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KAYO MOTOR TD125 - User Manual

KAYO MOTOR TD125
93 pages
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KAYO MOTO
TD125
SERVICE MANUAL
www.kayomoto.com

Table of Contents

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Summary

Technical Information and Safety

Meaning of Symbols and Technical Terms

Explains symbols and technical terms used in the manual.

Hazard Warnings: DANGER, WARNING, CAUTION

Defines DANGER, WARNING, and CAUTION levels for safety.

Motorcycle Overview and Specifications

Vehicle Component Identification

Labels and identifies all major motorcycle parts with a diagram.

VIN and Engine Number Location

Guides on locating the Vehicle Identification Number (VIN) and engine number.

Motorcycle and Engine Specifications

Details dimensions, weight, engine parameters, and frame specifications.

Motorcycle Operation and Riding Guidance

Controls and Operation

Explains operation of brakes, throttle, ignition, fuel, and gears.

Riding Guide and Pre-Ride Checks

Provides riding tips, pre-ride checks, and notes for various conditions.

Suspension and Steering Adjustment

Suspension System Setup

Procedures for setting up suspension components, including sag measurements.

Shock Absorber and Handlebar Adjustment

Adjusting rear shock preload and checking/adjusting front shock and handlebars.

General Maintenance Procedures

Motorcycle Placement for Maintenance

Proper positioning of the motorcycle for maintenance tasks.

Front and Rear System Maintenance

Maintenance of front/rear suspension, brakes, steering, seat, and chain.

Air Filter, Exhaust, and Fuel Tank Maintenance

Maintenance of air filter, exhaust system, and fuel tank.

Brake System Maintenance

Brake System Inspection and Fluid Checks

Inspecting brake system components, fluid levels, and free stroke.

Brake Fluid Refill and Rear Brake Checks

Guides on refilling brake fluid and checking rear brake system.

Engine Maintenance and Repair

Tire and Wheel Checks

Inspecting tires, pressure, and wheels.

Engine Installation

Step-by-step guide for engine installation.

Engine Component Checks and Adjustments

Bolt/nut inspection, valve clearance, compression, clutch, carburetor, shift lever.

Engine Lubrication System

Selection, inspection, and replacement of engine oil.

Cylinder and Valve System

Cylinder and Valve Notes & Standards

Important notes, standards, and fault analysis for cylinder and valves.

Cylinder Head Maintenance

Covers head cover removal, timing check, valve clearance, and head removal.

Valve Seat and Guide Maintenance

Procedures for checking, grinding valve seats, and inspecting valve guides.

Cylinder Head Assembly and Installation

Steps for assembling and installing the cylinder head.

Crankcase, Piston, and Shafts

Cylinder Block and Piston Maintenance

Standards and fault analysis for cylinder block and piston.

Crankcase and Shaft Assembly

Procedures for assembling crankcase, crankshaft, and shafts.

Transmission and Clutch Systems

Clutch, Gears, and Oil Pump Maintenance

Maintenance standards and procedures for clutch, gears, and oil pump.

Shift Mechanism and Crankcase Covers

Details disassembly of shift mechanism and inspection of crankcase covers.

Ignition and Starting Systems

Magneto, Timing Chain, and Covers

Covers removal/installation of magneto, timing chain, and covers.

Starting Motor and Sprocket Installation

Details installation of starting motor, sprocket, and transition plate.

Magneto Stator and Rotor Inspection

Guides on inspecting magneto stator and rotor.

Troubleshooting and Final Procedures

Engine Troubleshooting Guide

Lists common engine problems, causes, and solutions.

Motorcycle Cleaning and Storage

Procedures for cleaning and storing the motorcycle.

Vehicle Tightening Torque Specifications

A table of critical torque specifications for assembly.

KAYO MOTOR TD125 Specifications

General IconGeneral
Engine TypeSingle cylinder, 4-stroke, air-cooled
Fuel SystemCarburetor
IgnitionCDI
Front SuspensionTelescopic fork
Front BrakeDisc
Rear BrakeDrum
Front Tire2.75-18
Rear Tire3.00-18
Seat Height780mm
Curb Weight115kg
Starting SystemElectric / Kick
Frame TypeSteel
Wheel Size Front18 inches
Wheel Size Rear18 inches

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