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.

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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

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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

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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

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Checking tyre air pressure ............................................................................................................34
Checking rim spoke ......................................................................................................................35
Installing Engine..................................................................................................................................36
Service and Adjust Work on Engine....................................................................................................36
Checking the bolts and nuts of cylinder head and cylinder ..........................................................36
Checking the valve clearance........................................................................................................36
Checking the compression pressure..............................................................................................36
Tuning the Engine................................................................................................................................37
Adjusting the idle speed of carburetor..........................................................................................37
Cleaning air filter..........................................................................................................................38
Lubrication System of the Engine........................................................................................................38
Choose lubricating oil...................................................................................................................38
Checking the lubricating oil..........................................................................................................39
Changing lubricating oil ...............................................................................................................39
Lubrication system........................................................................................................................39
Overhauling the Engine .......................................................................................................................40
Cylinder head and valve 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 valve mechanism I .............................................................................................43
Installing the valve mechanism I ..................................................................................................45
Dismounting the cylinder head assembly.....................................................................................45
Overhauling cylinder head pars....................................................................................................46
Install cylinder head assembly......................................................................................................49
Cylinder and piston.......................................................................................................................50
Main parameters and maintenance standards ...............................................................................50
Troubleshooting............................................................................................................................50
Dismounting the cylinder block, piston and piston ring...............................................................51
Overhauling of cylinder block, piston and piston ring .................................................................52
Installing the cylinder block, piston and piston ring.....................................................................53
Clutch and valve mechanism II.....................................................................................................55
Main parameters and maintenance standards ...............................................................................55
Troubleshooting............................................................................................................................55
Dismounting the right crankcase and clutch.................................................................................56

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Overhauling right crankcase and clutch........................................................................................57
Installing the right crankcase and clutch.......................................................................................59
Maintain the valve mechanism .....................................................................................................59
Dismounting valve mechanism II.................................................................................................60
Overhauling the valve mechanism................................................................................................61
Installing valve mechanism...........................................................................................................62
Magneto and electric start mechanism..........................................................................................63
Parts specifications........................................................................................................................63
Troubleshooting............................................................................................................................63
Magneto breakdown......................................................................................................................63
Electric start mechanism breakdown............................................................................................64
Dismounting magneto and electric start mechanism ....................................................................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 and maintenance standards ...............................................................................68
Troubleshooting............................................................................................................................68
Dismounting crankcase, crankshaft, oil pump and main and auxiliary shafts..............................69
Overhauling crankcase, crankshaft, oil pump and main and auxiliary shafts...............................70
Installing crankcase, crankshaft, oil pump and main and auxiliary shafts....................................72
Engine Troubleshooting.......................................................................................................................73
Cleaning the motorcycle......................................................................................................................75
Storage .................................................................................................................................................76
Preparation for long period storage...............................................................................................76
Preparing for use after storage......................................................................................................76
Service Work .......................................................................................................................................77
Tightening Torques..............................................................................................................................81

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Symbols and Technical Terms
* Requires professional operation. If you can’t handle it on your own, please send motorcycle to
maintenance shop or consult Kayo after-sales service.
→Page reference (more information is provided on the specified page).
Danger /Warning / Caution
You will find safety messages preceded by 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 instructions or you can be killed or seriously hurt.
Caution Follow the instructions or you can be hurt.
We provide maintenance procedures and information on labels and in owner's manual, it alerts you
some potential hazards, but it’s not possible to list all associated hazards all. You should have your
own judgment, if you can’t finish it seek for professional help.

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General Safety
This model is designed for younger riders. We suggest parents and youngsters read this manual
carefully.
Wear a Helmet
Helmets can reduce the number and severity of head injuries significantly while riding. We urge you
always wear property safety gear such as helmets, gloves, boots.
Single-seat Off-road motorcycle
This motorcycle is for off-road use only. It is designed for one person, there are no handholds,
footrests or seat for a second person, so never 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 accessories, these parts were all designed and tested for your model. We
also suggest you not to remove any original parts from the motorcycle also not to modify it.
We are not responsible for accidents which caused by above behaviors.
motorcycle in Good Condition
Inspect your motorcycle and perform maintenance before and after riding, it’s important for your
riding.
Caution hot
When you’re riding, engine and exhaust pipe are in high temperature, don’t touch it or you will be
scalded. Do not wear shorts when riding.

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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
Breather pipe
13
Footrest

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5
Fuel tank cap
14
Side stand
6
Fuel tank tap
15
Chain 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
Rear brake caliper
21
seat
27
Swing arm
22
Rear shock
28
Spark plug
23
Upper raiser
29
Exhaust pipe

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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 crankcase.

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General Parameters
motorcycle
L*W*H（mm）
1250×600×810
wheelbase（mm）
870
Dry weight（kg）
42
Tyre size
F 2.50-10；R 2.50-10
Seat 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
Compression Ratio
8.5:1
Shift type
Constantly meshing two stage transmission stepless transmission
Starting
Electric
Ignition
CDI
Battery
12v/1.6Ah
Chain
#420H；10T/45T

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Frame/shock/Brake/Wheel
Frame
Steel
Front shock
L=540mm，non-adjustable
Rear shock
L=245mm，non-adjustable
Swing arm
Steel
Handlebar
Alloy
Rim
F 1.40×10，R 1.40×10；Alloy
Front brake
Hydraulic，disc Φ160mm
Rear brake
Hydraulic，disc Φ160mm
Other part
Air filter
Sponge
Operating Controls
Front brake
Front brake lever
Front brake caliper
The front brake lever is used to slow or stop the motorcycle.
Pull the lever to operate.
Adopts caliper disk brake, fixed with 2 bolts.

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Throttle
Throttle
The throttle controls speed. To speed up, rotate the grip toward
you. To slow down, rotate the grip away from you. The throttle
will automatically 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 motorcycle to avoid
engine start with gear.
Make sure there’s fuel in tank. Turning fuel tap ON before
starting the engine.
Stop
Long press stop switch (red) to turn the engine off and stop the
motorcycle.

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Stop switch
Fuel tap
Fuel tap
Fuel tap is under the left side of fuel tank.
The tap is used to control the flow of fuel from thank to
carburetor.
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 carburetor.
Rear brake
Brake lever
The rear brake is used to slow or stop your motorcycle. To
operate, pull the brake lever.
Rear brake caliper
Adopts caliper disc brake, fixed by brake bracket.

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Side stand
The side stand is used to support your motorcycle while parked.
To operate, use your foot to lower the stand. Before riding,
raise the stand.
Preparation before Riding
Advice to Beginners
1. Before 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 help.
4. Clean the motorcycle after each riding, then inspect your motorcycle for leaks or damage.
5. Avoid riding in bad weather such as during heavy snow and rains.
6. We are not responsible for motorcycles problems which cause by malicious act.
Running in

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Running in is an important phrase of your preparation work before using motorcycle. Good running-in can ensure
great engine performance.
Running-in phrase
Maximum engine performance
0-2.5h
50%～75%, long time at one speed and rapidly accelerate is forbidden,
2.5-4h
50%～75%, full throttle is allowed but not exceed 5-10s. Let the engine 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 add fuel if needed, make sure the fuel fill cap is securely fastened.
2. Squeeze the front brake lever to check that the controls operate normally. Adjust freeplay, if necessary.
3. Squeeze the rear brake lever to check that the controls operate normally. Adjust freeplay, if necessary.
4. Check the front brake caliper disc.
5. Check the rear brake caliper disc.
6. Check the brake system.

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7. Check the chain.
8. Check the rear sprocket, engine sprocket and drive chain.
9. Check the chain adjuster.
10. Check the tire surface.
11. Check tire pressure.
12. Check the battery power.
13. Check the front brake disc thickness.
14. Check the rear brake disc thickness.
15. Check the fasteners torque.
16. Check the engine gears.
17. Check the plastics.
18. Check the fuel tank tap.
19. Wear complete protective apparel.
Starting Procedure
1、Turn the fuel tap 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 protective apparel.
2、When start the speed should not be too fast.
3、When start use first gear.
Turning cautions
1、Slow down your motorcycle before turning.
2、When turning, lower your center of gravity to avoid rollover.
3、No gears shifting while turning.
Acceleration Cautions
1、Do not accelerate on curves.
2、After accelerating, shift gears in time.
Braking Cautions
1、Brake should be based on the foot brake, hand brake is auxiliary.
2、check the brake fluid frequently.
3、add proper brake fluid in time.

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Parking Cautions
1、Before stopping, 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
Every 10 hours/After every race
Every 1 hour
Battery
●
●
●
Front brake pad
●
●
●
Rear brake pad
●
●
●