KAYO MOTOR K4 Service Manual Download Page 2

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ZHEJIANG KAYO MOTOR CO., LTD.

www.kayomoto.us

- 2 -

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.

Summary of Contents for K4

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

Page 2: ...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...

Page 3: ...e life of each part improve the performance of the engine and the reliability of the whole vehicle For the sake of technological development Kayo reserves the right to modify the construction equipmen...

Page 4: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto com 4 March 2021 Content...

Page 5: ...ad the following words carefully to protect yourself and your motorcycle The meanings of danger warning and attention are as follows Danger Be on high alert for danger Warning to be alert to moderate...

Page 6: ...t responsible for any vehicle problems caused by personal modification and the use of unauthorized parts Our K4 product are specially designed for off road and woodland crossing so they are not suitab...

Page 7: ...Once a fire source or electric spark approaches there is a danger of explosion So please charge in a well ventilated place 5 As gasoline is flammable fireworks are strictly prohibited at the work site...

Page 8: ...eel stuck in rotation should be cleaned and those that still feel stuck after cleaning should be replaced and those that cannot be cleaned should be replaced directly not tight after disassembly repla...

Page 9: ...able 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 com...

Page 10: ...20 21 22 23 24 25 26 27 28 29 30 31 32 33 No Name No Name 19 Rear fender 27 swingarm 20 Exhaust pipe muffler 28 Triangle rocker arm 21 Seat 29 U shape rocker arm 22 Rear shock 30 Rear brake pump body...

Page 11: ...late of the front extension tube Engine Number The engine number of the K4 is located on the inside of the engine gearshift lever The Vehicle Parameter Vehicle Dimensions and Mass Parameter L W H mm 2...

Page 12: ...Wheel system Parameters Frame type Central double cradle type high strength steel tube frame Front shock Inverted single adjustable front shock absorber L 880mm Rear shock Double adjustable nitrogen a...

Page 13: ...exagon flange self locking nuts M10 1 25 2 9 Exhaust pipe mounting nut Hexagon flange self locking nuts M8 2 10 Chain guide sleeve mounting screws Phillips flat head machine screw M6 15 4 11 Flat fork...

Page 14: ...2 27 Screws connecting the left and right guard plates to the fuel tank Cross half round head with gasket M5 10 full thread 6 28 Muffler mounting bolt Outer hexagon big head flange bolts M8 35 half t...

Page 15: ...een 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 The front brake adopts a floating ca...

Page 16: ...e from starting with gear Note There should be fuel in the fuel tank before starting the engine and the fuel tank switch is required to be in the open position Extinguish The engine s flameout switch...

Page 17: ...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 The K4 engine gear is the int...

Page 18: ...ehicle to the left to make the single support contact the ground and support the motorcycle Precautions Before Use Advice for beginners 1 Please read this manual before driving especially the The Vehi...

Page 19: ...throttle can not be sudden and small 2 2 5 4h stage at 50 75 throttle the motorcycle can run for a long time at the same throttle In the working process the throttle can reach 100 but the duration is...

Page 20: ...he 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 Precautio...

Page 21: ...first and then stop and should not brake in an emergency 2 When parking unfold the single support and tilt to the left for parking operation 3 Please put the gear in neutral before stopping Suggested...

Page 22: ...ottle cable is intact free of sharp bends and set correctly Clean air filter and air filter housing Check whether screws and nuts are tightened Replace the fuel filter Check the carburetor idle speed...

Page 23: ...amping 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 damping compression damping is reduced...

Page 24: ...ycle set up so that the rear wheel is completely suspended 2 Select a fixed point on the side of the rear fender and mark it as point 1 3 Measure the distance from Point 1 to the center of the rear ax...

Page 25: ...nd record it as A3 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 i...

Page 26: ...ion procedure of the front shock absorber is as follows 1 Place the whole motorcycle on the ground 2 Righten the vehicle 3 Hold the handlebars with both hands and press down on the front shock absorbe...

Page 27: ...eeds to be reduced turn the adjusting screw counterclockwise If you need to increase the compression damping adjust the screw dozens of rotation Adjustment for the handlebar The handlebars of the vehi...

Page 28: ...absorber guard plate The disassembly and installation steps of the front shock absorber guard plate are as follows 1 Remove the front shock absorber protection plate fixing screw 2 remove the front di...

Page 29: ...dle 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 fro...

Page 30: ...nal column Installation is carried out in the reverse order of disassembly Check the head steering Check the head steering steps as follows 1 Aerial the whole vehicle 2 By turning the handlebar left t...

Page 31: ...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 Remove the mounting b...

Page 32: ...nd the frame 3 Loosen the connecting bolts of the U shaped rocker arm and the triangular rocker arm do not remove it 4 Remove the connecting bolts between the rear shock absorber and the triangular ro...

Page 33: ...n the parts of the air filter you need to check first as follows 1 Check whether there are cracks on the surface of the air filter hose 2 Check whether the air filter sponge is damaged 3 Check whether...

Page 34: ...he gas emission and reduce the noise If the exhaust pipe is rusty or ruptured or damaged by impact please replace it with a new one immediately If the noise is too high or the engine performance is de...

Page 35: ...The inspection of the chain is carried out from the following aspects 1 Observe the chain from the rear of the vehicle to check whether the chain is generally skewed 2 Rotate the rear wheel by hand t...

Page 36: ...equent inspection and maintenance to ensure its normal use The chain tension can be adjusted according to requirements the steps are as follows 1 Fix the motorcycle so that the rear wheel is completel...

Page 37: ...t parts should use KAYO original factory production or authorized products The chain needs to be lubricated regularly see the general lubrication section for details Note The alternating wet and dry w...

Page 38: ...cracks on the surface of the swing arm 2 Check whether there is any deformation at the mounting point of the cradle on the swing arm 3 Check whether the surface paint of the swing arm is damaged or n...

Page 39: ...r may be mixed into the oil pump or oil pipe Then check the entire brake system and take corresponding measures Adjust the stroke of the front brake lever front brake lever The front brake lever can b...

Page 40: ...nt brake disc Limit thickness of rear brake disc K4 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...

Page 41: ...pads of the caliper If the thickness of the brake pads is less than the minimum then it must be replaced The minimum thickness of the brake pad is 1mm Note The brake pads should be replaced as a compl...

Page 42: ...mediately Note Do not splash the brake fluid on the paint surface which may cause corrosion Danger Please pay attention to check whether the brake fluid is leaking and whether the brake fluid pipe is...

Page 43: ...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 Danger If it is found that the brake system is too...

Page 44: ...hand and slowly pull out the front wheel axle with the other hand 5 Remove the front wheel and place it in a suitable position 6 Installation is carried out in the reverse order of removal Removal an...

Page 45: ...the minimum height replace the tire immediately The minimum height of the tire pattern h 3mm Check the tire pressure Use a pressure gauge to check whether the tire pressure level meets the vehicle s...

Page 46: ...d weak you must check all the spokes and both wheels If there is any problem please contact the KAYO dealer Electrical system Battery removal and installation The steps for removing K4 battery are as...

Page 47: ...e intake elbow and fasten it with nuts and bolts Install the throttle cable and air filter the interface should be sealed and the clutch control cable should be installed Install the transmission chai...

Page 48: ...tric and kick Idle speed 1400 100 r min lubricat ing oil Specification SJ 10W 40 capacity First raise 1100ml Maintenance refill 1000ml Net weight without oil 32Kg Transmissi on system clutch Manual we...

Page 49: ...of cylinder head parts No item standard value Repair limit value Remar k 1 Free length of valve spring 40 5 39 5 2 Valve clearance Intake valve 0 04 0 06 0 04 or 0 06 Exhaust valve 0 04 0 06 0 04 or...

Page 50: ...r head bracket fixing bolt 2 NC250S Chain pressure plate 3 NC250S Intake bracket combination 4 NC250S Exhaust bracket combination 5 NC250S Exhaust cam bearing C ring 6 NC250S Intake cam bearing C ring...

Page 51: ...t cylinder head cover Valve cover Cylinder head left cover 1 Remove the valve cover 2 Remove the bolts of the left cover of the cylinder head Remove the left cover of the engine cylinder head as shown...

Page 52: ...ve the upper valve spring seat valve spring combination and valve 5 Remove the camshaft components Inspection of valves and valve springs 1 Check whether the valve is bent or the valve stem is abnorma...

Page 53: ...ad The inspection steps of the cylinder head are as follows 1 Check whether the airtightness of the cylinder head is good If the airtightness of the cylinder head is poor replace the cylinder head or...

Page 54: ...aust valve rods install the valve guide and install the valve spring valve spring upper seat and valve lock clip 3 Then use the valve disassembly tool to press down the valve spring and then install t...

Page 55: ...0 04 0 05 0 07 2 Piston Skirt diameter of piston H 7 71 96 71 97 81 94 Pin outer diameter 16 002 16 008 16 015 Clearance between piston pin and piston pin hole 0 002 0 016 0 02 3 Piston ring Closed in...

Page 56: ...he inner diameter of the cylinder and take three positions namely the top middle and bottom of the piston stroke and measure two directions at right angles to each other 3 Maintenance limit 72 02mm Di...

Page 57: ...ap Maintenance limit one ring 0 35mm Second ring 0 40mm Oil ring 0 8 mm 6 Measure the outer diameter of the piston pin Maintenance limit 15 99 mm 7 Calculate the clearance between the piston pin hole...

Page 58: ...nstall the piston pin retaining ring on the other side Installation of the cylinder block 1 Install cylinder block positioning pins and new cylinder block gaskets 2 Apply lubricating oil evenly on the...

Page 59: ...es slowly Free travel is too small Clutch friction plate wear 4 Difficulty operating the clutch Clutch cover chute has burrs 5 Shift pedal does not rebound Broken return spring The transmission shaft...

Page 60: ...the oil pump fastening screws 2 Remove the right oil pump assembly 3 Remove the oil pump seal Removal of the gearshift mechanism positioning plate combination shift arm assembly Five star board 1 Remo...

Page 61: ...ng arm Inspection of the clutch 1 Measure the free length of the clutch spring Maintenance limit 32 3mm 2 If there are scratches or fading marks on the clutch friction plate it should be replaced Meas...

Page 62: ...embly of the gearshift mechanism 1 First install the O ring of the oil pump on the box 2 Install the oil pump parts into the holes of the right box body fasten the oil pump with 2 GB819 1 screws M6 30...

Page 63: ...g bolts of the left crankcase cover and take off the left crankcase cover 2 Remove the left cover positioning pin and the left cover gasket 3 Remove the double gear 2 Disassembly of the magneto stator...

Page 64: ...Install the magneto rotor on the left crank 3 After applying thread glue the magneto electronic fastening bolts are installed in the left crank threaded hole and tightened Tightening torque 70 80N m N...

Page 65: ...venly on the cogging end of the starter motor assemble the starter motor in place and fasten it with 2 GB T16674 small plate bolts M6 25 the tightening torque is 11 13N m Crankcase Transmission Precau...

Page 66: ...ft fork Shift fork shaft bent 3 Crankshaft noise The needle roller bearing oft the big end of the connecting rod is worn Connecting rod wear crankshaft bearing is worn 4 Gearshift gear noise Gearshift...

Page 67: ...rings of the left and right boxes rotate flexibly if the rotation is not flexible or there is a phenomenon of hairpin the bearings of the same type should be replaced 2 Remove the crankshaft bearings...

Page 68: ...ding holes of the left body and then assemble the shift fork to the corresponding position Notice 1 The shift fork marked with R is installed on the right side of the secondary shaft 2 The fork marked...

Page 69: ...motorcycle for a short period of time until the engine reaches the working temperature 8 Lubricate the chain and all other parts that need to be lubricated WARINING Never use high pressure water to c...

Page 70: ...the items that need to be checked before daily driving 5 Routine lubrication for motorcycles MAINTENANCE POINTS In the following content we will enumerate the problems that occurred during your use f...

Page 71: ...s After three times the water in the carburetor is almost gone If water enters the cylinder depress the start lever several times after the flame is turned off Step on it for a few times the water in...

Page 72: ...enter Engine sound is abnormal Problem with ignition Contact KAYO Service Center overheat See Engine Overheating section Exhaust pipe backfire phenomenon Carbon deposits in the combustion chamber Cont...

Page 73: ...ce Center Tire pressure is too high Check tire pressure and adjust to proper pressure Damping adjustment error Re adjust damping Damping is too soft Insufficient front fork oil level Add the right amo...

Page 74: ...nce is too large Check the steering shaft pressure bearing clearance The steering shaft nut is loose and the handlebar is not fixed Check and re tighten The motorcycle skews to one side Bent chassis C...

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KAYO MOTOR K4, Service Manual

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