KAYO MOTO KT250 User manual

KAYO MOTO
KT250
Assembly Manual
WWW.KAYOMOTO.COM

1.Tools for opening and assembling the dirt
bike.
①Torque wrench
②Phillips screwdriver
③5mm hexagon wrench
④10-12mm wrench
⑤21mm socket
⑥6 hexagon socket
⑦Needle nose pliers
⑧8mm socket
⑨10mm socket
2.Remove the straps and cardboard cover.
3.Take out the parts attached to the vehicle and
iron frame, remove the iron frame screws, wait for
subsequent installation.

4.The parts shown above need to be installed
on the vehicle.
Name
Quantity
1
Handlebar cover
1
Handlebar sponge
1
2
Spark plug socket
1
3
Cable tie (handlebar)
2
4
Coolant
1
5
Front wheel assy
1
6
Front mud fender
1
7
Fuel mix ratio container
1
8
Two stroke engine oil
1
9
Front disc brake cover
1
5.Use tool ④⑧ to remove the screw on the left
side of headlight, then pull the brake oil pipe
out.
6. Remove the cable tie from handlebar. Use tool
①⑥to tighten the handlebar clamps, tighten
evenly, first start by hand tightening all four clamp
bolts then (torque: 25-30N.m). Install the lower
screw of headlight last.
7.Use tool ①⑤⑦ remove the front axle and
cut the wire holding the rear wheel.
8.Put the vehicle on the stand for easy installation
of other accessories.

9.Install the handlebar cover and sponge on the
vehicle.
10.Use tool ⑧to remove screws of lower clamp
assy, then install the front fender and tighten the
screws.
11.Remove the plastic wedges between the
front brake lever and between the brake pads .
12.Install the front axle then use tool ①⑤ to
tighten the fixing nut. (bushings are on the left,
torque: 80-90N.m) .
13.Use tool ①⑥to tighten the screws of front
shock at the torque of 25-30 N.m.
14.Install the front disc brake cover to the left
shock and tighten the screws with tool ③.

15.Use tool ⑨to remove the screws on seat
then remove the seat.
17.Use ratio mix jar to mix the 2-stroke oil and
fuel at a ratio of 30:1, add it to the fuel tank and
tighten the fuel tank cap. Fill the radiator up with
coolant and tighten radiator cap.
16.Put the battery in and use tool ②to install the
battery screws (red is positive, black is negative).
Use tool ⑨to install the seat.
18.Turn the fuel tank petcock to the position shown
above.
19. Please read the user’s manual carefully befo
re riding to better understand the performance
of the vehicle.