KAYO MOTOR T4, Service Manual

Page 1: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us KAYO MOTO T4 SERVICE MANUAL W W W K A Y OMOTO US...

Page 2: ...h this service manual This will increase your motorcycle s lifespan Notification and Warning This service manual is edited by KAYO Manufacturer reserves the right to improve and update this manual mod...

Page 3: ...ing 4 Warranty info 4 Vehicle profile 7 Vehicle component and location 8 VIN number 10 Specifications 11 Circuit diagram 15 Fasteners torque table 16 Operation instruction 18 Check before riding 19 St...

Page 4: ...ric parts inspection 37 Electric parts inspection and replacement 38 Vehicle troubleshooting 47 Possible failures and troubleshooting methods 48 Engine maintenance manual 52 Main performance parameter...

Page 5: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 5 Vehicle profile Vehicle component and location 8 VIN number 10 Specification 11 Circuit diagram 15 Fasteners torque table 16...

Page 6: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 6 Vehicle component and location No Name No Name 1 Front fender 10 Front brake caliper 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17...

Page 7: ...w kayomoto us 7 2 Headlight 11 Front fork 3 Handlebar 12 Fuel tank 4 Vent pipe 13 Carburetor 5 Fuel tank cap 14 Gear shift lever 6 Fuel tank petcock 15 Pedal 7 Air filter 16 Chain 8 Chain slider 17 Ch...

Page 8: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 8 No Name No Name 18 Rear fender 24 U shape rocker arm 18 19 20 21 22 23 24 25 26 27 28...

Page 9: ...cker arm 20 Seat 26 Rear brake master cylinder 21 Rear shock 27 Brake pedal 22 Rear brake disc 28 Muffler pipe 23 Rear brake caliper VIN number VIN number Located on frame plate Frame plate Located on...

Page 10: ...learance mm 335 Fuel tank capacity L 10 engine parameter Engine type Single cylinder four stroke air cooled vertical Clutch type Wet multi plate Cylinder diameter stroke 65 5 66 2mm method of lubricat...

Page 11: ...ssion recovery double adjustable nitrogen charged shock L 450mm Rear swing arm Aluminum swingarm L 570mm handlebar Aluminum alloy tapered handlebar material 7075 28 6mm Front rear rim Front 1 60 21 re...

Page 12: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 12 Circuit diagram...

Page 13: ...heel axle mounting nut M16 1 5 H14 1 175 218 7 Footpedal seat mounting bolt M8 20 full thread 2 20 32 8 shift lever mounting bolt M6 25 1 7 11 9 Engine hanger bolt M8 60 3 20 32 10 Engine mounting nut...

Page 14: ...hread 2 7 11 27 brake pedal bolt M6 25 full thread 1 7 11 28 Ignition coil mounting bolt M6 20 2 7 11 29 Plastics mounting bolt M6 16 full thread 10 7 11 30 CDI mounting bolt M6 16 full thread 2 7 11...

Page 15: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 15 OPERATION INSTRUCTIONS Check before riding 19 Starting steps 21 Vehicle run in 23 Vehicle cleaning 23 Storage and use of vehicles 24...

Page 16: ...fuel tank switch is open If the fuel tank switch is OFF there is no fuel in the carburetor and the engine cannot run If fuel is low in the tank switch the tank to the RES position and refuel immediate...

Page 17: ...age or wear If any please replace Check the master cylinder calipers for damage or wear if any please replace Note Do not leave brake reservoirs open for extended periods of time Note Always use brake...

Page 18: ...pressure level is in specification Recommended pressure front 2 23 bar 2 23 kgf cm2 rear 2 77bar 2 77 kgf cm2 Note the tire pressure check should be done under cool conditions Riding with over or unde...

Page 19: ...r needs to vent When the ambient temperature is high the gas in the shock absorber is heated and expands At this time it is necessary to exhaust the gas through the exhaust screw at the front and the...

Page 20: ...tank to the ON position 2 turn the key switch on 3 the left hand pull in clutch lever 4 the right hand pull in front brake lever 5 push the start button 6 once then engine starts make sure you are in...

Page 21: ...Avoid rapid acceleration and deceleration 2 4 5 7h stage work under 50 75 throttle at this time the motorcycle can run at the same throttle for longer times While running the throttle can reach 100 bu...

Page 22: ...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 4 Start the engine for about 5 minutes...

Page 23: ...his may cause rubber parts to deteriorate After the motorcycle is stored for a long time please follow these steps before putting it into use 1 Remove the obstruction in the exhaust pipe 2 Tighten the...

Page 24: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 24 Routine maintenance Maintenance Periodic Table 26 Specific maintenance content 27...

Page 25: ...ge runout Check spoke tension Check the chain rear sprocket engine sprocket chain guide and chain stopper Checking chain tension Oil all moving parts such as chains handles etc and check for smooth op...

Page 26: ...djustment does not change the internal structure of the clutch so it will not affect the normal use of the clutch Note The clamping force of the clutch handle should not be adjusted too much otherwise...

Page 27: ...een the electrodes If the spark plug contains oil or carbon clean with a wire brush or similar Measure the distance between the electrodes with a measuring instrument and adjust it to prevent abnormal...

Page 28: ...ly to prevent dust or dirt from entering the engine which may cause engine wear or even damage Filters should be cleaned in a well ventilated area and ensure that there are no sparks flames or strong...

Page 29: ...th a damaged throttle cable is undoubtedly a very dangerous behavior A normal throttle cable should have a free travel of at least 10mm Start the engine and turn the handlebar left and right If the en...

Page 30: ...ed to be changed regularly to ensure the life of the engine The replacement steps are as follows Start the engine and let it run for 5 minutes to mix any sediment with the oil Stop the engine and plac...

Page 31: ...guide gas emission and reduce noise If the exhaust pipe is rusted or damaged due to impacts please replace it with a new one immediately If the noise is too high or the engine performance is reduced...

Page 32: ...dle The front brake lever can be adjusted to suit the operating habits of different groups of people Rear brake pedal Under normal circumstances the brake pedal should have a free travel of 20 to 30 m...

Page 33: ...hould replace the corresponding parts immediately to avoid causing further damage accident or injury The specific replacement should be performed after consulting the KAYO dealer caliper brake pads Br...

Page 34: ...If the center of the rim is offset some spokes can be stretched which will easily deform or cause the rim to break If the inspection shows that the tire center is slightly off center you can use a ten...

Page 35: ...absorbers whose damping hardness can be adjusted by adjusting screws If you wish to replace the front shock absorber please contact your KAYO dealer This requires relevant professional knowledge and s...

Page 36: ...lower fork gently push and pull the fork if there is a free moving clearance the column is not installed tightly steering column tightness adjustment Fix bike and keep front fork suspended Loosen upp...

Page 37: ...brake pedal bearing Rear brake pedal Gear shift lever Chain Spray with tubing for pressure lubrication Lubricate the throttle cable with grease note After driving on wet roads even if the chain looks...

Page 38: ...e muffler Remove sub frame Remove rear shock and frame mounting bolts Loosen the connection bolt between linkage and swing arm do not remove Remove bolt of rear shock at swing arm Make sure here is no...

Page 39: ...be inspected If the chain is overused or stretch excess 2 replace it If replace different specification chain guide rail and sprocket should be replaced together To keep performance it s better to ch...

Page 40: ...D www kayomoto us 35 28 battery inspection Remove seat use multimeter to test the positive and negative voltage and current output If battery runs low charge it If battery damaged replace it note repl...

Page 41: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 36 Vehicle settings Specific settings and methods 35...

Page 42: ...You can update carburetor to make bikes more suitable Two way transmission ratio setup Two way transmission ratio can adjusted by changing sprocket teeth KAYO T4 rear and front sprocket teeth Rear sp...

Page 43: ...he max speed reduced too but this better for acceleration Low speed is easy to bike control and suitable in rough road If increase transmission ratio the max speed increased too high speed is not good...

Page 44: ...mpression adjusting screw on the top Exhaust screw on the top Rebound adjusting screw on the bottom note when adjust front fork both sides adjusted together or it may cause accident Compression adjust...

Page 45: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 40 Electric parts inspection Electric parts inspection and replacement 38...

Page 46: ...w Remove headlight front panel Dispatch connector between electric lock and main cable Take electric lock off Inspection Check whether the terminals connectors can be conducted as the table shows blac...

Page 47: ...nt Disassembly As bellow Remove headlight front panel Dispatch connector between electric lock and main cable Remove meter fixed screw Remove meter Inspection Open electric lock Check the meter data I...

Page 48: ...ew Disconnect the connector between switch and main cable Remove switch Inspection Check whether the terminals connectors can be conducted as the table shows Conduction is normal headlight switch wiri...

Page 49: ...wiring table yellow red green white eletric turning lights switch wiring table orange grey Light blue horn switch wiring table purple yellow horn If doesn t connected replace switch Installation In re...

Page 50: ...onnector between headlight and main cable connector Take off the headlight Inspection Check whether the terminals of the headlight connector can be conducted as the table shows blue green white brown...

Page 51: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 46 In reverse order of disassembly...

Page 52: ...ect the left and right turn lights from the main cable Inspection Check whether the terminals of the turn lights connector can be conducted as the table shows orange green blue Left turn light Right t...

Page 53: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 48...

Page 54: ...el 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 no...

Page 55: ...and right lights Inspection Check whether the turn signal terminals are on orange green blue Left turning light Right turning light The conduction is normal Replace the corresponding turn signal if i...

Page 56: ...whether the tail lights terminals are on The conduction is normal If the taillight is not on replace the tail light Installation Installation in reverse order of disassembly brown green yellow green...

Page 57: ...spection Check whether the license plate light terminals are on brown green license plate light The conduction is normal If the license plate light is not on replace the license plate light Installati...

Page 58: ...ed normally the relay is normal conversely if other parts are normal the relay needs to be replaced Installation Installation in reverse order of disassembly relay Inspection and replacement of steady...

Page 59: ...ation Installation in reverse order of disassembly steady voltage rectifier Inspection and replacement of igniter Disassembly he igniter is removed as below Remove seat cushion Remove air filter cover...

Page 60: ...oil tank Disconnect the ignition coil from the main cable Remove the ignition coil mounting bolts Take down the ignition coil Inspection Start the vehicle if can be started normally the ignition coil...

Page 61: ...r 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 senso...

Page 62: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 57...

Page 63: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto us 58 Vehicle Troubleshooting Possible failures and troubleshooting methods 48...

Page 64: ...d check the battery Engine can not be started The motorcycle was parked for a long time and the fuel had deteriorated Drain old fuel and inject new fuel The spark plug is wet or dirt Clean or dry spar...

Page 65: ...e air filter duct Open the exhaust valve Check exhaust valve and correct The engine can start but it will stall immediately Incorrect air supply Close the stop valve clean the tank vent and adjust the...

Page 66: ...park plug is in poor condition or in poor specification Replace new spark plugs with correct specifications Exhaust gasket aging Check that the exhaust system is damaged that the gasket is in good con...

Page 67: ...t or damaged clutch disc spring Replace it The clutch is too small Adjust the free travel of clutch Motorcycle hard to turn Cables make turning difficult Moving cables to reduce interference Steering...

Page 68: ...adjustment Re adjust chain tension Chain worn Replace the chain and front and rear sprocket rear sprocket gear worn Replace the rear sprocket Insufficient lubrication of chain Follow the manual to lub...

Page 69: ...and re fasten The motorcycle inclines to one side Chassis bent Contact KAYO Service Centre Improper steering adjustment Check and readjust Steering shaft bent Contact KAYO Service Centre Problems with...

Page 70: ...65 Engine maintenance manual Main performance parameters 53 Structure 53 Engine Installation 54 Engine maintenance and adjustment 54 Disassembly of the engine 57 Torque gauge for engine bolts and nuts...

Page 71: ...1 5 rpm c Idling speed 1500 1 10 r min d min fuel consume ratio 354 g kw h Structure parameters a Cylinder bore stroke 66 5 66 2mm b Displacement 223mL c Compression ratio 9 2 1 d Lubricating system...

Page 72: ...gear 2 063 3 gear 1 450 4 gear 1 130 5 gear 0 957 6 gear 0 815 Starting method Electric Spark type D8EA Fuel and oil Gasoline brand RQ90 Lubrication brand SJ 10W 40 four stroke gasoline engine oil Lub...

Page 73: ...der head cover and lubricate the rocker arm valve valve spring cam surface etc Three way from the right cover to the crank pin through the oil hole on the right end of the crank to lubricate the conne...

Page 74: ...ke turn the magnetomotor rotor until the engraved line on the rotor and the left front cover Until the timing holes are aligned Insert a standard feeler gauge between the valve stem end and the adjust...

Page 75: ...Note Before testing the engine compression pressure make sure that the cylinder head nuts and bolts are tightened according to the specified torque and the valve clearance is adjusted correctly Inspe...

Page 76: ...and let it run at idle speed for 3 5 minutes Turn off the engine wait for about 3 minutes check the oil height through the oil dipstick and check the oil level of the motorcycle horizontally and vert...

Page 77: ...ve with full throttle but under no circumstances should the engine speed exceed 8500r min During the running in period the throttle opening should be changed frequently and the engine should not be al...

Page 78: ...bly of cylinder block and piston Remove the cylinder head seal positioning pin and chain guide plate Remove the cylinder block Remove the piston pin retaining ring piston pin and piston with piston ri...

Page 79: ...chain baffle and timing chain remove the gear display screws and gear display Assembly shall be in the opposite order of disassembly Disassembly and assembly of the right crankcase cover remove the cl...

Page 80: ...head bolts M6 10 15N m 3 Timing sprocket bolts M6 10 15N m 4 Clutch fastening nut 40 50N m 5 Magnetic motor rotor bolts 65 71N m 6 Valve bonnet 12 18N m 7 Box bolts 10 15N m Engine failures and troub...

Page 81: ...e spark plug and test spark The spark is weak or completely sparkless Spark plug failure Spark plug is not clean Electrical ignition malfunction Magnetor failure Spark is good Bad wiring or broken Hig...

Page 82: ...adjustment of valve clearance or poor quality of rocker adjusting screw correct Improper adjustment of timing Check the adjustment of the screw on the plunger of the carburetor incorrect improper adju...

Page 83: ...Block in measuring hole of chemical oil Not blocked Float blocked Filter blocked Check timing of distribution incorrect Adjust timing of air distribution correct Check valve spring pressure Not enough...

Page 84: ...ing chain automatic tensioner failure or guide wheel worn Check if there is abnormal noise from the main and driven gears The main and driven gears have abnormal noise The accuracy of gear machining i...