KAYO MOTOR T4 User manual

ZHEJIANG KAYO MOTOR CO., LTD.
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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