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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

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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