ZHEJIANG KAYO MOTOR CO., LTD. This service manual is edited by KAYO Please do not modify the content without authorization。 Manufacturer has the right to improve and update the model’s structure and spare parts without notice. The model in the image may differ slightly from production models.
ZHEJIANG KAYO MOTOR CO., LTD. Content Preface………………………………………………………………3 Notification and warning…………………………………………..4 Warranty info……………………………………………………..4 Vehicle profile……………………………………………………….7 Vehicle component and location……………………………………………………………....8 VIN number……………………………………………………………………………………..10 Specifications……………………………………………………………………………………...11 Circuit diagram…………………………………………………………………………………..15 Fasteners torque table………………………………………………………………………………16 Operation instruction…………………………………………….18 Check before riding……………………………………………………………………….....19 Starting steps………………………………………………………………………………....21 Vehicle run in……………………………………………………………………………………...23 Vehicle cleaning………………………………………………………………………………..23 Storage and use of vehicles……………………................24 www.kayomoto.us...
Page 4
ZHEJIANG KAYO MOTOR CO., LTD. Routine maintenance…………………………………………...25 Maintenance Periodic Table……………………………………………………………………...26 Specific maintenance content…………………………………………………………………..27 Vehicle settings……………………………………………..34 Specific settings and methods……………………………………………………………………35 Electric parts inspection………………………………………37 Electric parts inspection and replacement……………………………………………………….38 Vehicle troubleshooting…………………………………………47 Possible failures and troubleshooting methods………………………………………………..48 Engine maintenance manual…………………………………...52 Main performance parameters…………………………………………........53 Structure………………………………………………………………........53...
ZHEJIANG KAYO MOTOR CO., LTD. Vehicle component and location ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Name Name Front fender Front brake caliper - 6 - www.kayomoto.us...
Page 7
ZHEJIANG KAYO MOTOR CO., LTD. Headlight Front fork Handlebar Fuel tank Vent pipe Carburetor Fuel tank cap Gear shift lever Fuel tank petcock Pedal Air filter Chain Chain slider Chain guide Front brake disc - 7 - www.kayomoto.us...
Page 8
ZHEJIANG KAYO MOTOR CO., LTD. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Name Name Rear fender U-shape rocker arm - 8 - www.kayomoto.us...
ZHEJIANG KAYO MOTOR CO., LTD. Muffler Triangle rocker arm Seat Rear brake master cylinder Rear shock Brake pedal Rear brake disc Muffler pipe Rear brake caliper VIN number ○ ○ ○ ① VIN number Located on frame plate ② Frame plate Located on frame head tube ③...
Page 13
ZHEJIANG KAYO MOTOR CO., LTD. Fastener torque table Note: before installing the thread, apply anti-rust grease on the thread and joint surface. Torque (N•m) Item Fastener specification Front brake caliper mounting bolt M8×40 full thread 20~32 front brake shield mounting screw M6×16...
ZHEJIANG KAYO MOTOR CO., LTD. OPERATION INSTRUCTIONS ………………………………………………………19 Check before riding Starting steps ……………………………………………………………..21 Vehicle run in………………………………………………………..23 Vehicle cleaning ………………………………………………………..23 Storage and use of vehicles................24 - 15 - www.kayomoto.us...
ZHEJIANG KAYO MOTOR CO., LTD. Check before riding 1.Fuel level Tank cap Open the tank cap and shake the handlebars, and observe the fuel the level of the tank. If fuel is low, please add fuel. 2. Fuel tank switch...
Page 17
ZHEJIANG KAYO MOTOR CO., LTD. Brake fluid level. Through the brake fluid sight glass (①and②), checking the brake fluid in the brake master cylinder. If brake fluid level is lower than half of the observation hole, or "LOWER" position, then add brake fluid.
Page 18
ZHEJIANG KAYO MOTOR CO., LTD. brake disc Check for damage to the brake disc surface, (scratches, gouges, warping, bluing) and check the thickness, if the brake disc is less than the limit thickness, the brake disc must be replaced immediately.
ZHEJIANG KAYO MOTOR CO., LTD. 9.Check the chain and its supporting parts Check chain tension. If the chain is too loose, it can be adjusted by loosening the rear axle and adjusting the chain adjusters. Do not make the chain too tight.
Page 20
ZHEJIANG KAYO MOTOR CO., LTD. The electric starting steps are as follows: Clutch handlebar 1. Switch the fuel tank to the "ON" position; 2. turn the key switch on; Key switch Start button 3, the left hand pull in clutch lever;...
ZHEJIANG KAYO MOTOR CO., LTD. Vehicle Break in procedure Motorcycle engines have many parts that make relative movements, such as pistons, piston rings, cylinder blocks, and meshing transmission gears. Therefore, in the initial stage of use, the engine must be regularly run-in. The running-in can adapt the moving parts to each other, correct the working gap, and form a good smooth friction surface that can withstand large loads.
ZHEJIANG KAYO MOTOR CO., LTD. 5. Rinse with low pressure water; 6. Let the motorcycle air dry naturally; 7. Drive the motorcycle for a short time until the engine reaches the working temperature; 8. Lubricate the chain and all other components that need lubrication.
Page 23
ZHEJIANG KAYO MOTOR CO., LTD. Note: when applying anti-rust oil, please do not splash oil on the brake and rubber parts, This may cause rubber parts to deteriorate. After the motorcycle is stored for a long time, please follow these steps before putting it into use: 1.
ZHEJIANG KAYO MOTOR CO., LTD. Maintenance Periodic Table Every 30 hours Every 20 hours Every 10 hours/after racing Once after 1 hour of riding ● ● ● Check and charge the battery ● ● ● Check the front disc brake pads ●...
ZHEJIANG KAYO MOTOR CO., LTD. ● Periodic interval Note: This table is for reference only. Please adjust the specific cycle according to the use of the motorcycle. Warning: For inspection, adjustment and replacement of engine parts, please consult Kayo Service Center to avoid damage to the engine.
Page 27
ZHEJIANG KAYO MOTOR CO., LTD. Rotate the adjuster until free play is correct, Then tighten the lock nut.Rotate the adjuster for best results, Then tighten the lock nut. 4.Spark plug Engine spark plug torque is 25-30N • m. The spark plug must be removed regularly to check the gap (0.6 to 0.7 mm) between the electrodes.
Page 28
ZHEJIANG KAYO MOTOR CO., LTD. 5.Air filter The air filter should be checked on time, as follows: Remove the seat cushion; Remove the air filter cover; Check the air filter. Installation is performed in the reverse order of removal. seat...
Page 29
If the motorcycle has just been used, wait for a few minutes after the engine has stopped to check; Observe the amount of lubricating oil in the engine through the oil dipstick. The status of the CP250 engine of the T4 model can be observed through the oil level hole; www.kayomoto.us...
Page 30
ZHEJIANG KAYO MOTOR CO., LTD. The level of lubricating oil in the engine should be between the maximum and minimum values, that is, between "H" and "L"; If the oil level is too high, remove excess oil through the drain bolt;...
Page 31
ZHEJIANG KAYO MOTOR CO., LTD. oil level meets the requirements; Close the oil fill hole and tighten the oil cap. 8.Piston and piston ring For the inspection, adjustment and replacement of this project, please refer to the engine maintenance manual for details.
Page 32
ZHEJIANG KAYO MOTOR CO., LTD. 11.Crankshaft connecting rod and bearing For the inspection, adjustment and replacement of this item, please refer to the engine maintenance manual for details. 12.Starter, shift pedal and brake pedal Lubricate the moving parts and joints with oil or grease, use caution as excessive lubrication may cause the boots to slip on the pedals and affect riding.
Page 33
ZHEJIANG KAYO MOTOR CO., LTD. Check the thickness of the front and rear brake caliper brake pads. The caliper brake pads thickness should be not less than 1mm. If the brake pad thickness is less than or equal to the minimum thickness, the entire set of brake pads should be replaced immediately.
Page 34
ZHEJIANG KAYO MOTOR CO., LTD. Check the brake fluid level through the brake fluid level observation hole. The liquid level should be more than half of the observation hole, that is, the liquid level should be higher than "LOWER". If the brake fluid is insufficient, add it immediately.
Page 35
After placing the motorcycle on the ground, press the handlebars by hand to test whether the spring back is sensitive after pressing down.Our T4 models use FASTACE dual adjustable front shock absorbers, whose damping hardness can be adjusted by adjusting screws.
Page 36
ZHEJIANG KAYO MOTOR CO., LTD. 22.Fuel system inspection Make sure oil tank, oil tank cap, switch etc. has no leaks before driving. 23.Steering column adjustment Steering column should be adjusted frequently to keep the handlebar rotate freely. Directional column nut Place the motorcycle on mounting bracket and make the front fork completely suspended.
Page 37
ZHEJIANG KAYO MOTOR CO., LTD. parts need to be lubricated: Rear brake pedal bearing Rear brake pedal Gear shift lever Chain Spray with tubing for pressure lubrication. Lubricate the throttle cable with grease. note:After driving on wet roads, even if the chain looks dry, it must be lubricated.
Page 38
ZHEJIANG KAYO MOTOR CO., LTD. 25.rear shock inspection T4 model equipped with FASTACE double adjustable nitrogen charged rear shock.. Check the rear shock, see the reservoir condition and the spring for damage. Replace the shock if necessary. Please follow the following steps to disassemble the rear shock ...
Page 39
ZHEJIANG KAYO MOTOR CO., LTD. Loosen rear axle nut. Find out the max chain tension position. Adjust front and rear position of tensioner, align wheel. Tighten tensioner nut. Tight rear axle nut. Check max tension point, adjust tension if necessary.。...
Page 40
ZHEJIANG KAYO MOTOR CO., LTD. 28.battery inspection Remove seat, use multimeter to test the positive and negative voltage and current output. If battery runs low, charge it. If battery damaged, replace it. note:replace KAYO recommend brand. - 35 - www.kayomoto.us...
ZHEJIANG KAYO MOTOR CO., LTD. Vehicle settings Specific settings and methods…………………………………………35 - 36 - www.kayomoto.us...
Page 42
You can update carburetor to make bikes more suitable. Two way transmission ratio setup Two way transmission ratio can adjusted by changing sprocket teeth. KAYO T4 rear and front sprocket teeth: Rear sprocket:45T Front sprocket:13T note:Consult dealer before replacing sprocket.
Page 43
ZHEJIANG KAYO MOTOR CO., LTD. If reduce transmission ratio, the max speed reduced too, but this better for acceleration. Low speed is easy to bike control and suitable in rough road. If increase transmission ratio, the max speed increased too. high speed is not good for low speed bike control and acceleration.
Page 44
Pressure adjusting screw Spring preload adjustment Rear suspension T4 equipped with FASTACE double adjustable nitrogen balloon rear suspension, adjusted as bellow: Compression adjusting screw. Spring preload adjustment Rebound adjusting screw ...
ZHEJIANG KAYO MOTOR CO., LTD. Electric parts inspection and replacement Electric lock inspection and replacement Disassembly As bellow: Remove headlight/ front panel Dispatch connector between electric lock and main cable. Take electric lock off. Inspection Check whether the terminals connectors can be...
Page 47
ZHEJIANG KAYO MOTOR CO., LTD. Meter inspection and replacement Disassembly As bellow: Remove headlight/ front panel Dispatch connector between electric lock and main cable. Remove meter fixed screw Remove meter Inspection Open electric lock Check the meter data If meter doesn’t work, replace it.
Page 48
ZHEJIANG KAYO MOTOR CO., LTD. Multi-function switch inspection and replacement Disassembly Remove the switch mounting screw Disconnect the connector between switch and main cable. Remove switch Inspection Check whether the terminals connectors can be conducted as the table shows: ● — ●...
Page 50
ZHEJIANG KAYO MOTOR CO., LTD. Headlight inspection and replacement Disassembly As follows: Remove mounting bolt from the headlight bracket Bulb Remove the mounting screw from the lower headlight bracket Disconnect the connector between headlight and main cable connector. Take off the headlight.
Page 51
ZHEJIANG KAYO MOTOR CO., LTD. In reverse order of disassembly. - 46 - www.kayomoto.us...
Page 52
ZHEJIANG KAYO MOTOR CO., LTD. Front turn light inspection replacement Disassembly Left turn light Right turn light As below: Remove headlight Disconnect the left and right turn lights from the main cable. Inspection Check whether the terminals of the turn lights connector...
Page 54
ZHEJIANG KAYO MOTOR CO., LTD. Inspection and replacement of horn Disassembly Disassemble the horn as below: Remove headlight/head panel Disconnect the horn from the main cable Remove horn mounting bolt Remove electric horn Inspection Connect the horn to the battery by wire If the horn can make a continuous loud sound, the horn is normal.
Page 55
ZHEJIANG KAYO MOTOR CO., LTD. Disassembly The steps for removing the rear left and right turn lights Rear left turning light Rear right turning light are as below: Disconnect the left and right turn lights from the main cable Remove the shelf...
Page 56
ZHEJIANG KAYO MOTOR CO., LTD. Disconnect the taillight from the main cable Remove taillight mounting nut Remove tail lights Inspection brown green yellow/green ● ● stoplight ● ● anti-fog light tail light Check whether the tail lights terminals are on ●...
Page 57
ZHEJIANG KAYO MOTOR CO., LTD. Disconnect the light from the main cable Remove plate lamp fixing bolts Remove licence lamp Inspection Check whether the license plate light terminals are on brown green Licence lamp fixing bolts ● ● license plate light ●...
Page 58
ZHEJIANG KAYO MOTOR CO., LTD. Remove Removal of seat cushion Removal of the rear right upper and lower panels Disconnect relay from main cable Remove relay Inspection relay Start the car, if the car can be started normally, the relay is normal;...
Page 59
ZHEJIANG KAYO MOTOR CO., LTD. Inspection Start the vehicle, if can be started normally, the steady voltage rectifier is normal; conversely, if other parts are normal, the rectifier needs to be replaced. Installation Installation in reverse order of disassembly steady voltage rectifier...
Page 60
ZHEJIANG KAYO MOTOR CO., LTD. Installation in reverse order of disassembly Inspection and replacement of ignition coil Disassembly Remove seat cushion Remove oil tank Disconnect the ignition coil from the main cable Remove the ignition coil mounting bolts Take down the ignition coil...
Page 61
ZHEJIANG KAYO MOTOR CO., LTD. Speed sensor inspection and replacement Disassembly The speed sensor is removed as below: Remove the headlight Disconnect sensor from main cable Remove the fixing nut Speed sensor fixing nut Take out the sensor Inspection Check whether the sensor is normal through the instrument, if the sensor is damaged, replace the sensor.
ZHEJIANG KAYO MOTOR CO., LTD. Possible failures and troubleshooting methods In the following, we will list the problems that arise during your use, find out the possible causes and give general solutions. Problem Reason Solution The engine crank Crank stuck...
Page 65
ZHEJIANG KAYO MOTOR CO., LTD. should be changed and changed again within 500 kilometers. After three times, the carburetor's moisture is almost gone. If you want to test the carburetor for moisture, you can remove the oil from the crankcase, observe its color, if white, that means there is moisture.
Page 66
ZHEJIANG KAYO MOTOR CO., LTD. leaking fittings if necessary Dirt in carburetor nozzle Remove the carburetor and clean the nozzle Crankshaft bearings damaged Contact KAYO Service Centre or worn Engine sound Ignition problem Contact KAYO Service Centre abnormally overheating See the "engine overheating section"...
Page 67
ZHEJIANG KAYO MOTOR CO., LTD. Ratchet unit damaged Replace the ratchet unit Stiter position spring loose or Replace the stiter position spring broken Gear jump Fork worn Replace the fork Tooth worn Check gears and replace if necessary Gear worn...
Page 68
ZHEJIANG KAYO MOTOR CO., LTD. Error in damping adjustment Regulating shock absorption Damping too soft Insufficient front fork oil level Add proper amount of prong oil Warning:Request for the same oil The viscosity of the fork oil is Replace with front fork oil with suitable viscosity...
Page 69
ZHEJIANG KAYO MOTOR CO., LTD. Motorcycle front Tyre worn Replace the tyre wheel shimmy Wheel offset Contact KAYO Service Centre front wheel bearings worn Check bearings and replace if necessary Vehicle misalignment Check spokes and adjust spokes tension if necessary...
ZHEJIANG KAYO MOTOR CO., LTD. Engine maintenance manual Main performance parameters………………………………………….53 Structure………………………………………………………………...53 Engine Installation……………………………………………………...54 Engine maintenance and adjustment…………………………....54 Disassembly of the engine……………………………………………..57 Torque gauge for engine bolts and nuts………………………………..58 Engine failures and troubleshooting…………………………………..59 - 65 - www.kayomoto.us...
ZHEJIANG KAYO MOTOR CO., LTD. Main performance parameters 1-cylinder, vertical, 4-stroke, cooling, Manual, Type: overhead-cam parameters: a.max net power/speed:12.0(1±5%)kW /7500(1±5%)rpm b.max torque/speed:17(1±5%)N·m /6000(1±5%)rpm c. Idling speed: 1500(1±10%) r /min d. min fuel-consume ratio: 354 g / kw.h Structure parameters: a. Cylinder bore*stroke:66.5×66.2mm b.
ZHEJIANG KAYO MOTOR CO., LTD. 1.Gas distribution mechanism The timing driven sprocket on the crankshaft drives the timing driven sprocket on the camshaft to rotate the camshaft. The cam wheel drives the rocker arm with the rotation of the camshaft.
Page 74
ZHEJIANG KAYO MOTOR CO., LTD. Check at the first 1000km and every 5000km. When the engine is cold, use a torque wrench to tighten the bolts and nuts according to the specified torque. 28~32N.m torque 10~15N.m Inspection of valve clearance Check at the first 1000km and every 5000km.
Page 75
ZHEJIANG KAYO MOTOR CO., LTD. pressure value of the engine cylinder. standard value 1200~1250Pa Limit value 1100Pa Low pressure indicates the following faults: Excessive wear on the cylinder wall. The piston or piston ring is worn. The piston ring snaps into the ring groove. The valve does not engage well with the valve seat.
Page 76
ZHEJIANG KAYO MOTOR CO., LTD. The parking rack supports the motorcycle, warm up the engine for (5 ~ 10) minutes, and stop waiting for (5 ~ 10) minutes。 Unscrew the oil filter cover, remove the oil filter and spring, unscrew the oil dipstick, release the oil, and clean and dry the oil filter and spring at the same time.
ZHEJIANG KAYO MOTOR CO., LTD. It is necessary for the new car to run in all moving parts before the engine runs at full load. The future performance and reliability of the engine depend on strict and careful running in and maintenance during the initial period of use.
Page 78
ZHEJIANG KAYO MOTOR CO., LTD. Note: When assembling the cylinder head cover, the joint surface must be glued. Disassembly and assembly of cylinder block and piston Remove the cylinder head seal, positioning pin and chain guide plate. Remove the cylinder block.
Page 79
ZHEJIANG KAYO MOTOR CO., LTD. Disassemble the left front cover remove the shift treadle remove electric start double gear shaft, double gear washer and double gear. remove the left front cover and box body connection bolts, remove the left front cover (with magnetic ...
ZHEJIANG KAYO MOTOR CO., LTD. remove the box body connecting bolts and remove the right crankshaft box body. remove the crank connecting rod parts, crankshaft adjustment gasket and balance shaft parts from crankcase. remove the fork shaft, fork, variable speed drum and main and secondary shaft sleeve.
Page 81
ZHEJIANG KAYO MOTOR CO., LTD. Failure Inspection methods Inspection result Possible causes performance No fuel in the tank Fuel didn’t flow into the carburetor Check if the fuel has Blocking from fuel tank to carburetor tubing flowed into the Float assembly stuck in carburetor...
Page 82
ZHEJIANG KAYO MOTOR CO., LTD. can’t start Improper adjustment of carburetor fine-tuning screw Air leakage in intake pipe Engine not ignition wrong ignition High oil level of carburetor Spark plug is damp The carburetor chock is shut too tightly Remove spark plug...
Page 83
ZHEJIANG KAYO MOTOR CO., LTD. performance and valve clearance Improper adjustment of valve clearance is poor at high Magnetor failure speed Valve clearance ignition timing are all correct Fuel in tank is running out Disassemble the fuel Insufficient fuel flow...
Page 84
ZHEJIANG KAYO MOTOR CO., LTD. timing chain The chain is stretched Timing chain automatic tensioner failure or guide wheel worn The accuracy of gear machining is not enough Check if there is The main and driven Gear teeth are worn...