KAYO MOTOR K2 User manual

ZHEJIANG KAYO MOTOR CO., LTD.
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KAYO MOTO
K2
Service Manual
WWW.KAYOMOTO.COM

ZHEJIANG KAYO MOTOR CO., LTD.
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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.

ZHEJIANG KAYO MOTOR CO., LTD.
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Preface
Hereby, on behalf of KAYO all staff thank you for choosing our dirt bike: K2, and we believe
that this choice will not disappoint you.
This manual is designed to help you better use our products, and it introduces the
maintenance adjustment procedure, disassembly and assembly essentials, inspection and
maintenance points, troubleshooting methods and maintenance technical data of K2 model
in detail, with detailed graphic data attached to guide the operation.
Please carefully read this manual and conduct inspection and repair in accordance with the
standard operating practices, which can effectively extend the service 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, equipment and accessories of the motorcycle without prior notice. Due to the
different regulations and requirements in different markets, we have made appropriate
adjustments to the models, so the images in the manual may be different from the standard
samples.In addition, if you have any questions, please refer to our official website
www.kayo.com.cn and contact with our service staff, we will be humbly accept.
Please understand that the contents in this maintenance manual which subject to
change due to vehicle improvement, upgrading will not notify again. The actual
condition of the vehicle shall prevail in the maintenance.
ZHE JIANG KAYO MOTOR CO., LTD
Technical Department

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Content
Symbols and Meanings of Special Words......................................................................................................................... 8
Suggestions for Daily Use............................................................................................................................................. 9
Operation notes.............................................................................................................................................................. 10
Precautions for safety ................................................................................................................................................. 10
Precautions for disassembly and assembly......................................................................................................... 10
Vehicle components and location............................................................................................................................. 12
VIN Code and Engine Number.................................................................................................................................... 14
The Vehicle Parameter.................................................................................................................................................. 15
Important fastener specifications.............................................................................................................................. 16
The Vehicle Control....................................................................................................................................................... 18
Clutch lever inspection............................................................................................................................................ 18
Front brake lever inspection................................................................................................................................... 18
Throttle knob............................................................................................................................................................. 19
Start ........................................................................................................................................................................... 19
Extinguish ................................................................................................................................................................. 19
Fuel Tank Switch ..................................................................................................................................................... 20
Shift check ................................................................................................................................................................ 20
Inspection of rear disc brake.................................................................................................................................. 21
Parking support........................................................................................................................................................ 21
Precautions Before Use ............................................................................................................................................... 21
Advice for beginners................................................................................................................................................ 22
The running-in process........................................................................................................................................... 22
Drive Guide...................................................................................................................................................................... 23
Check items before driving..................................................................................................................................... 23
Precautions for ignition ........................................................................................................................................... 23
Precautions for start ................................................................................................................................................ 24
Precautions for turning............................................................................................................................................ 24
Precautions for acceleration................................................................................................................................... 24
Precautions for shift gears...................................................................................................................................... 24
Precautions for brake.............................................................................................................................................. 24
Precautions for stop & park.................................................................................................................................... 24
Suggested inspection time for all parts of the vehicle ........................................................................................ 25
Suspension system....................................................................................................................................................... 26
Check the vehicle's compression and rebound（with rider）........................................................................... 26
Measure the distance from the center of the rear wheel to the rear fender in suspension .......................... 26
Measure distance from center of rear wheel to rear fender under no load..................................................... 27
Measure distance from center of rear wheel to rear fender in driving condition ............................................ 27
Adjustment for the spring preload of rear shock absorber ................................................................................ 28
Check for the setting of front shock absorber...................................................................................................... 28
Adjustment for the handlebar................................................................................................................................. 28
Disassembly and inspection of vehicle parts......................................................................................................... 29

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Placement................................................................................................................................................................. 29
Disassembly and installation of front shock absorber guard plate................................................................... 29
Disassembly and installation of front disc brake................................................................................................. 30
Disassembly and installation of front shock absorber........................................................................................ 30
Disassembly and installation of clamps................................................................................................................ 31
Check the head steering......................................................................................................................................... 31
Disassembly,installation and lubrication of steering head bearing................................................................... 31
Removal and installation of front fender............................................................................................................... 32
Removal and installation of rear shock absorber........................................................................................................ 32
Removal and installation of seat cushion ................................................................................................................... 33
Removal and installation of air filter.......................................................................................................................... 33
Cleaning and maintenance of air filter ....................................................................................................................... 33
Removal and installation of exhaust pipe................................................................................................................... 34
Removal and installation of muffler........................................................................................................................... 34
Removal and installation of fuel tank......................................................................................................................... 35
Check the chain and clean it....................................................................................................................................... 35
Removal and installation of chain .............................................................................................................................. 36
Check And Adjustment of chain tension.................................................................................................................... 36
Inspection of rear sprocket, engine sprocket and chain guide structure ..................................................................... 37
Inspection of the frame ........................................................................................................................................... 37
Inspection of the swing arm ................................................................................................................................... 37
Inspection of throttle cable ..................................................................................................................................... 38
Inspection of handlebar........................................................................................................................................... 38
Check and maintain of brake system ....................................................................................................................... 38
Check the free stroke of the front brake lever ..................................................................................................... 38
Adjust the stroke of the front brake lever ............................................................................................................. 39
Check the brake disc............................................................................................................................................... 39
Check the front brake fluid level............................................................................................................................ 39
Add the front brake fluid.......................................................................................................................................... 40
Check the front brake pads.................................................................................................................................... 40
Check the free stroke of the foot brake ................................................................................................................ 41
Check the rear disc brake fluid level .......................................................................................................................... 41
Replenish the rear disc brake fluid........................................................................................................................ 42
Check the rear brake pads..................................................................................................................................... 42
Tire inspection and maintenance .............................................................................................................................. 43
Removal and installation of front wheels.............................................................................................................. 43
Removal and installation of rear wheels .............................................................................................................. 43
Check the outside surface of the tire.................................................................................................................... 44
Check the tire pressure........................................................................................................................................... 44
Check the rim and spokes...................................................................................................................................... 44
Electrical system............................................................................................................................................................ 45
Battery removal and installation ............................................................................................................................ 45
Replace the battery ................................................................................................................................................. 45
Engine installation......................................................................................................................................................... 46

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Engine inspection and maintenance ........................................................................................................................ 47
Cylinder head part ................................................................................................................................................... 47
Main parameters and maintenance standards of cylinder head parts............................................................. 47
Troubleshooting.......................................................................................................................................................... 47
Removal of the left cylinder head cover..................................................................................................................... 48
Removal of cylinder head........................................................................................................................................... 48
Decomposition of cylinder head ............................................................................................................................ 49
Inspection of valves and valve springs................................................................................................................. 49
Inspection of camshaft parts.................................................................................................................................. 50
Inspection of cylinder head..................................................................................................................................... 50
Inspection and grinding of valve seat ................................................................................................................... 51
Inspection of valve guide............................................................................................................................................ 51
Assembly of the cylinder head ................................................................................................................................... 51
Installation of the cylinder head ................................................................................................................................. 52
Valve clearance adjustment........................................................................................................................................ 52
Cylinder and Piston .................................................................................................................................................... 53
Precaution:.................................................................................................................................................................. 53
Troubleshooting.......................................................................................................................................................... 53
Disassembly of the cylinder block.............................................................................................................................. 54
Cylinder block inspection........................................................................................................................................... 54
Disassembly of piston and piston ring........................................................................................................................ 55
Inspection of pistons and piston rings ........................................................................................................................ 55
Piston Ring Installation .............................................................................................................................................. 56
Piston installation....................................................................................................................................................... 56
Installation of the cylinder block................................................................................................................................ 57
Right cover, clutch, starting mechanism, shifting mechanism ................................................................................... 57
Precautions ................................................................................................................................................................. 57
Main parameters and maintenance standards ............................................................................................................. 57
Troubleshooting.......................................................................................................................................................... 58
Removal of right crankcase cover .............................................................................................................................. 58
Disassembly of the clutch........................................................................................................................................... 59
Removal of the right body oil pump........................................................................................................................... 59
Removal of the gearshift mechanism ......................................................................................................................... 59
Inspection of Right Crankcase Cover......................................................................................................................... 60
Inspection of the clutch .............................................................................................................................................. 60
Inspection of active teeth............................................................................................................................................ 61
Oil pump inspection ................................................................................................................................................... 61
Shifter inspection........................................................................................................................................................ 61
Assembly of the gearshift mechanism........................................................................................................................ 61
Assembly of the right body oil pump......................................................................................................................... 62
Assembly of the drive gear......................................................................................................................................... 62
Assembly of the clutch............................................................................................................................................... 62
Assembly of the right crankcase cover....................................................................................................................... 62
Left cover, double gear, magneto............................................................................................................................... 63

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Precautions ................................................................................................................................................................. 63
Removal of starter motor............................................................................................................................................ 63
Disassembly of the double gear (1)............................................................................................................................ 63
Removal of left crankcase cover ................................................................................................................................ 63
Disassembly of the magneto stator............................................................................................................................. 63
Disassembly of the magneto rotor.............................................................................................................................. 63
Inspection of Left Crankcase Cover and Duplex Gear Cover .................................................................................... 64
Magneto Inspection.................................................................................................................................................... 64
Start the inspection of the platter teeth ....................................................................................................................... 64
Inspection of starter motor and double gear ............................................................................................................... 64
Start the assembly of large plate teeth and magneto................................................................................................... 64
Assembly of double gear (two) .................................................................................................................................. 65
Installation of magneto stator ..................................................................................................................................... 65
Installation of the left crankcase cover....................................................................................................................... 65
Assembly of double gear (1) ...................................................................................................................................... 66
Assembly of the starter motor .................................................................................................................................... 66
Crankcase, Transmission............................................................................................................................................ 66
Precautions:................................................................................................................................................................ 66
Main parameters and maintenance standards ............................................................................................................. 66
Troubleshooting.......................................................................................................................................................... 67
Crankcase Removal.................................................................................................................................................... 67
Removal of crankshaft, main and auxiliary shafts...................................................................................................... 68
Crankshaft inspection................................................................................................................................................. 68
Inspection of Left and Right Crankcase Bearings ...................................................................................................... 68
Inspection of shift fork, shift fork shaft, shift drum ................................................................................................... 69
Inspection of main and auxiliary shaft combinations ................................................................................................. 69
Checking the oil filter................................................................................................................................................. 69
Assembly of main and auxiliary shafts and crankshaft .............................................................................................. 70
Assembly of closing box and oil filter........................................................................................................................ 70
Assembly of double gear (two) .................................................................................................................................. 70
MOTORCYCLE CLEANING ........................................................................................................................................ 71
STORAGE......................................................................................................................................................................... 71
MAINTENANCE POINTS.............................................................................................................................................. 72

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Symbols and Meanings of Special Words
* This symbol indicates that this operation requires the operator to have professional
knowledge and technical understanding. If you do not have the confidence to complete this
operation, you can go to a professional repair shop or KAYO after-sale service point to be
operated by professionals.
→ This symbol indicates that the specific information is on the following page number.
Danger/warning/attention
In this manual, the words "Danger/Warning/attention" will appear. Please read 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 danger.
Attention: to be alert to minor danger.
However, please note that in this manual, we only enumerate the main safety issues related
to vehicle maintenance and repair, and the contents of warning slogans cannot cover all the
potential dangers during the use and repair of the vehicle.Therefore, in addition to the
"Danger", "Warning" and "Attention" related matters, users must also have basic
mechanical safety knowledge, if you do not grasp the entire maintenance and repair
operation process, please consult a more experienced senior technician before operation.

ZHEJIANG KAYO MOTOR CO., LTD.
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Suggestions for Daily Use
The vast majority of off-road motorcycle fatalities are caused by head injuries. Without
helmets, the chances of serious injury or death from a head-hit are much higher. Therefore,
we strongly recommend that you wear a full set of safety equipment such as helmet, goggles,
gloves and boots when driving, which will save your life at the critical moment.
This series of models is designed for off-road racing at the beginning, without considering
the problem of carrying passengers, and there is no backseat, handlebar and pedal for
carrying people, so please be sure not to use this motorcycle to carry other people except
the driver, which behavior can easily lead to safety accidents.
Try to avoid using non-original parts to modify the car, also do not arbitrarily delete the
original components of the car, if you need to replace any parts, please choose the original
parts produced by KAYO or products authorized by KAYO manufacturers.In addition, the
company is not responsible for any vehicle problems caused by personal modification and
the use of unauthorized parts.
Our K2 product are specially designed for off-road and woodland crossing, so they are not
suitable for highway riding or long-distance motorcycling. If you insist on using them, the
tires may accelerate the wear of the pattern due to high speed rotation and reduce the
service life .It is also not suitable for urban use, as prolonged periods at traffic lights may
cause the engine to overheat and thus shorten its life. Please take care of your vehicle and
avoid problems caused by improper use.
Please check your motorcycle carefully before each use and maintain it in accordance with
the maintenance manual after use. After the motorcycle falls, please first check whether the
main parts are damaged. If you drive a faulty motorcycle, it is very easy to lead to the
occurrence of an accident and endanger your own safety.
When using this motorcycle, the temperature of the engine and exhaust pipe is very high, so
it needs to cool down for a period of time after parking. During this period, do not touch or
move the engine and exhaust pipe, so as not to cause scald. Do not wear shorts while riding,
otherwise leg injuries may result.

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Operation notes
Precautions for safety
1. You must wear work clothes (covered overalls, etc.), hats, and safety boots that are
suitable for the job. If necessary, you should also wear dust-proof glasses, dust-proof masks,
gloves and other safety protection products to protect your body.
2. Because the exhaust contains harmful components, it is forbidden to run the engine for a
long time in a closed place or a place with poor ventilation.
3. When the engine is just stopped, the temperature of the engine and the muffler is still very
high. Do not touch them before cooling to avoid burns.
4. The storage battery solution (dilute sulfuric acid) is a strong corrosive agent, which may
cause burns and blindness when it touches the skin and eyes. If your clothes or skin are
accidentally stained with battery solution, please wash them immediately with plenty of water
and go to the hospital for treatment. The storage battery and storage battery solution should
be kept strictly, and must be placed in a safe place out of the reach of children. When the
battery is charged, it will produce flammable and explosive hydrogen. 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. Pay attention
not only to open flames, but also to electric sparks. In addition, the vaporized gasoline may
explode. Please choose a well-ventilated site for operation.
6. Be careful not to let the rear wheels, clutches and other rotating parts and movable parts
pinch hands and clothes during maintenance.
7. When two or more people are doing homework, they must greet each other continuously
to confirm safety.
Precautions for disassembly and assembly
1. Parts, lubricating oil and grease must use KAYO recommended products.
2. The parts of each system should be sorted and kept separately, so that the parts can be
installed back to their original positions.
3. Please clean the dirt and dust on the car before maintenance.
4. Gaskets, O-rings, piston pin retaining rings, split pins, etc. must be replaced with new
ones after disassembly.
5. When the elastic retaining ring is disassembled, if the opening is too large, it will be
deformed and will easily fall off after reassembly. Please do not use elastic retaining rings
that have become loose or have lost their elasticity.
6. After the parts are disassembled and inspected, they should be cleaned and the cleaning
agent should be blown off with compressed air before the measurement. Apply lubricating oil