KAYO MOTOR TD125 Service Manual Download

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Summary of Contents for TD125

Page 1: ...KAYO MOTO TD125 SERVICE MANUAL www kayomoto com...

Page 2: ...e disappointed with this choice This manual is designed to help you better use our products This manual describes in detail the maintenance and adjustment procedures disassembly and assembly essential...

Page 3: ...ontact our service staff We must accept with humility The contents of this manual are subject to change without prior notice due to vehicle improvement The actual state of the vehicle shall prevail du...

Page 4: ...ly of front shock 24 Disassembly and assembly of clamp 24 Check the head steering 25 Lubrication and installation of steering head bearing 25 Disassembly and assembly of front fender 25 Disassembly an...

Page 5: ...ylinder and valves 39 Notes 39 Main parameters and maintenance standards of cylinder parts 39 Fault symptom and cause analysis 39 Removal of left cover of cylinder head 40 Timing check 40 Removal of v...

Page 6: ...over 60 Removal of left front cover 60 Removal of magneto stator 60 Removal of magneto rotor 61 Removal of starting motor and starting sprocket 61 Removal of transition plate 62 Removal of timing chai...

Page 7: ...s that the specific information is on the following page number DANGER WARNING CAUTION In this manual the words DANGER WARNING CAUTION will appear Please read their following words carefully to protec...

Page 8: ...nts Try to avoid using non original parts to modify the bike and do not arbitrarily delete the original parts of the bike if you need to replace the parts of the bike please choose the original parts...

Page 9: ...17 18 No Name No Name 1 Front fender 10 Front fork 2 Headlight 11 Fuel tank 3 Handlebar 12 Carburetor 4 Vent pipe 13 Gear shift lever 5 Fuel tank cap 14 Pedal 6 Fuel tank petcock 15 Side stand 7 Chai...

Page 10: ...19 Rear fender 26 Rear brake caliper 20 Muffler 27 Swing arm 21 Seat 28 Rear brake oil cup 22 Rear shock 29 Brake pedal 23 Upper clamp 30 Steel chassis 24 Lower clamp 31 Muffler pipe 25 Rear brake di...

Page 11: ...21 TD125 is carved on the engine crankcase body behind gear lever Specification TD125 size and quality parameters Length Width Height mm 1600 750 990 Wheelbase mm 1125 Weight kg 65 Tyre size Front 60...

Page 12: ...ock nonadjustable absorber L 280mm Rear swing arm Steel swing arm Handlebar Steel handlebar Front rear rim Front 1 40 14 Rear 1 85 12 steel rim Front brake system Hydraulic brake system brake disc 210...

Page 13: ...d on the right side of the engine and the motorcycle engine can be started by stepping on the starting lever Note The brake should be pinched when starting to prevent the engine from starting with the...

Page 14: ...ifting Gearshift lever The shift lever is located on the left side of the engine which is operated by stepping on and lifting the shift lever The 21 TD125 engines are in four gear gear with constant m...

Page 15: ...nts 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 e...

Page 16: ...rake 4 Check the foot brake clamp pad 5 Check the hand brake clamp pad 6 Check braking effect of braking system 7 Check the chain 8 Check rear sprocket engine sprocket and chain guide 9 Check the chai...

Page 17: ...rs Notes when acceleration 1 Do not accelerate on the corners 2 After acceleration shift gears in time Notes when gear shifting 1 Do not increase the throttle while shifting gears 2 Do not shift gears...

Page 18: ...y 30 hours Every 20 hours Every 10 hours after racing Once after 1 hour riding C h e c k t h e s u rf a c e o f t h e ti r e s C h e c k s h o c k c o n n e c ti n g r o d C h Check and charge the bat...

Page 19: ...e c k s h o c k t o p C h e c k i n g t h e fr a m e C h e c k i n g t h e fr e e s tr o k e o f t h e b r a k e p e d a l...

Page 20: ...C h e c k t h e r e a r d i s c b r a k e fl u i d l e v e l C h e c k t h e b r a k e h o s e f o r d a m a g e o r l e...

Page 21: ...a k s C h e c k t h e fr o n t a n d r e a r d i s c b r a k e s C h e c k t h e r e a r d i s c b r a k e p a d s C...

Page 22: ...awing arm shocks rocker arms and frame the basic setting of the suspension components must match the rider s weight The standard weight of rider for 21 TD125 off road motorcycles is shown in the tabl...

Page 23: ...l i n s p e c o n c h e c k if t h e v e h i c l e i s r u n n i n g s a f e l y a n d t e s t r u n C...

Page 24: ...h e c k t h e c a r b u r e t o r i d l e s p e e d R e p l a c e t h e a i r lt e r C h e c...

Page 25: ...k if t h e s c r e w s a n d n u t s a r e g h t C l e a n t h e a i r c l e a n e r a n d a i r c l...

Page 26: ...e a n e r c a s e C h e c k c a b l e s f o r d a m a g e a n d s h a r p b e n d s C h a n g e t...

Page 27: ...h e g e a r o il C h e c k a ll h o s e s s u c h a s f u e l e x h a u s t e t c a n d b u s h...

Page 28: ...i n g s f o r c r a c k s l e a k s a n d i n c o r r e c t w i r i n g C h e c k c l u t c h...

Page 29: ...C h e c k v a l v e c l e a r a n c e C h e c k if t h e s t e e r i n g h e a d b e a r i n g i s l...

Page 30: ...o o s e C h e c k i n g t h e f r e e s t r o k e o f t h e h a n d b r a k e l e v e r C h e c...

Page 31: ...k t h e f r o n t d i s c b r a k e u i d l e v e l O il a ll m o v i n g p a r t s s u c h a s c...

Page 32: ...h a i n s h a n d l e s e t c a n d c h e c k f o r s m o o t h o p e r a o n C h e c k c h a...

Page 33: ...i n t e n s i o n C h e c k t h e c h a i n r e a r s p r o c k e t e n g i n e s p r o c k e t...

Page 34: ...c h a i n g u i d e a n d c h a i n c o v e r C h e c k s p o k e t e n s i o n C h e c k t...

Page 35: ...h e r i m C h e c k f o r r i m e d g e r u n o u t C h e c k if t h e r i m b e a r i n g i s...

Page 36: ...l o o s e C h e c k r e p r e s s u r e P e r i o d i c i n t e r v a l N o t e T h i s t a b l e i s...

Page 37: ...f o r r e f e r e n c e o n l y P l e a s e a d j u s t t h e s p e c i f i c c y c l e a c c o r d i n g t o t h...

Page 38: ...e u s e o f t h e m o t o r c y c l e W a r n i n g F o r i n s p e c t i o n a d j u s t m e n t a n d r e p...

Page 39: ...l a c e m e n t o f e n g i n e p a r t s p l e a s e c o n s u l t K a y o S u s p e n s i o n...

Page 40: ...s y s t e m s e t u p C h e c k t h e c o m p r e s s i o n a n d r e b o u n d o f t h e...

Page 41: ...m o t o r c y c l e w h e n r i d i n g Measure distance from center of rear wheel to rear fender in suspension...

Page 42: ...ance from center of rear wheel to rear fender in riding condition The measurement procedure is as follows 1 The rider rides the motorcycle engine does not start 2 Righten the motorcycle so that the ce...

Page 43: ...e motorcycle 3 Hold the handlebars with both hands and press down the front shock 4 Observe the effect of reduction and rebound Adjust handlebar The handlebars of the motorcycle can be adjusted accord...

Page 44: ...e clamp of front brake 3 Disassemble the front shock protector 4 Assembly shall be carried out in the reverse order of disassembly Disassembly and assembly of front disc brake Steps of disassembly and...

Page 45: ...umn 6 Assembly shall be carried out in the reverse order of disassembly Check the head steering Steps of head steering checking are as follows 1 Suspend the motorcycle 2 Steer the motorcycle head thro...

Page 46: ...ront fender Steps of disassembly and assembly of front fender are as follows 1 Remove the bolts 2 Remove the front fender 3 Assembly shall be carried out in the reverse order of disassembly Disassembl...

Page 47: ...and the plastic parts 5 Assembly shall be carried out in the reverse order of disassembly Disassembly and assembly of air filter Steps of disassembly and assembly of air filter are as follows 1 Loosen...

Page 48: ...de gas emission and reduce noise If the exhaust pipe is broken or damaged due to rust or impact please replace the new one immediately If the noise is too high or the engine performance degrades repla...

Page 49: ...distance between the back of the swing arm and the chain the normal distance should be 30 40mm about the width of two fingers The distance is close to the normal distance do not have to be very deman...

Page 50: ...e normal movement of the chain affecting its transmission function So severely worn chain slider and chain guard should be replaced in time to ensure the normal work of the motorcycle Inspection of th...

Page 51: ...Use the forefinger and middle finger of your right hand to check for free movement Both fingers should be able to hook and pull the handle 3 Pinch and release the handlebar and feel the resistance ea...

Page 52: ...d for a long time Inspection of the disc brake Front brake sheet Check the caliper brake sheet thickness if the thickness of the brake sheet is less than the minimum thickness the brake sheet must be...

Page 53: ...he corresponding parts should be replaced immediately to avoid safety accidents The specific replacement should be carried out after consulting the dealer of KAYO Tire inspection and maintenance Remov...

Page 54: ...essure of rear wheel TD125 250kPa 250kPa Note The tire pressure should be checked under cooling condition Check the wheel spokes Spokes Pull the adjacent spokes with your fingers to check whether the...

Page 55: ...e rod end and rocker arm and the inlet and exhaust valve clearance is 0 03 0 05mm If the valve clearance is not within the range mentioned above use a special tool to adjust it within the specified ra...

Page 56: ...rous act A normal throttle cable should have at least 10mm free travel Start the engine and turn the handlebars left and right If the engine stalls or accelerates due to the movement of the handlebars...

Page 57: ...st be replaced Note Spark plugs should be checked every 10 hours and replaced every 20 hours Note If engine performance deteriorates replace the spark plug to restore normal performance Lubrication sy...

Page 58: ...discharge bolt and gasket and tighten them Tightening torque 15 20N m refill new lubricating oil and check the oil position Engine repair cylinder and valves Notes The camshaft is lubricated by the o...

Page 59: ...hole in cylinder head Piston ring clearance is too large or broken The piston has cracks or excessive wear The inner diameter of the cylinder block is too large or sand holes 2 Black smoke in the exha...

Page 60: ...ocket is aligned with the timing mark of the cylinder head from the left cover of the engine cylinder head Removal of valve cover Valve cover 1 Remove the valve cover on both sides of the intake and e...

Page 61: ...f cylinder head are as follows 1 Remove valve cover 2 Remove 2 bolts GB T 5787 M6x20 fastening the right cover of cylinder head 3 Remove the right cylinder head cover and the right cylinder head cover...

Page 62: ...rocker arm shaft has wear phenomenon if the wear is serious it is necessary to replace a new rocker arm shaft Inspection of camshaft components The camshaft convex has no obvious concave and convex f...

Page 63: ...ely removed If the valve guide needs to be replaced the valve seat should be re ground surface treatment and the valve inserted into the guide observe its movement and finally calculate the clearance...

Page 64: ...ssembly proceed to the next step 6 The camshaft into cylinder head CAM shaft hole and assembly in place then turn the CAM CAM direction downward rocker arm curved surface on the base circle of the cam...

Page 65: ...and then tighten Timing adjustment method 1 Remove the large and small viewing hole cover on the left front cover 2 rotate the rotor of the magneto so that the rotor timing scale line one is aligned...

Page 66: ...olt is unimpeded otherwise it is easy to cause engine damage Can not make dust or dust into the crankcase Main parameters and maintenance standards of cylinder block and piston No Items Standard value...

Page 67: ...orn Excessive carbon accumulation in piston Removal of cylinder block The removal steps of the cylinder are as follows 1 Remove cylinder head 2 Remove the fastening chain guide roller pin and aluminum...

Page 68: ...7 mm above piston skirt Maintenance limit value 52 36mm 2 Calculate the cylinder clearance Maintenance limit value 0 1mm 3 Measure the inner diameter of the piston pin hole Maintenance limit value 13...

Page 69: ...Then the piston inlet direction is arranged into the small end of the connecting rod upward and the piston pin surface is coated with an appropriate amount of oil and inserted into the piston pin hole...

Page 70: ...he clutch in case of failure usually by adjusting the free stroke of the clutch handle and get a better correction Main parameters and maintenance standards No Items Standard value Maintenance limit v...

Page 71: ...2 Remove the two GB T5777 M6x80 1 fastening the right cover GB T 5777 M6 65 5 GB T 5777 M6 40 Bolts take down the right crankcase cover right crankcase cover gasket and positioning pin 8 12 two 3 Rem...

Page 72: ...p are as follows 1 Remove one GB T819 M6x30 one GB T819 M6x35 and two GB T819 M6x35 cross reckled countersunk screws for securing the oil pump 2 Remove the oil pump oil pump gasket and 2 8 12 position...

Page 73: ...e limit value 2 5mm 3 Check whether the surface of the clutch driven plate is distorted Maintenance limit value 0 14mm 4 Check the gap between the clutch cover and the friction plate Maintenance limit...

Page 74: ...stuck into the shift drum baffle plate 2 The positioning plate spring hook in the positioning plate hanging groove hole and combination in place 3 Move the big end roller of the positioning plate to...

Page 75: ...s not damaged Assembly of driving and driven teeth The assembly steps of the driving and driven teeth are as follows 1 In the right crank into the driving gear ring driving gear sleeve and driving tee...

Page 76: ...led in place 4 Place the adjusting bolt on the upper part of the push rod align the screw holes on the limit plate with the threaded holes on the right cover and tighten the M6x12 cross countersunk sc...

Page 77: ...on a flat surface 2 Remove two GB T 5787 M6x20 bolts for securing the stator of the magneto two GB T 5783 M5 12 bolts for securing the trigger and one GB T 818 M5 61 cross recited pan head screw for s...

Page 78: ...de roller on the cylinder body 4 Remove the chain tensioning roller on the tensioning arm 5 Remove the timing chain Method two 1 Lower cylinder head and cylinder body 2 Remove the timing chain Removal...

Page 79: ...riously worn if there is it is necessary to replace the new roller of the unidirectional roller 3 Check whether the stator of the magneto is worn or damaged If so replace the stator of the magneto wit...

Page 80: ...the starting chain load the starting motor mounting hole on the transition plate and load the bolt to tighten Note the clearance between the starting sprocket press plate and the end face of the star...

Page 81: ...and tighten it with three GB T 5777 M6x32 bolts and one GB T 5777 M6x50 bolt The tightening torque is 10 to 14 N m Crankcase crankshaft main and auxiliary shafts and speed drum Matters needing attent...

Page 82: ...shaft retainer ring remove the starting shaft return spring and the starting shaft return spring seat 2 Place the left crankcase of the engine upward Remove 1 GB T 5787 M6x12 bolt and baffle at the h...

Page 83: ...ial gap between the two points in the X and Y direction of the big head of the connecting rod Maintenance limit value 0 015mm Left and right crankshaft box bearing inspection Check the left and right...

Page 84: ...starting shaft of the starting shaft are excessively or abnormally worn 2 Check whether the ring is deformed and falls off 3 Check whether the gasket is deformed or missing Assembly of variable speed...

Page 85: ...orque 10 14 N m 3 Install rubber plug baffle and 1 GB T 5787 M6x12 bolt at the variable speed drum hole and tighten and turn the engine over Note the bolts are not loose and the auxiliary shaft is fle...

Page 86: ...isconnected or short circuited The ignition switch is faulty Test cylinder pressure The pressure is too low The starting mechanism skidded and failed to turn the engine The pressure is normal Valve cl...

Page 87: ...carburetor nozzles for blockage Blocking The carburetor gauge hole is blocked Unplugged Float stuck filter clogging Check valve timing Incorrect Adjust valve timing Correct Check valve spring pressure...

Page 88: ...any electrical element Storage of motorcycles The preparation of the motorcycle before long unused When you plan to store your vehicle and not use it for a long time follow these steps 1 Plug the exh...

Page 89: ...First of all put the mixture of fuel in the engine and the engine crankcase removed clean it with a strong cleaning agent and then remove the spark plug with a fan to inflate the tires of the machine...

Page 90: ...st pipe tempered There is carbon deposition in the combustion chamber Contact KAYO Service Center Fuel inferior Replace the fuel Spark plug in poor condition or wrong specification Replace the spark p...

Page 91: ...le is pumped to the appropriate air pressure Error in damping adjustment Readjust the shock absorption Abnormal noise when running Improper chain adjustment Readjust the chain tension The chain worn R...

Page 92: ...less than the minimum friction thickness Vehicle tightening torque meter Note Before installing the thread apply anti rust grease on the thread and bonding surface No Item Fastener specification Qty...

Page 93: ...6 20 full thread 2 7 11 21 Bolts for FBG M6 20 1 7 11 22 Voltage stabilizer bolts M6 16 full thread 1 7 11 23 Front fender bolts M6 16 3 7 11 24 Connecting screws between left and right guard plates a...

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KAYO MOTOR TD125, Service Manual

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