KAYO MOTOR TT 125 User Manual

74 pages

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KAYO MOTO

TT 125

SERVICE MANUAL

www.kayomoto.com

Table of Contents4
Meaning of Symbols and Technical Terms7
Suggestions for Daily Use8
Parts and Position9
21 TT 125 Parts and Position9
Steel Chassis10
VIN and Engine Number10
VIN Number10
Engine Number11
Specification11
Manipulation12
Front Disc Brake12
Throttle13
Ignition13
Stall13
Fuel Tank Switch13
Gear Shifting14
Rear Disc Brake14
Parking Stand14
Notes before Use15
Suggestions for First-Time Users15
Running-In Process15
Riding Guide16
Checking Items before Riding16
Notes When Ignition17
Notes When Starting17
Notes When Cornering17
Notes When Acceleration17
Notes When Gear Shifting17
Notes When Braking17
Notes When Parking17
Maintenance Periodic Table17
Suspension System Setup19
Check the Compression and Rebound of the Motorcycle When Riding19
Measure Distance from Center of Rear Wheel to Rear Fender in Suspension19
Measure Distance from Center of Rear Wheel to Rear Fender under no Load19
Measure Distance from Center of Rear Wheel to Rear Fender in Riding Condition20
Adjust the Spring Preload of the Rear Shock20
Check the Setup of the Front Shock21
Adjust Handlebar21
Maintenance21
Placement of Motorcycle21
Disassembly and Assembly of Front Shock Protector22
Disassembly and Assembly of Front Disc Brake22
Disassembly and Assembly of Front Shock22
Disassembly and Assembly of Clamp23
Check the Head Steering23
Lubrication and Installation of Steering Head Bearing23
Disassembly and Assembly of Front Fender24
Disassembly and Assembly of Rear Shock24
Disassembly and Assembly of Seat24
Disassembly and Assembly of Air Filter25
Cleaning and Maintenance of Air Filters25
Disassembly and Assembly of Exhaust Pipe25
Disassembly and Assembly of Muffler25
Disassembly and Assembly of Fuel Tank26
Check the Chain and Clean26
Disassembly and Assembly of the Chain26
Check and Adjust the Chain Tension26
Inspect Rear Sprocket, Engine Sprocket and Chain Guide Structure27
Inspection of the Frame27
Inspection of the Swing Arm27
Inspection of the Throttle Cable28
Inspection of the Handle Bar28
Check and Maintain the Brake System28
Check the Free Stroke of the Front Brake Handle28
Inspection of the Disc Brake28
Check the Fluid Level of Front Brake Disc29
Refill the Front Brake Disc Fluid Oil29
Inspection of the Disc Brake29
Check the Free Movement of the Foot Brake30
Check the Rear Disc Brake Fluid Level30
Refill Rear Disc Brake Fluid30
Tire Inspection and Maintenance31
Removal and Installation of Front Wheel31
Removal and Installation of Rear Wheel32
Check the Outside Surface of the Tire32
Check Tire Pressure32
Check the Wheel Spokes32
Engine Installation33
Engine Maintenance and Adjustment33
Inspection of Bolts and Nuts of Cylinder and Cylinder Body33
Check Valve Clearance34
Inspection of Compression Pressure34
Adjustment of Clutch Control System34
Adjustment Around the Engine35
Idle Speed Adjustment of Carburetor35
Clean the Carburetor35
Check Shift Lever Position35
Adjust the Position of the Shift Lever35
Check and Replace Spark Plug36
Lubrication System of Engines36
Selection of Lubrication Oil36
Lubricating Oil Inspection37
Lubricating Oil Replacement37
Engine Repair37
Cylinder and Valves37
Main Parameters and Maintenance Standards of Cylinder Parts37
Fault Symptom and Cause Analysis38
Removal of Left Cover of Cylinder Head38
Timing Check39
Removal of Valve Cover39
Check Valve Clearance40
Removal of Cylinder Head40
Disassembly of Cylinder Head40
Inspection of Valves and Valve Springs41
Inspection of Rocker Arm and Rocker Arm Shaft41
Inspection of Camshaft Components42
Inspection of Cylinder Head42
Check and Grind Valve Seats42
Inspection of Valve Guide42
Replacement of Valve Guide43
Measure Width of Valve Seat Contact Area43
Assembly of Cylinder Head43
Installation of Cylinder Head44
Cylinder Block and Piston45
Main Parameters and Maintenance Standards of Cylinder Block and Piston45
Fault Symptom and Cause Analysis46
Inspection of Cylinder Block46
Removal of Piston and Piston Ring47
Inspection of Piston and Piston Ring47
Installation of Piston Ring48
Installation of Piston48
Installation of Cylinder Block48
Clutch, Driving Gear, Driven Gear, Oil Pump, Shifting Mechanism49
Main Parameters and Maintenance Standards49
Fault Symptom and Cause Analysis49
Removal of Right Trim Cover50
Adjustment of Clutch Stroke50
Removal of Right Crankcase Cover50
Clutch Disassembly50
Disassembly of Driving and Driven Gears51
Removal of Engine Oil Pump51
Disassemble Shift Mechanism51
Inspection of Right Crankcase Cover52
Inspection of Driving and Driven Tooth52
Check the Oil Pump53
Check Shift Mechanism53
Assembly of Shift Mechanism53
Assembly of Oil Pump53
Assembly of Driving and Driven Teeth54
Clutch Assembly54
Installation of Clutch54
Assembly of Right Crankcase Cover55
Right Trim Cover for Installation55
Magneto, Timing Chain56
Removal of Left Rear Cover56
Removal of Left Front Cover56
Removal of Magneto Stator56
Removal of Magneto Rotor56
Removal of Starting Motor and Starting Sprocket57
Removal of Transition Plate57
Removal of Timing Chain57
Removal of Tensioning Arm, Tensioning Rod and Tensioning Roller58
Inspection of Left Front Cover and Left Back Cover58
Transition Plate, Starting Motor, Starting Sprocket Inspection58
Magneto Stator, Rotor Inspection58
Installation of Tensioning Arm, Tensioning Rod and Tensioning Roller59
Transition Plate Installation60
Installation of Starting Motor and Starting Sprocket60
Installation of Magneto Stator60
Installation of Magneto Rotor61
Installation of Left Cover61
Crankcase, Crankshaft, Main and Auxiliary Shafts and Speed Drum61
Main Parameters and Maintenance Standards61
Fault Symptom and Cause Analysis61
Decomposition of Crankcase62
Disassembly of Crankshaft, Main and Auxiliary Shaft62
Decomposition of Variable Speed Drum62
Inspection of Crankshaft62
Left and Right Crankshaft Box Bearing Inspection63
Check Shift Fork, Fork Shaft and Shift Drum63
Check the Combination of Main and Auxiliary Shafts63
Inspection of Starting Shaft64
Assembly of Variable Speed Drum64
Installation of Variable Speed Drum, Main and Auxiliary Shaft, Crankshaft and Starting Shaft64
Installation of Crankcase64
Engine Troubleshooting66
Motorcycle Cleaning68
Storage of Motorcycles69
The Preparation of the Motorcycle before Long Unused69
The Main Points of Maintenance70
Vehicle Tightening Torque Meter74

Questions and Answers:

N
Nancy LeeAug 12, 2025
What to do if KAYO MOTOR Motorcycle engine performs poorly at high speeds?
- P
  Penny AndersonAug 12, 2025
  If your KAYO MOTOR Motorcycle engine performs poorly at high speeds, it could be due to a faulty ignition control or the magneto being out of order. Also, improper valve clearance adjustment can be the cause. To resolve this, check the ignition timing and valve clearance.