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KAYO MOTOR KMB60 2021 - User Manual

KAYO MOTOR KMB60 2021
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ZHEJIANG KAYO MOTOR CO., LTD.
www.kayomoto.com
1
KAYO MOTO
KMB60
SERVICE MANUAL 2021
WWW.KAYOMOTO.COM

Table of Contents

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Summary

Preface

Symbols and Technical Terms

Page Reference Symbols

Explains the meaning of page reference symbols used in the manual.

Safety Signal Definitions

Explains safety messages preceded by signal words like Danger, Warning, Caution.

General Safety

Rider Safety Guidelines

Covers helmet use, single-seat operation, and accessory advice.

Hot Surface Warning

Warns about hot engine and exhaust parts and advises against wearing shorts.

Component Locations

Front Component Identification

Identifies front parts of the motorcycle with numbered labels.

Mid and Rear Component Identification

Identifies mid and rear parts of the motorcycle with numbered labels.

Serial Number Identification

Chassis Number Location

Shows where the chassis number is engraved on the frame.

Engine Number Location

Shows where the engine number is located on the engine crankcase.

General Parameters

Motorcycle Specifications

Lists dimensions, weight, tyre size, seat height, ground clearance, and fuel capacity.

Engine Specifications

Lists engine type, displacement, power, torque, compression ratio, starting, ignition, battery, and chain type.

Operating Controls

Front Brake Operation

Explains how to operate the front brake lever and describes the front brake caliper.

Throttle Operation

Explains how the throttle controls speed and its return function.

Ignition and Stop Switch Operation

Details how to use ignition and stop switches for starting and stopping the engine.

Fuel Tap Operation

Describes the fuel tap's location and function for controlling fuel flow.

Rear Brake Operation

Explains how to operate the rear brake lever and describes the rear brake caliper.

Preparation before Riding

Side Stand Operation

Explains how to use the side stand for parking and before riding.

Advice for New Riders

Provides essential advice for new riders, including reading the manual and maintenance.

Running-in Procedure

Introduces the running-in process for new motorcycles to ensure engine performance.

Riding Instructions

Running-in Phase Details

Details the running-in periods and recommended engine performance levels.

Pre-ride Inspection Checklist

Lists essential checks before riding the motorcycle for safety and proper function.

Starting Procedure and Cautions

Step-by-step guide and safety precautions for starting the motorcycle engine.

Turning, Acceleration, and Braking Cautions

Provides advice on safe turning, acceleration, and braking techniques.

Parking Cautions

Provides guidelines for safely parking the motorcycle.

Maintenance Schedule

Initial Maintenance Items

Lists initial maintenance tasks for battery, brake pads at specified intervals.

Regular Maintenance Checks

Details regular checks for brake disc, hose, frame, tire, and bearings.

Periodic and One-time Maintenance

Lists maintenance tasks for valve clearance, gear oil, hoses, air filter, and overall inspection.

Suspension System

Chassis Setting with Rider Weight

Explains how rider weight affects suspension settings for optimal performance.

Measuring Rear Wheel Sag (Suspended)

Details the procedure to measure rear wheel sag when the motorcycle is suspended.

Measuring Rear Wheel Sag (Unloaded)

Details the procedure to measure rear wheel sag when the motorcycle is unloaded.

Measuring Riding Sag

Describes how to measure riding sag with the rider on the motorcycle.

Adjusting Rear Shock Spring Preload

Explains how to adjust the rear shock's spring preload for optimal suspension.

Checking the Front Shock

Outlines the procedure for checking the front shock absorber's condition.

Service Work

Adjusting Handlebar Position

Details the steps to adjust the handlebar position for rider comfort.

Raising Motorcycle with Lift Stand

Explains how to securely raise the motorcycle using a lift stand.

Front Brake Removal and Installation

Provides instructions for removing and installing the front brake assembly.

Front Shock Removal and Installation

Guides on how to remove and install the front shock absorbers.

Removing Triple Clamp

Details the procedure for removing the triple clamp assembly.

Checking Steering Head Condition

Explains how to check the condition of the steering head bearing and components.

Greasing Steering Head Bearing

Describes the process of greasing the steering head bearing for smooth operation.

Front Fender Removal and Installation

Provides instructions for removing and installing the front fender.

Rear Shock Removal and Installation

Details the steps for removing and installing the rear shock absorber.

Seat Removal and Installation

Explains how to remove and install the motorcycle seat.

Air Filter Removal

Guides on how to remove the air filter for cleaning or replacement.

Air Filter Cleaning and Maintenance

Provides instructions for inspecting, cleaning, and maintaining the air filter.

Exhaust Pipe Removal

Details the procedure for removing the exhaust pipe.

Muffler Removal and Replacement

Explains how to remove and replace the muffler, and when to consult dealers.

Fuel Tank Removal and Installation

Provides instructions for removing and installing the fuel tank.

Chain Checking and Cleaning

Guides on how to check the chain's position, smoothness, and cleanliness.

Chain Removal

Details the procedure for removing the drive chain.

Checking Chain Tension

Explains how to measure and adjust the chain tension correctly.

Checking Sprockets and Chain Guide

Guides on inspecting rear sprocket, engine sprocket, and chain guide for wear.

Frame Inspection

Outlines how to inspect the frame for painting, deformation, or cracks.

Swingarm Inspection

Details how to check the swingarm for cracks, deformation, or paint damage.

Throttle Cable Check

Explains how to check throttle cable operation and adjust if necessary.

Handlebar Check

Advises checking handlebar operation for ease of use while riding.

Check and Maintain the Brake System

Brake Lever Free Play Check

Explains how to check and adjust the free play of the brake levers.

Brake Disc Inspection

Guides on inspecting brake discs for cracks, depressions, and measuring thickness.

Brake Lever Play Check

Describes how to check and adjust the play in the brake levers.

Front Braking Pad Check

Details how to check the thickness of the front braking pads.

Foot Brake Pad Play Check

Explains how to check and adjust the play of the foot brake lever.

Rear Brake Pad Check

Details how to check the thickness of the rear braking pads.

Check and Maintain the Wheels

Front Wheel Removal and Installation

Provides instructions for removing and installing the front wheel.

Rear Wheel Removal and Installation

Provides instructions for removing and installing the rear wheel.

Tyre Condition Inspection

Guides on inspecting the tyre for damage, cuts, and tread depth.

Tyre Air Pressure Check

Explains how to check tyre air pressure and recommended values.

Rim Spoke Tension Check

Details how to check and correct spoke tension for wheel trueness.

Installing Engine

Engine Installation Procedure

Lists the steps for installing the engine into the motorcycle frame.

Service and Adjust Work on Engine

Checking Cylinder Head Bolts and Nuts

Details torque specifications and intervals for checking cylinder head bolts.

Checking Valve Clearance

Explains how to check and adjust valve clearance for optimal engine performance.

Checking Compression Pressure

Guides on how to check the engine's compression pressure.

Tuning the Engine

Provides guidance on engine tuning for optimal performance.

Adjusting Carburetor Idle Speed

Provides detailed steps for adjusting the carburetor idle speed for best performance.

Carburetor Cleaning

Explains how to clean the carburetor after each ride.

Choosing Lubricating Oil

Advises on selecting the correct lubricating oil based on specifications.

Checking Lubricating Oil Level

Details how to check the engine's lubricating oil level using the sight window.

Changing Lubricating Oil

Provides instructions for draining and refilling engine oil, including torque specs.

Overhauling the Engine

Cylinder Head and Valve Mechanism I

Introduces overhaul procedures for the cylinder head and valve mechanism.

Cylinder Head Parts Specifications

Lists standard and maintenance values for cylinder head components.

Engine Troubleshooting: Low Pressure

Lists faults, possible causes, and remarks for low cylinder pressure issues.

Maintenance of Valve Mechanism I

Covers maintenance procedures for the valve mechanism.

Dismounting Valve Mechanism I

Step-by-step guide to disassemble the valve mechanism I.

Overhauling Valve Mechanism I

Details the overhaul process for the valve mechanism I components.

Valve Clearance and Rocker Assembly Check

Explains checking valve clearance and inspecting rocker assembly and push rods.

Installing Valve Mechanism I

Provides instructions for reassembling the valve mechanism I.

Dismounting Cylinder Head Assembly

Details the procedure to remove the cylinder head assembly.

Overhauling Cylinder Head Parts

Covers inspection and overhaul of cylinder head appearance, flatness, and valve seats.

Valve Seat Grinding and Valve Guide Inspection

Explains valve seat grinding and inspecting valve guides.

Valve Overhauling and Spring Inspection

Details overhauling valves and inspecting valve springs.

Spark Plug Overhauling

Explains how to overhaul and check the spark plug.

Installing Cylinder Head Assembly

Provides steps and torque values for installing the cylinder head assembly.

Cylinder and Piston

Cylinder and Piston Specifications

Lists main parameters and maintenance standards for cylinder and piston components.

Cylinder and Piston Troubleshooting

Lists faults, possible causes for cylinder and piston issues.

Dismounting Cylinder Block, Piston, and Piston Ring

Step-by-step guide to disassemble the cylinder block, piston, and piston rings.

Overhauling Cylinder Block, Piston, and Piston Ring

Details inspection and overhaul of cylinder block, piston, and piston rings.

Installing Cylinder Block, Piston, and Piston Ring

Provides instructions for reassembling the cylinder block, piston, and piston rings.

Piston and Piston Ring Installation

Details correct installation of piston rings, piston, and cylinder block.

Clutch and Valve Mechanism II

Clutch and Timing Chain Specifications

Lists main parameters and maintenance standards for clutch and timing chain.

Clutch Troubleshooting

Lists faults and possible causes for clutch issues like slipping.

Dismounting Right Crankcase and Clutch

Step-by-step guide to disassemble the right crankcase and clutch assembly.

Overhauling Right Crankcase and Clutch

Details inspection and overhaul of the right crankcase and clutch components.

Clutch Housing and Driven Disc Inspection

Covers inspection of clutch housing, driven disc, and their components.

Installing Right Crankcase and Clutch

Provides instructions for reassembling the right crankcase and clutch.

Maintaining the Valve Mechanism

Introduces maintenance procedures for the valve mechanism.

Dismounting Valve Mechanism II

Step-by-step guide to disassemble the valve mechanism II.

Overhauling Valve Mechanism

Details the overhaul process for the valve mechanism components.

Installing Valve Mechanism

Provides instructions for reassembling the valve mechanism, including torque specs.

Magneto and Electric Start Mechanism

Magneto and Electric Start Specifications

Lists specifications for magneto and electric start components.

Magneto and Electric Start Troubleshooting

Lists faults and possible causes for magneto and electric start system issues.

Magneto Breakdown

Covers common issues and causes related to magneto breakdown.

Electric Start Mechanism Breakdown

Details common issues and causes related to the electric start mechanism.

Dismounting Magneto and Electric Start Mechanism

Step-by-step guide to disassemble the magneto and electric start mechanism.

Removing Magneto Rotor and Sprockets

Details removing the magneto rotor, big sprocket, and starting motor.

Overhauling Magneto and Electric Start Mechanism

Covers inspection and overhaul of magneto and electric start system components.

Installing Magneto and Electric Start Mechanism

Provides instructions for reassembling the magneto and electric start mechanism.

Crankcase, Crankshaft, Oil Pump, and Auxiliary Shafts

Crankcase, Crankshaft, Oil Pump Specifications

Lists main parameters and maintenance standards for crankcase, crankshaft, and oil pump.

Crankshaft and Gearshift Troubleshooting

Lists faults, possible causes for crankshaft noise, gearshift noise, and low oil pressure.

Dismounting Crankcase, Crankshaft, Oil Pump, and Auxiliary Shafts

Step-by-step guide to disassemble crankcase, crankshaft, oil pump, and shafts.

Overhauling Crankcase, Crankshaft, Oil Pump, and Auxiliary Shafts

Details inspection and overhaul of crankcase, crankshaft, oil pump, and shafts.

Crankshaft Connecting Rod and Shaft Overhaul

Covers overhauling crankshaft connecting rod, main, and auxiliary shafts.

Oil Pump Overhaul

Details the overhaul process for the oil pump, including clearance measurements.

Installing Crankcase, Crankshaft, Oil Pump, and Auxiliary Shafts

Provides instructions for reassembling crankcase, crankshaft, oil pump, and shafts.

Engine Troubleshooting

Engine Not Starting or Difficult to Start

Diagnoses issues related to fuel flow, spark, and compression for non-starting engines.

Compression Pressure and Restart Issues

Covers checking cylinder pressure and issues when restarting the engine.

Engine Poor Performance at Low Speed or Idle

Diagnoses causes for poor engine performance at low speeds or idle.

Engine Performance Poor at High Speed

Addresses issues causing poor engine performance at high speeds.

Abnormal Engine Noise Troubleshooting

Identifies causes of abnormal engine noises like timing chain or gears.

Gearbox Gear Mesh Issues

Diagnoses problems with gearbox gears not meshing correctly.

Gear Run-out Troubleshooting

Addresses issues related to gear run-out, including worn parts.

Clutch Slipping Troubleshooting

Covers causes of clutch slipping and related issues.

Motorcycle Difficult to Turn Troubleshooting

Diagnoses causes for the motorcycle being difficult to turn.

Suspension Damping Issues

Covers hard and soft damping issues in the front fork and shock.

Abnormal Noise During Motorcycle Driving

Identifies causes of abnormal noises during motorcycle operation.

Front Wheel Vibration Troubleshooting

Addresses causes of front wheel vibration.

Chassis Lean and Steering Issues

Addresses chassis lean, steering adjustment, and fork issues.

Brake Failure Troubleshooting

Covers issues related to brake disc wear, fluid, and pad wear.

Cleaning the Motorcycle

Motorcycle Cleaning Procedures

Provides steps for cleaning the motorcycle, including sealing points.

Storage

Preparation for Long-Term Storage

Outlines steps for preparing the motorcycle for long-term storage.

Preparing for Use After Storage

Provides steps for getting the motorcycle ready after a period of storage.

Service Work

Engine Not Turning Troubleshooting

Diagnoses causes when the engine does not turn over.

Starter and Engine Not Working

Addresses issues when the starter or engine fails to operate.

Engine Failure to Start Troubleshooting

Covers common causes and solutions for engine starting failures.

Incorrect Air;Fuel Mixture Troubleshooting

Diagnoses issues with incorrect air and fuel mixture.

Engine Shutting Down Immediately Troubleshooting

Addresses causes for the engine shutting down shortly after starting.

Engine Running Unevenly Troubleshooting

Diagnoses reasons for uneven engine running.

Inadequate Engine Power or Acceleration

Covers causes for reduced engine power or acceleration.

Engine Fuel Supply and Air Filter Issues

Addresses fuel supply problems and air filter issues affecting performance.

Spark Plug and Ignition System Issues

Covers spark plug condition, cap, rotor damage, and ignition system faults.

Abnormal Engine Sound Troubleshooting

Identifies causes of abnormal engine sounds like timing chain or gears.

Gearbox Gear Mesh Issues

Diagnoses problems with gearbox gears not meshing correctly.

Gear Run-out Troubleshooting

Addresses issues related to gear run-out, including worn parts.

Clutch Slipping Troubleshooting

Covers causes of clutch slipping and related issues.

Motorcycle Difficult to Turn Troubleshooting

Diagnoses causes for the motorcycle being difficult to turn.

Suspension Damping Issues

Covers hard and soft damping issues in the front fork and shock.

Abnormal Noise During Motorcycle Driving

Identifies causes of abnormal noises during motorcycle operation.

Front Wheel Vibration Troubleshooting

Addresses causes of front wheel vibration.

Chassis Lean and Steering Issues

Addresses chassis lean, steering adjustment, and fork issues.

Brake Failure Troubleshooting

Covers issues related to brake disc wear, fluid, and pad wear.

Tightening Torques

Front Brake and Steering Column Torque

Lists torque specifications for front brake and steering column components.

Engine and Exhaust Mounting Torque

Lists torque specifications for engine mounting bolts and muffler nuts.

Axle and Chain Slider Torque

Lists torque specifications for axle nuts and chain slider mounting screws.

Brake and Sprocket Torque Specifications

Lists torque specifications for brake disc, rear sprocket, and caliper mounting bolts.

Ignition Coil and Fender Mounting Torque

Lists torque specifications for ignition coil, stabilizer, and fender bolts.

Spark Plug Torque

Lists the torque specification for the spark plug.

Summary

Preface

Symbols and Technical Terms

Page Reference Symbols

Explains the meaning of page reference symbols used in the manual.

Safety Signal Definitions

Explains safety messages preceded by signal words like Danger, Warning, Caution.

General Safety

Rider Safety Guidelines

Covers helmet use, single-seat operation, and accessory advice.

Hot Surface Warning

Warns about hot engine and exhaust parts and advises against wearing shorts.

Component Locations

Front Component Identification

Identifies front parts of the motorcycle with numbered labels.

Mid and Rear Component Identification

Identifies mid and rear parts of the motorcycle with numbered labels.

Serial Number Identification

Chassis Number Location

Shows where the chassis number is engraved on the frame.

Engine Number Location

Shows where the engine number is located on the engine crankcase.

General Parameters

Motorcycle Specifications

Lists dimensions, weight, tyre size, seat height, ground clearance, and fuel capacity.

Engine Specifications

Lists engine type, displacement, power, torque, compression ratio, starting, ignition, battery, and chain type.

Operating Controls

Front Brake Operation

Explains how to operate the front brake lever and describes the front brake caliper.

Throttle Operation

Explains how the throttle controls speed and its return function.

Ignition and Stop Switch Operation

Details how to use ignition and stop switches for starting and stopping the engine.

Fuel Tap Operation

Describes the fuel tap's location and function for controlling fuel flow.

Rear Brake Operation

Explains how to operate the rear brake lever and describes the rear brake caliper.

Preparation before Riding

Side Stand Operation

Explains how to use the side stand for parking and before riding.

Advice for New Riders

Provides essential advice for new riders, including reading the manual and maintenance.

Running-in Procedure

Introduces the running-in process for new motorcycles to ensure engine performance.

Riding Instructions

Running-in Phase Details

Details the running-in periods and recommended engine performance levels.

Pre-ride Inspection Checklist

Lists essential checks before riding the motorcycle for safety and proper function.

Starting Procedure and Cautions

Step-by-step guide and safety precautions for starting the motorcycle engine.

Turning, Acceleration, and Braking Cautions

Provides advice on safe turning, acceleration, and braking techniques.

Parking Cautions

Provides guidelines for safely parking the motorcycle.

Maintenance Schedule

Initial Maintenance Items

Lists initial maintenance tasks for battery, brake pads at specified intervals.

Regular Maintenance Checks

Details regular checks for brake disc, hose, frame, tire, and bearings.

Periodic and One-time Maintenance

Lists maintenance tasks for valve clearance, gear oil, hoses, air filter, and overall inspection.

Suspension System

Chassis Setting with Rider Weight

Explains how rider weight affects suspension settings for optimal performance.

Measuring Rear Wheel Sag (Suspended)

Details the procedure to measure rear wheel sag when the motorcycle is suspended.

Measuring Rear Wheel Sag (Unloaded)

Details the procedure to measure rear wheel sag when the motorcycle is unloaded.

Measuring Riding Sag

Describes how to measure riding sag with the rider on the motorcycle.

Adjusting Rear Shock Spring Preload

Explains how to adjust the rear shock's spring preload for optimal suspension.

Checking the Front Shock

Outlines the procedure for checking the front shock absorber's condition.

Service Work

Adjusting Handlebar Position

Details the steps to adjust the handlebar position for rider comfort.

Raising Motorcycle with Lift Stand

Explains how to securely raise the motorcycle using a lift stand.

Front Brake Removal and Installation

Provides instructions for removing and installing the front brake assembly.

Front Shock Removal and Installation

Guides on how to remove and install the front shock absorbers.

Removing Triple Clamp

Details the procedure for removing the triple clamp assembly.

Checking Steering Head Condition

Explains how to check the condition of the steering head bearing and components.

Greasing Steering Head Bearing

Describes the process of greasing the steering head bearing for smooth operation.

Front Fender Removal and Installation

Provides instructions for removing and installing the front fender.

Rear Shock Removal and Installation

Details the steps for removing and installing the rear shock absorber.

Seat Removal and Installation

Explains how to remove and install the motorcycle seat.

Air Filter Removal

Guides on how to remove the air filter for cleaning or replacement.

Air Filter Cleaning and Maintenance

Provides instructions for inspecting, cleaning, and maintaining the air filter.

Exhaust Pipe Removal

Details the procedure for removing the exhaust pipe.

Muffler Removal and Replacement

Explains how to remove and replace the muffler, and when to consult dealers.

Fuel Tank Removal and Installation

Provides instructions for removing and installing the fuel tank.

Chain Checking and Cleaning

Guides on how to check the chain's position, smoothness, and cleanliness.

Chain Removal

Details the procedure for removing the drive chain.

Checking Chain Tension

Explains how to measure and adjust the chain tension correctly.

Checking Sprockets and Chain Guide

Guides on inspecting rear sprocket, engine sprocket, and chain guide for wear.

Frame Inspection

Outlines how to inspect the frame for painting, deformation, or cracks.

Swingarm Inspection

Details how to check the swingarm for cracks, deformation, or paint damage.

Throttle Cable Check

Explains how to check throttle cable operation and adjust if necessary.

Handlebar Check

Advises checking handlebar operation for ease of use while riding.

Check and Maintain the Brake System

Brake Lever Free Play Check

Explains how to check and adjust the free play of the brake levers.

Brake Disc Inspection

Guides on inspecting brake discs for cracks, depressions, and measuring thickness.

Brake Lever Play Check

Describes how to check and adjust the play in the brake levers.

Front Braking Pad Check

Details how to check the thickness of the front braking pads.

Foot Brake Pad Play Check

Explains how to check and adjust the play of the foot brake lever.

Rear Brake Pad Check

Details how to check the thickness of the rear braking pads.

Check and Maintain the Wheels

Front Wheel Removal and Installation

Provides instructions for removing and installing the front wheel.

Rear Wheel Removal and Installation

Provides instructions for removing and installing the rear wheel.

Tyre Condition Inspection

Guides on inspecting the tyre for damage, cuts, and tread depth.

Tyre Air Pressure Check

Explains how to check tyre air pressure and recommended values.

Rim Spoke Tension Check

Details how to check and correct spoke tension for wheel trueness.

Installing Engine

Engine Installation Procedure

Lists the steps for installing the engine into the motorcycle frame.

Service and Adjust Work on Engine

Checking Cylinder Head Bolts and Nuts

Details torque specifications and intervals for checking cylinder head bolts.

Checking Valve Clearance

Explains how to check and adjust valve clearance for optimal engine performance.

Checking Compression Pressure

Guides on how to check the engine's compression pressure.

Tuning the Engine

Provides guidance on engine tuning for optimal performance.

Adjusting Carburetor Idle Speed

Provides detailed steps for adjusting the carburetor idle speed for best performance.

Carburetor Cleaning

Explains how to clean the carburetor after each ride.

Choosing Lubricating Oil

Advises on selecting the correct lubricating oil based on specifications.

Checking Lubricating Oil Level

Details how to check the engine's lubricating oil level using the sight window.

Changing Lubricating Oil

Provides instructions for draining and refilling engine oil, including torque specs.

Overhauling the Engine

Cylinder Head and Valve Mechanism I

Introduces overhaul procedures for the cylinder head and valve mechanism.

Cylinder Head Parts Specifications

Lists standard and maintenance values for cylinder head components.

Engine Troubleshooting: Low Pressure

Lists faults, possible causes, and remarks for low cylinder pressure issues.

Maintenance of Valve Mechanism I

Covers maintenance procedures for the valve mechanism.

Dismounting Valve Mechanism I

Step-by-step guide to disassemble the valve mechanism I.

Overhauling Valve Mechanism I

Details the overhaul process for the valve mechanism I components.

Valve Clearance and Rocker Assembly Check

Explains checking valve clearance and inspecting rocker assembly and push rods.

Installing Valve Mechanism I

Provides instructions for reassembling the valve mechanism I.

Dismounting Cylinder Head Assembly

Details the procedure to remove the cylinder head assembly.

Overhauling Cylinder Head Parts

Covers inspection and overhaul of cylinder head appearance, flatness, and valve seats.

Valve Seat Grinding and Valve Guide Inspection

Explains valve seat grinding and inspecting valve guides.

Valve Overhauling and Spring Inspection

Details overhauling valves and inspecting valve springs.

Spark Plug Overhauling

Explains how to overhaul and check the spark plug.

Installing Cylinder Head Assembly

Provides steps and torque values for installing the cylinder head assembly.

Cylinder and Piston

Cylinder and Piston Specifications

Lists main parameters and maintenance standards for cylinder and piston components.

Cylinder and Piston Troubleshooting

Lists faults, possible causes for cylinder and piston issues.

Dismounting Cylinder Block, Piston, and Piston Ring

Step-by-step guide to disassemble the cylinder block, piston, and piston rings.

Overhauling Cylinder Block, Piston, and Piston Ring

Details inspection and overhaul of cylinder block, piston, and piston rings.

Installing Cylinder Block, Piston, and Piston Ring

Provides instructions for reassembling the cylinder block, piston, and piston rings.

Piston and Piston Ring Installation

Details correct installation of piston rings, piston, and cylinder block.

Clutch and Valve Mechanism II

Clutch and Timing Chain Specifications

Lists main parameters and maintenance standards for clutch and timing chain.

Clutch Troubleshooting

Lists faults and possible causes for clutch issues like slipping.

Dismounting Right Crankcase and Clutch

Step-by-step guide to disassemble the right crankcase and clutch assembly.

Overhauling Right Crankcase and Clutch

Details inspection and overhaul of the right crankcase and clutch components.

Clutch Housing and Driven Disc Inspection

Covers inspection of clutch housing, driven disc, and their components.

Installing Right Crankcase and Clutch

Provides instructions for reassembling the right crankcase and clutch.

Maintaining the Valve Mechanism

Introduces maintenance procedures for the valve mechanism.

Dismounting Valve Mechanism II

Step-by-step guide to disassemble the valve mechanism II.

Overhauling Valve Mechanism

Details the overhaul process for the valve mechanism components.

Installing Valve Mechanism

Provides instructions for reassembling the valve mechanism, including torque specs.

Magneto and Electric Start Mechanism

Magneto and Electric Start Specifications

Lists specifications for magneto and electric start components.

Magneto and Electric Start Troubleshooting

Lists faults and possible causes for magneto and electric start system issues.

Magneto Breakdown

Covers common issues and causes related to magneto breakdown.

Electric Start Mechanism Breakdown

Details common issues and causes related to the electric start mechanism.

Dismounting Magneto and Electric Start Mechanism

Step-by-step guide to disassemble the magneto and electric start mechanism.

Removing Magneto Rotor and Sprockets

Details removing the magneto rotor, big sprocket, and starting motor.

Overhauling Magneto and Electric Start Mechanism

Covers inspection and overhaul of magneto and electric start system components.

Installing Magneto and Electric Start Mechanism

Provides instructions for reassembling the magneto and electric start mechanism.

Crankcase, Crankshaft, Oil Pump, and Auxiliary Shafts

Crankcase, Crankshaft, Oil Pump Specifications

Lists main parameters and maintenance standards for crankcase, crankshaft, and oil pump.

Crankshaft and Gearshift Troubleshooting

Lists faults, possible causes for crankshaft noise, gearshift noise, and low oil pressure.

Dismounting Crankcase, Crankshaft, Oil Pump, and Auxiliary Shafts

Step-by-step guide to disassemble crankcase, crankshaft, oil pump, and shafts.

Overhauling Crankcase, Crankshaft, Oil Pump, and Auxiliary Shafts

Details inspection and overhaul of crankcase, crankshaft, oil pump, and shafts.

Crankshaft Connecting Rod and Shaft Overhaul

Covers overhauling crankshaft connecting rod, main, and auxiliary shafts.

Oil Pump Overhaul

Details the overhaul process for the oil pump, including clearance measurements.

Installing Crankcase, Crankshaft, Oil Pump, and Auxiliary Shafts

Provides instructions for reassembling crankcase, crankshaft, oil pump, and shafts.

Engine Troubleshooting

Engine Not Starting or Difficult to Start

Diagnoses issues related to fuel flow, spark, and compression for non-starting engines.

Compression Pressure and Restart Issues

Covers checking cylinder pressure and issues when restarting the engine.

Engine Poor Performance at Low Speed or Idle

Diagnoses causes for poor engine performance at low speeds or idle.

Engine Performance Poor at High Speed

Addresses issues causing poor engine performance at high speeds.

Abnormal Engine Noise Troubleshooting

Identifies causes of abnormal engine noises like timing chain or gears.

Gearbox Gear Mesh Issues

Diagnoses problems with gearbox gears not meshing correctly.

Gear Run-out Troubleshooting

Addresses issues related to gear run-out, including worn parts.

Clutch Slipping Troubleshooting

Covers causes of clutch slipping and related issues.

Motorcycle Difficult to Turn Troubleshooting

Diagnoses causes for the motorcycle being difficult to turn.

Suspension Damping Issues

Covers hard and soft damping issues in the front fork and shock.

Abnormal Noise During Motorcycle Driving

Identifies causes of abnormal noises during motorcycle operation.

Front Wheel Vibration Troubleshooting

Addresses causes of front wheel vibration.

Chassis Lean and Steering Issues

Addresses chassis lean, steering adjustment, and fork issues.

Brake Failure Troubleshooting

Covers issues related to brake disc wear, fluid, and pad wear.

Cleaning the Motorcycle

Motorcycle Cleaning Procedures

Provides steps for cleaning the motorcycle, including sealing points.

Storage

Preparation for Long-Term Storage

Outlines steps for preparing the motorcycle for long-term storage.

Preparing for Use After Storage

Provides steps for getting the motorcycle ready after a period of storage.

Service Work

Engine Not Turning Troubleshooting

Diagnoses causes when the engine does not turn over.

Starter and Engine Not Working

Addresses issues when the starter or engine fails to operate.

Engine Failure to Start Troubleshooting

Covers common causes and solutions for engine starting failures.

Incorrect Air;Fuel Mixture Troubleshooting

Diagnoses issues with incorrect air and fuel mixture.

Engine Shutting Down Immediately Troubleshooting

Addresses causes for the engine shutting down shortly after starting.

Engine Running Unevenly Troubleshooting

Diagnoses reasons for uneven engine running.

Inadequate Engine Power or Acceleration

Covers causes for reduced engine power or acceleration.

Engine Fuel Supply and Air Filter Issues

Addresses fuel supply problems and air filter issues affecting performance.

Spark Plug and Ignition System Issues

Covers spark plug condition, cap, rotor damage, and ignition system faults.

Abnormal Engine Sound Troubleshooting

Identifies causes of abnormal engine sounds like timing chain or gears.

Gearbox Gear Mesh Issues

Diagnoses problems with gearbox gears not meshing correctly.

Gear Run-out Troubleshooting

Addresses issues related to gear run-out, including worn parts.

Clutch Slipping Troubleshooting

Covers causes of clutch slipping and related issues.

Motorcycle Difficult to Turn Troubleshooting

Diagnoses causes for the motorcycle being difficult to turn.

Suspension Damping Issues

Covers hard and soft damping issues in the front fork and shock.

Abnormal Noise During Motorcycle Driving

Identifies causes of abnormal noises during motorcycle operation.

Front Wheel Vibration Troubleshooting

Addresses causes of front wheel vibration.

Chassis Lean and Steering Issues

Addresses chassis lean, steering adjustment, and fork issues.

Brake Failure Troubleshooting

Covers issues related to brake disc wear, fluid, and pad wear.

Tightening Torques

Front Brake and Steering Column Torque

Lists torque specifications for front brake and steering column components.

Engine and Exhaust Mounting Torque

Lists torque specifications for engine mounting bolts and muffler nuts.

Axle and Chain Slider Torque

Lists torque specifications for axle nuts and chain slider mounting screws.

Brake and Sprocket Torque Specifications

Lists torque specifications for brake disc, rear sprocket, and caliper mounting bolts.

Ignition Coil and Fender Mounting Torque

Lists torque specifications for ignition coil, stabilizer, and fender bolts.

Spark Plug Torque

Lists the torque specification for the spark plug.

KAYO MOTOR KMB60 2021 Specifications

General IconGeneral
BrandKAYO MOTOR
ModelKMB60 2021
CategoryMotorcycle
LanguageEnglish

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