maintenance In the following sections, we will list the problems you encountered, identify the possible causes, and give general solutions.
  • Page 90 Close the choke valve, clean the tank Incorrect air supply ventilation pipe, and adjust the air filter The engine will start, but it duct will stall immediately The lack of fuel make-up fuel supply The spark plug is stained, damaged or Remove the spark plug, clean it, adjust incorrectly adjusted it, and replace it if necessary...
  • Page 91 Clutch pressure plate spring is too soft Replace clutch spring or damaged Clutch free stroke too small Adjust clutch free stroke The cables make it difficult to turn the Move the cable to reduce interference handlebars Steering shaft nut too tight Adjust the steering shaft nut The motorcycle is hard to steer...
  • Page 92 Chassis bending Contact KAYO Service Center Improper steering adjustment Check and readjust Bending of steering shaft Contact KAYO Service Center The motorcycle tilted to one There is a problem with the front fork Contact KAYO Service Center side Re-adjust the tension of spokes, and Vehicle misalignment contact KAYO...
  • Page 93 Rear sprocket screw M8×25 10.9 27～35 Rear axle nuts M14×1.5 124～165 Rear brake disc cover bolts M6×12 7～11 Rear brake pump bolts M6×20 full thread 7～11 Bolts for FBG M6×20 7～11 V oltage stabilizer bolts M6×16 full thread 7～11 Front fender bolts M6×16 7～11 Connecting screws between left...

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