KAYO MOTOR K6-R - User Manual

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KAYO MOTO
K6-R
Service Manual
W W W . K A Y OMOTO.US

Summary

Preface and Warnings

Preface

Introduction to the service manual.

Notification and Warning

Important safety notices and disclaimers regarding manual use.

Operating and Maintenance Instructions

Operating instruction

Pre-ride checks, starting, run-in, cleaning, and storage guidelines.

Check before use

Pre-ride checks for safety and proper function.

starting steps

Procedures for starting the motorcycle.

run-in period

Initial usage guidelines for engine break-in.

cleaning

Instructions for cleaning the vehicle.

Storage and usage

Guidelines for storing and using the motorcycle.

Fuel level

Procedure for checking the motorcycle's fuel level.

Fuel tank switch

Explanation of fuel tank switch positions and operation.

Engine Oil level

How to check the engine oil level using the sight glass.

Coolant level

Procedure for checking and topping up coolant level.

Brake fluid level

Check and maintain the brake fluid level in the master cylinder.

Brake pads

Inspect brake pad thickness and condition; replace if necessary.

Brake rotors

Check brake disc for damage, wear, and thickness; replace if worn.

check tire pressure

How to check and recommended tire pressure values.

Check spoke tension

Method for checking spoke tension and truing.

Check the chain and its supporting parts

Inspect chain tension, sprockets, and guides for wear.

Check whether the front shock needs to vent

Procedure for venting the front shock absorber.

Inspection of the remaining components

Visual inspection for loose parts and bolts.

Check the battery charge

Check battery charge and lights before riding.

Starting steps

Step-by-step guide for kick-starting and electric starting.

Engine break-in period

Guidelines for the initial engine break-in period.

Vehicle cleaning

Steps for cleaning the motorcycle to maintain its condition.

Storage and use of vehicles

Procedures for storing the vehicle for long periods and preparing it for use.

Specific maintenance content

Detailed procedures for specific maintenance tasks.

Clutch handle

Adjusting the clutch handle for optimal feel and operation.

Clutch disc

Reference to engine manual for clutch disc inspection/replacement.

Throttle

Checking throttle operation and adjusting cable free play.

Spark plug

Spark plug torque, gap checking, cleaning, and replacement.

Air filter

Procedures for checking and maintaining the air filter.

Carburetor

Carburetor settings for performance and driving habits.

Engine oil

Procedures for checking and changing engine oil.

Oil level check

Procedure for checking engine oil level using dipstick/sight glass.

Oil Change

Steps for changing engine oil and recommended lubricants.

Piston and piston ring

Maintenance instructions for piston and piston rings.

Cylinder, cylinder head and exhaust valve

Maintenance instructions for cylinder, head, and valves.

Exhaust system inspection

Inspection of the exhaust pipe and muffler condition.

Crankshaft connecting rod and bearing

Maintenance instructions for crankshaft, rod, and bearings.

Start, shift and brake pedal

Lubrication and inspection of pedals.

Coolant liquid

Information and procedures regarding engine coolant.

Check of the coolant level

Steps to check and top up coolant level.

Replacement of coolant

Procedure for replacing the engine coolant.

Tank tube and fin strip

Inspection of coolant tank hoses and radiator fins.

Check the control part of the brake system

Inspection and adjustment of brake system controls.

Front brake handle

Adjusting the front brake lever for user preference.

Rear brake lever

Checking the free travel of the rear brake lever.

Brake system wear inspection

Inspection of brake system components for wear.

brake fluid

Information and recommendations for brake fluid.

brake fluid quantity inspection

Procedure for inspecting brake fluid level.

Check brake pump piston and dust cover

Inspection of brake pump piston and dust cover.

Spokes and wheels

Inspection and maintenance of spokes and wheels.

Check the chain guide

Inspection of chain guide and stopper wear.

Check the front shock absorber

Inspection and adjustment of the front shock absorber.

Steering column adjustment

Procedure for adjusting the steering column for free rotation.

Check the gasoline pipe

Inspection of the fuel line for damage or leaks.

Fuel system inspection

General inspection of the fuel system components.

Conventional lubrication

Lubrication points and procedures for the vehicle.

Rear shock absorber inspection

Inspection of the rear shock absorber for damage or wear.

Chain inspection

Procedure for inspecting and adjusting chain tension.

Tire inspection

Inspection of tire tread depth and condition.

Battery check

Procedure for checking battery voltage and output current.

Vehicle settings

Adjustments and settings for vehicle performance.

Carburetor settings

Adjusting carburetor for performance and driving habits.

Second gear ratio setting

Changing sprockets to adjust gear ratios for performance.

Front shock absorber settings

Adjusting front shock absorber damping hardness.

Rear shock absorber settings

Adjusting rear shock absorber compression, preload, and rebound.

Vehicle troubleshooting

Common faults and troubleshooting methods for the motorcycle.

Engine crank does not turn

Reasons and solutions for engine not turning over.

The engine does not respond when I press the electric starter

Troubleshooting for starter response issues.

Engine cannot start

Common causes and solutions for engine not starting.

Incorrect air and fuel mixing

Causes and solutions for incorrect air/fuel mixture.

The engine can start, but it will stop immediately

Troubleshooting for engine stopping after starting.

Engine overheating

Causes and solutions for engine overheating.

Engine running unevenly

Causes and solutions for uneven engine running.

Insufficient engine power or poor acceleration

Troubleshooting for low power and acceleration issues.

Engine sound abnormal

Troubleshooting for abnormal engine noises.

Tempering of the exhaust pipe

Causes and solutions for exhaust pipe issues.

White smoke from exhaust pipe

Troubleshooting for white smoke from the exhaust.

Black smoke from the exhaust pipe

Troubleshooting for black smoke from the exhaust.

Transmission gears are not meshing

Causes and solutions for transmission gear meshing problems.

The gears are not engaged.

Troubleshooting for gears not engaging.

Clutch slip

Causes and solutions for clutch slippage.

Difficult to turn motorcycle

Troubleshooting for difficulty in turning the motorcycle.

Damping too hard

Troubleshooting for overly stiff damping.

Damping too soft

Troubleshooting for overly soft damping.

Abnormal noise when driving a motorcycle

Troubleshooting for general abnormal noises during operation.

Motorcycle front wheel wobble

Causes and solutions for front wheel wobble.

Motorcycles lean towards one side

Troubleshooting for motorcycle leaning to one side.

Brake failure

Troubleshooting for brake system failure.

Engine maintenance manual

Comprehensive manual for engine maintenance procedures.

Cylinder head and valve

Maintenance procedures for cylinder head and valves.

Troubleshooting

Troubleshooting common cylinder head and valve issues.

Cylinder head cover disassemble

Steps for disassembling the cylinder head cover.

cylinder head disassemble

Detailed steps for cylinder head disassembly.

Disintegrate cylinder head cover

Procedures for dismantling the cylinder head cover.

Disintegrate cylinder head

Procedures for dismantling the cylinder head.

Inspection of valves and valve springs

How to inspect valves and valve springs.

Inspection of swing arm and swing arm shaft

Inspecting swing arm and its shaft for wear.

Inspection of camshaft components

Checking camshaft surface condition and components.

Inspection and grinding of valve seat

Cleaning and grinding valve seats for proper sealing.

Inspection of valve pipe

Measuring inner diameter of valve pipes.

Replacement of valve guide

Procedure for replacing valve guides.

Measure the width of valve seat contact surface

Measuring valve seat contact surface width.

Cylinder head cove assembly

Assembling the cylinder head cover.

Cylinder head assembly

Assembling the cylinder head components.

NC250 engine timing adjustment

Steps for adjusting engine timing using timing marks.

Cylinder head cover assembly

Final assembly of the cylinder head cover.

Cylinder and piston

Maintenance instructions for cylinder and piston.

Maintenance instructions

General notes and parameters for cylinder and piston maintenance.

Maintenance parameters

Table of standard and limit values for cylinder and piston components.

Trouble shooting

Troubleshooting common cylinder and piston issues.

Disassembly of cylinder

Steps for disassembling the cylinder.

Inspection of cylinder body

Checking cylinder body for wear, damage, and measuring diameter.

Disassembly of piston

Steps for disassembling the piston from the connecting rod.

Inspection of piston and piston pin

Inspecting piston, piston pin, and ring groove wear.

Piston ring assembly

Procedure for cleaning and installing piston rings.

Piston assembly

Assembling the piston, pin, and rings.

Cylinder body assembly

Assembling the cylinder body onto the engine.

Clutch, drive tooth, overrunning clutch, oil pump and shift mechanism

Maintenance for clutch, drive, oil pump, and shift systems.

Maintenance instructions

Notes on maintenance procedures for these components.

Maintenance parameters

Table of standard and limit values for clutch and oil pump.

Troubleshooting

Common problems and solutions related to clutch and shifting.

Disassembly of water pump impeller

Steps for removing the water pump impeller.

Disassembly of right crankcase cover

Steps for removing the right crankcase cover.

Disassembly of water pump shaft, water seal components and oil seal

Steps for disassembling water pump shaft and seals.

Disassembly of clutch

Steps for disassembling the clutch assembly.

Disassembly of drive tooth, overrun clutch and big starter gear

Steps for disassembling drive tooth, overrun clutch, and starter gear.

Disassembly of right oil pump

Steps for disassembling the right oil pump.

Disassembly of duplicate gear

Steps for disassembling the duplicate gear.

Disassembly of start motor

Steps for disassembling the starter motor.

Disassembly of gear shifting mechanism

Steps for disassembling the gear shifting mechanism.

Inspection of right crankcase

Inspecting the right crankcase and oil seals.

Inspection of Pump shaft, pump impeller, water seal components and oil seal

Inspecting pump components and oil seals.

Inspection of start shaft

Checking the wear condition of the start shaft gear.

Inspection of clutch spring

Measuring the free length of the clutch spring.

Inspection of clutch friction disc

Inspecting clutch friction discs for wear and thickness.

Inspection of clutch cover

Checking clutch cover grooves for wear and damage.

Inspection of active teeth

Checking active teeth for damage and wear.

Inspection of free wheel device

Checking the free wheel device wedge for wear.

Inspection of the starting gear

Checking the starting gear for wear or damage.

Inspection of the right body oil pump

Inspecting the right body oil pump rotor and cover plate.

Inspection of starting motor and double gear

Checking starting motor and double gear for damage.

Inspection of change gear device

Checking positioning plate roller for wear and flexibility.

Assembly of the starting shaft

Installing the starting shaft into the engine.

Assembly of Double Gear

Assembling the double gear and washer.

Starting Shaft Component Assembly

Assembling starting shaft components.

Assembly of Right Body Oil Pump

Assembling the right body oil pump.

Assembly of free-wheeling clutch

Installing the free-wheeling clutch wedge.

Installation of starting gear and overrunning clutch

Installing starting gear and overrunning clutch.

Installation of active teeth

Installing active teeth and locking nut.

Installation of clutch

Steps for installing the clutch assembly.

Magnetors and balancing main and driven Gear

Maintenance for magneto and gears.

Maintenance instructions

Notes on magneto and gear maintenance procedures.

Removal of the left crankcase cover

Steps for removing the left crankcase cover.

Removal of the stator of the magneto

Steps for removing the magneto stator.

Removal of the motor rotor

Steps for removing the motor rotor.

Disassembly of balancing main and driven gears

Steps for disassembling balancing gears.

Removal of oil pump for left body machine

Steps for removing the left body oil pump.

Inspection of left crankcase cover

Checking the left crankcase cover for oil seal damage.

Inspection of magnetic motor stator and rotor

Inspecting magneto stator and rotor for cracks or wear.

Inspection of main and driven gear

Checking main and driven gears for wear or damage.

Inspection of the left body oil pump

Inspecting the left body oil pump rotor and cover plate.

Installation of the left body oil pump

Installing the left body oil pump.

Installation of the main and driven gear

Installing main and driven gears and related components.

Installation of the magneto rotor

Installing the magneto rotor onto the crank.

Installation of the magneto stator

Installing the magneto stator onto the crankcase cover.

Installation of the left crankcase cover

Installing the left crankcase cover with a new gasket.

crankcase, crankshaft, variable speed drive, balance shaft

Maintenance of crankcase, crankshaft, and related drive systems.

Maintenance instructions

Notes on crankcase, crankshaft, and transmission maintenance.

Trouble shooting

Troubleshooting common crankcase and shaft issues.

crankcase decomposition

Steps for separating the crankcase halves.

crankshaft, balance shaft, main and secondary shaft disassembly

Steps for disassembling crankshaft and shafts.

Inspection of crankshaft

Inspecting crankshaft diameter and radial clearance.

Inspection of left and right box

Inspecting bearings in the left and right boxes.

Inspection of left and right box bearing

Checking box bearings for flexibility and wear.

Inspection of shift fork, shift fork shaft, transmission hub

Inspecting shift forks, shafts, and transmission hubs.

Inspection the assembly of main and counter shaft

Checking main and counter shaft assembly for wear and deformation.

Inspection of oil filter parts, oil filter

Checking oil filter parts and screen for cleanliness and damage.

Assembly of transmission, crankshaft and balance shaft

Assembling transmission, crankshaft, and balance shaft.

Assembly of box and oil Filter

Assembling the gearbox and oil filter.

Vehicle Profile and Specifications

Vehicle profile

Identification of vehicle components.

Vehicle component and location

Visual guide to component placement on the motorcycle.

VIN number

Information about the Vehicle Identification Number.

Specifications

Technical specifications of the motorcycle.

Vehicle dimension and mass parameter

Physical dimensions and weight of the motorcycle.

Engine

Engine type, displacement, power, and torque details.

Chassis;Suspension;Braking;Wheel

Specifications for chassis, suspension, brakes, and wheels.

Circuit diagram

Electrical system schematic.

Fasteners torque table

Torque specifications for various fasteners.

KAYO MOTOR K6-R Specifications

General

Fuel System	Carburetor
Front Suspension	Telescopic fork
Front Brake	Disc
Rear Brake	Disc
Seat Height	780 mm
Engine Type	Single cylinder, 4-stroke
Transmission	5-speed
Starting System	Electric and kick
Rear Suspension	Monoshock