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KAYO MOTOR K4 - User Manual

KAYO MOTOR K4
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ZHEJIANG KAYO MOTOR CO., LTD.
www.kayomoto.us
- 1 -
KAYO MOTO
K4
Service Manual
WWW.KAYOMOTO.COM

Questions and Answers

Summary

Preface

Content

Symbols and Meanings of Special Words

Danger, Warning, and Attention Symbols

Meanings of danger, warning, and attention terms used in the manual.

Suggestions for Daily Use

Operation Notes

Safety Precautions

Important safety guidelines for operating and maintaining the vehicle.

Disassembly and Assembly Precautions

Guidelines for safely disassembling and reassembling vehicle components.

Vehicle Components and Location

K4 Specific Components and Locations

Diagram and labels identifying key parts of the K4 model.

VIN Code and Engine Number

VIN Code Location

Location of the Vehicle Identification Number (VIN) on the motorcycle.

Engine Number Location

Location of the engine number on the motorcycle.

Vehicle Parameters

Table listing key vehicle dimensions and mass specifications.

Engine Parameters

Frame, Shock, Brake, and Wheel System Parameters

Specifications for the frame, suspension, and braking systems.

Other Specifications

Miscellaneous specifications not covered in other categories.

Important Fastener Specifications

Vehicle Control

Clutch Lever Inspection

Procedure for inspecting the clutch lever and its adjustment.

Front Brake Lever Inspection

Procedure for inspecting the front brake lever and its adjustment.

Throttle Knob Operation

Description of the throttle knob's location and operation.

Starting the Engine

Instructions for starting the motorcycle engine using the start button or lever.

Engine Flameout Switch

Location and operation of the engine flameout (kill) switch.

Fuel Tank Switch Operation

How to operate the fuel tank switch for fuel supply control.

Shift Lever and Gear Check

Inspection of the shift lever and gear shifting mechanism.

Rear Disc Brake Inspection

Inspection of the rear disc brake operation and pedal.

Precautions Before Use

Advice for Beginners

Essential guidance for new riders operating the motorcycle.

The Running-In Process

Drive Guide

Pre-Ride Checks

List of essential checks to perform before riding the motorcycle.

Ignition Precautions

Guidelines for safely starting the motorcycle's electrical system.

Starting Precautions

Safety measures to follow when starting the motorcycle.

Turning Precautions

Safety tips for maneuvering the motorcycle during turns.

Acceleration Precautions

Safety advice for accelerating the motorcycle.

Suggested Inspection Schedule

Gear Shifting Precautions

Guidelines for safe and proper gear shifting.

Braking Precautions

Important safety instructions for using the brakes.

Stopping and Parking Precautions

Steps and safety advice for stopping and parking the motorcycle.

Suspension System

Rear Shock Low-Speed Compression Damping Adjustment

Procedure to adjust low-speed compression damping on the rear shock absorber.

Rear Shock High-Speed Compression Damping Adjustment

Procedure to adjust high-speed compression damping on the rear shock absorber.

Rear Wheel to Fender Distance Measurement (Suspension)

Rear Wheel to Fender Distance Measurement (No Load)

Rear Wheel to Fender Distance Measurement (Driving Condition)

Rear Shock Absorber Spring Preload Adjustment

Front Shock Absorber Setting Check

Front Shock Compression Damping Adjustment

Handlebar Adjustment

Disassembly and Inspection of Vehicle Parts

Vehicle Placement for Maintenance

Proper positioning of the motorcycle for maintenance tasks.

Front Shock Absorber Guard Plate Disassembly;Installation

Steps for removing and installing the front shock absorber guard plate.

Front Disc Brake Disassembly;Installation

Front Shock Absorber Disassembly;Installation

Coupling Plate Disassembly;Installation

Head Steering Check

Steering Head Bearing Disassembly, Installation, and Lubrication

Front Fender Removal and Installation

Rear Shock Absorber Removal and Installation

Seat Cushion Removal and Installation

Air Filter Removal and Installation

Air Filter Cleaning and Maintenance

Exhaust Pipe Removal and Installation

Muffler Removal and Installation

Fuel Tank Removal and Installation

Chain Inspection and Cleaning

Chain Removal and Installation

Chain Tension Adjustment

Rear Sprocket, Engine Sprocket, and Chain Guide Inspection

Frame Inspection

Swing Arm Inspection

Throttle Cable Inspection

Handlebar Inspection

Brake System Check and Maintenance

Front Brake Lever Free Stroke Check

Procedure to check the free play of the front brake lever.

Front Brake Lever Stroke Adjustment

How to adjust the front brake lever stroke.

Brake Disc Inspection

Front Brake Fluid Level Check

Adding Front Brake Fluid

Front Brake Pad Inspection

Foot Brake Pedal Free Stroke Check

Rear Disc Brake Fluid Level Check

Replenishing Rear Disc Brake Fluid

Rear Brake Pad Inspection

Tire Inspection and Maintenance

Front Wheel Removal and Installation

Steps for dismantling and refitting the front wheel.

Rear Wheel Removal and Installation

Steps for dismantling and refitting the rear wheel.

Tire Outer Surface Inspection

Tire Pressure Check

Rim and Spoke Inspection

Electrical System

Battery Removal and Installation

Steps for removing and installing the motorcycle battery.

Battery Replacement

Engine Installation

Main Engine Performance Parameters

Engine Inspection and Maintenance

Cylinder Head Parts Inspection

Precautions and standards for inspecting cylinder head components.

Cylinder Head Troubleshooting

Common problems and their possible causes related to the cylinder head.

Cylinder Head Assembly Diagram

Left Cylinder Head Cover Removal

Cylinder Head Removal

Cylinder Head and Block Connecting Bolts

Cylinder Head Decomposition

Valve and Valve Spring Inspection

Camshaft Parts Inspection

Cylinder Head Inspection

Valve Seat Inspection and Grinding

Valve Guide Inspection

Cylinder Head Assembly

Valve Clearance Adjustment

Cylinder and Piston

Cylinder Block and Piston Parameters and Standards

Specifications and maintenance limits for cylinder and piston.

Cylinder and Piston Troubleshooting

Common issues and solutions for cylinder and piston problems.

Cylinder Block Disassembly

Cylinder Block Inspection

Piston and Piston Ring Disassembly

Piston and Piston Ring Inspection

Piston Ring Installation

Piston Installation

Cylinder Block Installation

Right Cover, Clutch, Starting, and Shifting Mechanisms

Mechanism Precautions

Important considerations before working on these mechanisms.

Mechanism Parameters and Standards

Specifications and maintenance limits for these mechanisms.

Clutch Parameters

Oil Pump Parameters

Clutch and Oil Pump Troubleshooting

Clutch Disassembly

Right Body Oil Pump Removal

Gearshift Mechanism Removal

Right Crankcase Cover Inspection

Clutch Inspection

Active Teeth Inspection

Oil Pump Inspection

Shifter Inspection

Gearshift Mechanism Assembly

Right Body Oil Pump Assembly

Drive Gear Assembly

Clutch Assembly

Right Crankcase Cover Assembly

Left Cover, Double Gear, and Magneto

Left Cover, Double Gear, Magneto Precautions

Precautions for working on these components.

Starter Motor Removal

Steps for removing the starter motor.

Double Gear Disassembly (1)

Steps for disassembling the double gear assembly.

Left Crankcase Cover Removal

Steps for removing the left crankcase cover.

Magneto Stator Disassembly

Steps for disassembling the magneto stator.

Magneto Rotor Disassembly

Steps for disassembling the magneto rotor.

Left Crankcase and Duplex Gear Cover Inspection

Checking the integrity of these covers.

Magneto Inspection

Checking the magneto stator and rotor for damage.

Platter Teeth Inspection

Starter Motor and Double Gear Inspection

Large Plate Teeth and Magneto Assembly

Double Gear Assembly (Two)

Magneto Stator Installation

Left Crankcase Cover Installation

Double Gear Assembly (1)

Starter Motor Assembly

Crankcase and Transmission

Crankcase and Transmission Precautions

Precautions for transmission and crankshaft work.

Crankcase and Transmission Parameters and Standards

Specifications and maintenance limits for crankcase and transmission.

Change Fork Specifications

Crankshaft Connecting Shaft Specifications

Crankcase and Transmission Troubleshooting

Crankcase Removal

Crankshaft, Main, and Auxiliary Shaft Removal

Crankshaft Inspection

Left and Right Crankcase Bearing Inspection

Shift Fork, Shaft, and Drum Inspection

Main and Auxiliary Shaft Combinations Inspection

Oil Filter Check

Main, Auxiliary Shafts, and Crankshaft Assembly

Closing Box and Oil Filter Assembly

Motorcycle Cleaning

Storage

Preparing for Long Storage

Steps to prepare the motorcycle for extended storage periods.

Preparing for Use After Long Storage

Maintenance Points and Troubleshooting

Engine Water Intake Issues

Troubleshooting and solutions for water entering the engine.

Air;Fuel Mixture Issues

Problems related to incorrect air and fuel mixture.

Engine Stops Immediately After Starting

Troubleshooting for engines that stop shortly after starting.

Engine Overheating

Causes and solutions for engine overheating.

Unbalanced Engine Issues

Troubleshooting for unbalanced engine operation.

Operation or Adjustment Errors

Issues arising from incorrect operation or adjustments.

Insufficient Engine Power or Poor Acceleration

Troubleshooting for reduced engine power and acceleration.

Abnormal Engine Sound

Diagnosing and resolving abnormal engine noises.

Exhaust Pipe Backfire

Causes and solutions for exhaust pipe backfiring.

White Smoke from Exhaust Pipe

Troubleshooting for white smoke emitted from the exhaust.

Black Smoke from Exhaust Pipe

Troubleshooting for black smoke emitted from the exhaust.

Gearbox Gear Meshing Issues

Problems with gears not meshing properly in the gearbox.

Gear Bounce

Issues related to gear bounce.

Tooth Wear and Gear Damage

Issues related to worn teeth or damaged gears.

Gear Damage

Specifics on gear damage.

Damaged Displacement Drum Groove

Problems with the displacement drum groove.

Worn Fork Shaft

Issues related to a worn fork shaft.

Damaged Selector Position Spring

Problems with a damaged selector position spring.

Motorcycle Steering Difficulty

Troubleshooting for steering that is difficult or stiff.

Suspension Damping Too Hard

Issues related to overly stiff suspension damping.

Suspension Damping Too Soft

Issues related to overly soft suspension damping.

Abnormal Noise During Driving

Diagnosing and fixing abnormal noises during motorcycle operation.

Motorcycle Front Wheel Shimmy

Troubleshooting for front wheel wobble or shimmy.

Motorcycle Skewing to One Side

Diagnosing why the motorcycle pulls to one side.

Brake Failure Issues

Troubleshooting and solutions for brake system failures.

Summary

Preface

Content

Symbols and Meanings of Special Words

Danger, Warning, and Attention Symbols

Meanings of danger, warning, and attention terms used in the manual.

Suggestions for Daily Use

Operation Notes

Safety Precautions

Important safety guidelines for operating and maintaining the vehicle.

Disassembly and Assembly Precautions

Guidelines for safely disassembling and reassembling vehicle components.

Vehicle Components and Location

K4 Specific Components and Locations

Diagram and labels identifying key parts of the K4 model.

VIN Code and Engine Number

VIN Code Location

Location of the Vehicle Identification Number (VIN) on the motorcycle.

Engine Number Location

Location of the engine number on the motorcycle.

Vehicle Parameters

Table listing key vehicle dimensions and mass specifications.

Engine Parameters

Frame, Shock, Brake, and Wheel System Parameters

Specifications for the frame, suspension, and braking systems.

Other Specifications

Miscellaneous specifications not covered in other categories.

Important Fastener Specifications

Vehicle Control

Clutch Lever Inspection

Procedure for inspecting the clutch lever and its adjustment.

Front Brake Lever Inspection

Procedure for inspecting the front brake lever and its adjustment.

Throttle Knob Operation

Description of the throttle knob's location and operation.

Starting the Engine

Instructions for starting the motorcycle engine using the start button or lever.

Engine Flameout Switch

Location and operation of the engine flameout (kill) switch.

Fuel Tank Switch Operation

How to operate the fuel tank switch for fuel supply control.

Shift Lever and Gear Check

Inspection of the shift lever and gear shifting mechanism.

Rear Disc Brake Inspection

Inspection of the rear disc brake operation and pedal.

Precautions Before Use

Advice for Beginners

Essential guidance for new riders operating the motorcycle.

The Running-In Process

Drive Guide

Pre-Ride Checks

List of essential checks to perform before riding the motorcycle.

Ignition Precautions

Guidelines for safely starting the motorcycle's electrical system.

Starting Precautions

Safety measures to follow when starting the motorcycle.

Turning Precautions

Safety tips for maneuvering the motorcycle during turns.

Acceleration Precautions

Safety advice for accelerating the motorcycle.

Suggested Inspection Schedule

Gear Shifting Precautions

Guidelines for safe and proper gear shifting.

Braking Precautions

Important safety instructions for using the brakes.

Stopping and Parking Precautions

Steps and safety advice for stopping and parking the motorcycle.

Suspension System

Rear Shock Low-Speed Compression Damping Adjustment

Procedure to adjust low-speed compression damping on the rear shock absorber.

Rear Shock High-Speed Compression Damping Adjustment

Procedure to adjust high-speed compression damping on the rear shock absorber.

Rear Wheel to Fender Distance Measurement (Suspension)

Rear Wheel to Fender Distance Measurement (No Load)

Rear Wheel to Fender Distance Measurement (Driving Condition)

Rear Shock Absorber Spring Preload Adjustment

Front Shock Absorber Setting Check

Front Shock Compression Damping Adjustment

Handlebar Adjustment

Disassembly and Inspection of Vehicle Parts

Vehicle Placement for Maintenance

Proper positioning of the motorcycle for maintenance tasks.

Front Shock Absorber Guard Plate Disassembly;Installation

Steps for removing and installing the front shock absorber guard plate.

Front Disc Brake Disassembly;Installation

Front Shock Absorber Disassembly;Installation

Coupling Plate Disassembly;Installation

Head Steering Check

Steering Head Bearing Disassembly, Installation, and Lubrication

Front Fender Removal and Installation

Rear Shock Absorber Removal and Installation

Seat Cushion Removal and Installation

Air Filter Removal and Installation

Air Filter Cleaning and Maintenance

Exhaust Pipe Removal and Installation

Muffler Removal and Installation

Fuel Tank Removal and Installation

Chain Inspection and Cleaning

Chain Removal and Installation

Chain Tension Adjustment

Rear Sprocket, Engine Sprocket, and Chain Guide Inspection

Frame Inspection

Swing Arm Inspection

Throttle Cable Inspection

Handlebar Inspection

Brake System Check and Maintenance

Front Brake Lever Free Stroke Check

Procedure to check the free play of the front brake lever.

Front Brake Lever Stroke Adjustment

How to adjust the front brake lever stroke.

Brake Disc Inspection

Front Brake Fluid Level Check

Adding Front Brake Fluid

Front Brake Pad Inspection

Foot Brake Pedal Free Stroke Check

Rear Disc Brake Fluid Level Check

Replenishing Rear Disc Brake Fluid

Rear Brake Pad Inspection

Tire Inspection and Maintenance

Front Wheel Removal and Installation

Steps for dismantling and refitting the front wheel.

Rear Wheel Removal and Installation

Steps for dismantling and refitting the rear wheel.

Tire Outer Surface Inspection

Tire Pressure Check

Rim and Spoke Inspection

Electrical System

Battery Removal and Installation

Steps for removing and installing the motorcycle battery.

Battery Replacement

Engine Installation

Main Engine Performance Parameters

Engine Inspection and Maintenance

Cylinder Head Parts Inspection

Precautions and standards for inspecting cylinder head components.

Cylinder Head Troubleshooting

Common problems and their possible causes related to the cylinder head.

Cylinder Head Assembly Diagram

Left Cylinder Head Cover Removal

Cylinder Head Removal

Cylinder Head and Block Connecting Bolts

Cylinder Head Decomposition

Valve and Valve Spring Inspection

Camshaft Parts Inspection

Cylinder Head Inspection

Valve Seat Inspection and Grinding

Valve Guide Inspection

Cylinder Head Assembly

Valve Clearance Adjustment

Cylinder and Piston

Cylinder Block and Piston Parameters and Standards

Specifications and maintenance limits for cylinder and piston.

Cylinder and Piston Troubleshooting

Common issues and solutions for cylinder and piston problems.

Cylinder Block Disassembly

Cylinder Block Inspection

Piston and Piston Ring Disassembly

Piston and Piston Ring Inspection

Piston Ring Installation

Piston Installation

Cylinder Block Installation

Right Cover, Clutch, Starting, and Shifting Mechanisms

Mechanism Precautions

Important considerations before working on these mechanisms.

Mechanism Parameters and Standards

Specifications and maintenance limits for these mechanisms.

Clutch Parameters

Oil Pump Parameters

Clutch and Oil Pump Troubleshooting

Clutch Disassembly

Right Body Oil Pump Removal

Gearshift Mechanism Removal

Right Crankcase Cover Inspection

Clutch Inspection

Active Teeth Inspection

Oil Pump Inspection

Shifter Inspection

Gearshift Mechanism Assembly

Right Body Oil Pump Assembly

Drive Gear Assembly

Clutch Assembly

Right Crankcase Cover Assembly

Left Cover, Double Gear, and Magneto

Left Cover, Double Gear, Magneto Precautions

Precautions for working on these components.

Starter Motor Removal

Steps for removing the starter motor.

Double Gear Disassembly (1)

Steps for disassembling the double gear assembly.

Left Crankcase Cover Removal

Steps for removing the left crankcase cover.

Magneto Stator Disassembly

Steps for disassembling the magneto stator.

Magneto Rotor Disassembly

Steps for disassembling the magneto rotor.

Left Crankcase and Duplex Gear Cover Inspection

Checking the integrity of these covers.

Magneto Inspection

Checking the magneto stator and rotor for damage.

Platter Teeth Inspection

Starter Motor and Double Gear Inspection

Large Plate Teeth and Magneto Assembly

Double Gear Assembly (Two)

Magneto Stator Installation

Left Crankcase Cover Installation

Double Gear Assembly (1)

Starter Motor Assembly

Crankcase and Transmission

Crankcase and Transmission Precautions

Precautions for transmission and crankshaft work.

Crankcase and Transmission Parameters and Standards

Specifications and maintenance limits for crankcase and transmission.

Change Fork Specifications

Crankshaft Connecting Shaft Specifications

Crankcase and Transmission Troubleshooting

Crankcase Removal

Crankshaft, Main, and Auxiliary Shaft Removal

Crankshaft Inspection

Left and Right Crankcase Bearing Inspection

Shift Fork, Shaft, and Drum Inspection

Main and Auxiliary Shaft Combinations Inspection

Oil Filter Check

Main, Auxiliary Shafts, and Crankshaft Assembly

Closing Box and Oil Filter Assembly

Motorcycle Cleaning

Storage

Preparing for Long Storage

Steps to prepare the motorcycle for extended storage periods.

Preparing for Use After Long Storage

Maintenance Points and Troubleshooting

Engine Water Intake Issues

Troubleshooting and solutions for water entering the engine.

Air;Fuel Mixture Issues

Problems related to incorrect air and fuel mixture.

Engine Stops Immediately After Starting

Troubleshooting for engines that stop shortly after starting.

Engine Overheating

Causes and solutions for engine overheating.

Unbalanced Engine Issues

Troubleshooting for unbalanced engine operation.

Operation or Adjustment Errors

Issues arising from incorrect operation or adjustments.

Insufficient Engine Power or Poor Acceleration

Troubleshooting for reduced engine power and acceleration.

Abnormal Engine Sound

Diagnosing and resolving abnormal engine noises.

Exhaust Pipe Backfire

Causes and solutions for exhaust pipe backfiring.

White Smoke from Exhaust Pipe

Troubleshooting for white smoke emitted from the exhaust.

Black Smoke from Exhaust Pipe

Troubleshooting for black smoke emitted from the exhaust.

Gearbox Gear Meshing Issues

Problems with gears not meshing properly in the gearbox.

Gear Bounce

Issues related to gear bounce.

Tooth Wear and Gear Damage

Issues related to worn teeth or damaged gears.

Gear Damage

Specifics on gear damage.

Damaged Displacement Drum Groove

Problems with the displacement drum groove.

Worn Fork Shaft

Issues related to a worn fork shaft.

Damaged Selector Position Spring

Problems with a damaged selector position spring.

Motorcycle Steering Difficulty

Troubleshooting for steering that is difficult or stiff.

Suspension Damping Too Hard

Issues related to overly stiff suspension damping.

Suspension Damping Too Soft

Issues related to overly soft suspension damping.

Abnormal Noise During Driving

Diagnosing and fixing abnormal noises during motorcycle operation.

Motorcycle Front Wheel Shimmy

Troubleshooting for front wheel wobble or shimmy.

Motorcycle Skewing to One Side

Diagnosing why the motorcycle pulls to one side.

Brake Failure Issues

Troubleshooting and solutions for brake system failures.

KAYO MOTOR K4 Specifications

General IconGeneral
BrandKAYO MOTOR
ModelK4
CategoryMotorcycle
LanguageEnglish

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