Liu was born Sin Kam-hei in Guangdong Province, China on August 22, 1951, prior to his adoption into another family. He is often wrongly cited as being the adopted son of Lau Cham, and adoptive brother of directors and actors Lau Kar-leung (Liu Chia-liang) and Lau Kar-wing (Liu Chia-Yung). He was not adopted by the family but is Lau Cham's godson.
In his youth (ages 15–20), he skipped school to train in Chinese martial arts without his parents' knowledge. He trained at Lau Cham's martial arts school of Hung Gar discipline, which descended from Wong Fei-hung's grand student (father to Lau Kar Leung). Lau Cham's wife assisted in his training and due to the friendship and respect Liu felt for Lau and his wife, he took on the name Lau Ka-fai. As he grew up, he found a job as a shipping clerk to make ends meet. His interests had always been towards martial arts and he was eventually offered a role by Lau Kar-leung.
Liu's first break was with Chang's Film Company (a Shaw Brothers subsidiary operating in Taiwan) acting small parts for such films as 5 Shaolin Masters, Shaolin Martial Arts, and 4 Assassins. He starred in Challenge of the Masters (1976), as the folk hero Wong Fei Hung, and was featured in Executioners From Shaolin (1977) before starring in his signature role as Shaolin hero San Te in The 36th Chamber of Shaolin.

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