KAYO MOTOR KMB60 2021 User manual

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

ZHEJIANG KAYO MOTOR CO., LTD.
www.kayomoto.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 information available before printing.

ZHEJIANG KAYO MOTOR CO., LTD.
www.kayomoto.com
3
Zhejiang KAYO Motor Co., Ltd reserves the right to make changes at any time without notice and
without incurring any obligation.
PREFACE
Thank you for choosing Kayo KMB pit motorcycle. We believe you and your child will enjoy your
riding.
We recommend 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 instructions for both required servicing and specific tasks.
If you have any queries, please visit our website at www.kayomoto.com.
All contents in this manual are subject to improve and update without notice. Maintenance is
based on actual condition.
Zhengjiang Kayo Motor., Ltd
R&D Department
07/2021

ZHEJIANG KAYO MOTOR CO., LTD.
www.kayomoto.com
4
CONTENTS
Symbols and Technical Terms...............................................................................................................8
General Safety........................................................................................................................................9
Component Locations..........................................................................................................................10
Serial Number......................................................................................................................................12
Chassis Number............................................................................................................................12
Engine number..............................................................................................................................12
General Parameters..............................................................................................................................13
Operating Controls...............................................................................................................................14
Front brake....................................................................................................................................14
Throttle..........................................................................................................................................15
Ignition..........................................................................................................................................15
Stop...............................................................................................................................................15
Fuel tap..........................................................................................................................................16
Rear brake.....................................................................................................................................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
Braking Cautions ..........................................................................................................................19
Parking Cautions...........................................................................................................................20
Maintenance Schedule .........................................................................................................................20
Suspension System...............................................................................................................................22
Checking the basic chassis setting with the rider’s weight...........................................................22
Measuring rear wheel sag suspended............................................................................................22
Measuring rear wheel sag unloaded..............................................................................................22
Measuring the riding sag...............................................................................................................23
Adjusting the spring preload of rear shock...................................................................................23

ZHEJIANG KAYO MOTOR CO., LTD.
www.kayomoto.com
5
Checking the front shock..............................................................................................................23
Adjusting handlebar......................................................................................................................24
Service Work .......................................................................................................................................24
Raising your motorcycle...............................................................................................................24
Front brake removal......................................................................................................................24
Front shock removal .....................................................................................................................25
Removing triple clamp..................................................................................................................25
Checking condition of steering head.............................................................................................25
Greasing the steering head bearing...............................................................................................26
Dismounting and installing the front fender.................................................................................26
Removing and installing the rear shock........................................................................................27
Removing the seat.........................................................................................................................27
Removing the air filter..................................................................................................................27
Cleaning and maintenance the air filter ........................................................................................28
Removing the exhaust 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 chain guide......................................................30
Checking the frame.......................................................................................................................31
Checking the swingarm.................................................................................................................31
Checking the throttle cable ...........................................................................................................31
Checking the handlebar.................................................................................................................31
Check and Maintain the Brake System................................................................................................32
Checking the free play of brake lever...........................................................................................32
Checking the brake discs ..............................................................................................................32
Checking the play of brake lever..................................................................................................32
Checking the front braking pad.....................................................................................................32
Checking the play of foot brake pad.............................................................................................33
Checking the rear brake pad .........................................................................................................33
Check and maintain the wheels............................................................................................................34
Removing the front wheel.............................................................................................................34
Removing the rear wheel..............................................................................................................34
Checking the tyre condition..........................................................................................................34