Related Manuals for KAYO MOTOR KT250
Summary of Contents for KAYO MOTOR KT250
- Page 1 ZHEJIANG KAYO MOTOR CO., LTD. KAYO MOTO KT250 USER’S MANUAL WWW.KAYOMOTO.COM - 1 - www.kayomoto.com...
- Page 2 This service manual is edited by KAYO No part of this publication may be reproduced without authorization. ZHEJIANG KAYO MOTOR CO., LTD reserves the right to make changes at any time without notice and without incurring any obligation. The vehicle pictured in this owner’s manual may not match your actual vehicle.
- Page 3 ZHEJIANG KAYO MOTOR CO., LTD. PREFACE Congratulations on your purchase of the KT250 Dirt Bike, and we believe that this choice won’t let you down. This manual will give you an understanding of the better use of our product. It has specialized the...
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Page 4: Table Of Contents
ZHEJIANG KAYO MOTOR CO., LTD. CONTENT MEANINGS OF REPRESENTATION ……………………………………………………………….8 SYMBOLS USED…………………………….………………………………………………….8 DEGREES OF RISK AND SYMBOLS ..…………………………………………………...8 ADVICE………….……………………………………………………………………………………9 APPEARANCE …………………………………...…………………………………………………10 KT250 COMPONENTS AND POSITIONS………………………….…………………………10 VIN CODE AND ENGINE NUMBER………………………………………………………...……12 V IN C O D E … … … … … … … … … … … … … … … … … … … … … . . . … … … … … . … 1 2 ENGINE NUMBER………………………………………………………………….…...……12... - Page 5 ZHEJIANG KAYO MOTOR CO., LTD. ADJUSTING THE REBOUND DAMPING OF THE REAR SHOCK ABSORBER………….25 MEASURE THE DISTANCE BETWEEN THE CENTER OF THE REAR WHEEL AND THE REAR FENDER IN SUSPENSION…………………….…….………...………………………25 MEASURE DISTANCE BETWEEN CENTER OF REAR WHEEL AND REAR FENDER UNDER NO LOAD…………………….…….………...……………………………………….25...
- Page 6 ZHEJIANG KAYO MOTOR CO., LTD. CHECK THE DISC BRAKE…………………………..............41 REFUEL THE FRONT BRAKE LIQUID LEVEL…..............41 CHECK THE FRONT BRAKE PADS…..................41 CHECK THE FREE-PLAY OF FOOT BRAKE…...............42 CHECK THE REAR BRAKE DISK LIQUID LEVEL..............43 REFUEL THE REAR BRAKE DISK LIQUID LEVEL..............43 CHECK THE REAR BRAKE PADS....................44...
- Page 7 ZHEJIANG KAYO MOTOR CO., LTD. TROUBLESHOOTING........................60 SELECTION AND RATIO OF ENGINE OIL..................63 MOTORCYCLE CLEANING......................64 STORAGE............................65 PREPARING FOR LONG STORAGE..................65 PREPARING FOR USE AFTER LONG STORAGE..............65 MAINTENANCE POINTS........................66 TIGHTENING TORQUE TABLE FOR THE WHOLE VEHICLE............71 - 7 - www.kayomoto.com...
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Page 8: Meanings Of Representation
ZHEJIANG KAYO MOTOR CO., LTD. MEANINGS OF REPRESENTATION SYMBOLS USED The meaning of specific symbols is described below * All work marked with this symbol requires specialist knowledge and technical understanding. If you do not have the confidence to perform that, you can go to an authorized KAYO workshop or KAYO after-sale service point. -
Page 9: Advice
ZHEJIANG KAYO MOTOR CO., LTD. ADVICE Most of off-road motorcycle fatalities are caused by head injuries. Without helmets, the chances of serious injury or death caused by head injuries are much higher. So always wear an approved motorcycle helmet and protective apparel such as goggles, gloves and boots while riding, which will save your life at the critical moment. -
Page 10: Appearance
ZHEJIANG KAYO MOTOR CO., LTD. APPEARANCE KT250 COMPONENTS AND POSITIONS 11 12 13 Name Name Front fender Front brake caliper Headlight Front shock Handlebar Fuel tank Vent pipe Carburetor Fuel tank cap Gear shift lever Fuel tank petcock Pedal Air filter cover... - Page 11 ZHEJIANG KAYO MOTOR CO., LTD. Name Name Taillight Rear brake caliper Rear fender Aluminum swingarm Exhaust pipe muffler Triangle rocker arm Seat U-shape rocker arm Rear shock Rear brake oil cup Upper clamp Brake pedal Cooling water tank Exhaust pipe...
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Page 12: Engine Number
ZHEJIANG KAYO MOTOR CO., LTD. VIN CODE Vin code of KT250 is located on the head pipe and Name Plate. ENGINE NUMBER The engine number of KT250 is located on the engine box behind the cylinder block. - 12 -... -
Page 13: Parameter
ZHEJIANG KAYO MOTOR CO., LTD. PARAMETER DIMENSIONS AND QUALITY PARAMETER - KT250 L*W*H（mm） 2180×820×1254 Wheelbase（mm） 1488 Net weight（kg） Tire size F: 80/100-21；R: 110/100-18 Seat height（mm） Min ground clearance （mm） Tank volume（L） Engine Parameters Engine type Single cylinder, two stroke, water cooling, vertical... - Page 14 ZHEJIANG KAYO MOTOR CO., LTD. Competitive high-strength aluminum alloy fat bar (imported),，material Handlebar 7075 Φ28.6mm, with Kayo special ultra-soft off-road grip rim ， 1.60×21, 2.15×18, 7050 high strength aluminum F/R rims forged CNC wheel hub Double piston pump hydraulic brake system, Ø240mm, CNC ergonomic...
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Page 15: Controls
ZHEJIANG KAYO MOTOR CO., LTD. CONTROL CLUTCH The clutch is controlled by the clutch lever, which is fitted on the left side of the handlebar and functioned by pinching the lever with your left hand. By adjusting the screw, you can change the distance between the clutch lever and handlebar as you wish. -
Page 16: Throttle Lever
ZHEJIANG KAYO MOTOR CO., LTD. THROTTLE LEVER The throttle lever is located on the right side of the handlebar and is controlled by turning with the right hand. Turn the handle counterclockwise to increasing the engine. It will back to normal smoothly once you lease the handle. -
Page 17: Fuel Tank Switch
ZHEJIANG KAYO MOTOR CO., LTD. FUEL TANK SWITCH The fuel tank switch is located on the bottom left side of the fuel tank. By turning the switch, you can control the entrance of the fuel into into the carburetor, so as to achieve the control purpose. -
Page 18: Rear Disc Brake
ZHEJIANG KAYO MOTOR CO., LTD. The KT250 engine has six gear as International Standard, and you can find the illustration on the left. REAR DISC BRAKE The foot brake pedal is located on the right side of the engine and is functioned by stepping. -
Page 19: Hour Counter
HOUR COUNTER The KT250 hour meter is located on the main beam tube at the front end of the fuel tank of the frame. - 19 -... -
Page 20: Prepareing For Use
ZHEJIANG KAYO MOTOR CO., LTD. PREPARING FOR USE ADVICE ON FIRST USE 1. Before your first trip, read the entire operating instructions carefully, especially the section of “Controls” and “Riding Instructions”. 2. When driving, please carry out a standardized run-in first. -
Page 21: Riding Instructions
ZHEJIANG KAYO MOTOR CO., LTD. RIDING INSTRUCTIONS PREPARATION BEFORE RIDING 1. Check fuel level in fuel tank and replenish if necessary. 2. Check fluid level in hand brake fluid reservoir and replenish if necessary. 3. Check fluid level in foot brake fluid reservoir and replenish if necessary. -
Page 22: Preacutions For Turning
ZHEJIANG KAYO MOTOR CO., LTD. PRECAUTIONS FOR TURNING 1. Take care to slow down in advance when turning 2. Lower your center of gravity to reduce the risk of side rolling when turning 3. Do not shift gears when turning PRECAUTIONS FOR ACCELERATION 1. -
Page 23: Suggested Inspection Time For All Parts Of The Vehicle
ZHEJIANG KAYO MOTOR CO., LTD. SUGGESTED INSPECTION TIME FOR ALL PARTS OF THE VEHICLE every 30 hours every 20 hours every 10 hours/after every race 1 hour after each ride ● ● ● Check and charge the battery Check the front disc brake plate→p.49 ●... -
Page 24: Suspension System
The total standard rider mass of the KT250 off-road motorcycle is shown in the table below. KT250 75～85KGS If the rider's weight is above or below the standard range, the basic setting must be adjusted accordingly. -
Page 25: Adjusting The Rebound Damping Of The Rear Shock Absorber
"A2". 3. Use a single stand to support the vehicle 4. Calculate the difference between "A1" and "A2" and denote it as "D1". The value of "D1" when KT250 motorcycle leaves factory is shown below KT250 10～34mm - 25 -... -
Page 26: Measure Distance Between Rear Wheel Center And Rear Fender In Driving Condition
ZHEJIANG KAYO MOTOR CO., LTD. MEASURE DISTANCE BETWEEN REAR WHEEL CENTER AND REAR FENDER IN DRIVING CONDITION The measurement procedure is as follows: 1. The driver rides the motorcycle (the engine does not start) 2. Up right the motorcycle so that the center surface of the tire is perpendicular to the ground 3. -
Page 27: Adjusting The Compression Damping Of Front Shock Absorber
ZHEJIANG KAYO MOTOR CO., LTD. 4. Observe the effect of pressure and rebound of front shock absorber If it is difficult to press the front shock absorber, decrease the compression damping appropriately. If it is difficult to rebound the front shock absorber, decrease the rebound damping appropriately. -
Page 28: Vehicle Maintenance
The installment should be carried out in the reverse order of removal. NOTE: when removing the front shock absorber guard plate of KT250, the front wheel should be removed first, otherwise the screws on the inside near the tire - 28 -... -
Page 29: Removing Or Installing The Front Disc Brake
5. Remove the front disc brake. Installing Steps: The installment should be carried out in the reverse order of removal. NOTE: For KT250 model, remove the disc brake cover first. REMOVING OR INSTALLING THE FRONT SHOCK ABSORBER Removing Steps as follows: 1. -
Page 30: Check The Front Steering
ZHEJIANG KAYO MOTOR CO., LTD. The installment should be carried out in the reverse order of removal. CHECK THE FRONT STEERING Check the front steering steps are as follows: 1. Aerial the whole vehicle 2. By turning the handlebar left to right to control the motorcycle head, if it turns smoothly and there is no obstruction, the motorcycle head turning is normal 3. -
Page 31: Removing Or Installing Front Headlight
ZHEJIANG KAYO MOTOR CO., LTD. REMOVING OR INSTALLING FRONT HEADLIGHT Removing Steps are as follows: 1. Remove the fixing bolts of the upper bracket 2. Remove the headlight 3. Pull out the connector between headlight and main cable Installing Steps: The installment should be carried out in the reverse order of removal. -
Page 32: Removing Or Installing The Rear Shock Absorber
ZHEJIANG KAYO MOTOR CO., LTD. REMOVING OR INSTALLING THE REAR SHOCK ABSORBER Check the rear shock absorber whether the airbag is normal and the spring is cracked or not,etc. If necessary, replace the rear shock absorber. Please follow the steps below to removing the rear shock absorber: 1. -
Page 33: Removing Or Installing The Air Filter Housing
The installment should be carried out in the reverse order of removal. NOTE: KT250 adopts a unique tool-free maintenance design. The side cover of the air filter can be removed or installed from the main body of the cover only by hands. -
Page 34: Cleaning And Maintenance Of Air Filter
ZHEJIANG KAYO MOTOR CO., LTD. CLEANING AND MAINTENANCE OF AIR FILTER Before performing maintenance on the air filter parts, it is necessary to check first, the contents of which are as follows: 1. Check whether there are cracks on the surface of the air filter hose. -
Page 35: Removing Or Installing The Muffler Tube
ZHEJIANG KAYO MOTOR CO., LTD. REMOVING OR INSTALLING THE MUFFLER TUBE The exhaust pipe and the muffler tube can guide the gas emission and reduce the noise. If the exhaust pipe is rusty or ruptured or damaged by impact, please replace it with a new one immediately. If the noise is too high or the engine performance is degraded, replace the muffler tube. -
Page 36: Check And Clean The Chain
ZHEJIANG KAYO MOTOR CO., LTD. CHECK AND CLEAN THE CHAIN Checking Steps are as follows: 1. Observe the chain from the rear of the vehicle to check whether the chain is skewed as a whole 2. Rotate the rear wheel by hand and observe whether the rotation of the rear wheel is smooth 3. -
Page 37: Check And Adjust The Chain Tension
ZHEJIANG KAYO MOTOR CO., LTD. CHECK AND ADJUST THE CHAIN TENSION The chain can transfer the output-power from the engine to the wheels, so that the motorcycle can move normally. It is an important part of the motorcycle. Therefore, the chain needs frequent inspection and maintenance to ensure its normal use. -
Page 38: Check The Structure Of The Rear Sprocket, Engine Sprocket And Guide Chain
ZHEJIANG KAYO MOTOR CO., LTD. sprocket, rear sprocket and the chain, please contact KAYO dealer for a thorough inspection to avoid safety problems. CHECK THE STRUCTURE OF THE REAR SPROCKET, ENGINE SPROCKET AND GUIDE CHAIN Chain guide Check the worn condition of the chain guide and the chain protector on the rear fork. -
Page 39: Check The Steering Handle
ZHEJIANG KAYO MOTOR CO., LTD. Checking Steps are as follows: 1 Turn the throttle knob to observe whether the throttle rebounds properly. 2 Start the engine, observe the engine power changing when turn the head from side to side, if there is any difference, it indicates that the throttle line is too short. -
Page 40: Check And Maintenance The Brake System
ZHEJIANG KAYO MOTOR CO., LTD. CHECK AND MAINTENANCE THE BRAKE SYSTEM CHECK THE FREE-PLAY OF FRONT BRAKE LEVER Checking steps as below: 1. Rest your right hand on the right hand grip naturally 2. Use the index finger and middle finger of your right hand to check the free play. -
Page 41: Check The Disc Brake
2.5mm 3.5mm CHECK THE FRONT BRAKE LIQUID LEVEL KT250 uses hydraulic disc brakes, and you can check the liquid level through the observation hole. If the liquid level is lower than the bottom edge of the observation hole, you should immediately refuel the fluid to the upper edge. -
Page 42: Refuel The Front Brake Liquid Level
ZHEJIANG KAYO MOTOR CO., LTD. REFUEL THE FRONT BRAKE LIQUID LEVEL You should check/refuel the liquid level regularly. If the brake fluid is mixed with water, soil or other particles, the brake fluid should also be replaced. It is recommended to use DOT4 brake fluid. -
Page 43: Check The Rear Brake Disk Liquid Level
ZHEJIANG KAYO MOTOR CO., LTD. In normal use,the free-play of the brake pedal is shown in the table below. Check the brake lever and pay attention to whether the stroke is correct. Model Free-Play KT250 45～60mm CHECK THE REAR BRAKE DISK LIQUID LEVEL Check the Liquid level through the Observing Hole. -
Page 44: Check The Rear Brake Pads
ZHEJIANG KAYO MOTOR CO., LTD. Refueling Steps are as follows: 1. Remove the screw. 2. Remove the cap. 3. Refuel brake fluid to a proper level. 4. Re-load the cap. It is recommended to use DOT4 brake fluid. CHECK THE REAR BRAKE PADS... -
Page 45: Tire Inspection And Maintenance
ZHEJIANG KAYO MOTOR CO., LTD. TIRE INSPECTION AND MAINTENANCE REMOVING OR INSTALLING THE FRONT WHEEL Removing Steps are as follows: Lift the motorcycle off the ground and Stabilize it by using a motorcycle stand. Remove front disc brake cover if have, ... -
Page 46: Tire Inspection
ZHEJIANG KAYO MOTOR CO., LTD. Removing Steps are as follows: Remove the chain. Loosen the rear wheel axle bolts Holding the rear wheel with one hand, withdraw the rear wheel axle gradually with another hand Remove the rear wheel... -
Page 47: Electrical System
ZHEJIANG KAYO MOTOR CO., LTD. Use your fingers to move the adjacent spokes to check whether the tire spokes lack tension. If you find that the spokes are loose and weak, you must check all the spokes and both wheels. -
Page 48: Changing The Battery
ZHEJIANG KAYO MOTOR CO., LTD. Removing Steps are as follows: 1. Removing the passenger seat 2. Disconnect cable from the battery 3. Remove the screw on battery holder 4. Pull the battery up and out. Installing Steps: The installment should be carried out in the reverse order of removal. -
Page 49: Cooling System
ZHEJIANG KAYO MOTOR CO., LTD. COOLING SYSTEM COOLING SYSTEM PROFILE - 49 - www.kayomoto.com... -
Page 50: Removing Or Installing The Cowling And Hose
ZHEJIANG KAYO MOTOR CO., LTD. The excess heat can be absorbed by antifreeze and be transferred to air through radiator. If the antifreeze in the tank does not match the specified value, it can’t work properly and thereby the motor may be overheated and damaged. -
Page 51: Drain Out The Coolant
ZHEJIANG KAYO MOTOR CO., LTD. Stop and stand the motorcycle upright on a horizontal surface. Release the tank cap and let the hot steam spill out. Then open the cap to complete the disassembly. Sway the motorcycle from side to side and then check the antifreeze level, which should be between Min and Max. -
Page 52: Introducing About The Engine Structure
ZHEJIANG KAYO MOTOR CO., LTD. You should change the coolant regularly to increase service lift. Main work: Drain out the coolant. → p.50 Mount the screw after draining the coolant completely. Fill in a little of coolant through water tank. -
Page 53: Installing The Engine
2. COOLING SYSTEM KT250 uses coolant to cool the engine. The coolant enters the engine from the water tank through the water pipe, takes away the heat of the engine, flows back to the water tank, and then exchanges heat with the air. -
Page 54: Compression Pressure Check
ZHEJIANG KAYO MOTOR CO., LTD. Reinstall the valve cover, magneto plug and timing plug. NOTE: The valve clearance should be checked and adjusted when the engine is cold. COMPRESSION PRESSURE CHECK The inspection is carried out for the first 1000km and every 5000km. -
Page 55: The Engine Adjustment
2. Turn off the fuel tank switch 3. Unscrew the drain bolt of the carburetor and wait for the fuel to flow out 4. After the fuel is drained, screw the drain bolt back KT250 carburetor oil drain bolt - 55 - www.kayomoto.com... -
Page 56: Check The Shift Lever Position
ZHEJIANG KAYO MOTOR CO., LTD. CHECK THE SHIFT LEVER POSITION The inspection steps are as follows: 1. Raise the whole vehicle so that the center plane of the tire is perpendicular to the ground 2. The line of sight is level with the tread surface, and observe the position of the shift head 3. -
Page 57: Lubricant Selection
ZHEJIANG KAYO MOTOR CO., LTD. ENGINE LUBRICATION SYSTEM LUBRICANT SELECTION Lubricating oil is an important factor affecting engine performance and life. It must be selected according to regulations. It is forbidden to substitute ordinary engine oil, gear oil, vegetable oil, etc. -
Page 58: Lubricant Replacement
The lubrication of the heat engine part of the KT250 model engine must be a special two-stroke engine oil by mixing gasoline into a special burning oil. Adjust the opening of the oil pump according to the throttle to mix a proper proportion of the burning oil. -
Page 59: Oil Pump Inspection
ZHEJIANG KAYO MOTOR CO., LTD. OIL PUMP INSPECTION After the oil pump is installed, the oil pump needs to be drained and filled. As shown in the figure on the left, insert the nozzle of the oil can into the output pipe of the oil pump, remove the oil cap, and then fill the oil. -
Page 60: Engine Tightening Torque Table
ZHEJIANG KAYO MOTOR CO., LTD. ENGINE TIGHTENING TORQUE TABLE The engine tightening torque table is as follows: Applicable parts TORQUE VALUE 20～24N•m Spark Plug M10 Cylinder Head Cover 22～26N•m Nut M8 Cylinder Block 28～32N•m Fastening Nut M8 Primary Driving Gear 65～75N•m... -
Page 61: Troubleshooting
ZHEJIANG KAYO MOTOR CO., LTD. TROUBLESHOOTING If the engine wants to be operated normally, it should meet the following four requirements: 1. Good fuel: There is a certain ratio of combustible mixture in the cylinder. 2. Good spark: The spark plug can emit a strong spark at the specified time. - Page 62 ZHEJIANG KAYO MOTOR CO., LTD. Cylinder head gasket is broken Improper valve timing The choke door is opened too much The engine ignites but Improper adjustment does not start of the carburetor Re-start the engine fine-tuning screw Air intake pipe leaks...
- Page 63 ZHEJIANG KAYO MOTOR CO., LTD. The spark plug cap is faulty Good spark plug The power circuit is faulty The ignition controller is faulty Incorrect Improper valve Check the ignition clearance adjustment timing and valve The magneto is faulty clearance...
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Page 64: Selection And Ratio Of Engine Oil
ZHEJIANG KAYO MOTOR CO., LTD. abnormal noise sprocket wear Timing chain stretched The timing chain automatic tensioner fails, or the guide wheel is worn Gear machining accuracy is not enough The gear teeth are Check whether the worn Abnormal noise in the... -
Page 65: Motorcycle Cleaning
Regarding the choice of engine oil, KAYO recommends you choose TORCO GP-7 fully synthetic engine oil (Exceeds JASO-FC, ISO-L-EGD, API-TC) as the one for KT250 models. A bottle of that will be sent with the corresponding model. (Actually, This implementation will be operated according to the relevant regulations of the country where the customer.) -
Page 66: Storage
ZHEJIANG KAYO MOTOR CO., LTD. STORAGE PREPARING FOR LONG STORAGE If you want to garage the motorcycle for a longer period, take the following steps. 1. Block the exhaust port of the muffler tube. 2. Remove the battery 3. Clean the motorcycle 4. -
Page 67: Maintenance Points
ZHEJIANG KAYO MOTOR CO., LTD. MAINTENANCE POINTS In the following content, we will enumerate the problems that occurred during your use, find out the possible causes and give general solutions. Problems Reason Solution Crank stuck Contact KAYO Service Center The crank of the engine... - Page 68 ZHEJIANG KAYO MOTOR CO., LTD. depress the start lever several times after the flame is turned off. Step on it for a few times, the water in the cylinder will be drained from the exhaust pipe, and then use a fan to blow on the mouth of the oil dipstick for a few minutes.
- Page 69 ZHEJIANG KAYO MOTOR CO., LTD. Damaged worn crankshaft Contact KAYO Service Center bearings Problem with ignition Contact KAYO Service Center Engine sound is abnormal overheat See "Engine Overheating" section Carbon deposits in the combustion Contact KAYO Service Center chamber Poor gasoline...
- Page 70 ZHEJIANG KAYO MOTOR CO., LTD. Worn damaged steering Check the steering bearing and bearings replace if necessary Bent steering shaft Contact KAYO Service Center Lower the front fork oil level to a Fork oil level is too high suitable position...
- Page 71 ZHEJIANG KAYO MOTOR CO., LTD. Check the spokes and adjust the The vehicle is not aligned spoke tension if necessary Steering shaft tolerance is too Check the steering shaft pressure large bearing clearance The steering shaft nut is loose, and...
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Page 72: Tightening Torque Table For The Whole Vehicle
ZHEJIANG KAYO MOTOR CO., LTD. TIGHTENING TORQUE TABLE FOR THE WHOLE VEHICLE NOTE: Before installing the thread, apply anti-rust grease on the thread and the joint surface ITEM DESCRIPTION QUANTITY TORQUE（NM） Front brake caliper mounting M8×40 full thread 20～32 bolt Front brake guard mounting M6×16... - Page 73 ZHEJIANG KAYO MOTOR CO., LTD. High voltage package M6×20 7～11 mounting bolt Plastic mounting bolts M6×16 full thread 7～11 Igniter mounting bolt M6×16 full thread 7～11 Voltage stabilizer mounting M6×25 full thread 7～11 bolt Electric door lock bracket bolt M6×12 7～11...