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KAYO MOTOR TT 125 - User Manual

KAYO MOTOR TT 125
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KAYO MOTO
TT 125
SERVICE MANUAL
www.kayomoto.com

Table of Contents

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.
  • P
    Patrick RangelAug 25, 2025
    What to do if KAYO MOTOR Motorcycle engine ignites but will not start?
    • N
      Nicole WilliamsonAug 25, 2025
      If the engine of your KAYO MOTOR Motorcycle ignites but will not start, it might be due to the choke opening too large or the carburetor trimmer screw not being properly adjusted. Try restarting the engine.
  • K
    kodomAug 30, 2025
    Why KAYO MOTOR Motorcycle engine performs poorly at low speeds?
    • J
      Jill MooreAug 30, 2025
      If your KAYO MOTOR Motorcycle engine performs poorly at low or idle speeds, this could be due to improper adjustment of valve clearance, poor quality of rocker arm adjustment screw, or improper valve timing adjustment. Check the valve timing and valve clearance.
  • H
    Henry HurstNov 5, 2025
    Why my KAYO MOTOR Motorcycle engine will not start?
    • M
      Marc HerreraNov 5, 2025
      If the engine of your KAYO MOTOR Motorcycle doesn't start or has difficulty starting, several factors could be at play. Begin by checking the fuel flow to the carburetor, as the issue might stem from no fuel in the tank, a blocked fuel line, a stuck float assembly, or a blocked vent on the tank cap. Additionally, examine the spark plug by removing it to test for a spark. The spark plug may not be clean, or there may be a failure of the spark plug, a fault in the electronic ignition, or an issue with the magneto. Other potential causes include a bad or broken connection, a disconnected or short-circuited high-voltage cable or ignition coil, or a faulty ignition switch. If these aren't the cause, test the cylinder pressure, as the starting mechanism might have skidded, the valve clearance ma...
  • S
    Samantha ParrishNov 17, 2025
    How to diagnose abnormal noise in KAYO MOTOR Motorcycle engine?
    • T
      Tammy LeonNov 18, 2025
      If the engine of your KAYO MOTOR Motorcycle is making an abnormal noise, check whether the valve has abnormal sound, because the valve clearance may be too large or the valve is worn. Also check whether abnormal sound occurs in the cylinder, because the piston and cylinder may be worn, there may be wear on small end holes of piston pins and connecting rods, or the crankpin and connecting rod is worn. In addition, check whether the timing chain produces abnormal sound, because the camshaft may be worn, the timing driven sprocket may be worn, the timing chain may be elongated, or there may be a failure of automatic chain tensioner or wear of guide wheel. Finally, check whether abnormal sound occurs in driving gear and driven gear, because gear machining accuracy may be insufficient, the teet...
  • В
    ВаняMar 23, 2026
    Сколько раз нужно менять масло приобкатке

    Summary

    Preface

    Meaning of Symbols and Technical Terms

    Suggestions for Daily Use

    Parts and Position

    21 TT 125 Parts and Position

    Identifies and labels specific components of the 21 TT 125 motorcycle model.

    Steel Chassis

    VIN and Engine Number

    VIN Number

    Details the Vehicle Identification Number (VIN) for the motorcycle.

    Engine Number

    Details the Engine Number for the motorcycle.

    Specification

    Manipulation

    Front Disc Brake Operation

    Describes how to operate the front disc brake system.

    Throttle Operation

    Explains the operation and location of the throttle control.

    Ignition System

    Details the motorcycle's ignition system and starting procedure.

    Stall Switch

    Describes the function and location of the engine stall switch.

    Fuel Tank Switch

    Explains the function and location of the fuel tank switch.

    Gear Shifting

    Describes the gear shifting mechanism and operation.

    Rear Disc Brake Operation

    Describes how to operate the rear disc brake system.

    Parking Stand

    Explains the function and use of the parking stand.

    Notes Before Use

    Suggestions for First-Time Users

    Provides essential advice for individuals new to operating this motorcycle.

    Running-in Process

    Details the recommended procedure for breaking in the new engine.

    Riding Guide

    Pre-Ride Checks

    Lists essential checks to perform before each ride for safety and performance.

    Notes on Ignition

    Provides guidance for starting the engine.

    Notes on Starting

    Details important considerations and checks before starting the engine.

    Notes on Cornering

    Offers advice for safe and effective cornering techniques.

    Notes on Acceleration

    Provides guidance on proper acceleration techniques.

    Notes on Gear Shifting

    Offers advice for smooth and safe gear changes.

    Notes on Braking

    Provides guidance on effective braking techniques.

    Notes on Parking

    Offers advice for safely parking the motorcycle.

    Maintenance Periodic Table

    Suspension System Setup

    Check Suspension Compression and Rebound

    Procedure to check motorcycle suspension behavior during riding.

    Measure Rear Wheel to Fender Distance (Suspended)

    Measures rear wheel to fender distance with the motorcycle suspended.

    Measure Rear Wheel to Fender Distance (No Load)

    Measures rear wheel to fender distance with the motorcycle under no load.

    Measure Rear Wheel to Fender Distance (Riding)

    Measures rear wheel to fender distance with the rider on the motorcycle.

    Adjust Rear Shock Spring Preload

    Instructions for adjusting the rear shock absorber's spring preload.

    Check Front Shock Setup

    Procedure to inspect the front shock absorber's condition and performance.

    Adjust Handlebar Position

    Guides on how to adjust the handlebar for optimal rider comfort and control.

    Maintenance

    Motorcycle Placement for Maintenance

    Guidance on properly positioning the motorcycle for maintenance tasks.

    Front Shock Protector Disassembly and Assembly

    Steps for removing and installing the front shock protector.

    Front Disc Brake Disassembly and Assembly

    Detailed procedure for disassembling and reassembling the front disc brake.

    Front Shock Disassembly and Assembly

    Instructions for removing and installing the front shock absorber.

    Clamp Disassembly and Assembly

    Steps for disassembling and reassembling various clamps.

    Check Head Steering

    Procedure to inspect the motorcycle's head steering for smooth operation.

    Steering Head Bearing Lubrication and Installation

    Guidance on lubricating and installing the steering head bearing.

    Front Fender Disassembly and Assembly

    Steps for removing and installing the front fender.

    Rear Shock Disassembly and Assembly

    Instructions for removing and installing the rear shock absorber.

    Seat Disassembly and Assembly

    Steps for removing and installing the motorcycle seat.

    Air Filter Disassembly and Assembly

    Procedure for removing and installing the air filter.

    Air Filter Cleaning and Maintenance

    Details on how to clean and maintain the air filter.

    Exhaust Pipe Disassembly and Assembly

    Steps for removing and installing the exhaust pipe.

    Muffler Disassembly and Assembly

    Instructions for removing and installing the muffler.

    Fuel Tank Disassembly and Assembly

    Steps for removing and installing the fuel tank.

    Chain Inspection and Cleaning

    Procedure for inspecting and cleaning the drive chain.

    Chain Disassembly and Assembly

    Instructions for removing and installing the drive chain.

    Chain Tension Check and Adjustment

    Guidance on checking and adjusting the drive chain tension.

    Inspect Sprockets and Chain Guide

    Inspection of rear sprocket, engine sprocket, and chain guide structure.

    Frame Inspection

    Procedure for inspecting the motorcycle frame for damage or defects.

    Swing Arm Inspection

    Inspection of the swing arm for wear, damage, or deformation.

    Throttle Cable Inspection

    Procedure for inspecting the throttle cable for proper function.

    Handlebar Inspection

    Inspection of the handlebar for comfort and control.

    Brake System Check and Maintenance

    Check Front Brake Lever Free Stroke

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

    Disc Brake Inspection

    Inspection of the disc brake system for proper function and wear.

    Check Front Brake Fluid Level

    Procedure to check the fluid level in the front brake system.

    Refill Front Brake Fluid

    Instructions on how to refill the front brake fluid.

    Disc Brake Thickness Inspection

    Inspection of disc brake thickness against limit values.

    Check Foot Brake Pedal Free Movement

    Procedure to check the free movement of the rear brake pedal.

    Check Rear Brake Fluid Level

    Procedure to check the fluid level in the rear brake system.

    Refill Rear Brake Fluid

    Instructions on how to refill the rear brake fluid.

    Check Rear Brake Friction Plate

    Inspection of the rear brake friction plate thickness.

    Tire Inspection and Maintenance

    Front Wheel Removal and Installation

    Steps for removing and installing the front wheel.

    Rear Wheel Removal and Installation

    Steps for removing and installing the rear wheel.

    Check Tire Surface

    Procedure to inspect the tire surface for damage.

    Check Tire Pressure

    Guidance on checking and maintaining correct tire pressure.

    Check Wheel Spokes

    Procedure to inspect the tension and condition of wheel spokes.

    Engine Installation

    Engine Maintenance and Adjustment

    Cylinder and Cylinder Body Bolt Inspection

    Procedure for inspecting and tightening cylinder and cylinder body bolts.

    Check Valve Clearance

    Procedure for checking and adjusting engine valve clearance.

    Inspect Compression Pressure

    Procedure for measuring engine cylinder compression pressure.

    Adjust Clutch Control System

    Guidance on adjusting the clutch control system for proper operation.

    Engine Adjustment

    Carburetor Idle Speed Adjustment

    Procedure for adjusting the idle speed of the carburetor.

    Carburetor Cleaning

    Instructions for cleaning the motorcycle carburetor.

    Check Shift Lever Position

    Procedure to check the position of the gear shift lever.

    Adjust Shift Lever Position

    Instructions for adjusting the position of the gear shift lever.

    Spark Plug Check and Replacement

    Procedure for checking and replacing the spark plug.

    Engine Lubrication System

    Lubrication Oil Selection

    Guidance on selecting the correct lubrication oil for the engine.

    Lubricating Oil Inspection

    Procedure for inspecting the engine oil level.

    Lubricating Oil Replacement

    Instructions for draining and refilling the engine lubricating oil.

    Engine Repair

    Cylinder and Valves

    Details on the cylinder and valve components and their maintenance.

    Cylinder Parts Parameters and Standards

    Specifications and maintenance limits for cylinder components.

    Cylinder Fault Symptoms and Causes

    Troubleshooting guide for common cylinder faults and their causes.

    Left Cylinder Head Cover Removal

    Steps for removing the left cover of the cylinder head.

    Timing Check Procedure

    Procedure for checking the engine timing marks.

    Valve Cover Removal

    Steps for removing the engine's valve cover.

    Cylinder Head Removal

    Steps for removing the engine cylinder head.

    Cylinder Head Disassembly

    Detailed steps for disassembling the cylinder head.

    Inspect Valves and Valve Springs

    Procedure for inspecting valve and valve spring condition and dimensions.

    Inspect Rocker Arm and Shaft

    Procedure for inspecting rocker arms and their shafts for wear.

    Inspect Camshaft Components

    Procedure for inspecting camshaft components for wear and damage.

    Inspect Cylinder Head

    Procedure for inspecting the cylinder head for damage and flatness.

    Check and Grind Valve Seats

    Procedure for checking and grinding valve seats for proper sealing.

    Inspect Valve Guide

    Procedure for inspecting the valve guides for wear and clearance.

    Replace Valve Guide

    Steps for replacing the valve guides.

    Measure Valve Seat Contact Area

    Procedure to measure the valve seat contact area width.

    Cylinder Head Assembly

    Steps for assembling the cylinder head.

    Cylinder Head Installation

    Procedure for installing the assembled cylinder head.

    Cylinder Block and Piston

    Cylinder Block and Piston Specs and Standards

    Specifications and maintenance limits for cylinder block and piston.

    Cylinder Block;Piston Faults and Causes

    Troubleshooting guide for cylinder block and piston issues.

    Cylinder Block Removal

    Steps for removing the cylinder block from the engine.

    Inspect Cylinder Block

    Procedure for inspecting the cylinder block for wear and damage.

    Piston and Piston Ring Removal

    Steps for removing the piston and piston rings.

    Inspect Piston and Piston Ring

    Procedure for inspecting the piston and piston rings.

    Piston Ring Installation

    Steps for correctly installing piston rings.

    Piston Installation

    Steps for installing the piston into the cylinder.

    Cylinder Block Installation

    Steps for installing the cylinder block onto the crankcase.

    Clutch, Gears, Oil Pump, and Shift Mechanism

    Clutch, Oil Pump Specs and Standards

    Specifications and maintenance limits for clutch and oil pump.

    Clutch;Oil Pump Faults and Causes

    Troubleshooting guide for clutch and oil pump issues.

    Right Trim Cover Removal

    Steps for removing the right decorative trim cover.

    Clutch Stroke Adjustment

    Procedure for adjusting the clutch lever's free stroke.

    Right Crankcase Cover Removal

    Steps for removing the right crankcase cover.

    Clutch Disassembly

    Detailed steps for disassembling the clutch assembly.

    Driving and Driven Gears Disassembly

    Steps for disassembling the driving and driven gears.

    Engine Oil Pump Removal

    Steps for removing the engine oil pump.

    Shift Mechanism Disassembly

    Steps for disassembling the gear shift mechanism.

    Inspect Right Crankcase Cover

    Procedure for inspecting the right crankcase cover for damage.

    Clutch Inspection

    Procedure for inspecting the clutch components for wear and damage.

    Inspect Driving and Driven Teeth

    Procedure for inspecting driving and driven gear teeth for wear.

    Check Oil Pump

    Procedure for checking the oil pump for wear and damage.

    Check Shift Mechanism

    Procedure for checking the gear shift mechanism.

    Shift Mechanism Assembly

    Steps for assembling the gear shift mechanism.

    Oil Pump Assembly

    Steps for assembling the engine oil pump.

    Driving and Driven Teeth Assembly

    Steps for assembling the driving and driven gears.

    Clutch Assembly

    Steps for assembling the clutch assembly.

    Clutch Installation

    Procedure for installing the assembled clutch.

    Right Crankcase Cover Assembly Steps

    Detailed steps for assembling the right crankcase cover.

    Right Crankcase Cover Reassembly

    Steps for reassembling the right crankcase cover with new gasket.

    Right Trim Cover Installation

    Steps for installing the right decorative trim cover.

    Magneto and Timing Chain

    Left Rear Cover Removal

    Steps for removing the left rear cover.

    Left Front Cover Removal

    Steps for removing the left front cover.

    Magneto Stator Removal

    Steps for removing the magneto stator.

    Magneto Rotor Removal

    Steps for removing the magneto rotor.

    Starting Motor and Sprocket Removal

    Steps for removing the starting motor and starting sprocket.

    Transition Plate Removal

    Steps for removing the transition plate.

    Timing Chain Removal

    Methods for removing the engine timing chain.

    Tensioning Arm, Rod, and Roller Removal

    Steps for removing the timing chain tensioning arm, rod, and roller.

    Inspect Left Front and Rear Covers

    Inspection of left front and rear covers for damage.

    Inspect Transition Plate, Starter, Sprocket

    Inspection of transition plate, starting motor, and starting sprocket.

    Magneto Stator and Rotor Inspection

    Inspection of magneto stator and rotor for damage.

    Install Tensioning Arm, Rod, and Roller

    Steps for installing the timing chain tensioning components.

    Transition Plate Installation

    Steps for installing the transition plate.

    Install Starting Motor and Sprocket

    Steps for installing the starting motor and starting sprocket.

    Magneto Stator Installation

    Steps for installing the magneto stator.

    Magneto Rotor Installation

    Steps for installing the magneto rotor.

    Align Rotor Keyway with Crankshaft

    Aligning the magneto rotor keyway with the crankshaft key.

    Left Cover Installation

    Steps for installing the left engine cover.

    Crankcase, Crankshaft, Shafts, and Speed Drum

    Crankcase, Shafts Specs and Standards

    Specifications and maintenance limits for crankcase and shafts.

    Crankcase;Shaft Faults and Causes

    Troubleshooting guide for crankcase and shaft issues.

    Crankcase Decomposition

    Steps for disassembling the crankcase.

    Crankshaft, Main and Auxiliary Shaft Disassembly

    Steps for disassembling the crankshaft and shafts.

    Variable Speed Drum Decomposition

    Steps for disassembling the variable speed drum.

    Inspect Crankshaft

    Procedure for inspecting the crankshaft for runout and wear.

    Inspect Crankshaft Box Bearings

    Procedure for inspecting crankshaft box bearings for smooth rotation.

    Inspect Shift Fork, Shaft, and Drum

    Procedure for inspecting shift fork, shaft, and drum for wear.

    Inspect Main and Auxiliary Shaft Combination

    Procedure for inspecting main and auxiliary shaft gear combinations.

    Inspect Starting Shaft

    Procedure for inspecting the starting shaft for wear.

    Variable Speed Drum Assembly

    Steps for assembling the variable speed drum.

    Install Speed Drum, Shafts, and Crankshaft

    Steps for installing the speed drum, shafts, and crankshaft.

    Crankcase Installation

    Steps for installing the crankcase.

    Crankcase Installation Procedure

    Detailed steps for installing the crankcase onto the engine.

    Crankcase Final Installation Steps

    Final steps for crankcase installation, including spring and bolt tightening.

    Engine Troubleshooting

    Engine Will Not Start or Starts with Difficulty

    Troubleshooting for starting issues: no start, difficult start.

    Engine Runs Unevenly

    Troubleshooting for uneven engine operation.

    Engine Underpower or Poor Acceleration

    Troubleshooting for lack of power or poor acceleration.

    Abnormal Engine Sound

    Troubleshooting for unusual noises from the engine.

    Exhaust Pipe Issues

    Troubleshooting exhaust pipe issues: noise, smoke, and leaks.

    Transmission Gear Engagement Issues

    Troubleshooting for problems with transmission gear engagement.

    Gear Beating Issues

    Troubleshooting for gear beating problems.

    Clutch Slipping Issues

    Troubleshooting for clutch slippage during acceleration.

    Motorcycle Steering Difficulty

    Troubleshooting for a motorcycle that is hard to steer.

    Suspension Damping Issues (Too Hard;Soft)

    Troubleshooting for suspension damping that is too hard or too soft.

    Abnormal Noise During Running

    Troubleshooting for abnormal noises occurring while the motorcycle is running.

    Front Wheel Shimmering

    Troubleshooting for front wheel shimmering or vibration.

    Motorcycle Cleaning

    Motorcycle Storage

    Prepare Motorcycle for Long-Term Storage

    Steps for preparing the motorcycle before storing it for an extended period.

    Prepare Motorcycle After Long Storage

    Steps for preparing the motorcycle after it has been stored for a long time.

    Key Maintenance Points

    Engine Crank Cannot Rotate

    Troubleshooting when the engine crank cannot rotate.

    Starter Does Not Respond

    Troubleshooting when the starter motor does not engage or respond.

    Engine Failure Troubleshooting

    Troubleshooting common engine failure causes.

    Incorrect Air-Fuel Mixture

    Troubleshooting incorrect air-fuel mixture issues.

    Engine Starts Then Stalls

    Troubleshooting when the engine starts but then stalls.

    Engine Running Unevenly

    Troubleshooting for uneven engine running.

    Engine Underpower or Poor Acceleration

    Troubleshooting for reduced engine power or poor acceleration.

    Rim Bias Issues

    Troubleshooting for rim bias problems.

    Front Wheel Bearing Wear

    Troubleshooting front wheel bearing wear.

    Motorcycle Misalignment

    Troubleshooting motorcycle misalignment.

    Motorcycle Tilting to One Side

    Troubleshooting for the motorcycle tilting to one side.

    Brake Failure Troubleshooting

    Comprehensive troubleshooting for brake system failures.

    Disc Brake Wear

    Troubleshooting worn disc brakes.

    Insufficient Brake Fluid

    Troubleshooting issues related to insufficient brake fluid.

    Brake Fluid Deterioration

    Troubleshooting brake fluid deterioration.

    Piston Damage

    Troubleshooting piston damage.

    Brake Pad Wear

    Troubleshooting worn brake pads.

    Vehicle Tightening Torque Meter

    KAYO MOTOR TT 125 Specifications

    General IconGeneral
    BrandKAYO MOTOR
    ModelTT 125
    CategoryMotorcycle
    LanguageEnglish

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