KAYO MOTOR K2 Dirt Bike Manuals

Manuals and User Guides for KAYO MOTOR K2 Dirt Bike. We have 1 KAYO MOTOR K2 Dirt Bike manual available for free PDF download: Service Manual

KAYO MOTOR K2 Service Manual (77 pages)

Brand: KAYO MOTOR | Category: Motorcycle | Size: 3.9 MB

Table of Contents
4
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
14
The Vehicle Parameter
15
Important Fastener Specifications
16
The Vehicle Control
18
Clutch Lever Inspection
18
Front Brake Lever Inspection
18
Throttle Knob
19
Start
19
Extinguish
19
Fuel Tank Switch
20
Shift Check
20
Inspection of Rear Disc Brake
21
Parking Support
21
Precautions before Use
21
Advice for Beginners
22
The Running-In Process
22
Drive Guide
23
Check Items before Driving
23
Precautions for Ignition
23
Precautions for Start
24
Precautions for Turning
24
Precautions for Acceleration
24
Precautions for Shift Gears
24
Precautions for Brake
24
Precautions for Stop & Park
24
Suggested Inspection Time for All Parts of the Vehicle
25
Suspension System
26
Check the Vehicle's Compression and Rebound（With Rider
26
Measure the Distance from the Center of the Rear Wheel to the Rear Fender in Suspension
26
Measure Distance from Center of Rear Wheel to Rear Fender under no Load
27
Measure Distance from Center of Rear Wheel to Rear Fender in Driving Condition
27
Adjustment for the Spring Preload of Rear Shock Absorber
28
Check for the Setting of Front Shock Absorber
28
Adjustment for the Handlebar
28
Disassembly and Inspection of Vehicle Parts
29
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
31
Disassembly,Installation and Lubrication of Steering Head Bearing
31
Removal and Installation of Front Fender
32
Removal and Installation of Rear Shock Absorber
32
Removal and Installation of Seat Cushion
33
Removal and Installation of Air Filter
33
Cleaning and Maintenance of Air Filter
33
Removal and Installation of Exhaust Pipe
34
Removal and Installation of Muffler
34
Removal and Installation of Fuel Tank
35
Check the Chain and Clean It
35
Removal and Installation of Chain
36
Check and Adjustment of Chain Tension
36
Inspection of Rear Sprocket, Engine Sprocket and Chain Guide Structure
37
Inspection of the Frame
37
Inspection of the Swing Arm
37
Inspection of Throttle Cable
38
Inspection of Handlebar
38
Check and Maintain of Brake System
38
Check the Free Stroke of the Front Brake Lever
38
Adjust the Stroke of the Front Brake Lever
39
Check the Brake Disc
39
Check the Front Brake Fluid Level
39
Add the Front Brake Fluid
40
Check the Front Brake Pads
40
Check the Free Stroke of the Foot Brake
41
Check the Rear Disc Brake Fluid Level
41
Replenish the Rear Disc Brake Fluid
42
Check the Rear Brake Pads
42
Tire Inspection and Maintenance
43
Removal and Installation of Front Wheels
43
Removal and Installation of Rear Wheels
43
Check the Outside Surface of the Tire
44
Check the Tire Pressure
44
Check the Rim and Spokes
44
Electrical System
45
Battery Removal and Installation
45
Replace the Battery
45
Engine Installation
46
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
49
Inspection of Valves and Valve Springs
49
Inspection of Camshaft Parts
50
Inspection of Cylinder Head
50
Inspection and Grinding of Valve Seat
51
Inspection of Valve Guide
51
Assembly of the Cylinder Head
51
Installation of the Cylinder Head
52
Valve Clearance Adjustment
52
Cylinder and Piston
53
Precaution
53
Troubleshooting
53
Disassembly of the Cylinder Block
54
Cylinder Block Inspection
54
Disassembly of Piston and Piston Ring
55
Inspection of Pistons and Piston Rings
55
Piston Ring Installation
56
Piston Installation
56
Installation of the Cylinder Block
57
Right Cover, Clutch, Starting Mechanism, Shifting Mechanism
57
Precautions
57
Main Parameters and Maintenance Standards
57
Troubleshooting
58
Removal of Right Crankcase Cover
58
Disassembly of the Clutch
59
Removal of the Right Body Oil Pump
59
Removal of the Gearshift Mechanism
59
Inspection of Right Crankcase Cover
60
Inspection of the Clutch
60
Inspection of Active Teeth
61
Oil Pump Inspection
61
Shifter Inspection
61
Assembly of the Gearshift Mechanism
61
Assembly of the Right Body Oil Pump
62
Assembly of the Drive Gear
62
Assembly of the Clutch
62
Assembly of the Right Crankcase Cover
62
Left Cover, Double Gear, Magneto
63
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
64
Magneto Inspection
64
Start the Inspection of the Platter Teeth
64
Inspection of Starter Motor and Double Gear
64
Start the Assembly of Large Plate Teeth and Magneto
64
Assembly of Double Gear (Two)
65
Installation of Magneto Stator
65
Installation of the Left Crankcase Cover
65
Assembly of Double Gear (1)
66
Assembly of the Starter Motor
66
Crankcase, Transmission
66
Precautions
66
Main Parameters and Maintenance Standards
66
Troubleshooting
67
Crankcase Removal
67
Removal of Crankshaft, Main and Auxiliary Shafts
68
Crankshaft Inspection
68
Inspection of Left and Right Crankcase Bearings
68
Inspection of Shift Fork, Shift Fork Shaft, Shift Drum
69
Inspection of Main and Auxiliary Shaft Combinations
69
Checking the Oil Filter
69
Assembly of Main and Auxiliary Shafts and Crankshaft
70
Assembly of Closing Box and Oil Filter
70
Assembly of Double Gear (Two)
70
Motorcycle Cleaning
71
Storage
71
Maintenance Points
72

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