KAYO MOTOR K4 Service Manual
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KAYO MOTOR K4 Service Manual

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ZHEJIANG KAYO MOTOR CO., LTD.
KAYO MOTO
K4
Service Manual
WWW.KAYOMOTO.COM
- 1 -
www.kayomoto.us

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  • Page 1 ZHEJIANG KAYO MOTOR CO., LTD. KAYO MOTO Service Manual WWW.KAYOMOTO.COM - 1 - www.kayomoto.us...
  • 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: K4, 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 ZHEJIANG KAYO MOTOR CO., LTD. March, 2021 Content - 4 - www.kayomoto.com...
  • Page 5 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 6 Our K4 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 7: 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 8 ZHEJIANG KAYO MOTOR CO., LTD. agent should be blown off with compressed air before the measurement. Apply lubricating oil 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.
  • Page 9 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 K4 specific components and locations Name Name Front fender Front brake caliper...
  • Page 10 ZHEJIANG KAYO MOTOR CO., LTD. Air filter cover Chain guide Chain guide cover Rear sprocket Name Name Rear fender swingarm Exhaust pipe muffler Triangle rocker arm Seat U-shape rocker arm Rear shock Rear brake pump body Upper clamp Brake pedal...
  • Page 11 ZHEJIANG KAYO MOTOR CO., LTD. VIN Code and Engine Number VIN Code The VIN Code of the K4 is located on the nameplate of the front extension tube. Engine Number The engine number of the K4 is located on the...
  • Page 12 ZHEJIANG KAYO MOTOR CO., LTD. Tank volume（L） Engine Parameters Engine type Single cylinder, four stroke, Air-cooled, 4 Valves Clutch type Wet type, Multiple disk Cylinder diameter×stroke 72×61.4mm Displacement 249.9 Max. Power（kw/r/min） 15/8500 Max. Torque（N•m/r/min） 18/6500 Compression Ratio 9.25：1 Usually engaged two - stage transmission five - speed...
  • Page 13 ZHEJIANG KAYO MOTOR CO., LTD. Important fastener specifications Item Fastener specifications Quantity Front brake caliper Outer hexagon small head mounting bolt flange M8×45 half thread Steering column nut Aluminum silver M25×1×H9 Upper pressure block Hexagon socket head M8×25 mounting screws...
  • Page 14 The angle of the K4 clutch lever can be adjusted according to the wishes of customers. By adjusting the screw, the angle between the clutch lever and the handlebar can be changed.
  • Page 15 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 K4 model can be adjusted according to the needs of customers. For details, see "Adjusting the Stroke of the Front Brake lever".
  • Page 16 Long press it to turn off the engine. Fuel Tank Pump/Fuel Tank Switch The K4 carburetor version adjusts the fuel supply through the fuel tank switch, which is located at the bottom of the left side of the fuel tank. By rotating the switch, you can control whether the fuel enters the carburetor, so as to achieve the control effect.
  • Page 17 "RES" symbol indicates that the reserve oil is enabled. Shift check The K4 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 18: Parking Support

    Parking support K4 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 19 ZHEJIANG KAYO MOTOR CO., LTD. The running-in process Motorcycle engines have a lot of relatively moving parts, such as pistons, piston rings, cylinder blocks, and transmission gears that mesh with each other. Therefore, at the initial stage of use, the engine must be run-in to a standard. The running-in can make the moving parts adapt to each other, correct the working gap, and form a good smooth friction surface that can withstand larger loads.
  • Page 20 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 K4 carburetor models, turn the fuel tank switch to the "ON" position.
  • Page 21 ZHEJIANG KAYO MOTOR CO., LTD. Precautions for shift gears 1、Do not skip gears when shifting gears. 2、Do not increase the throttle when shifting gears. 3、Shifting should not be done in corners. Precautions for brake 1、When braking should be based on the foot brake, hand brake as a supplement.

  • Page 22: Suspension System

    The total standard rider mass of the K4 off-road motorcycle is shown in the table below. - 22 - www.kayomoto.com...
  • Page 23 ZHEJIANG KAYO MOTOR CO., LTD. 75～85kg If the rider's weight is above or below the standard range, the basic setting of these sections must be adjusted accordingly. A small weight difference can be compensated by adjusting the rear shock absorber spring preload, but if the weight difference is large, the spring must be replaced.
  • Page 24 ZHEJIANG KAYO MOTOR CO., LTD. Adjustment for the rebound damping of the rear shock absorber The rebound damping of the rear shock absorber is controlled by an adjusting screw, which can be adjusted with a flat-blade screwdriver. When it is turned counterclockwise, the rebound damping decreases;...
  • Page 25 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 K4 leave the factory is shown below Model 90～100mm If "D2"...
  • Page 26 ZHEJIANG KAYO MOTOR CO., LTD. Adjustment for the spring preload of rear shock absorber lock piece The spring preload of the rear shock absorber controlled adjusting lock piece. Adjust the lock piece to move down, the spring preload increases; Adjust the lock piece to move up, the spring preload is reduced.
  • Page 27 ZHEJIANG KAYO MOTOR CO., LTD. Adjustment for the compression damping of front shock absorber Steps of compression damping adjustment of front shock absorber are as follows: 1, check the front shock absorber, to determine whether the need to adjust the damping 2.
  • Page 28 4. Installation shall be carried out in the reverse order of disassembly Note: when removing the front shock absorber guard plate of K4, the front wheel should be removed first, otherwise the screws on the inside near the tire cannot be removed.
  • Page 29 4, Remove the front disc brake 6. Installation shall be carried out in the reverse order of disassembly Note: For K4 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 30 ZHEJIANG KAYO MOTOR CO., LTD. Disassembly and installation of coupling plate The disassembly and installation steps of the coupling plate are as follows: 1. Remove the front shock absorber 2, remove the directional column lock nut 3. Remove the upper connecting plate 4.
  • Page 31 ZHEJIANG KAYO MOTOR CO., LTD. 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 The disassembly and assembly steps of the front fender are as follows: 1.
  • Page 32 ZHEJIANG KAYO MOTOR CO., LTD. Removal and installation of 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 ZHEJIANG KAYO MOTOR CO., LTD. Removal and installation of air filter The removal and installation steps of air filter are as follows: 1. Remove the side cover of the air filter; 2. Loosen the connection between the air filter hose and the throttle body/carburetor;...
  • Page 34 ZHEJIANG KAYO MOTOR CO., LTD. Removal and installation of exhaust pipe The removal and installation steps of exhaust pipe are as follows: 1. Remove the muffler 2. Remove the fixing bolts of the exhaust pipe 3. Remove the fixing nut at the connection of the engine exhaust pipe 4.
  • Page 35 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 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 ZHEJIANG KAYO MOTOR CO., LTD. 6. Tighten the tensioner nut; 7. Tighten the rear axle nut; 8. Check the point of maximum tension and readjust the tension if necessary. When checking the chain tension, in addition, a visual inspection of the chain guide and sprocket is required.
  • Page 38 ZHEJIANG KAYO MOTOR CO., LTD. Chain protector chain protector should be replaced in time to ensure that the motorcycle works normally. Inspection of the frame Checking steps are as follows: 1. Check whether the paint layer on the surface of the frame is damaged or not.
  • Page 39 ZHEJIANG KAYO MOTOR CO., LTD. Check and maintain of brake system Check the free stroke of the front brake lever The method of checking the stroke of the front brake lever is as follows: 1. Put your right hand on the right hand grip naturally;...
  • Page 40 3.5mm 3.5mm Check the front brake fluid level K4 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...

  • Page 41: Check The Front Brake Pads

    ZHEJIANG KAYO MOTOR CO., LTD. Please do not use the brake fluid in an unsealed container. The brake fluid may deteriorate when exposed to the air, which will affect the braking effect. Do not use used brake fluid. Note: Even if the motorcycle is not used for a long time, the brake fluid should be changed once a year.
  • Page 42 ZHEJIANG KAYO MOTOR CO., LTD. Check the rear disc brake fluid level Observe through the liquid level hole to check the level of brake fluid. The liquid level should exceed half of the observation hole, that is, the liquid level should be higher than "LOWER".
  • Page 43 ZHEJIANG KAYO MOTOR CO., LTD. Check the rear brake pads brake pads check the thickness of the brake pads of the brake caliper, the thickness should not be less than 1 mm. If the thickness of the brake pads is lower than the minimum thickness, the entire set of brake pads should be replaced immediately.
  • Page 44 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: 1. Put the whole car on the stool and let it hang in the air.

  • Page 45: Check The Tire Pressure

    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 46: Electrical System

    KAYO dealer. spokes Electrical system Battery removal and installation The steps for removing K4 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 47: Replace The Battery

    ZHEJIANG KAYO MOTOR CO., LTD. Replace the battery If you find bulging on the surface of the battery or the battery is charged frequently, you need to replace the battery. New batteries need to use KAYO original products or KAYO authorized products.
  • Page 48 ZHEJIANG KAYO MOTOR CO., LTD. Compression Ratio 9.2：1 Max. Power（kw/r/min） 14(1±5%)kW/8500(1±5%)r/min Max. Torque（N•m/r/min） 18(1±5%)N.m/6500(1±5%) r/min Turn on Before top dead center3° Intake closure After bottom dead center46° Valve phase Turn on Before bottom dead center48° exhaust closure After top dead center 8°...

  • Page 49: 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 50 ZHEJIANG KAYO MOTOR CO., LTD. piston, Piston is cracked or excessively worn piston ring Excessive cylinder inner diameter or blisters Valve guide wear Black smoke Leaking or damaged oil baffle exhaust Cylinder head gasket leakage Piston ring clearance is too large...
  • Page 51 ZHEJIANG KAYO MOTOR CO., LTD. NC250 Tension plate bushing GB16674 Small plate bolt M5×25(Blue White Zinc) NC250S Exhaust valve NC250 Cam pressure relief valve reset torsion spring (2#) NC250S Camshaft pressure reducing valve baffle (φ6.5×2×φ25_Blue White Zinc) GB16674 Small plate bolt M6×16(Blue...
  • Page 52 ZHEJIANG KAYO MOTOR CO., LTD. Cylinder head 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 53: Inspection Of Cylinder Head

    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 54: Inspection Of Valve Guide

    ZHEJIANG KAYO MOTOR CO., LTD. exhaust valve seats, and then apply abrasives on the valve seat, and then use the rubber head grinding tool to suck up the valve and grind the valve seat. Inspection of valve guide Use a dial indicator to measure the inner diameter of each valve catheter and make a record.
  • Page 55 ZHEJIANG KAYO MOTOR CO., LTD. ◆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 56: Cylinder Block Inspection

    ZHEJIANG KAYO MOTOR CO., LTD. Disassembly of the cylinder block 1. Remove the cylinder head gasket combination; 2. Remove the positioning pin; 3. Remove the chain guide plate; 4. Remove the cylinder block. Cylinder block inspection 1. Check whether the cylinder block is worn or damaged;...

  • Page 57: Piston Ring Installation

    ZHEJIANG KAYO MOTOR CO., LTD. 1. Measure the outer diameter at a height of 7 mm from the piston skirt Maintenance limit: φ71.94mm; 2. Calculate the cylinder clearance Maintenance limit: 0.07mm; 3. Measure the inner diameter of the piston pin hole Maintenance limit: φ16.015 mm...

  • Page 58: Piston Installation

    ZHEJIANG KAYO MOTOR CO., LTD. piston rings should rotate flexibly. 3. The gap between each ring in the oil ring should be matched with the gap of the spacer ring; when installing the oil ring, the spacer ring should be installed first, and then the side guide rails should be installed.
  • Page 59 ZHEJIANG KAYO MOTOR CO., LTD. Free height of active disc tension spring 34.8~35.8 Active disc keyway width 2.95-3.05 2.85 Clutch Flatness of follower disc 0.14 Cover and friction plate clearance 0.1-0.3 Inner and outer rotor radial clearance 0.06-0.15 oil pump Gap between rotor and cover plate 0.04-0.1...
  • Page 60 ZHEJIANG KAYO MOTOR CO., LTD. 1. Remove the oil filter parts; 2. Remove the clutch lever and bearing; 3. Remove the clutch collar; 4. Remove the clutch center sleeve assembly; 5. Take out the clutch cover. Removal of the right body oil pump 1.

  • Page 61: Oil Pump Inspection

    ZHEJIANG KAYO MOTOR CO., LTD. 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 62 ZHEJIANG KAYO MOTOR CO., LTD. 1. Check whether the inner and outer rotors of the oil pump are worn or damaged. If the wear and damage are serious, you need to replace the new oil pump parts; 2. Check whether the oil pump gear combination is...
  • Page 63 ZHEJIANG KAYO MOTOR CO., LTD. 2. Remove the old right crankcase gasket and install a new gasket; 3. Assemble the right crankcase cover to the box body; 4. And use GB/T16674 small plate bolts to fit into the mounting holes of the right cover and fasten them. Tightening torque: 11～13N m;...
  • Page 64 ZHEJIANG KAYO MOTOR CO., LTD. 1. Check whether the magnetic tile of the magneto stator is cracked or damaged, and if so, replace it with a new magneto rotor. 2. Check whether the magneto rotor is worn or damaged, and if so, replace it with a new one.

  • Page 65: Crankcase, Transmission

    ZHEJIANG KAYO MOTOR CO., LTD. 1. Take 2 locating pins φ10×14 (RoHS) and assemble them into the locating pin holes of the left box; 2. Remove the old gasket and install a new gasket; 3. Assemble the left crankcase cover in place and fasten it with bolts.

  • Page 66: Crankcase Removal

    ZHEJIANG KAYO MOTOR CO., LTD. External diameter of φ11.966~φ11.984 φ11.95 Change fork shaft fork shaft cylindricity 0.01 Inner diameter of connecting rod φ16.010~φ16.018 φ16.025 Crankshaft small end connecting Backlash at the big shaft end of the 0.10~0.3 connecting rod Troubleshooting...

  • Page 67: Crankshaft Inspection

    ZHEJIANG KAYO MOTOR CO., LTD. 1. Take out the crankshaft assembly from the box; 2. Take out the shift fork shaft, shift fork, shift drum and main and auxiliary shaft components from the box. Notice: Make sure that no parts are left behind when taking...

  • Page 68: Checking The Oil Filter

    ZHEJIANG KAYO MOTOR CO., LTD. Service limit: 4.9 mm Inspect gear drum surfaces and grooves for wear or damage Inspection of main and auxiliary shaft combinations Check whether the gears of the main and countershaft assemblies have excessive or abnormal wear, and check whether the collars between the gears are deformed or fallen off.
  • Page 69 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 70 ZHEJIANG KAYO MOTOR CO., LTD. 9. Move the motorcycle into a dry room and place it. NOTE: When applying anti-rust oil, please do not splash the oil on the brake and rubber parts, otherwise the rubber may be aged. PREPARING FOR USE AFTER LONG STORAGE...
  • Page 71 ZHEJIANG KAYO MOTOR CO., LTD. First, drain the mixed fuel out the engine and remove the crankcase of the engine, clean it with a strong cleaning agent, then remove the spark plug, blow it dry with a fan (the machine that inflates the tires), and then wipe the air filter element.
  • Page 72 ZHEJIANG KAYO MOTOR CO., LTD. operation or adjusted incorrectly adjustment, replacement necessary Check the condition of the spark plug cap, check whether the spark plug cap There is a problem with the is in good contact with the cable spark plug cap...
  • Page 73 ZHEJIANG KAYO MOTOR CO., LTD. Tooth wear Check gears and replace if necessary Gear damage Change gear Damaged displacement drum Replace the shift drum groove Check the fork shaft and replace if Worn fork shaft necessary The selector position spring is...
  • Page 74 ZHEJIANG KAYO MOTOR CO., LTD. Damaged cylinder head Contact KAYO Service Center Brackets, nuts, and bolts are not Check and adjust the torque of the tightly fastened corresponding fasteners gasket installed Readjust the gasket and replace if incorrectly, is worn, or is too...

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