KAYO MOTOR K2 Service Manual
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KAYO MOTOR K2 Service Manual

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ZHEJIANG KAYO MOTOR CO., LTD.
KAYO MOTO
K2
Service Manual
WWW.KAYOMOTO.COM
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Summary of Contents for KAYO MOTOR K2

  • Page 1 ZHEJIANG KAYO MOTOR CO., LTD. KAYO MOTO Service Manual WWW.KAYOMOTO.COM...
  • Page 2 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 be different from the real model.
  • Page 3 ZHEJIANG KAYO MOTOR CO., LTD. Preface Hereby, on behalf of KAYO all staff thank you for choosing our dirt bike: K2, and we believe that this choice will not disappoint you. This manual is designed to help you better use our products, and it introduces the...

  • Page 4: Table Of Contents

    ZHEJIANG KAYO MOTOR CO., LTD. Content Symbols and Meanings of Special Words ......................... 8 Suggestions for Daily Use ............................. 9 Operation notes ................................10 Precautions for safety ..............................10 Precautions for disassembly and assembly......................10 Vehicle components and location ..........................12 VIN Code and Engine Number ............................
  • Page 5 ZHEJIANG KAYO MOTOR CO., LTD. Placement ................................. 29 Disassembly and installation of front shock absorber guard plate ..............29 Disassembly and installation of front disc brake ....................30 Disassembly and installation of front shock absorber ..................30 Disassembly and installation of clamps ........................ 31 Check the head steering ............................
  • Page 6 ZHEJIANG KAYO MOTOR CO., LTD. Engine inspection and maintenance ........................47 Cylinder head part ..............................47 Main parameters and maintenance standards of cylinder head parts ............. 47 Troubleshooting................................47 Removal of the left cylinder head cover ........................48 Removal of cylinder head ............................48 Decomposition of cylinder head ..........................
  • Page 7 ZHEJIANG KAYO MOTOR CO., LTD. Precautions ................................. 63 Removal of starter motor ............................63 Disassembly of the double gear (1) ..........................63 Removal of left crankcase cover ..........................63 Disassembly of the magneto stator ..........................63 Disassembly of the magneto rotor ..........................63 Inspection of Left Crankcase Cover and Duplex Gear Cover ..................

  • Page 8: Symbols And Meanings Of Special Words

    ZHEJIANG KAYO MOTOR CO., LTD. Symbols and Meanings of Special Words * This symbol indicates that this operation requires the operator to have professional knowledge and technical understanding. If you do not have the confidence to complete this operation, you can go to a professional repair shop or KAYO after-sale service point to be operated by professionals.

  • Page 9: Suggestions For Daily Use

    Our K2 product are specially designed for off-road and woodland crossing, so they are not suitable for highway riding or long-distance motorcycling. If you insist on using them, the tires may accelerate the wear of the pattern due to high speed rotation and reduce the service life .It is also not suitable for urban use, as prolonged periods at traffic lights may...

  • Page 10: Operation Notes

    ZHEJIANG KAYO MOTOR CO., LTD. Operation notes Precautions for safety 1. You must wear work clothes (covered overalls, etc.), hats, and safety boots that are suitable for the job. If necessary, you should also wear dust-proof glasses, dust-proof masks, gloves and other safety protection products to protect your body.
  • Page 11 ZHEJIANG KAYO MOTOR CO., LTD. on the moving surface before assembling. 7. When disassembling, check the necessary places and measure relevant data so that it can be restored to the state before disassembly during assembly. 8. Fasteners such as bolts, nuts, and screws must be pre-tightened first, and then tightened on the diagonal according to the specified tightening torque according to the principle of from large to small, from inside to outside.

  • Page 12: Vehicle Components And Location

    21. Do not twist or bend the cable too much. Deformed and damaged cables can cause malfunction or breakage. 22. When assembling protective cap parts, if there is a groove, the protective cap must be inserted into the groove. Vehicle components and location K2 specific components and locations 11 12 Name Name Front fender...
  • Page 13 ZHEJIANG KAYO MOTOR CO., LTD. Name Name Rear fender Rear brake caliper Exhaust pipe muffler Steel swingarm Seat Rear brake pump Rear shock Brake pedal Upper clamp Muffler Lower clamp Front brake disc Rear brake disc...

  • Page 14: Vin Code And Engine Number

    ZHEJIANG KAYO MOTOR CO., LTD. VIN Code and Engine Number VIN Code The VIN Code of the K2 is located on the nameplate of the front extension tube. Engine Number The engine number of the K2 is located on the...

  • Page 15: The Vehicle Parameter

    ZHEJIANG KAYO MOTOR CO., LTD. The Vehicle Parameter Vehicle Dimensions and Mass Parameter L*W*H（mm） 2010×840×1160 L*W*H（mm） 1340 Net weight（kg） Tire size F：80/100-21；R：110/90-18 Seat height（mm） Tank volume（L） Engine Parameters Engine type Single cylinder, four stroke, Air-cooled, 4 Valves Clutch type Wet type, Multiple disk Cylinder diameter×stroke 65.5×66.2mm...

  • Page 16: Important Fastener Specifications

    ZHEJIANG KAYO MOTOR CO., LTD. Important fastener specifications Item Fastener specifications Quantity Front brake caliper mounting Outer hexagon small head flange bolt M8×40 full thread Steering column nut Aluminum silver M26×1 Upper pressure block Hexagon socket cap screws mounting screws M8×110...
  • Page 17 ZHEJIANG KAYO MOTOR CO., LTD. Rear sprocket mounting Socket cap screw screws M8×31 10.9S Hexagon flange self-locking nuts Rear sprocket fastening nut M10×1.25 Hexagon flange self-locking nuts Rear axle nut M14×1.5 Rear brake pump mounting Hexagon socket head M6×20 bolt...

  • Page 18: The Vehicle Control

    Which located at the right end of the handlebar, and operated by the right hand. The angle between the brake lever and the handlebar of K2 model can be adjusted according to the needs of customers. For details, see "Adjusting the Stroke of the Front Brake lever".

  • Page 19: Throttle Knob

    ZHEJIANG KAYO MOTOR CO., LTD. Throttle knob The throttle knob is located on the right side of the handlebar and is controlled by turning with the right hand. When the handle is turned counterclockwise, increase the throttle, release the handle and return it to the position.

  • Page 20: Fuel Tank Switch

    "RES" symbol indicates that the reserve oil is enabled. Shift check The K2 shift lever is located on the left side of the engine, and the shift operation is performed by stepping on and hooking up the shift lever.

  • Page 21: Inspection Of Rear Disc Brake

    Parking support K2 use a single support for parking support. The single support is located on the left side of the whole vehicle. When in use, the vehicle is centered and the single support is kicked to expand it.

  • Page 22: Advice For Beginners

    ZHEJIANG KAYO MOTOR CO., LTD. Advice for beginners 1.Please read this manual before driving, especially the "The Vehicle Control" and "Drive Guide" sections. 2.Please carry out a standard run-in when driving. 3.If any part problem is found during use, please refer to this manual for repair or contact KAYO dealer.

  • Page 23: Drive Guide

    3、Hold the ignition switch with your right finger. 4、The engine starts to work, loosen the ignition switch, and the start of the vehicle is over Note：Before starting the engine for K2 models, turn the fuel tank switch to the "ON" position.

  • Page 24: Precautions For Start

    ZHEJIANG KAYO MOTOR CO., LTD. Precautions for start 1、An inspection should be carried out before starting, including the state of the vehicle and the driver’s dress. 2、When starting, the motorcycle should not go too fast. 3、To ensure safety, please use the first gear to start driving for a certain distance before shifting gears.

  • Page 25: 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 ride 1 hour after each ride ● ● ● Check and charge the battery ● ●...

  • Page 26: Suspension System

    The total standard rider mass of the K2 off-road motorcycle is shown in the table below. 65～75kg If the rider's weight is above or below the standard range, the basic setting of these sections must be adjusted accordingly.

  • Page 27: Measure Distance From Center Of Rear Wheel To Rear Fender Under No Load

    4. The driver uses single stand to support the vehicle and leave the seat 5. Calculate the difference between "A1" and "A2" and denote it as "D2". The value of "D2" when K2 leave the factory is shown below MODEL 90～100mm If "D2"...

  • Page 28: Adjustment For The Spring Preload Of Rear Shock Absorber

    ZHEJIANG KAYO MOTOR CO., LTD. higher than the factory value, the spring preload can be adjusted higher; If "D2" is far less than the factory value, it is necessary to replace the spring with a lower hardness; If "D2" is much greater than the factory value, it is necessary to replace the spring with a greater hardness.

  • Page 29: Disassembly And Inspection Of Vehicle Parts

    3. Remove the front shock absorber guard plate 4. Installation shall be carried out in the reverse order of disassembly Note: when removing the front shock absorber guard plate of K2, the front wheel should be removed first, otherwise the screws on the inside...

  • Page 30: Disassembly And Installation Of Front Disc Brake

    4, Remove the front disc brake 6. Installation shall be carried out in the reverse order of disassembly Note: For K2 model, disc brake cover should be removed first. Disassembly and installation of front shock absorber The steps of the front shock absorber are as...

  • Page 31: Disassembly And Installation Of Clamps

    ZHEJIANG KAYO MOTOR CO., LTD. Disassembly and installation of clamps The disassembly and installation steps of the clamps are as follows: 1. Remove the front shock absorber 2, remove the turning column lock nut 3. Remove the upper clamp 4. Remove the adjusting nut of the turning column 5.

  • Page 32: Removal And Installation Of Front Fender

    ZHEJIANG KAYO MOTOR CO., LTD. When installing the steering bearing of the vehicle head, apply a layer of lithium-based grease on the surface of the roller. Refer to the figure on the left for specific installation. Removal and installation of front fender...

  • Page 33: Removal And Installation Of Seat Cushion

    ZHEJIANG KAYO MOTOR CO., LTD.  When installing the rear shock, proceed in the reverse order of removal. Removal and installation of seat cushion The removal and installation steps of the seat cushion are as follows: 1. Remove the fixing bolt on both sides of the rear seat.

  • Page 34: Removal And Installation Of Exhaust Pipe

    ZHEJIANG KAYO MOTOR CO., LTD. the dust on the sponge is really difficult to handle, you can also replace the new air filter sponge. 3. Clean the surface of the air filter sponge support, let it dry naturally, and then apply a layer of oil on the surface 4.

  • Page 35: Removal And Installation Of Fuel Tank

    ZHEJIANG KAYO MOTOR CO., LTD. Removal and installation of fuel tank Removal and installation of fuel tank are as follows: 1. Remove the seat cushion 2. Remove the front left and right guard plates 3. Unscrew the fuel tank installation screws 4.

  • Page 36: Removal And Installation Of Chain

    ZHEJIANG KAYO MOTOR CO., LTD. Removal and installation of chain The removal and installation steps of the chain are as follows: 1. Remove the spring on the chain 2. Remove the movable section of the chain 3. Pull out the chain from below the sprocket 4.

  • Page 37: Inspection Of Rear Sprocket, Engine Sprocket And Chain Guide Structure

    ZHEJIANG KAYO MOTOR CO., LTD. quickly reach the limit of use and have to be replaced. Therefore, even from an economic point of view, it is worthwhile to replace the entire chain drive system at the same time. Replacement parts should use KAYO original factory production or authorized products.

  • Page 38: Inspection Of Throttle Cable

    ZHEJIANG KAYO MOTOR CO., LTD. Inspection of throttle cable The method of checking the throttle cable is as follows: 1. Turn the throttle lever to feel whether the throttle rebounds smoothly 2. Start the motorcycle engine, turn the front of the...

  • Page 39: Adjust The Stroke Of The Front Brake Lever

    ZHEJIANG KAYO MOTOR CO., LTD. Adjust the stroke of the front brake lever front brake lever： The front brake lever can be adjusted to suit the operating habits of different people. The adjustment steps are as follows: satisfied with; Danger: Please test the brake system (including front brake and rear brake) every time the motorcycle starts.

  • Page 40: Add The Front Brake Fluid

    ZHEJIANG KAYO MOTOR CO., LTD. K2 model use hydraulic disc brakes, and the brake fluid level of the disc brakes can be checked through the observation hole. If the liquid level is lower than the lower edge of the observation hole, you should immediately add brake fluid to the upper edge of the observation hole.

  • Page 41: Check The Free Stroke Of The Foot Brake

    ZHEJIANG KAYO MOTOR CO., LTD. Check the free stroke of the foot brake Rear brake pedal： Normally, the free stroke of the brake pedal is shown in the table below. Check the brake pedal and pay attention to whether the stroke is correct.

  • Page 42: Replenish The Rear Disc Brake Fluid

    ZHEJIANG KAYO MOTOR CO., LTD. Replenish the rear disc brake fluid The steps for replenishing rear brake fluid are as follows: 1. Remove the cup cover screw; 2. Remove the cover of the cup; 3. Add brake fluid to a suitable position;...

  • Page 43: Tire Inspection And Maintenance

    ZHEJIANG KAYO MOTOR CO., LTD. Tire inspection and maintenance Removal and installation of front wheels The front wheels can be dismantled in the following order: Put the whole car on the stool and let it hang in the air. Remove the front brake disc guard (if there is no guard, skip this step).

  • Page 44: Check The Outside Surface Of The Tire

    ZHEJIANG KAYO MOTOR CO., LTD. Check the outside surface of the tire The inspection steps for the outer surface of the tire are as follows: 1. Check whether there are scratches, holes or foreign matter attached to the outer surface of the tire;...

  • Page 45: Electrical System

    ZHEJIANG KAYO MOTOR CO., LTD. spokes Electrical system Battery removal and installation The steps for removing K2 battery are as follows: 1. Remove the seat cushion 2. Disconnect the battery from the main cable 3. Remove the screws of the battery fixing bracket 4.

  • Page 46: Engine Installation

    ZHEJIANG KAYO MOTOR CO., LTD. Engine installation The installation steps of the engine are as follows: ⑴ Hang the engine on the frame (pay attention to protect the appearance of the engine); ⑵ Install the throttle body/carburetor to the intake elbow and fasten it with nuts and bolts;...

  • Page 47: Engine Inspection And Maintenance

    ZHEJIANG KAYO MOTOR CO., LTD. Engine inspection and maintenance Cylinder head part Precautions 1. The camshaft journal is lubricated by the oil passage on the cylinder head. No foreign matter can enter the oil passage. The camshaft bearing rotates flexibly without jamming. The pressure reducing valve sling rotates flexibly and can return normally, otherwise it will easily cause engine damage.;...

  • Page 48: Removal Of The Left Cylinder Head Cover

    ZHEJIANG KAYO MOTOR CO., LTD. Cracks or blisters in the cylinder head Piston ring clearance is too large or broken Piston is cracked or excessively worn Excessive cylinder inner diameter or blisters Valve guide wear Leaking or damaged oil baffle...

  • Page 49: Decomposition Of Cylinder Head

    ZHEJIANG KAYO MOTOR CO., LTD. Cylinder head and cylinder block connecting bolt Decomposition of cylinder head 1. Remove the camshaft limit bolt; 2. Remove the mandrel bolts of the tension plate, and remove the tension plate; 3. Remove the valve rocker arm shaft and valve rocker arm assembly;...

  • Page 50: Inspection Of Camshaft Parts

    ZHEJIANG KAYO MOTOR CO., LTD. Inspection of camshaft parts 1. Check whether the camshaft peach tip and base circle are worn out, and whether the camshaft bearing rotates flexibly. If the camshaft is worn out or the bearing is spinning, new camshaft parts should be replaced;...

  • Page 51: Inspection And Grinding Of Valve Seat

    ZHEJIANG KAYO MOTOR CO., LTD. Inspection and grinding of valve seat Completely remove the carbon deposits in the combustion chamber, apply a thin layer of red stamping oil evenly on the valve seat, place the valve on the valve seat and knock the valve lightly without rotating, and then pull out the valve.

  • Page 52: Installation Of The Cylinder Head

    ZHEJIANG KAYO MOTOR CO., LTD. with bolts; bolt torque: (8~12) N.m; 8. Check the air tightness of the assembled cylinder head assembly. If there is no leakage of the cylinder head assembly, proceed to the next step. Installation of the cylinder head 1.

  • Page 53: Cylinder And Piston

    ZHEJIANG KAYO MOTOR CO., LTD. Cylinder and Piston Precaution: ◆The lubricating oil of the cylinder head goes to the cylinder head through the oil hole beside the AB bolt on the right body of the engine. Before installing the cylinder block, make sure that the oil hole beside the AB bolt on the left body is unblocked, otherwise the engine will be damaged easily;...

  • Page 54: Disassembly Of The Cylinder Block

    ZHEJIANG KAYO MOTOR CO., LTD. Abnormal wear of cylinder block, piston or piston ring Black smoke emission Incorrectly installed piston ring Scratches or scrapes on piston or cylinder walls Engine overheats Too much carbon deposit in piston Piston or cylinder block is worn...

  • Page 55: Disassembly Of Piston And Piston Ring

    ZHEJIANG KAYO MOTOR CO., LTD. Disassembly of piston and piston ring 1. Remove the piston pin retaining ring with needle nose pliers; 2. Remove the piston pin; 3. Remove the piston; 4. Remove the piston ring. Note: Do not drop the retaining ring into the...

  • Page 56: Piston Ring Installation

    ZHEJIANG KAYO MOTOR CO., LTD. Piston Ring Installation 1. Clean the piston ring groove; 2. Install the piston ring; Notice: (1) During installation, the piston and piston ring should be prevented from being damaged; (2) When installing the piston ring, the first...

  • Page 57: Installation Of The Cylinder Block

    ZHEJIANG KAYO MOTOR CO., LTD. Installation of the cylinder block 1. Install cylinder block positioning pins and new cylinder block gaskets; 2. Apply lubricating oil evenly on the surface of cylinder block, piston and piston ring; 3. Assemble the cylinder block in place;...

  • Page 58: Troubleshooting

    ZHEJIANG KAYO MOTOR CO., LTD. Troubleshooting Faults Possible causes Remark Not enough free travel Clutch slips when Clutch release spring force accelerating attenuation clutch disc wear Clutch cable stuck, damaged or Too much pressure on dirty the handle Lifting mechanism damaged...

  • Page 59: Disassembly Of The Clutch

    ZHEJIANG KAYO MOTOR CO., LTD. Disassembly of the clutch 1. Remove the oil filter parts; 2. Remove the clutch lever and bearing; 3. Remove the clutch collar; Remove clutch center sleeve assembly; 5. Take out the clutch cover. Removal of the right body oil pump 1.

  • Page 60: Inspection Of Right Crankcase Cover

    ZHEJIANG KAYO MOTOR CO., LTD. positioning plate combination. Five-star board Inspection of Right Crankcase Cover 1. Check whether the crankshaft oil seal of the right crankcase cover is damaged. If the oil seal is found to be broken, it needs to be replaced with a new oil seal;...

  • Page 61: Inspection Of Active Teeth

    ZHEJIANG KAYO MOTOR CO., LTD. Inspection of active teeth Check whether the driving teeth are worn or damaged. If the wear and damage are serious, the driving teeth need to be replaced with new ones. Oil pump inspection 1. Check whether the inner and outer rotors of the oil pump are worn or damaged.

  • Page 62: Assembly Of The Right Body Oil Pump

    ZHEJIANG KAYO MOTOR CO., LTD. Assembly of the right body oil pump 1. First install the O-ring of the oil pump on the box; 2. Install the oil pump parts into the holes of the right box body; fasten the oil pump with 2 GB819.1 screws M6×30;...

  • Page 63: Left Cover, Double Gear, Magneto

    ZHEJIANG KAYO MOTOR CO., LTD. Left cover, double gear, magneto Precautions ◆The removal and installation of the magneto, the left cover and the double gear introduced in this section can be completed only by removing the left crankcase cover without removing the engine;...

  • Page 64: Inspection Of Left Crankcase Cover And Duplex Gear Cover

    ZHEJIANG KAYO MOTOR CO., LTD. Notice: 1. When disassembling the magneto rotor, it can only be disassembled with special tools, and it is not allowed to knock the magneto rotor; 2. The magneto rotor is accidentally impacted during the disassembly and assembly process.

  • Page 65: Assembly Of Double Gear (Two)

    ZHEJIANG KAYO MOTOR CO., LTD. starting gear; 2. Before installing the starter gear, check whether the pot-shaped tooth washer is missing. Assembly of double gear (two) 1. Install the double gear washer on the end face of the double gear;...

  • Page 66: Assembly Of Double Gear (1)

    ZHEJIANG KAYO MOTOR CO., LTD. Assembly of double gear (1) 1. Install the double gear washer on the end face of the double gear; 2. Install the double gear assembly (1) into the double gear hole of the left cover.

  • Page 67: Troubleshooting

    ZHEJIANG KAYO MOTOR CO., LTD. Inner diameter φ12~φ12.018 φ12.025 of main shaft Claw thickness 4.925~5 External φ11.966~φ11.984 φ11.95 diameter of fork Change shaft fork shaft cylindricity 0.01 Inner diameter φ16.010~φ16.018 φ16.025 of connecting Crankshaft rod small end connecting Backlash at the...

  • Page 68: Removal Of Crankshaft, Main And Auxiliary Shafts

    ZHEJIANG KAYO MOTOR CO., LTD. pins; 5. Separate the left crankcase body from the right crankcase body, and remove the left case body. Removal of crankshaft, main and auxiliary shafts 1. Take out the crankshaft assembly from the box; 2. Take out the shift fork shaft, shift fork, shift...

  • Page 69: Inspection Of Shift Fork, Shift Fork Shaft, Shift Drum

    ZHEJIANG KAYO MOTOR CO., LTD. Inspection of shift fork, shift fork shaft, shift drum Check each shift fork for wear, bending or any other malfunction, measure the inner diameter of the shift fork Main shaft fork maintenance limit: φ12.025 Maintenance limit value of countershaft fork: φ12.025 mm...

  • Page 70: Assembly Of Main And Auxiliary Shafts And Crankshaft

    ZHEJIANG KAYO MOTOR CO., LTD. Assembly of main and auxiliary shafts and crankshaft 1. Install the crankshaft into the corresponding hole of the left body; 2. Install the main and auxiliary shaft components into the corresponding holes of the left body, and then assemble the shift fork to the corresponding position.

  • Page 71: Motorcycle Cleaning

    ZHEJIANG KAYO MOTOR CO., LTD. MOTORCYCLE CLEANING The cleaning of the vehicle is also an important part of the daily use and maintenance of the motorcycle. Frequent cleaning of your motorcycle can keep your car in a good state of motion and prolong its service life.

  • Page 72: Maintenance Points

    ZHEJIANG KAYO MOTOR CO., LTD. 8. Cover the motorcycle to prevent dust and dirt. 9. Move the motorcycle into a dry room and place NOTE: When applying anti-rust oil, please do not splash the oil on the brake and rubber parts, otherwise the rubber may be aged.
  • Page 73 ZHEJIANG KAYO MOTOR CO., LTD. fuel has deteriorated Clean or dry the spark plug, if Dirt or wet spark plug necessary, replace the spark plug First, drain the mixed fuel out the engine and remove the crankcase of the engine, clean it with a...
  • Page 74 ZHEJIANG KAYO MOTOR CO., LTD. engine Close the choke valve, clean the started, but it will stop Incorrect air supply fuel tank vent pipe, and adjust the immediately air filter duct Lack of fuel Add fuel Engine overheated Use low-pressure water to clean...
  • Page 75 ZHEJIANG KAYO MOTOR CO., LTD. exhaust pipe The combustible mixture is Adjust the carburetor valve too rich Contact KAYO Service Center Clutch abnormality The fork is bent or stuck Check and adjust the fork Gearbox gear does not Damaged gear lever...
  • Page 76 ZHEJIANG KAYO MOTOR CO., LTD. driving rear sprockets Wear of rear sprocket teeth Replace the sprocket Follow the manual to lubricate the Insufficient chain lubrication chain Check the spokes and adjust the Rear wheel off center spoke tension centrally necessary...
  • Page 77 ZHEJIANG KAYO MOTOR CO., LTD. minimum friction thickness, replace the brake pads...

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