Kayo motor K2 User manual

ZHEJIANG KAYO MOTOR CO., LTD.

KAYO MOTO

Service Manual

WWW.KAYOMOTO.COM

ZHEJIANG KAYO MOTOR CO., LTD.

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.

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

ZHEJIANG KAYO MOTOR CO., LTD.

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

ZHEJIANG KAYO MOTOR CO., LTD.

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