KAYO MOTOR TT 125 Manuals

Manuals and User Guides for KAYO MOTOR TT 125. We have 1 KAYO MOTOR TT 125 manual available for free PDF download: Service Manual

KAYO MOTOR TT 125 Service Manual (74 pages)

Brand: KAYO MOTOR | Category: Motorcycle | Size: 9.66 MB

Table of Contents
4
Meaning of Symbols and Technical Terms
7
Suggestions for Daily Use
8
Parts and Position
9
21 TT 125 Parts and Position
9
Steel Chassis
10
VIN and Engine Number
10
VIN Number
10
Engine Number
11
Specification
11
Manipulation
12
Front Disc Brake
12
Throttle
13
Ignition
13
Stall
13
Fuel Tank Switch
13
Gear Shifting
14
Rear Disc Brake
14
Parking Stand
14
Notes before Use
15
Suggestions for First-Time Users
15
Running-In Process
15
Riding Guide
16
Checking Items before Riding
16
Notes When Ignition
17
Notes When Starting
17
Notes When Cornering
17
Notes When Acceleration
17
Notes When Gear Shifting
17
Notes When Braking
17
Notes When Parking
17
Maintenance Periodic Table
17
Suspension System Setup
19
Check the Compression and Rebound of the Motorcycle When Riding
19
Measure Distance from Center of Rear Wheel to Rear Fender in Suspension
19
Measure Distance from Center of Rear Wheel to Rear Fender under no Load
19
Measure Distance from Center of Rear Wheel to Rear Fender in Riding Condition
20
Adjust the Spring Preload of the Rear Shock
20
Check the Setup of the Front Shock
21
Adjust Handlebar
21
Maintenance
21
Placement of Motorcycle
21
Disassembly and Assembly of Front Shock Protector
22
Disassembly and Assembly of Front Disc Brake
22
Disassembly and Assembly of Front Shock
22
Disassembly and Assembly of Clamp
23
Check the Head Steering
23
Lubrication and Installation of Steering Head Bearing
23
Disassembly and Assembly of Front Fender
24
Disassembly and Assembly of Rear Shock
24
Disassembly and Assembly of Seat
24
Disassembly and Assembly of Air Filter
25
Cleaning and Maintenance of Air Filters
25
Disassembly and Assembly of Exhaust Pipe
25
Disassembly and Assembly of Muffler
25
Disassembly and Assembly of Fuel Tank
26
Check the Chain and Clean
26
Disassembly and Assembly of the Chain
26
Check and Adjust the Chain Tension
26
Inspect Rear Sprocket, Engine Sprocket and Chain Guide Structure
27
Inspection of the Frame
27
Inspection of the Swing Arm
27
Inspection of the Throttle Cable
28
Inspection of the Handle Bar
28
Check and Maintain the Brake System
28
Check the Free Stroke of the Front Brake Handle
28
Inspection of the Disc Brake
28
Check the Fluid Level of Front Brake Disc
29
Refill the Front Brake Disc Fluid Oil
29
Inspection of the Disc Brake
29
Check the Free Movement of the Foot Brake
30
Check the Rear Disc Brake Fluid Level
30
Refill Rear Disc Brake Fluid
30
Tire Inspection and Maintenance
31
Removal and Installation of Front Wheel
31
Removal and Installation of Rear Wheel
32
Check the Outside Surface of the Tire
32
Check Tire Pressure
32
Check the Wheel Spokes
32
Engine Installation
33
Engine Maintenance and Adjustment
33
Inspection of Bolts and Nuts of Cylinder and Cylinder Body
33
Check Valve Clearance
34
Inspection of Compression Pressure
34
Adjustment of Clutch Control System
34
Adjustment Around the Engine
35
Idle Speed Adjustment of Carburetor
35
Clean the Carburetor
35
Check Shift Lever Position
35
Adjust the Position of the Shift Lever
35
Check and Replace Spark Plug
36
Lubrication System of Engines
36
Selection of Lubrication Oil
36
Lubricating Oil Inspection
37
Lubricating Oil Replacement
37
Engine Repair
37
Cylinder and Valves
37
Main Parameters and Maintenance Standards of Cylinder Parts
37
Fault Symptom and Cause Analysis
38
Removal of Left Cover of Cylinder Head
38
Timing Check
39
Removal of Valve Cover
39
Check Valve Clearance
40
Removal of Cylinder Head
40
Disassembly of Cylinder Head
40
Inspection of Valves and Valve Springs
41
Inspection of Rocker Arm and Rocker Arm Shaft
41
Inspection of Camshaft Components
42
Inspection of Cylinder Head
42
Check and Grind Valve Seats
42
Inspection of Valve Guide
42
Replacement of Valve Guide
43
Measure Width of Valve Seat Contact Area
43
Assembly of Cylinder Head
43
Installation of Cylinder Head
44
Cylinder Block and Piston
45
Main Parameters and Maintenance Standards of Cylinder Block and Piston
45
Fault Symptom and Cause Analysis
46
Inspection of Cylinder Block
46
Removal of Piston and Piston Ring
47
Inspection of Piston and Piston Ring
47
Installation of Piston Ring
48
Installation of Piston
48
Installation of Cylinder Block
48
Clutch, Driving Gear, Driven Gear, Oil Pump, Shifting Mechanism
49
Main Parameters and Maintenance Standards
49
Fault Symptom and Cause Analysis
49
Removal of Right Trim Cover
50
Adjustment of Clutch Stroke
50
Removal of Right Crankcase Cover
50
Clutch Disassembly
50
Disassembly of Driving and Driven Gears
51
Removal of Engine Oil Pump
51
Disassemble Shift Mechanism
51
Inspection of Right Crankcase Cover
52
Inspection of Driving and Driven Tooth
52
Check the Oil Pump
53
Check Shift Mechanism
53
Assembly of Shift Mechanism
53
Assembly of Oil Pump
53
Assembly of Driving and Driven Teeth
54
Clutch Assembly
54
Installation of Clutch
54
Assembly of Right Crankcase Cover
55
Right Trim Cover for Installation
55
Magneto, Timing Chain
56
Removal of Left Rear Cover
56
Removal of Left Front Cover
56
Removal of Magneto Stator
56
Removal of Magneto Rotor
56
Removal of Starting Motor and Starting Sprocket
57
Removal of Transition Plate
57
Removal of Timing Chain
57
Removal of Tensioning Arm, Tensioning Rod and Tensioning Roller
58
Inspection of Left Front Cover and Left Back Cover
58
Transition Plate, Starting Motor, Starting Sprocket Inspection
58
Magneto Stator, Rotor Inspection
58
Installation of Tensioning Arm, Tensioning Rod and Tensioning Roller
59
Transition Plate Installation
60
Installation of Starting Motor and Starting Sprocket
60
Installation of Magneto Stator
60
Installation of Magneto Rotor
61
Installation of Left Cover
61
Crankcase, Crankshaft, Main and Auxiliary Shafts and Speed Drum
61
Main Parameters and Maintenance Standards
61
Fault Symptom and Cause Analysis
61
Decomposition of Crankcase
62
Disassembly of Crankshaft, Main and Auxiliary Shaft
62
Decomposition of Variable Speed Drum
62
Inspection of Crankshaft
62
Left and Right Crankshaft Box Bearing Inspection
63
Check Shift Fork, Fork Shaft and Shift Drum
63
Check the Combination of Main and Auxiliary Shafts
63
Inspection of Starting Shaft
64
Assembly of Variable Speed Drum
64
Installation of Variable Speed Drum, Main and Auxiliary Shaft, Crankshaft and Starting Shaft
64
Installation of Crankcase
64
Engine Troubleshooting
66
Motorcycle Cleaning
68
Storage of Motorcycles
69
The Preparation of the Motorcycle before Long Unused
69
The Main Points of Maintenance
70
Vehicle Tightening Torque Meter
74

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KAYO MOTOR TT 125 Service Manual (74 pages)

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