KAYO MOTOR TT 125 Service Manual Download Page 6

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Cylinder block and piston

Main parameters and maintenance standards of cylinder block and piston

Fault symptom and cause analysis

Inspection of cylinder block

Removal of piston and piston ring

Inspection of piston and piston ring

Installation of piston ring

Installation of piston

Installation of cylinder block

Clutch, driving gear, driven gear, oil pump, shifting mechanism

Main parameters and maintenance standards

Fault symptom and cause analysis

Removal of right trim cover

Adjustment of clutch stroke

Removal of right crankcase cover

Clutch disassembly

Disassembly of driving and driven gears

Removal of engine oil pump

Disassemble shift mechanism

Inspection of right crankcase cover

Inspection of driving and driven tooth

Check the oil pump

Check shift mechanism

Assembly of shift mechanism

Assembly of oil pump

Assembly of driving and driven teeth

Clutch assembly

Installation of clutch

Assembly of right crankcase cover

Right trim cover for installation

Magneto, timing chain

Removal of left rear cover

Removal of left front cover

Removal of magneto stator

Removal of magneto rotor

Removal of starting motor and starting sprocket

Removal of transition plate

Removal of timing chain

Removal of tensioning arm, tensioning rod and tensioning roller

Inspection of left front cover and left back cover

Transition plate, starting motor, starting sprocket inspection

Magneto stator, rotor inspection

Installation of tensioning arm, tensioning rod and tensioning roller

Transition plate installation

Installation of starting motor and starting sprocket

Installation of magneto stator

Installation of magneto rotor

Installation of left cover

Crankcase, crankshaft, main and auxiliary shafts and speed drum

Main parameters and maintenance standards

Fault symptom and cause analysis

Decomposition of crankcase

Disassembly of crankshaft, main and auxiliary shaft

Decomposition of variable speed drum

Inspection of crankshaft

Left and right crankshaft box bearing inspection

Check shift fork, fork shaft and shift drum

Summary of Contents for TT 125

Page 1: ...KAYO MOTO TT 125 SERVICE MANUAL www kayomoto com ...

Page 2: ...be 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 essentials inspection and maintenance points troubleshooting methods and maintenance technical data of TD125 with detailed graphic data to guide the operation Please read this manual carefully and carry out m...

Page 3: ...ustments to the models so the images in the manual may be different from the standard motorcycle In addition if you have any questions please go to our official website www kayomoto com and contact 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 during main...

Page 4: ...tance from center of rear wheel to rear fender in suspension 20 Measure distance from center of rear wheel to rear fender under no load 20 Measure distance from center of rear wheel to rear fender in riding condition 21 Adjust the spring preload of the rear shock 22 Check the setup of the front shock 22 Adjust handlebar 22 Maintenance 23 Placement of motorcycle 23 Disassembly and assembly of front...

Page 5: ...uts of cylinder and cylinder body 37 Check valve clearance 37 Inspection of compression pressure 38 Adjustment of clutch control system 38 Adjustment around the engine 39 Idle speed adjustment of carburetor 39 Clean the carburetor 39 Check shift lever position 40 Adjust the position of the shift lever 40 Check and replace spark plug 41 Lubrication system of engines 42 Selection of lubrication oil ...

Page 6: ...cover 66 Assembly of right crankcase cover 67 Right trim cover for installation 67 Magneto timing chain 67 Removal of left rear cover 68 Removal of left front cover 68 Removal of magneto stator 68 Removal of magneto rotor 69 Removal of starting motor and starting sprocket 69 Removal of transition plate 70 Removal of timing chain 70 Removal of tensioning arm tensioning rod and tensioning roller 70 ...

Page 7: ... you do not have confidence to complete this operation you can go to a professional maintenance shop or KAYO after sale service to operate by professionals The symbol indicates 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 protect yourself and your vehic...

Page 8: ...s for carrying people so please be sure not to use this bike to carry other people except the driver this behavior can easily lead to safety accidents 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 produced by KAYO or parts from authorized manufacture...

Page 9: ...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 Chain slider 16 Chain 8 Front brake disc 17 Chain guide 9 Front brake caliper 18 Rear sprocket 19 20 21 22 23 24 ...

Page 10: ...e 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 disc VIN and Engine Number VIN Number ...

Page 11: ...f 21 TT125 is carved on the engine crankcase body behind gear lever Specification TT125 size and quality parameters Length Width Height mm 1780 750 1120 Wheelbase mm 1220 Weight kg 72 Tyre size Front 70 100 17 Rear90 100 14 Seat height mm 855 Ground clearance mm 290 Fuel tank capacity L 5 5 ...

Page 12: ... Normal rear shock nonadjustable absorber L 360mm Rear swing arm Steel swing arm Handlebar Steel handlebar Front rear rim Front 1 60 17 Rear 1 85 14 steel rim Front brake system Hydraulic brake system brake discΦ210mm Rear brake system Hydraulic brake system brake discΦ200mm Other Air filter Sponge filter Manipulation Front disc brake Hand brake handle The front disc brake is controlled by the han...

Page 13: ...arted by stepping on the starting lever Note The brake should be pinched when starting to prevent the engine from starting with the gear Note there should be fuel in the fuel tank before starting the engine and the fuel tank switch should be in the open position Stall Stall switch The stall switch of the engine is located on the left side of the handlebar near the handle cover It is a round red bu...

Page 14: ...es are in four gear gear with constant meshing Rear disc brake Foot brake pedal The foot brake pedal is located on the right side of the engine and is operated by stepping Note when brake the foot brake should be the main brake hand brake as a supplement Rear brake caliper The rear brake adopts a floating clamp disc brake whose clamp body is located on the right side of the rear wheel and is fixed...

Page 15: ...le needs to be cleaned with water 5 Do not drive in inclement weather e g rainstorm blizzard etc unless necessary 6 The company is not responsible for any vehicle problems caused by malicious acts Running in process Motorcycle engines have many parts that make relative movements such as pistons piston rings cylinder blocks and meshing transmission gears Therefore in the initial stage of use the en...

Page 16: ... can easily lead to engine damage and safety accidents Therefore please pay attention to certain driving skills when using a motorcycle Riding guide Checking items before riding 1 Check the fuel level in the tank 2 Check the oil level in the oil cup of hand brake 3 Check the oil level in the oil cup of foot brake 4 Check the foot brake clamp pad 5 Check the hand brake clamp pad 6 Check braking eff...

Page 17: ... 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 on the corners Notes when braking 1 When braking the foot brake should be the main hand brake as a supplement 2 The level of the brake fluid in the brake fluid cup should be checked frequently 3 When the brake fl...

Page 18: ...k spoke tension Check the chain rear sprocket engine sprocket chain guide and chain cover Check chain tension Oil all moving parts such as chains handles etc and check for smooth operation Check the front disc brake fluid level Checking the free stroke of the hand brake lever Check if the steering head bearing is loose Check valve clearance Check clutch Change the gear oil Check all hoses such as ...

Page 19: ...ove or below the standard range the basic setting of these sections must be adjusted accordingly Measure distance from center of rear wheel to rear fender in suspension The measurement procedure is as follows 1 Set up the whole motorcycle so that the rear wheel is completely suspended 2 Select a fixed point on the side of the rear mud guard and mark it as Point 1 3 Measure the distance from Point ...

Page 20: ...s side stand to support the motorcycle and leave the seat cushion Calculate the difference between A1 and A2 and denote it as D2 The D2 value of 21 TT125 is shown as follows D2 TT125 55 110mm If D2 measured by the customer is lower than the factory value the spring preload can be lowered appropriately If measured D2 is higher than the factory value the spring preload can be adjusted higher If D2 i...

Page 21: ...ld 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 according to customers riding habits The specific steps are as follows 1 Remove the pad and cover from the handlebar 2 Unscrew the press bolt so that the handlebar can rotate 3 Sit on the motorcycle and adjust the handlebar...

Page 22: ... 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 assembly of front disc brake are as follows 1 Disassemble the mounting bolt of disc brake clamp 2 Disassemble the oil pipe clamp 3 Disassemble the brake lever 4 Disassemble the front number plate wire clamp 5 Remove the f...

Page 23: ...assemble the steering column 7 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 through the handlebars If the motorcycle head steer smoothly and there is no obstruction the motorcycle head steers normally 3 If it is found that there is a sense of delay and ob...

Page 24: ...shock Check the rear shock and observe whether the spring has cracks Replace rear shock if necessary Steps of disassembly and assembly of rear shock are as follows 1 Remove the bolts of the rear shock and the frame 2 Remove the bolt connecting the rear shock and the swing arm 3 Remove the rear shock from the back after confirming no more interference 4 Assembly shall be carried out in the reverse ...

Page 25: ...ummed with the sponge If the air filter is damaged replace the corresponding parts If no parts are damaged maintenance should be carried out in the following way 1 Clean the air filter hose with water and let it dry naturally 2 Clean up the dust attached to the air filter sponge and soak the surface with the air filter oil If the dust on the sponge is really difficult to deal with you can also rep...

Page 26: ...ean The checking of the chain is carried out from the following aspects 1 Inspect the chain from the back of motorcycle to see if the chain is skewed 2 Turn the rear wheel by hand to see if the rear wheel turns smoothly 3 Carefully check the chain clearance to see if there is sediment attached The chain cleaning steps are as follows Use special cleaning agent to wash the silt and oil in the surfac...

Page 27: ... worthwhile to replace the whole chain drive system at the same time The replacement parts should use the original production or authorized products of KAYO The chain needs to be lubricated regularly see General Lubrication section for details Note alternately wet and dry working conditions will greatly shorten the service life of the chain and its surrounding parts Therefore please choose the app...

Page 28: ...spection of the handle bar Let the rider sit on the motorcycle with both hands on the handlebars naturally Feel whether the position of clutch grip and brake grip is comfortable If it is difficult to control then the position of steering grip is determined Check and maintain the brake system Check the free stroke of the front brake handle The brake handle inspection is carried out from the followi...

Page 29: ...level is lower than the lower edge of the observation hole the brake fluid should be immediately added to the upper edge of the observation hole Refill the front brake disc fluid oil The brake fluid must be checked and replaced regularly If the brake fluid is mixed with water soil or other particulate matter the brake fluid should also be replaced DOT4 brake fluid is recommended Danger Do not mix ...

Page 30: ...t of the brake pedal should be shown in the table below Check the brake lever and make sure the movement is correct Model Brake pedal free movement TT125 20 55mm Check the rear disc brake fluid level Observe the fluid level hole and check the level of the brake fluid The fluid level should be more than half of the observation hole that is the fluid level should be higher than the LOWER If brake fl...

Page 31: ...er brake disc which should not be less than 1 mm If the thickness of the brake disc is less than the minimum thickness the whole set of brake discs should be replaced immediately Danger If it is found that the brake system is worn too much the corresponding parts should be replaced immediately to avoid safety accidents The specific replacement should be carried out after consulting the dealer of K...

Page 32: ...move the rear wheel and place it in place Assembly shall be carried out in the reverse order of disassembly Check the outside surface of the tire The steps for checking the tire surface are as follows 1 Check the outside surface of the tire for scratches holes 2 Check the tire tread height if it is less than or equal to the minimum height should immediately replace the tire Minimum tread height h ...

Page 33: ...nd air filter The interface should be sealed Install the clutch control cable Install the transmission chain Install the left rear cover or sprocket cover tighten it with bolts pay attention to magneto outlet Install exhaust muffler The M8 nut and the exhaust pipe sealing ring should be firmly installed and the tightening torque should be 25 30N m The exhaust port should not leak during the instal...

Page 34: ...heck at initial 1000km and every 5000km The inspection steps is as follows Warm the engine by idling the engine Unscrew the spark plug Install the pressure gauge and connector into the spark plug mounting hole and make sure the connection is firm Turn the throttle handle to full open position Start the engine several times with the starter motor and read the maximum pressure of the engine cylinder...

Page 35: ... movement of the handlebars the throttle cable should be improperly adjusted or damaged Make sure the throttle cable is normal before driving the motorcycle Clean the carburetor The carburetor retains a portion of fuel after each ride Therefore the carburetor should be cleaned after each ride to avoid oil dirt which affects the use of the carburetor Carburetor cleaning methods are as follows 1 A c...

Page 36: ... between the electrodes 0 5 0 8 mm If the spark plug contains oil or cinders wipe it off with a wire brush or similar The distance between the electrodes is measured with a meter and adjusted to prevent abnormal bending of the external electrodes If the spark plug electrode is rusted damaged or the insulator is broken the spark plug must be replaced Note Spark plugs should be checked every 10 hour...

Page 37: ...ow the lower scale lubricating oil should be added Lubricating oil replacement When changing the lubricating oil it should be carried out before the engine is warm and not yet cooled so as to ensure that the lubricating oil in the crankcase can be quickly and completely discharged When replacing place an oil pan under the engine and open the oil bolt A to discharge the oil Check the plug gasket fo...

Page 38: ...is not tight The valve timing is wrong The valve spring is broken Leakage of spark plug and cylinder head mounting parts The cylinder head gasket combination is not tight Crack or sand 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 exhaust Valve guide...

Page 39: ...otate C100 six level magneto locking nut at the same time through the small inspect hole on the left front cover to observe the magneto rotor on the timing scale line and the left front cover on the timing mark is correct 2 Observe whether the timing mark of the driven sprocket is aligned with the timing mark of the cylinder head from the left cover of the engine cylinder head Removal of valve cov...

Page 40: ...01 0 03mm Removal of cylinder head Cap nut Cover of cylinder head Connecting bolts for cylinder head and cylinder block The removal steps of cylinder head are as follows 1 Remove the 4 GB T 923 M6 cap nuts securing the cylinder head cover 2 Remove 3 φ 6 2 φ 13 2 iron washers and 1 φ 6 5 φ 13 2 copper washers 3 Remove cylinder head and cylinder head gasket 4 Remove left cylinder head cover 5 Remove...

Page 41: ...ginal assembly position during assembly 3 When removing the gasket ensure that it is in good condition If it is damaged replace it with a new one during assembly to avoid engine oil leakage Inspection of valves and valve springs Valves and valve springs are checked as follows 1 Check the valve for bending or abnormal wear of the valve stem and measure the outside diameter of the valve stem Mainten...

Page 42: ...core shaft are loose If so it is necessary to replace the pressure reducing valve swinging block combination Inspection of cylinder head Check the cylinder head as follows 1 Check whether the sealing of the cylinder head is good if the sealing of the cylinder head is poor it should be replaced with a new cylinder head or valve 2 Check spark plug hole and valve seat for cracks 3 Check whether the c...

Page 43: ...lve seat is too wide too narrow or dented the valve seat should be ground to achieve the correct degree of sealing 3 When grinding the valve use the electric gun sleeve on the rubber hose with a tight fit and then the valve rod sleeve on the rubber hose the grinding graphite paste coated on the valve sealing belt and then attached to the valve seat sealing line start the electric gun turn the valv...

Page 44: ...d install the new cylinder head gasket then install the positioning pin flanging bushing and rectangular ring 2 Pull the trap to TDC then attach the timing driven sprocket to the timing chain Timing sprocket O stamped upward 3 Install the cylinder head on the bolt A and B then load the cylinder head gasket and then load the cylinder head cover Place the iron washer and copper washer on the bolt A ...

Page 45: ...linder head into the threaded hole on the left cover of the cylinder head gasket and tighten the bolt tightening torque 8 12N m 8 Put the O ring into the groove of the valve cover and then install the valve cover on the cylinder head and tighten fastening torque 8 12N m 9 Put the spark plug into the spark plug thread of the cylinder head and tighten it Fastening torque 10 12N m Cylinder block and ...

Page 46: ...n accumulation in piston 4 Knock or abnormal noise The piston or cylinder is worn 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 pad φ 8 3 Remove the M6x28 cross groove connecting bolts connecting the cylinder body and the crankshaft box 4 Remove the...

Page 47: ...tion steps are as follows 1 Measure od 7 mm above piston skirt Maintenance limit value φ52 36mm 2 Calculate the cylinder clearance Maintenance limit value 0 1mm 3 Measure the inner diameter of the piston pin hole Maintenance limit value φ 13 017mm 4 Check whether the piston and piston ring grooves are worn and measure the side clearance between the piston ring and the piston ring grooves Maintenan...

Page 48: ...ion of piston IN side of intaking air The piston installation steps are as follows 1 Install the piston piston pin and a new piston pin retainer 2 Apply appropriate amount of oil on the surface of the piston pin 3 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 p...

Page 49: ...n after loading into the cylinder body Clutch driving gear driven gear oil pump shifting mechanism Matters needing attention After removing the right cover the disassembly installation and maintenance of the clutch oil pump and shift mechanism can be carried out without removing the engine The operation of the clutch in case of failure usually by adjusting the free stroke of the clutch handle and ...

Page 50: ...roke 5mm can be adjusted according to the actual motorcycle tighten the adjustment nut Removal of right crankcase cover Remove the right crankcase cover as follows 1 Drain the oil remove the oil drain plug M12x1 5 on the right side and wait until the oil in the box runs out 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 crank...

Page 51: ...s follows 1 Remove the driving tooth 18 teeth driving tooth shaft sleeve and driving tooth ring 3mm 2 Remove the rear ring of the driven gear and take out the driven gear 67 teeth Note when removing the driven gear rear ring prevent the driven gear rear ring from falling and falling into the crankcase Removal of engine oil pump The removal steps of the oil pump are as follows 1 Remove one GB T819 ...

Page 52: ...ver is broken and whether the oil channel is smooth Replace the right crankcase cover if damaged Clutch inspection Clutch inspection steps are as follows 1 Measure free length of clutch spring Maintenance limit value 20 5mm Limit value of damping spring maintenance 21mm 2 Measure the thickness of each clutch friction plate If the clutch friction plate shows scratches or faded marks it should be re...

Page 53: ... the forearm is 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 the positioning pin of the speed shifting drum and tighten it in place 4 There is slight clearance when the shift arm dial plate is moved by hand and the clearance is uniform without un...

Page 54: ... into the friction plate clutch plate friction plate clutch plate Use special equipment to put the clutch driving plate into the clutch elastic retaining ring in the installation of 4 shock absorption spring 2 Load the clutch driving gear jacket Note two friction plate teeth should be aligned after clutch assembly Installation of clutch The installation steps of the clutch are as follows 1 Put the...

Page 55: ...nation through the right box cover mounting hole half circle rod plane and CAM dial plate spring end completely hook on the clutch camshaft can not fall off the positioning pin through the right box cover pin hole card into the clutch camshaft groove Note the clutch camshaft is flexible and the push rod does not fall off Assembly of right crankcase cover The assembly steps of the right crankcase c...

Page 56: ...6x50 bolts from the left front cover 2 Remove the left front cover 3 Remove the left front cover gasket and two 8 x 12 positioning pins Removal of magneto stator The removal steps of the magneto stator are as follows 1 Turn the left front cover over and place it 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 tr...

Page 57: ... motor 2 Remove the starting motor 3 Remove 1 hexagon head bolt GB T 5783 M6 10 for fastening the starting sprocket press plate 4 Remove the chain tension plate chain guide plate starting sprocket and starting chain Removal of transition plate The removal steps of the transition plate are as follows 1 Remove one GB T 5777 M6x105 bolt one GB T 5777 M6x35 bolt one GB T 5777 M6x25 bolt and one alumin...

Page 58: ...f the large and small viewing hole covers is not damaged and the O ring is not damaged or deformed If damaged replace the large and small viewing hole covers and o ring with new ones Transition plate starting motor starting sprocket inspection Transition plate starting motor starting sprocket check steps are as follows 1 Check whether the starting sprocket is damaged whether the transition plate i...

Page 59: ...ollows 1 Align the mounting holes of the tensing roller with the mounting holes of the box body insert the box body take the core shaft of the tensing roller through the tightening roller and secure it in place 2 Place the tensioning arm into the container and align the mounting holes with the mounting holes in the container Insert the tensioning arm manshaft through the mounting holes of the tens...

Page 60: ...te the clearance between the starting sprocket press plate and the end face of the starting sprocket should be in the range of 1mm 2mm Installation of magneto stator The installation steps of the magneto stator are as follows 1 Put the left front cover of the stator of the magneto motor After the stator is installed align the screw holes with the threaded holes of the left front cover Tightening t...

Page 61: ...aft main and auxiliary shafts and speed drum Matters needing attention This section describes the transmission crankshaft installation testing to do the above work the crankcase should be removed first about the other components of the engine should be removed before the crankcase Work before crankcase removal The disassembly of the cylinder head the disassembly of the cylinder the piston the clut...

Page 62: ... of the engine upward Remove 1 GB T 5787 M6x12 bolt and baffle at the hole of the variable speed drum take out the rubber plug take out 1 GB T 5787 M6x16 bolt and the washer of the variable speed drum 3 Remove 4 GB T5787 M6x65 bolts 2 GB T5787 M6x6 bolts and 1 GB T5787 M6x50 bolts turn the crankcase to separate the left crankcase from the right crankcase and remove 2 positioning pins and crankcase...

Page 63: ... flexibly If the rotation is not flexible or there is a hairpin phenomenon the bearing of the same type should be replaced 2 Take down the left and right boxes of the crankshaft bearing to check its diameter jump and end jump if there is noise or diameter jump and end jump it should be replaced with a new crankshaft bearing 3 Check whether the oil channels of the left and right containers are smoo...

Page 64: ...tall the fork pin 3 Clamp the spring clip Installation of variable speed drum main and auxiliary shaft crankshaft and starting shaft The installation steps of speed drum main and auxiliary shaft crankshaft and starting shaft are as follows 1 Install the crankshaft and starting shaft into the corresponding holes in the left body and install gaskets after installing the starting shaft 2 After the ma...

Page 65: ...lts pass through the corresponding bolt holes in the left body and tighten them Tightening torque 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 flexible without clamping 4 Rotate the spindle clockwise to make the spindle turn the starting shaft return spr...

Page 66: ... tank to carburetor is blocked Fuel flows into the carburetor The float assembly in the carburetor is stuck The vent on the tank cap is blocked Remove the spark plug to test the spark The spark is weak or completely absent Spark plug failure Spark plug is not clean The electronic ignition is faulty The magneto is out of order The spark is good The connection is bad and broken The high voltage cabl...

Page 67: ...m spark test The spark is weak or intermittent Faulty spark plug or charcoal accumulation The electronic igniter is faulty The magneto is out of order Spark plug is good The spark plug cap is faulty The power loop is faulty The engine performs poorly at high speeds Check ignition timing and valve clearance Incorrect Ignition control is faulty Improper valve clearance adjustment The magneto is out ...

Page 68: ... are worn he fit clearance between the main and driven gears is too small or too large Motorcycle cleaning Vehicle cleaning is also an important part of the daily use and maintenance of motorcycles often clean your motorcycle can make your car to maintain a good state of motion prolong its service life You can clean your motorcycle by following the steps 1 Cover the exhaust system to prevent water...

Page 69: ...gasoline will deteriorate 6 Lubrication chain 7 Apply oil to all unpainted metal surfaces to prevent rust 8 When storing the motorcycle keep the motorcycle wheel suspended if the condition cannot be reached the cardboard pad can be used under the motorcycle tire 9 Cover your motorcycle to prevent dirt and dirt from sticking 10 Move the motorcycle into a dry room Note When applying anti rust oil pl...

Page 70: ...ngine failure The fuel of the motorcycle has deteriorated from long parking The old fuel goes out and the new fuel goes in There is dirt on the spark plug or the spark plug is wet Clean or dry spark plug replace spark plug if necessary Water had got in the engine 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 remov...

Page 71: ... whether the exhaust system is damaged and replace the accessories if necessary Dirt in the carburetor nozzle Remove carburetor and clean nozzle Damaged or worn crankshaft bearings Contact KAYO Service Center Abnormal engine sound Ignition problem Contact KAYO Service Center Overheating See Engine overheating section The exhaust pipe tempered There is carbon deposition in the combustion chamber Co...

Page 72: ... to the appropriate pressure Error in damping adjustment Readjust the shock absorption Damping is too soft The oil level of the front fork is insufficient Add proper amount of fork oil Note The same oil is required Low viscosity of fork oil Replace with fork oil of suitable viscosity Tire pressure is too low Check whether the tire leaks if the tire vehicle is pumped to the appropriate air pressure...

Page 73: ...ing Contact KAYO Service Center Improper steering adjustment Check and readjust Bending of steering shaft Contact KAYO Service Center There is a problem with the front fork Contact KAYO Service Center Vehicle misalignment Re adjust the tension of spokes and contact KAYO service center if necessary Brake failure Disc brake worn Replace the disk brake Insufficient brake fluid Refill brake fluid Brak...

Page 74: ...M6 12 3 7 11 11 Swing arm nuts M10 1 25 1 40 70 12 Chain adjuster bolts M8 40 S10 2 20 25 13 Chain adjuster nuts M8 2 20 25 14 Rear shock bolts M10 45 1 25 2 40 70 15 Rear shock nuts M10 1 25 2 40 70 16 Rear brake disc bolts M8 16 4 25 35 17 Rear sprocket screw M8 25 10 9 6 27 35 18 Rear axle nuts M14 1 5 1 124 165 19 Rear brake disc cover bolts M6 12 2 7 11 20 Rear brake pump bolts M6 20 full thr...

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KAYO MOTOR TT 125, Service Manual

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Summary of Contents for TT 125

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