KAYO MOTOR T2 Service Manual
  1. Manuals
  2. Brands
  3. KAYO MOTOR Manuals
  4. Motorcycle
  5. T2
  6. Service manual

KAYO MOTOR T2 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

ZHEJIANG KAYO MOTOR CO., LTD.
KAYO MOTO
T2
SERVICE MANUAL
W W W . K A Y OMOTO.US
www.kayomoto.us

Advertisement

Table of Contents
loading

Related Manuals for KAYO MOTOR T2

Summary of Contents for KAYO MOTOR T2

  • Page 1 ZHEJIANG KAYO MOTOR CO., LTD. KAYO MOTO SERVICE MANUAL W W W . K A Y OMOTO.US www.kayomoto.us...

  • Page 2: Preface

    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.

  • Page 3: Table Of Contents

    ZHEJIANG KAYO MOTOR CO., LTD. Notification and Warning This service manual is edited by KAYO Manufacturer reserves the right to improve and update this manual, model’s structure, and spare parts without notice. The images in this manual may differ from the actual model.
  • Page 4 ZHEJIANG KAYO MOTOR CO., LTD. Specific settings and methods…………………………………………………………………………....39 Electric parts inspection…………………………………………..40 Electric parts inspection and replacement…………………………………………………………………..41 Vehicle troubleshooting……………………………………………..50 Possible failures and troubleshooting methods……………………………………………………………..51 Engine maintenance manual………………………………………..55 Main performance parameters…………………………………………………………………………………..56 Use and Maintenance…………………………………………………………………………………………...57 Engine failure checklist……………………………………................61 - 3 - www.kayomoto.us...

  • Page 5: Vehicle Profile

    ZHEJIANG KAYO MOTOR CO., LTD. Vehicle profile Vehicle component and location……………………………………………8 VIN number………………………………………………………………..12 Specification……………………………………………………………..13 Circuit diagram…………………………………………………………..15 Fasteners torque table……………………………………………………..17 - 4 - www.kayomoto.us...

  • Page 6: Vehicle Component And Location

    ZHEJIANG KAYO MOTOR CO., LTD. Vehicle component and location ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Name Name Front fender Front brake caliper Headlight Front fork Handlebar Fuel tank Vent pipe...
  • Page 7 ZHEJIANG KAYO MOTOR CO., LTD. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Name Name Rear fender U-shape rocker arm/linkage Muffler Triangle rocker arm/rear linkage Seat Rear brake oil cup Rear shock Brake pedal Rear brake disc...
  • Page 8 ZHEJIANG KAYO MOTOR CO., LTD. Vehicle component and location ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Name Name Front fender Front brake caliper Headlight Front fork Handlebar Fuel tank Vent pipe...
  • Page 9 ZHEJIANG KAYO MOTOR CO., LTD. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Name Name Rear fender U-shape rocker arm Muffler Triangle rocker arm Seat Rear brake oil cup Rear shock Brake pedal Rear brake disc Muffler pipe...

  • Page 10: Vin Number

    ZHEJIANG KAYO MOTOR CO., LTD. VIN number ○ ○ ○ ① VIN number Located on frame plate ② Frame plate Located on frame head tube ③ Engine number Located on engine crankcase body - 9 - www.kayomoto.us...

  • Page 11: Specification

    ZHEJIANG KAYO MOTOR CO., LTD. Specification T2（CB250）size and quality parameters Length × width × height 2195×820×1240 （mm） wheelbase（mm） 1436 weight（kg） Tyre spec. Front 80/100-21；rear 110/90-18 steering angle Minimum turning circle diameter 925mm Seat height（mm） Ground clearance（mm） 335mm Fuel tank capacity（L）...
  • Page 12 ZHEJIANG KAYO MOTOR CO., LTD. Frame/shock absorber/braking/wheel parameters Frame type High strength steel tube frame Front shock Inverted adjustable front shock，L=880mm double adjustable nitrogen charged shock with reservoir，L=430mm Rear shock absorber Rear swing arm Aluminum Aluminum alloy tapered handlebar，material 7075 Φ28.6mm handlebar Front &...

  • Page 13: Circuit Diagram

    ZHEJIANG KAYO MOTOR CO., LTD. Circuit diagram - 12 - www.kayomoto.us...
  • Page 14 ZHEJIANG KAYO MOTOR CO., LTD. T2-G - 13 - www.kayomoto.us...

  • Page 15: Fasteners Torque Table

    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...

  • Page 16: Operation Instructions

    ZHEJIANG KAYO MOTOR CO., LTD. OPERATION INSTRUCTIONS ………………………………………………………19 Check before riding Starting steps ……………………………………………………………...22 Vehicle run in……………………………………………………....24 Vehicle cleaning ……………………………………………………..24 Storage and use of vehicles................25 - 15 - www.kayomoto.us...

  • Page 17: Check Before Riding

    ZHEJIANG KAYO MOTOR CO., LTD. Check before riding Tank cap 1.Fuel level 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 18 ZHEJIANG KAYO MOTOR CO., LTD. 4.Brake system brake fluid levels 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 19 ZHEJIANG KAYO MOTOR CO., LTD. brake disc’s abrasion of brake system 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.

  • Page 20: Starting Steps

    ZHEJIANG KAYO MOTOR CO., LTD. chain adjuster 10.Inspection of the remaining components Visually inspect the entire motorcycle for loose parts. Tighten any loose bolt or parts . Check the battery charge. check the lights. Note: these pre ride checks won't take much time, but it can help you develop good riding habits and make your daily riding easier and safer.
  • Page 21 ZHEJIANG KAYO MOTOR CO., LTD. - 20 - www.kayomoto.us...

  • Page 22: Vehicle Run In

    ZHEJIANG KAYO MOTOR CO., LTD. Vehicle run in 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.

  • Page 23: Storage And Use Of Vehicles

    ZHEJIANG KAYO MOTOR CO., LTD. Storage and use of vehicles When you plan to store your vehicle for long periods of non-use, follow these steps: 1. Block the exhaust pipe; 2. Thoroughly clean the motorcycle; 3. Wait for the motorcycle to air dry naturally;...

  • Page 24: Routine Maintenance

    ZHEJIANG KAYO MOTOR CO., LTD. Routine maintenance Maintenance periodic table…………………………………………………27 Specific maintenance content……………………………………………….28 - 23 - www.kayomoto.us...

  • Page 25: Maintenance Periodic Table

    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 ●...

  • Page 26: Specific Maintenance Content

    ZHEJIANG KAYO MOTOR CO., LTD. Service Center to avoid damage to the engine. Specific maintenance content 1.Clutch handle The clutch handle can be adjusted according to your actual needs: By adjusting the nut, the pull of clutch lever can be changed.
  • Page 27 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. Danger: The air filter should be cleaned regularly to prevent dust or dirt from entering the engine, which may cause engine wear or even damage.
  • Page 28 ZHEJIANG KAYO MOTOR CO., LTD. cable is normal before driving the motorcycle. 7. Engine oil Lubricating oil is a very important part of normal engine operation. Insufficient lubricant, deterioration or pollution can cause engine wear and damage. Oil level check If the motorcycle has just been used, wait for a few minutes after the engine has stopped to check;...
  • Page 29 ZHEJIANG KAYO MOTOR CO., LTD. 9.Cylinder, cylinder head and exhaust valve For the inspection, adjustment and replacement of this item, please refer to the engine maintenance manual for details. 10. Exhaust system inspection Exhaust pipe and muffler can guide gas emission and reduce noise.
  • Page 30 ZHEJIANG KAYO MOTOR CO., LTD. this happens, please check the brake system immediately and contact KAYO dealer. caliper brake pads 14.Brake system wear inspection Check the thickness of the front and rear brake caliper brake pads. The 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 31 ZHEJIANG KAYO MOTOR CO., LTD. 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. Note: Do not allow the brake fluid to splash on the painted surface, which may cause corrosion.
  • Page 32 ZHEJIANG KAYO MOTOR CO., LTD. Before each ride, please check whether the gas lines are normal. If you find any shrinkage or rupture of the gas lines, please replace the fuel hose immediately to avoid leaks. DANGER: Riding a motorcycle with a broken hose may cause a fire by starting the engine, so if you find a problem with the fuel hose, do not start your motorcycle.
  • Page 33 ZHEJIANG KAYO MOTOR CO., LTD. 21.Fuel system inspection Make sure fuel tank, fuel tank cap, switch etc. has no leaks before driving. 22.Steering column adjustment Steering column should be checked and adjusted frequently. Place the motorcycle on stand with the front fork completely suspended.
  • Page 34 ZHEJIANG KAYO MOTOR CO., LTD. 24.Rear shock inspection The T2 model is equipped with non-adjustable nitrogen charged rear shock.. Check the rear shock, see the seals and reservoir condition and spring for damage. Replace the shock if necessary. Please follow the following steps to disassemble the rear shock ...
  • Page 35 ZHEJIANG KAYO MOTOR CO., LTD. 26.Wheel inspection Two aspects： thread：check the height, if shorter than min height, replace it. Min thread height 3 mm。 Tire pressure：use barometer test tire pressure. Recommend tire pressure: front 2.23bar；rear 2.77 bar。 27.Battery inspection Remove seat, use multimeter to test the positive and negative voltage and current output.

  • Page 36: Vehicle Settings

    ZHEJIANG KAYO MOTOR CO., LTD. Vehicle settings Specific settings and methods…………………………………………39 - 35 - www.kayomoto.us...

  • Page 37: Specific Settings And Methods

    Throttle screw Air screw Two way transmission ratio setup Two way transmission ratio can adjusted by changing sprocket teeth. KAYO model T2 rear and front sprocket teeth： Rear sprocket：45T Front sprocket：13T Note: Consult dealer before replace sprocket. note： adjust or replace chain based on actual condition. Worn or excessively tight chain will wear out sprockets and may cause accident.

  • Page 38: Electric Parts Inspection

    ZHEJIANG KAYO MOTOR CO., LTD. Electric parts inspection Electric parts inspection and replacement…………………………………41 - 37 - www.kayomoto.us...

  • Page 39: Electric Parts Inspection And Replacement

    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 40 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 41 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 42 ZHEJIANG KAYO MOTOR CO., LTD. Front turn light inspection replacement Left turn light Right turn light Disassembly 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 43 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 44 ZHEJIANG KAYO MOTOR CO., LTD. Inspection and replacement of taillights Disassembly The taillights are removed as below: Disconnect the taillight from the main cable Remove taillight mounting nut Remove tail lights Inspection brown green yellow/green ● ● stoplight ● ●...
  • Page 45 ZHEJIANG KAYO MOTOR CO., LTD. Check and replace relays Disassembly The relay is removed as below: Remove Removal of seat cushion Removal of the rear right upper and lower panels Disconnect relay from main cable Remove relay relay Inspection Start the car, if the car can be started normally, the relay is normal;...
  • Page 46 ZHEJIANG KAYO MOTOR CO., LTD. Inspection and replacement of igniter Disassembly he igniter is removed as below: Remove seat cushion Remove air filter cover Disconnect igniter from main cable Remove igniter Inspection Start the vehicle, if can be started normally, the igniter is normal;...
  • Page 47 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 Take out the sensor Inspection Check whether the sensor is normal through the instrument, if the sensor is damaged, replace the sensor.

  • Page 48: Vehicle Troubleshooting

    ZHEJIANG KAYO MOTOR CO., LTD. Vehicle Troubleshooting Possible failures and troubleshooting methods……………………………51 - 47 - www.kayomoto.us...

  • Page 49: Possible Failures And Troubleshooting Methods

    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 50 ZHEJIANG KAYO MOTOR CO., LTD. will stall filter duct immediately Lack of fuel supplementary fuel Uneven engine Dirt on spark plugs, damage or Remove spark plug for cleaning, adjustment and replacement operation adjustment error if necessary Problem with spark plug...
  • Page 51 ZHEJIANG KAYO MOTOR CO., LTD. Shift drum damaged Replace the shift drum Fork shaft worn Check the fork shaft and replace if necessary Speed selector position spring Replace it damaged clutch slip clutch disc worn Replace it Too soft or damaged clutch...
  • Page 52 ZHEJIANG KAYO MOTOR CO., LTD. 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 Excessive steering shaft Check steering shaft pressure bearing clearance...

  • Page 53: Engine Maintenance Manual

    ZHEJIANG KAYO MOTOR CO., LTD. Engine maintenance manual Main performance parameters..............56 Use and Maintenance................57 Engine failure checklist................61 - 52 - www.kayomoto.us...

  • Page 54: Main Performance Parameters

    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 /7000（1±5%）rpm b.max torque/speed：17.5（1±5%）N·m /5500（1±5%）rpm c. Idling speed： 1400（1±10%） r /min d. min fuel-consume ratio： 354 g / kw.h Structure parameters： a. Bore*stroke:65.5×66.2mm b.

  • Page 55: Use And Maintenance

    ZHEJIANG KAYO MOTOR CO., LTD. Use and Maintenance Clutch lever The steps for non-neutral starting the engine are as follows： Pinch the clutch lever so that the clutch is completely detached； Open the choke； Gently operate throttle to start； Choke Speed up after waiting engine running for 1-3 mins.
  • Page 56 ZHEJIANG KAYO MOTOR CO., LTD. After starting it in cooling condition, you should increase the engine rotate speed gradually after 1-3 mins running, and do not add the load while cooling. As for totally new engine, its inner components like piston, piston rign need to be run in. It is very important to deal with run-in correctly, if not, there’ll be more engine faults.
  • Page 57 ZHEJIANG KAYO MOTOR CO., LTD. to specified idle speed. 6. Repeat the procedure of 3,4,5, until the idle screw is tightened or relaxed and the rotate speed does not decrease. Now the idle adjustment is completed. - 56 - www.kayomoto.us...
  • Page 58 ZHEJIANG KAYO MOTOR CO., LTD. The clutch starts in neutral, but the idle gear stops running, it is necessary to tighten the clutch adjustment screw properly. When the car is difficult to start when the idle speed is refueling, it is necessary to clutch adjustment screw loosen the clutch adjustment screw properly.

  • Page 59: Engine Failure Checklist

    ZHEJIANG KAYO MOTOR CO., LTD. Engine failure checklist 1、Difficult or unable to start Fault clues fault cause elimination methods operation Improper operation Required operation The tank has run out of fuel Add fuel tank switch or carburetor is blocked Dredge fuel line...
  • Page 60 ZHEJIANG KAYO MOTOR CO., LTD. Adjust float chamber fuel level to specified Float chamber fuel level is too low height The throttle spring of carburetor has too little Replace spring Idle speed is tension too high Too much idle clearance...
  • Page 61 ZHEJIANG KAYO MOTOR CO., LTD. jammed Repair after identification Other machinery jammed replace Clutch failure 6． Clues Failure cause troubleshooting Improper adjustment or damage Adjust, repair or replace of clutch control system Clutch slip replace Friction plate is worn or damaged...

Table of Contents