KAYO MOTOR T4 User manual

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KAYO MOTO
T4
SERVICE MANUAL
W W W . K AY OMOTO.US

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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 differ slightly from production models.
Preface
This manual, it contains words like “Danger/Warning/Caution”, please read the manual carefully
and follow the instructions closely when performing inspections and repairs. KAYO strongly
recommends that users have authorized dealers perform maintenance, service, inspections, and
repairs. Please be sure to break in, check and maintain the motorcycle in accordance with this
service manual, This will increase your motorcycle’s lifespan.
Notification and Warning
This service manual is edited by KAYO
Manufacturer reserves the right to improve and update this manual, model’s structure, and spare
parts without notice.
The images in this manual may differ from the actual model.
This manual, contains words like “Danger/Warning/Caution”, please read the manual carefully
and follow the instructions closely when performing inspections and repairs, this will increase the
reliability, performance and overall lifespan of the vehicle. The meanings of "DANGER",
"WARNING" and "CAUTION" are as follows:
Danger: you should pay attention on the dangers that may cause severe injuries or death.
Warning: you should notice of the dangers that may cause injuries or vehicle damage.
Caution: you should focus on the dangers that may cause injury or vehicle lifespan decrease.

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Content
Preface………………………………………………………………3
Notification and warning…………………………………………..4
Warranty info…………………………………………………….....4
Vehicle profile……………………………………………………….7
Vehicle component and location……………………………………………………………............8
VIN number…………………………………………………………………………………….....10
Specifications……………………………………………………………………………………...11
Circuit diagram…………………………………………………………………………………....15
Fasteners torque
table………………………………………………………………………………16
Operation instruction…………………………………………….18
Check before riding……………………………………………………………………….............19
Starting steps………………………………………………………………………………............21
Vehicle run in……………………………………………………………………………………...23
Vehicle cleaning……………………………………………………………………………….......23
Storage and use of vehicles……………………............................................................................24

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Routine maintenance…………………………………………...25
Maintenance Periodic Table……………………………………………………………………...26
Specific maintenance content………………………………………………………………….....27
Vehicle settings…………………………………………….......34
Specific settings and methods……………………………………………………………………35
Electric parts inspection………………………………………37
Electric parts inspection and replacement……………………………………………………….38
Vehicle troubleshooting…………………………………………47
Possible failures and troubleshooting methods……………………………………………….....48
Engine maintenance manual…………………………………...52
Main performance parameters………………………………………….....................................53
Structure……………………………………………………………….......................................53
Engine Installation…………………………………………………….......................................54
Engine maintenance and adjustment…………………………....................................................54
Disassembly of the engine……………………………………....................................................57
Torque gauge for engine bolts and nuts.......................................................................................58
Engine failures and troubleshooting............................................................................................59

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Vehicle profile
Vehicle component and location……………………………………………8
VIN number………………………………………………………………..10
Specification……………………………………………………………….11
Circuit diagram…………………………………………………………….15
Fasteners torque table……………………………………………………...16

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Vehicle component and location
No.
Name
No.
Name
1
Front fender
10
Front brake caliper
○
1○ 2 ○ 3 ○ 4○ 5 ○ 6○ 7 ○ 8
○
9 ○ 10 ○ 11 ○ 12 ○ 13 ○ 14 ○ 15 ○ 16 ○ 17

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2
Headlight
11
Front fork
3
Handlebar
12
Fuel tank
4
Vent pipe
13
Carburetor
5
Fuel tank cap
14
Gear shift lever
6
Fuel tank petcock
15
Pedal
7
Air filter
16
Chain
8
Chain slider
17
Chain guide
9
Front brake disc

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No.
Name
No.
Name
18
Rear fender
24
U-shape rocker arm
○
18 ○ 19 ○ 20 ○ 21
○
22 ○ 23 ○ 24 ○ 25 ○ 26 ○ 27 ○
28

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19
Muffler
25
Triangle rocker arm
20
Seat
26
Rear brake master cylinder
21
Rear shock
27
Brake pedal
22
Rear brake disc
28
Muffler pipe
23
Rear brake caliper
VIN number
①
VIN number
Located on frame plate
②
Frame plate
Located on frame head tube
③
Engine number
Located on engine crankcase body
○
1 ○ 2 ○ 3

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Specifications
T4（CP250）size and quality parameters
Length ×width ×height
（mm）
2195×820×1240
wheelbase（mm）
1436mm
weight（kg）
107
Tire spec.
Front 80/100-21；rear 110/90-18
Seat height（mm）
925
Ground clearance（mm）
335
Fuel tank capacity（L）
10
engine parameter
Engine type
Single cylinder, four stroke, air - cooled, vertical
Clutch type
Wet, multi-plate
Cylinder diameter ×stroke
65.5×66.2mm
method of lubrication
Pressure lubrication, splash lubrication
Oil capacity
1000ml
Oil brand
SJ 10W-40
displacement
223cc
Max power（kw/r/min）
15/8500
Max torque（N•m/r/min）
18/6500
compression ratio
9.25:1
Gear shift type
International six gears 1-N-2-3-4-5-6

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Start method
Electric start
Fuel control system
PE28 carburetor
battery
12V/2.4Ah lithium battery
chain
#520H；13T/45T
Frame/shock absorber/braking/wheel parameters
Frame type
High strength steel tube frame
Front shock
Inverted double adjustable front shock，L=880mm
Rear shock absorber
Compression recovery double adjustable nitrogen charged shock，L=450mm
Rear swing arm
Aluminum swingarm，L=570mm
handlebar
Aluminum alloy tapered handlebar，material 7075 Φ28.6mm
Front&rear rim
Front 1.60×21，rear 2.15×18；Black aluminum rim，Bright silver hub
Front brake system
Double piston pump hydraulic brake system，brake disc Φ270mm
Rear brake system
Single piston pump hydraulic brake system, brake disc Φ240mm
other
Air filter type
Sponge filter type
Fuel type
Gasoline No. 92 and above
Persons capacity
1 person（driver）
Maximum load mass
120kg

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Circuit diagram

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Fastener torque table
Note: before installing the thread, apply anti-rust grease on the thread and joint surface.
No.
Item
Fastener specification
Qty
Torque （N•m）
1
Front brake caliper mounting bolt
M8×40 full thread
2
20～32
2
front brake shield mounting screw
M6×16
2
7～11
3
steering column screw
铝制银色
1
/
4
Upper lock block mounting screw
M8×30
4
20～32
5
Front brake disc mounting bolt
M6×16
6
7～11
6
Front wheel axle mounting nut
M16×1.5×H14
1
175～218
7
Footpedal seat mounting bolt
M8×20 full thread
2
20～32
8
shift lever mounting bolt
M6×25
1
7～11
9
Engine hanger bolt
M8×60
3
20～32
10
Engine mounting nut
M10×1.25
2
40～70
11
Water tank mounting screw
M6×25
4
7～11
12
Exhaust pipe mounting nut
M8
2
20～32
13
Chain guider mounting screw
M6×12
3
7～11
14
Swing arm axle mounting nut
M16×1.5×H14.8
1
175～218
15
Triangle linkage mounting nut
M12×1.25
3
68～85
16
Chain adjustment bolt
M10×40×1.25 S14
2
36～55
17
Chain adjustment nut
M10×1.25
2
40～70
18
Rear shock and frame connection bolt
M10×50×1.25
1
40～70
19
oval head bolt
M10×42×1.25+Φ10×28
1
40～70

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20
Rear brake disc mounting bolt
M6×16
4
7～11
21
Rear sproket mounting screw
M8×31 10.9 级
6
27～35
22
Rear wheel axle nut
M22×1.5
1
452～550
23
Rear brake shield mounting bolt
M6×12
4
7～11
24
Brake pedal head mounting screw
M5×10 full thread
2
4～7
25
brake limit bolt
M8×20 full thread
1
20～32
26
Rear brake pump mounting bolt
M6×16 full thread
2
7～11
27
brake pedal bolt
M6×25 full thread
1
7～11
28
Ignition coil mounting bolt
M6×20
2
7～11
29
Plastics mounting bolt
M6×16 full thread
10
7～11
30
CDI mounting bolt
M6×16 full thread
2
7～11
31
voltage regulator mounting bolt
M6×25 full thread
2
7～11
32
Electric switch lock bracket bolt
M6×12
2
7～11
33
Fuel tank switch mounting screw
M5×12 full thread
2
4～7
34
front mudguard bolt
M6×12
4
7～11
35
Left and right guard plate and fuel tank
connection screw
M5×10 full thread
6
4～7
36
Cross head screw
ST 4.2×12
10
/
37
Cross flat head screw
M6×10
4
/
38
sparking plug
/
1
25～30

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OPERATION INSTRUCTIONS
Check before riding
………………………………………………………19
Starting steps ……………………………………………………………..21
Vehicle run in………………………………………………………..........23
Vehicle cleaning ……………………………………………………….....23
Storage and use of vehicles
........................................................................24

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Check before riding
1.Fuel level
Open the tank cap and shake the handlebars, and observe the fuel the level of
the tank. If fuel is low, please add fuel.
Tank cap
2. Fuel tank switch
There are three positions of the fuel tank switch in this motorcycle, from top
to bottom: RES (the auxiliary fuel tank is open), OFF (the fuel tank switch is
closed), ON (the fuel tank switch is open).If the fuel tank switch is OFF,
there is no fuel in the carburetor and the engine cannot run. If fuel is low in
the tank, switch the tank to the RES position and refuel immediately. If fuel
is sufficient and the motorcycle is in good condition, switch to ON.
Note: when the engine is turned off, turn the tank switch to OFF
3. Engine Oil level.
Engine Oil capcity:1500ml. To check oil level run the vehicle
for a few minutes until it reaches operating temperature. Then stand
the bike up vertically and check the sight glass on the lower right
side of the engine case.
Low High

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4. Brake fluid level.
Through the brake fluid sight glass (①and②), checking the
brake fluid in the brake master cylinder. If brake fluid level is lower
than half of the observation hole, or "LOWER" position, then add
brake fluid.
Note: brake fluid should be replaced annually even if the
motorcycle has not been used for a long time.
Note: please check the brake fluid level frequently. Check the brake
line and connecting points for damage or wear. If any, please
replace. Check the master cylinder/calipers for damage or wear, if
any, please replace.
Note: Do not leave .brake reservoirs open for extended periods of
time
Note: Always use brake fluid from an unopened container
①Front Brake fluid sight
glass
②Rear Brake fluid sight
glass
Brake pad
5.Brake pads
Check the caliper brake pad’s thickness, if the brake pad’s thickness is less
than the minimum thickness, the brake pad must be replaced. Check the
caliper brake pad for damage or crack. If there is damage or crack, a new
brake pad should be replaced.
Minimum thickness of brake pad:
Front MIN = 1 mm
Rear MIN = 1 mm
Note: brake pads should be replaced as a set.

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6. brake disc
Check for damage to the brake disc surface, (scratches, gouges, warping,
bluing) and check the thickness, if the brake disc is less than the limit
thickness, the brake disc must be replaced immediately.
Limit thickness of brake disc:
Front MIN=3.5mm
Rear MIN=3.5mm
Brake disc
7.Check tire pressure
Use the pressure gauge to check whether the tire pressure level is in
specification,
Recommended pressure: front 2.23 bar (2.23 kgf /cm2); rear 2.77bar (2.77
kgf /cm2).
Note: the tire pressure check should be done under cool conditions. Riding
with over or under inflated tires will affect operation and ride comfort and
may result in irregular tire wear and loss of control
8.Check spoke tension
Pinch the two adjacent spokes with your fingers to check whether there is a
lack of tension in the spokes. If the spokes are found loose wheel truing and
tightening may need to be performed..
NOTE: spoke tensioning and truing should be performed by a professional

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9.Check the chain and its supporting parts
Check chain tension. If the chain is too loose, it can be adjusted by loosening
the rear axle and adjusting the chain adjusters. Do not make the chain too
tight.
Note: if the chain needs to be tensioned frequently, or if you find any signs
of wear on the front sprocket, rear sprocket and chain replace immediately.
chain adjuster
10.Check whether the front shock absorber needs to vent
When the ambient temperature is high, the gas in the shock absorber is
heated and expands. At this time, it is necessary to exhaust the gas through
the exhaust screw at the front and the upper end. Otherwise, it is easy to
expand and damage the oil seal, which will affect the use of the shock
absorber.
Exhaust screw
11.Inspection of the remaining components
Visually inspect the entire motorcycle for loose parts. Tighten any loose
bolt or parts
. Check the battery charge.
check the lights.
Note: these pre ride checks won't take much time, but it can help you
develop good riding habits and make your daily riding easier and safer.
.
starting steps

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Clutch handlebar
Key switch Start button
The electric starting steps are as follows:
1. Switch the fuel tank to the "ON" position;
2. turn the key switch on;
3, the left hand pull in clutch lever;
4, the right hand pull in front brake lever;
5. push the start button
6. once then engine starts make sure you are in neutral and release
clutch and brake levers
Note: when the vehicle starts, the brake should be applied to prevent
the vehicle from starting in gear.