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ZHEJIANG KAYO MOTOR CO., LTD.

www.kayomoto.com

Engine Troubleshooting

Below items are essential to support a engine work well.

Qualified fuel: There is a certain proportion of combustible mixture in the cylinder.

Spark: The spark plug emits a strong spark in limited time.

Compression: sufficient compression pressure in the cylinder.

Valve timing: correct opening time.

Faults

Inspection

Results

Possible causes

Engine does not

start or difficult to

start

Check if the fuel flow into

carburetor

No fuel in tank

Oil between tank and

carburetor is blocked.

Yes

Float components of

carburetor stuck.

Vent on tank cap blocked.

Remove the spark plug then

test

Weak or no spark

Spark plug fails

Spark plug is dirty

Electronic ignition faulty

Magneto faulty

Good spark

Poor or broken wiring

high-voltage cable is

disconnected or

short-circuited

Ignition coil break or short

circuit

Ignition switch faulty

Test cylinder pressure

Low

Starting mechanism skidded

Normal

Valve clearance is too small

Valve opening blocked

Cylinder or piston ring wear

Cylinder head gasket broken

Improper valve timing

Restart engine

Engine turns but does Choke opens too wide

Содержание KMB60 2021

Страница 1: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto com 1 KAYO MOTO KMB60 SERVICE MANUAL 2021 WWW KAYOMOTO COM...

Страница 2: ...to com 2 This service manual is prepared by Zhejiang KAYO Motor Co Ltd No part of this publication may be deleted or altered without written permission This publication includes the latest production...

Страница 3: ...mend you read the owner s manual before riding and maintenance based on the process requirements It s a good way to keep your motorcycle in good condition Here we list maintenance schedule and instruc...

Страница 4: ...16 Side stand 17 Preparation before Riding 17 Advice to Beginners 17 Running in 17 Riding Instructions 18 Pre ride Inspection 18 Starting Procedure 19 Turning cautions 19 Acceleration Cautions 19 Brak...

Страница 5: ...haust pipe 28 Removing the muffler 29 Removing the fuel tank 29 Checking and cleaning the chain 29 Removing the chain 29 Checking the chain tension 30 Checking the rear sprocket engine sprocket and ch...

Страница 6: ...alve mechanism I 40 Main parameters and maintenance standards of cylinder head parts 40 Troubleshooting 41 Maintenance of valve mechanism I 41 Dismounting the valve mechanism I 42 Overhauling the valv...

Страница 7: ...hanism 64 Overhauling the magneto and electric start mechanism 66 Installing the magneto and electric start mechanism 67 Crankcase crankshaft oil pump and main and auxiliary shafts 67 Main parameters...

Страница 8: ...three signal words please read them carefully These signals words mean Danger Make sure you follow the instructions or you will be killed or seriously hurt Warning Make sure you follow the instruction...

Страница 9: ...ver carry a passenger A passenger will lead to accident Accessories Modifications Modifying your motorcycle or using non Kayo accessories may make your motorcycle unsafe We recommend you use Kayo acce...

Страница 10: ...CO LTD www kayomoto com 10 Component Locations 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 No Item No Item 1 Front fender 10 Front shock 2 Front panel 11 Fuel tank 3 Handle bar 12 Carburetor 4 Breath...

Страница 11: ...cover 7 Chain slider 16 Chain 8 Front brake disc 17 Chain cover 9 Front brake caliper 18 Rear sprocket 19 20 21 22 23 24 25 26 27 28 29 No Item No Item 19 Rear fender 25 Rear brake disc 20 Muffler 26...

Страница 12: ...JIANG KAYO MOTOR CO LTD www kayomoto com 12 24 Lower raiser Serial Number Chassis Number Chassis number is engraved on the top of frame Engine number Engine number is on the rear left of engine crankc...

Страница 13: ...height mm 550 Ground clearance mm 160 Fuel tank capacity L 2 5 Engine Type Single cylinder 4 stroke Air cooling Full auto Displacement 56 8cc Max Power kw r min 1 6 7000 Max Torque N m r min 2 7 4000...

Страница 14: ...ing arm Steel Handlebar Alloy Rim F 1 40 10 R 1 40 10 Alloy Front brake Hydraulic disc 160mm Rear brake Hydraulic disc 160mm Other part Air filter Sponge Operating Controls Front brake Front brake lev...

Страница 15: ...utomatically return to the closed position when you remove your handle Ignition Ignition switch Long press ignition switch yellow to start the motorcycle Note Pull the brake lever while starting motor...

Страница 16: ...rburetor ON Turning the fuel tap ON before starting engine allows the fuel to flow from tank to carburetor OFF Turning the fuel tap OFF after stopping engine prevents the fuel flow from tank to carbur...

Страница 17: ...ride read this owner s manual especially Operating Controls and Riding Instructions 2 Running in before riding 3 If there s parts problems during riding please see this manual or ask Kayo dealers for...

Страница 18: ...cool out for 5 10min after each working hour 4 5h 75 100 5h 50 60km h Danger Reckless acceleration will damage engine and cause accident Riding Instructions Pre ride Inspection 1 Check the level and a...

Страница 19: ...to ON position 2 Pull the brake lever with right hand 3 Long press ignition switch yellow 4 The engine starts to work Starting Cautions 1 Before riding check the motorcycle and wear complete protecti...

Страница 20: ...ng slow down to avoid emergency braking 2 Lower the side stand to support your motorcycle 3 To stop motorcycle shift into neutral before parking Maintenance Schedule Every 30 hours Every 20 hours Ever...

Страница 21: ...vers etc check if they work smoothly Check front brake lever freeplay Check steering head bearing Valve clearance Replace gear oil Check all hoses and casing pipes Main cable Sponge and housing of air...

Страница 22: ...ht 15 30kg If the rider s weight is above or below this range the basic setting of the suspension system must be adjusted according Measuring rear wheel sag suspended 1 Raise the motorcycle with a lif...

Страница 23: ...between A1 and A2 as D2 D2 KMB difference 30 56mm If D2 is differ from specific measurement adjust the spring preload or change bigger spring Adjusting the spring preload of rear shock Adjustable loc...

Страница 24: ...ndlebar to required position 4 Tighten the screws Service Work Raising your motorcycle Raise your motorcycle firmly with a lift stand Front brake removal Removal Installation 1 Remove the brake bolt 2...

Страница 25: ...5 Installation is in the reverse order of removal Removing triple clamp Removal Installation 1 Remove the front shocks 2 Remove the locking nuts from steering column 3 Remove the upper triple clamps...

Страница 26: ...ndlebar to and fro to check if it works smoothly 3 If it s hard to move it remove the triple clamps and check the steering head bearing Greasing the steering head bearing roller Greasing the steering...

Страница 27: ...shock before removing 1 Remove the screws which connect the shock and frame 2 Remove the screws of shock and swing arm 3 Take the rear shock out 4 Installation is in the reverse order of removal Remov...

Страница 28: ...ell to sponge Replace worn parts Maintenance as below 1 Wash the filter hose and make it dry in open air 2 Clean the dust from sponge and soak the surface with filter oil If it hard to clean the spong...

Страница 29: ...stall fasteners parts Removing the fuel tank 1 Remove the seat 2 Remove the rear fixing bolts from fuel tank 3 Remove the front mounting bolts from fuel tank 4 Remove fuel tank from frame 5 Installati...

Страница 30: ...the maximum Tension point if necessary readjust it if the chain is tensioned too much or more than 2 replace the chain better to replace sprocket and chain guide together Because of other wearing par...

Страница 31: ...garm 1 Check if there is crack on swingarm 2 Check if the swingarm has deformation 3 Check the painting layer of swingarm Checking the throttle cable 1 Turn throttle grip then loose it Check if the th...

Страница 32: ...pump or oil pipe Check the whole brake system and adjust it Checking the brake discs disc 1 Check the discs surfaces if it gets cracked or depressed replace it 2 Measure the disc thickness If the dis...

Страница 33: ...Better to consult KAYO dealer Checking the play of foot brake pad Pull the lever if the distance to grip is less than 5mm adjust the play Checking the rear brake pad Brake pad Checking the thickness o...

Страница 34: ...el 1 Raise the motorcycle with a lift stand 2 Remove the chain 3 Loose the locking nut from wheel spindle 4 Holding the rear wheel withdraw the wheel spindle 5 Remove the front wheel 6 Installation is...

Страница 35: ...G KAYO MOTOR CO LTD www kayomoto com 35 KMB 250kPa 250kPa Note check tyre air pressure when tyre is colk Checking rim spoke spoke Check spoke tension regularly if the tension is too low correct spoke...

Страница 36: ...rque M8 28 32N m M6 10 15N m Checking the valve clearance Check valve clearance for first 1000km and per 5000km Excessive clearance will cause valve noise and too small clearance will reduce the engin...

Страница 37: ...testing engine pressure Tuning the Engine Adjusting the idle speed of carburetor Throttle screw air adjusting screw Good idle setting of carburetor is important to start engine Adjusting procedures se...

Страница 38: ...the screw Lubrication System of the Engine Choose lubricating oil Lubricating oil is important to engine performance and service life use specified oil for lubricating The fuel in transmission case is...

Страница 39: ...oil Changing the lubricating oil when engine is warm Put an oil pan under the engine remove the drain bolt and drain the lubricating oil If the plug gasket worn replace new one Install drain bolt and...

Страница 40: ...d value mm Maintenance mm Push rod length 135 85 136 15 135 80 Left and right backlash of rocker group 0 1 0 3 0 35 Free length of valve spring 22 7 24 7 22 5 Valve clearance 0 02 0 04 Valve Valve gui...

Страница 41: ...ead has crack or blister Piston rings with big clearance or get broken Piston has crack or worn out Inner diameter of cylinder is big or a blister in cylinder 2 muffler has black smoke when exhaust Va...

Страница 42: ...r assembly integral 10 straight pin 6 10 11 ZL60 push rods assembly Valve mechanism II 12 ZL60 push rod sleeve 13 ZL60 camshaft group timing driven sprocket included 14 ZL60 camshaft screw 15 ZL60 tim...

Страница 43: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto com 43 3 Remove the fastening screws on rocker assembly 4 Remove mounting bolts rocker assembly and push rod Overhauling the valve mechanism I...

Страница 44: ...ess cover gap Check the air inlet and exhaust valves clearance adjust it to standard value Valve clearance standard cooled engine 0 02 0 04 mm 2 Inspect the rocker assembly and push rod Check whether...

Страница 45: ...bolts M6 10 Rocket assembly fastening bolts 15 Cylinder head fastening bolts 15 Spark plug 15 Adjusting bolts for valve clearance 9 Dismounting the cylinder head assembly 1 Remove head cover rocker as...

Страница 46: ...tness Check the combustor air path door line and clean up the carbon deposit make sure there is no crack on spark plug and valve seat make sure cylinder head oil path is open Check if the cylinder hea...

Страница 47: ...clean up the valve guide measure valve guide inner diameter if it less than the limits replace new guide limits 5 53 remove the valve guide put the cylinder head into a thermostat until the temperatu...

Страница 48: ...ace it Measure the valve line width Length along the axis limits Air inlet valve 1 8 mm Exhaust valve 1 5 mm 5 Overhauling the valve spring check the valve appearance for deformation or abnormal wear...

Страница 49: ...Item Torque N m Bolts for cylinder head coverM6 10 Fastening bolts for rocker assembly 15 Cylinder head fastening bolts 15 Spark plug 15 Adjusting bolts for valve clearance 9 3 Precautions for install...

Страница 50: ...ce standards No Item Standard Limits Remark 1 Cylinder Cinder diameter 44 44 01 44 08 Cylindricity 0 005 0 01 Flatness of cylinder face 0 04 0 06 2 Piston Skirt diameter of piston H 7 43 975 43 985 43...

Страница 51: ...piston and piston ring 1 Remove cylinder head and sealing gaskets 2 Remove fixing screws of cylinder block then take the cylinder block out 3 Remove sealing gaskets and locating pin 4 Remove piston pi...

Страница 52: ...et if intrude into the gasoline Do not damage the contact surface of cylinder block if the bore has abnormal wear or damage replace it measure the inner diameter of bore Bore size limits 44 08 mm Cyli...

Страница 53: ...sure the piston ring end gap Limits 0 35mm 4 Inspect the piston pin check the piston pin if it with abnormal wear change new piston pin check and measure the outer diameter of piston pin Limits 12 98...

Страница 54: ...he opening direction is towards the piston skirt The openings of the two oil rings must be staggered 120 180 and cannot be aligned with the piston pin hole The piston rings should rotate flexibly Do n...

Страница 55: ...r clutch cover 94 94 15 94 5 Fit Outer diameter of clutch sleeve 20 43 20 45 20 35 Inner aperture of clutch housing 20 5 20 521 20 55 Clutch axle sleeve height 14 7 14 8 14 55 2 Timing chain Timing ch...

Страница 56: ...mshaft and rocker Inaccurate valve timing Timing chain wear Tension arm wear Push rod worn or bent Push rod seat cover worn Dismounting the right crankcase and clutch 1 Drain the engine oil and remove...

Страница 57: ...eck the driving disc of clutch if it has abnormal wear replace new parts check the friction plate of driving disc for wear check the free height of driving plate Spring free height limits 22mm Check t...

Страница 58: ...t size of clutch housing and friction plate Limits 90 5 mm 6 Inspect the driven disc of clutch check the driven gear for wear or defect if it has need to change new clutch gear Fixed the central part...

Страница 59: ...Installation is in reverse order of removal 2 Torque table Item Torque N m Fastening bolts M6 of right crankcase 10 Clutch locking nuts 42 3 Installation precautions for right crankcase and clutch app...

Страница 60: ...sembly Valve mechanism II 12 ZL60 push rod seat cover 13 ZL60 camshaft assembly include timing driven sprocket 14 ZL60 camshaft screw 15 ZL60 timing chain assembly 42 16 ZL60 chain tension arm spring...

Страница 61: ...ZHEJIANG KAYO MOTOR CO LTD www kayomoto com 61 driven chain and driving wheel Overhauling the valve mechanism...

Страница 62: ...d condition any defect or wear replace it 4 Inspect driving wheel make sure the parts in good condition any defect or wear replace them 5 Inspect tension arm assembly Observe that the tension arm can...

Страница 63: ...only remove left crankcase is enough Parts specifications Item standards Limits Remark Rotor diameter of supersonic roller pin 9 991 10 9 98 Big starting gear Bore diameter 15 03 15 05 15 08 Over sepa...

Страница 64: ...stator assembly Electric start mechanism breakdown 1 ZL60 starting motor 2 small rocket of starting motor 3 GB894 1 ring 4 Chain guide plate assembly 5 Chain guard plate combination 6 Starting chain...

Страница 65: ...Using special tools to remove magneto rotor Do not knock the magneto rotor 2 If the rotor and stator is hit or dropped replace new parts 4 Remove the baffle of big sprocket then remove chain cove gui...

Страница 66: ...verrunning clutch roller is worn or damaged and if the spring is broken or deformed 2 Overhaul the electric start mechanism Make sure the chain guide plate and guard plate is in good condition any dam...

Страница 67: ...fastening bolt M5 8 Large sprocket baffle bolt M6 10 3 Installation precautions After installing the electric starting mechanism the starting small sprocket chain and guide plate shall be coated with...

Страница 68: ...20 Radial clearance between pump body and outer rotor 0 15 0 21 0 25 End clearance between rotor and pump body 0 05 0 11 0 15 2 Crankshaft Small head diameter of connecting rod 13 010 13 025 13 044 Bi...

Страница 69: ...valve mechanism 3 Remove magneto and electric start mechanism 4 Remove the crankcase fastening screw gently knock the crankshaft and auxiliary shaft with a rubber hammer then remove the right crankca...

Страница 70: ...crankcase if any replace new one Check the left crankshaft bearing The bearing should in good condition Rotate the bearing by hand and it should be flexible without stuck 2 Overhaul right crankcase m...

Страница 71: ...he two points in the X and Y directions of the big connecting rod Limits 0 05mm Measure the big head backlash of connecting rod with a feeler gauge Limits 0 45mm Turn crankshaft bearing by hand check...

Страница 72: ...uxiliary shafts 1 Installation is reverse order of removal 2 Torque table Item Torque N m Crankcase fastening bolt M6 10 Oil pump baffle fastening bolt M6 10 3 Installation precautions Clean up the cr...

Страница 73: ...flow into carburetor No No fuel in tank Oil between tank and carburetor is blocked Yes Float components of carburetor stuck Vent on tank cap blocked Remove the spark plug then test Weak or no spark S...

Страница 74: ...trimming screw adjustment Faulty Improper adjustment Correct Check carburetor gaskets for leaks Yes Bad sealing gasket No Carburetor loose Carburetor gasket damaged Remove the spark plug and conduct...

Страница 75: ...connecting rod are worn Crank pin and connecting rod head worn Check whether the timing chain produces abnormal sound Yes Camshaft wear Timing driven sprocket wear The timing chain lengthens Timing c...

Страница 76: ...ith coils plugs carburetors or any electrical components Storage Preparation for long period storage If you want to store your motorcycle for a long time perform below steps 1 Cover the muffler exhaus...

Страница 77: ...k fuse If fuse is blown replace fuse Low battery Remove seat and check battery Engine failure to start The fuel deteriorated after long parking Replace new fuel Dirt on spark plugs or wet spark plugs...

Страница 78: ...dirt damage or incorrect adjustment on spark plugs Remove spark plugs for cleaning adjustment and replacement if necessary There is a problem with the spark plug cap Check the condition of the spark...

Страница 79: ...Shift drum damaged Replace the shift drum Ratchet device is damaged Replace ratchet gear The spring at the speed selector position is loose or broken Replace the speed selector position spring gear ru...

Страница 80: ...just the chain tension Chain wear Replace the chain and front and rear sprockets Rear sprocket teeth worn Replace rear sprocket Insufficient lubrication of chain Lubricate the chain according to the m...

Страница 81: ...ng nut M10 1 25 1 48 70 Excessive tolerance of steering shaft Check the clearance of steering shaft pressure bearing Steering shaft nut loosened handlebar unsecured Check and re tighten motorcycle lea...

Страница 82: ...8 20 10 9 6 27 35 15 Rear axle nut M12 1 25 1 90 120 16 Rear brake disc cover mounting bolt M6 4 7 11 17 Rear brake caliper mounting bolt M6 20 full thread 1 7 11 18 Ignition coil mounting bolt M6 16...

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