KAYO MOTOR T4 Bedienungsanleitung

ZHEJIANG KAYO MOTOR CO., LTD.

www.kayomoto.us

KAYO MOTO

SERVICE MANUAL

W W W . K AY OMOTO.US

ZHEJIANG KAYO MOTOR CO., LTD.

www.kayomoto.us

- 2 -

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.

ZHEJIANG KAYO MOTOR CO., LTD.

www.kayomoto.us

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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

ZHEJIANG KAYO MOTOR CO., LTD.

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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

ZHEJIANG KAYO MOTOR CO., LTD.

www.kayomoto.us

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Vehicle profile

Vehicle component and location……………………………………………8

VIN number………………………………………………………………..10

Specification……………………………………………………………….11

Circuit diagram…………………………………………………………….15

Fasteners torque table……………………………………………………...16

ZHEJIANG KAYO MOTOR CO., LTD.

www.kayomoto.us

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Vehicle component and location

No.

Name

No.

Name

Front fender

Front brake caliper

○

1○

2 ○

3 ○

4○

5 ○

6○

7 ○

○

9 ○

10 ○

11 ○

12 ○

13 ○

14 ○

15 ○

16 ○

ZHEJIANG KAYO MOTOR CO., LTD.

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Headlight

Front fork

Handlebar

Fuel tank

Vent pipe

Carburetor

Fuel tank cap

Gear shift lever

Fuel tank petcock

Pedal

Air filter

Chain

Chain slider

Chain guide

Front brake disc

ZHEJIANG KAYO MOTOR CO., LTD.

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No.

Name

No.

Name

Rear fender

U-shape rocker arm

○

18 ○

19 ○

20 ○

○

22 ○

23 ○

24 ○

25 ○

26 ○

27 ○

ZHEJIANG KAYO MOTOR CO., LTD.

www.kayomoto.us

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Muffler

Triangle rocker arm

Seat

Rear brake master cylinder

Rear shock

Brake pedal

Rear brake disc

Muffler pipe

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 ○

ZHEJIANG KAYO MOTOR CO., LTD.

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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）

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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