KEEWAY RKV125 Instruction And Maintenance Manual
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KEEWAY RKV125 Instruction And Maintenance Manual

Keeway rkv125 motorcycle
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Two-wheel Motorcycle RKV125
Instruction and Maintenance Manual
KEEWAY MOTORCYCLE CO., LTD.

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Summary of Contents for KEEWAY RKV125

  • Page 1 Two-wheel Motorcycle RKV125 Instruction and Maintenance Manual KEEWAY MOTORCYCLE CO., LTD.

  • Page 2: Table Of Contents

    Contents Contents..................................2 Preface .................................... 5 Preparatory Data ..............................6 Inspection/Adjustment ............................44 Inspection and Maintenance of Electric System ......................58 Battery/Charging System ............................ 60 1.1 Preparatory Data ............................. 60 1.2 Fault Diagnosis ............................... 61 1.3 Storage Battery ............................... 62 1.4 Charging System .............................
  • Page 3 Front Wheel/Front Suspension ........................... 98 7.1 Preparatory Data ............................. 98 7.2 Fault Diagnosis ............................... 99 7.3 Front Wheel ..............................99 7.4 Steering Handle ............................101 7.5 Front Fork ..............................102 VIII Rear Wheel/Rear Suspension ..........................107 8.1 Preparatory Data ............................107 8.2 Fault Diagnosis .............................
  • Page 4 14.4 Disassemble Main Shaft and Countershaft ....................148 Reduction Gear ..............................150 15.1 Service Data ..............................151 15.2 Fault Diagnosis ............................151 15.3 Gearshift Mechanism ..........................151 15.4 Installation ..............................154 XVI Crankcase ................................155 16.1 Preparatory Data ............................155 16.2 Fault Diagnosis ............................

  • Page 5: Preface

    Preface The Instruction and Maintenance Manual contains an introductory description of maintenance means on RKV125 motorcycle. Preparatory data include attentions that shall be paid on all the maintenance operations in the Instruction and Maintenance Manual. Please read the manual carefully before operation.

  • Page 6: Preparatory Data

    Preparatory Data General Safety Maintenance Rules Specification Table Fault Diagnosis General Safety Carbon monoxide (CO) When it is necessary to start the engine, please make sure the operation area is well ventilated. Never run the engine in an enclosed place. Attention Gas exhausted from the motorcycle contains harmful carbon monoxide, which may lead to loss of consciousness and death.

  • Page 7: Maintenance Rules

    Maintenance Rules While repairing and servicing, use tools of metric system as possible. Incorrect tools may damage the motorcycle. Before taking down or opening protecting plate for repair work, please clean the dirt on the external surfaces of components or combination parts and prevent the dirt from falling into engine, chassis or braking system After disassembly and before measuring friction, please clean the components and blow them with compressed air.
  • Page 8 Length of bolts and screws are different for assembly components and protecting plates. They shall be installed at correct positions. If confused, just put the bolt in the hole and see if it matches. Fill lubricating grease into the groove during oil seal installation. Check if the oil seal is smooth and if there is any damage to it.
  • Page 9 Slack cable implies potential safety hazard on electrics. Check the next cable when the cable is clamped to ensure electric safety; Cable clamp shall not be bent towards solder joint; Tie the cable at appointed position; Do not lay the cable at the end of frame or at the closed angle; Do not lay the cable at the end of a bolt or screw;...

  • Page 10: Important Notice

    Figure 1-3 Important Notice 1. Please use spare parts manufactured by KEEWAY Motorcycle Co., Ltd. Components that cannot comply with the designed specifications of KEEWAY Motorcycle Co., Ltd. may result in damage of the engine. 2. Only metric tools can be used for maintenance work. Metric bolts, nuts and screws cannot be exchanged with inch fasteners.

  • Page 11: Special Tools

    Special Tools Special tools are known as specially designed tools used at particular places for assembly or disassembly of certain components on a motorcycle. Suitable special tools are essential for complete and accurate adjusting and assembling work. Use of special tools can realize safe, reliable and quick disassembly or assembly of components, as well as working efficiency improvement and labor saving.
  • Page 12 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 1-9 Figure 1-10 ① Handle ① Pliers ② Piston Figure 1-11 Figure 1-12...
  • Page 13 Figure 1-13 Figure 1-14 Figure 1-15 Figure 1-16 Figure 1-17 Figure 1-18 Figure 1-19 Figure 1-20 Figure 1-21 Figure 1-22...
  • Page 14 Figure 1-23 Figure 1-24 2. Tools used for chassis overhaul Common and special tools, as well as their pictures for chassis component assembly and disassembly are listed in Table 1-25 and Table 1-26. Table 1-25 Name Remarks Torque wrench Figure 1-27 Allen wrench Figure 1-28 Socket wrench...
  • Page 15 Figure 1-31 Figure 1-32 Figure 1-33 Figure 1-34 Figure 1-35 Figure 1-36 （2）Special tools for chassis overhaul: Front fork seal driver Figure 1-37 （3）Steering nut wrench Figure 1-38...
  • Page 16 3. Tools used for electrical components Special tools and their pictures for electrical component test are listed in Table1-39 and 1-40. Table 1-39 Name Remarks Multimeter Figure 1-41 Ignition tester Figure 1-42 Continued Table 1-40 Figure 1-41 Figure 1-42...
  • Page 17 Specifications (RKV125) Model RKV125 Engine type KW157FMI-2B higher unleaded Overall Length 2090mm Fuel gasoline 830mm Number of cylinders Overall Width Overall height 1,060mm Bore*stroke 57.0× 48.8 1,330mm Displacement 125cc Wheelbase Front axle Starting mode Electric Weight (kg) Rear axle Cooling mode...
  • Page 18 RKV125...
  • Page 19 Fault Diagnosis Symptom: Engine will not start or is hard to start Diagnosis procedures Engine will not start or is hard to start Check ignition system Remove the spark plug and check if electrodes of the plus are connected by carbon. Perform spark-over test Clean deposited carbon Spark is weak between electrodes or no spark at all.
  • Page 20 Check leakage 1. Check if breather on external connection parts the fuel tank cap is of engine; 2.Check valve clogged; 2. Check if timing; Check fuel filter fuel tightness between valve switch are clogged; 3. and valve seat; 4. Check Check if fuel switch Remove if valve clearance is too...
  • Page 21 Symptom: Engine Overheats Diagnosis procedures Engine Overheats Check improper operation method 1. Check if gasoline brand being used is too Check cooling system low or the gasoline has been stored for a too long time; 2. Check if engine runs at a Air cooling the engine high speed for a very long time or overloaded...
  • Page 22 Clutch slips Remove the spark plug and check color of skirt section of insulating part Handle it according to and other abnormalities to judge Item 1.7. mixture ratio of air/fuel. Skirt section of insulating part is brown. Skirt section of insulating part is Skirt section of insulating part is black and when the white and engine generates an engine runs at middle or low speed, exhaust muffler gives...
  • Page 23 Symptom: Engine lacks power Diagnosis procedures Engine lacks power Lift it with main stand to have the wheels off the ground. Rotate wheels by hands. Wheels rotate freely. Wheels rotate inflexibly. Check tire pressure 1. Check braking drag; 2. Check if bearing of wheels are over worn or injured;...
  • Page 24 Symptom: Poor idle speed of engine Diagnosis procedures Poor idle speed Engine has no idle speed. Higher idle speed Unsteady idle speed Pull throttle valve of carburetor by hand Use an ignition timing lamp to Check compression pressure in cylinder and see if it is completely closed.
  • Page 25 Symptom: Too much fuel consumption by the engine Diagnosis procedures Too much fuel consumption Check operation method Lift it by main stand, rotate wheels by hands 1. Check if motorcycle is driven over speed or not at economical speed or driven at low gear; 2. Check if gasoline grade being Wheels rotate inflexibly.
  • Page 26 Symptom: Clutch slips Diagnosis procedures Clutch slips Manually controlled wet multi-plate clutch slips Automatic centrifugal dry type shoe clutch slips Check if braking shoe of shoe-type clutch is contaminated by oil Check if clearance of clutch handle bar is within 10mm~20mm. Check if braking shoe Clean greasy...
  • Page 27 Symptom: 4-stroke engine exhaust muffler gives off blue-white smoke Diagnosis procedures 4-stroke engine exhaust muffler gives off blue-white smoke Check if engine oil level in the crankcase exceeds the upper limit line Start engine and run it at high speed; screw off Too much engine oil in the crankcase, bleed surplus oil oil ruler and check if oil filler smokes.
  • Page 28 Symptom: Difficult gearshift on transmission Diagnosis procedures Difficult gearshift on transmission Start engine and check if idle is too high. Re-adjust Check if the operation is harmonious at gearshift. Check if clutch is completely separated. Improve operation method. 1. Check if clearance of clutch handle bar is Check if gearshift box is distorted and shift lever is deformed or over worn.
  • Page 29 Symptom: Transmission jumps of gear Diagnosis procedures Transmission jumps of gear Check if spring of position wheel is broken or of insufficient elasticity. Replace Disassemble crankcase and check if meshing depth of each gear meets requirement. Enough meshing depth Insufficient meshing depth Check if meshing end of cam pawl on end face of meshing gear is worn or Check if shift fork is over distorted.
  • Page 30 Symptom: Battery does not charge Diagnosis procedures Battery does not charge Disconnect connectors of magneto lead wire tied to the cables of the whole motorcycle. Measure with an Ohmmeter between out-put wires from charging coil Resistance is less than standard. Resistance meets the standard.
  • Page 31 Symptom: Battery runs down quickly Diagnosis procedures Battery runs down quick Check if braking lamp is always on. Set ignition switch to “OFF” position, disconnect negative wire from battery, and then Adjust or replace braking lamp switch. put negative probe of ammeter onto the negative pole terminal and positive probe on the negative wire to check current leakage.
  • Page 32 Symptom: Starting motor does not run Diagnosis procedures Starter motor does not run. Turn on ignition switch; press horn button or slide turn signal lamp switch. Electric horn does not sound or sound Electric horn sounds loudly. weakly. Turn signal lamp is dim. Turn signal lamp is bright.
  • Page 33 Disassemble starter motor and Coil in starter coil Check wiring in electrical Contact make following broken starter control system starting relay is inspections： shorted. burnt or injured. 1. Check if the carbon brush is over worn; 2. Check if carbon brush spring is broken or weak.
  • Page 34 Symptom: Starting motor runs weakly Diagnosis procedures Starter motor runs weakly. Turn on ignition switch; press horn button or slide turn on signal lamp switch. Electric horn does not sound or sound Electric horn sounds loudly. weakly. Turn signal lamp is bright. Battery is low or the lead wire Check if the lead wire connector from starter relay connector connected with battery is...
  • Page 35 Symptom: All the lights are not on Diagnosis procedures All the lights are not on AC power supplied lighting system power supplied lighting system Separate conductors of lead wire bundle of magneto from the cables of the whole vehicle. Check if there is power Press horn button or slide turn signal light.
  • Page 36 Replace headlamp bulb and Check if there is power output from power check other bulbs one by one. input wire of light switch by lamp test Use a piece of wire to short circuit power line and Wiring from magneto or ignition output line of lighting switch.
  • Page 37 Symptom: Light bulb is burnt frequently Diagnosis procedures Light bulb is burnt frequently Turn on ignition switch; press horn button or slide turn signal lamp switch. Electric horn does not sound or sound Electric horn sounds loudly. hoarse. Turn signal lamp is dim. Turn signal lamp is bright.
  • Page 38 Symptom: Headlamp is dim. Diagnosis procedures Headlamp is dim AC power supplied lighting system DC power supplied lighting system Separate conductors of lead wire bundle of magnet from Turn on ignition switch; press horn button cables of the whole vehicle. Measure and check with an or slide turn signal lamp switch.
  • Page 39 Check if power of bulb in the lighting Replace the bulb. system is up to the requirement. 1. Check if headlamp switch Replace bulb. and side-lamp switch is poorly contacted; 2. Check if connectors and earth wire poorly contacted.
  • Page 40 Symptom: Turn signal lamp is off. Diagnosis procedures Turn signal lamp is not on. Some of the turn signal lamps on one All the turn signal lamps are not All the turn signal lamps on side is not on. one side are not on. Take down the turn signal lamp Take down the turn signal lamp Press horn button and...
  • Page 41 Separate connectors of turn signal lamp switch and use Scintillator is damaged. a piece of wire to short circuit respectively power input line of the switch and power lines output to left and right turn signal lamps. Turn signal lamp is on after short circuit. Turn signal lamp is still off after short circuit.
  • Page 42 Symptom: Electric horn mutes. Diagnosis procedures Electric horn mutes. Turn on ignition switch; slide turn signal lamp switch and check. Turn signal lamp is not lit or dim. Turn signal lamp shines brightly. Battery is low or the wire from battery Power supply from battery is normal.
  • Page 43 Symptom: Brake lamp does not work. Diagnosis procedures Brake lamp does not work. Take down cover of brake lamp and check if bulb is burnt. Replace bulb Use a piece of wire to short circuit two terminals of brake lamp switch or plugs of two hatching lines. Lamp is not lit after short circuit.

  • Page 44: Inspection/Adjustment

    Inspection/Adjustment Preparatory standard Compression pressure of cylinder Periodic maintenance schedule chart Engine oil Engine oil/filter Replacement of engine oil Drive chain slackness Steering stem bearing and handle fixation Throttle cable adjustment Front/rear brake clearance Air cleaner Headlamp Spark plug Clutch Battery Front/rear suspension system Carburetor...

  • Page 45: Specifications

    Clearance of front brake handle 10-20mm Clearance of rear brake pedal 20-30mm Specification Tyre pressure Front wheel 100/80-17 210± 10kPa Pneumatic pressure unit of tyre： RKV125 Rear wheel 130/70-17 210± 10kPa Front shaft locknut 55-62 N· m Torque Rear shaft locknut 85-98 N· m...

  • Page 46: Periodic Maintenance Schedule

    Periodic Maintenance Schedule Every Every Every Every Every Every 1000 3000 6000 12000 14500 Mileage and interval Tools three Twelve Fifteen Vehicle month months months months months Items Air cleaner Common tool Gasoline filter Common tool Engine oil filter Common tool Engine oil replacement Once every 1000KM Common tool...

  • Page 47: Engine Oil Level

    Piston and cylinder -- when cylinder is over worn or stuck, please replace it. Please go to your local KEEWAY Motorcycle dealer periodically for inspection and adjustment to keep your vehicle in best conditions. In above table, monthly 1000km travel is employed as reference.

  • Page 48: Throttle Cable Adjustment

    When the engine oil is completely drained, put back cleaned drain plug and sealing ring. Refill engine oil to specified level. Check if there is engine oil leakage. Start the engine and run the engine on idle for a few minutes. Check engine oil level again.

  • Page 49: Spark Plug

    Replacing Time If driving under dusty condition or in rainy days frequently, replace the air cleaner earlier. * Attention While removing filter element of air cleaner, please do not run the engine, in case unfiltered air comes into the engine, which may result in fast wear of some components or damage the engine.
  • Page 50 Battery Removal Remove the seat and take down the right protecting plate. Remove the battery from the battery case (1). Disconnect the battery negative (-) lead wire first and then the positive (+) lead wire. Remove the battery. Warning! During positive lead wire disconnection, be sure to prevent the tools being used from touching the frame;...

  • Page 51: Ignition Timing

    • Battery shall be away from fire. • Shut off charger switch first before or after charging in case sparks may be generated at connection parts, which may result in explosion. • During charging, please take the current time labeled on the battery as basic time. * Attention •...

  • Page 52: Engine Oil

    Compression Pressure of Cylinder Warm up engine. Insert the pressure gauge. Turn choke valve to its full open position. Set throttle handle to its full open position and kick start the engine. Compression pressure of cylinder: 1-1.2 mpa * Attention Start the engine till reading of pressure gauge does not rise.
  • Page 53 * Attention Check if sealing ring is damaged. Install the engine oil ruler. Engine Oil Replacement Warm up engine. Place an oil pan below the engine and drain engine oil by removing drain plug and oil ruler. Kick start engine several times to drain thoroughly the engine oil.
  • Page 54 * Attention Do not install new drive chains onto worn sprockets or install worn drive chains onto the new sprockets. Keep both sprocket and drive chain in good conditions, or newly replaced chain or sprocket will be worn soon. Clearance of Front/Rear Brake Front brake clearance Measure the clearance of front brake at the tip of front brake handle.
  • Page 55 Install a new headlamp bulb (3). Screw tightly the new bulb into the adapter. Avoid touching bulb glass with your bare hands during installation and staining it with oil, which may affect transparency, service life and of bulb. luminous flux If oil is adhered to the bulb, clean it with a cloth moistened with alcohol or highly volatile rubber solution.

  • Page 56: Front Suspension

    Front/Rear Suspension System Front suspension Grasp the front brake handle and compress upward and downward the front shock absorber to check its actuator. Check if the front shock absorber leaks oil and if the components are loosened. Rear suspension Compress upward and downward the rear shock absorber to check its actuator.

  • Page 57: Wheel Rim/Tyre

    Inspect pneumatic pressure of tyres. * Attention Measure cold inflation tyre pressure Specified air pressure Unit: Kpa Tyre specifications Tyre pressure Front tyre 100/70-17 210± 10kPa RKV125 Rear tyre 130//60-17 210± 10kPa Tyre Specifications Front tubeless tyre 100/70-17 RKV125 Rear tubeless tyre 130//60-17 Check if lock nut of front shaft is loosened.

  • Page 58: Inspection And Maintenance Of Electric System

    Inspection and Maintenance of Electric System Table of tightening torque for fastening parts used in electric system Fastening position and fastening part name Tightening torque (N· m) Starting motor clutch cover bolt Starting motor clutch locknut Rectifier bolt High-voltage coil pinch bolt Flywheel locknut Vehicle block protecting plate bolt...
  • Page 59 Charging system 1. Starting relay 2. Scintillator 3. Battery 4. Electric igniter 5 High-voltage ignition coil 6. Power lock assembly...

  • Page 60: I Battery/Charging System

    I Battery/Charging System Preparatory data---------------1.1 Fault diagnosis--------------1.2 Battery--------------------------1.3 Charging system-------------1.4 Voltage/current adjuster------1.5 Magneto charging coil------- 1.6 Removal of magneto--------- 1.7 1.1 Preparatory Data Precautions on operation * Attentions 1. The battery can be charged and discharged, and used repeatedly. If a battery is laid aside after discharging, its service life will be shortened and its performance is degraded.

  • Page 61: Fault Diagnosis

    Preparatory Standard Item Specification Capacity/type 12V dry-charged type Voltage Fully recharged 13.1V （20℃） Battery Must be recharged 12.3V (not work for one hour) Recharging current Standard: 0.9A, Quick: 9A Recharging time Standard: 10-15hours; Quick: 30minutes Max. capacity 120W Magneto Coiling impedance value（20℃） White-white 0.5-10Ω...

  • Page 62: Storage Battery

    1.3 Storage Battery 1.3.1 Battery Removal Take down the right protecting plate (1). Disconnect the battery negative (-) lead wire first and then the positive (+) lead wire. Remove the battery breather. Remove battery mounting bracket (2). Remove the battery (3). Warning! During positive lead wire disconnection, be sure to prevent the tools being used from touching the frame;...

  • Page 63: Charging System

    Recharging current: Standard: 0.3A Quick charging: 3.0A Recharging time: Standard: 10-15hours Quick recharging: 30minutes Recharging completed: Open circuit voltage: over 12.8V 1.4 Charging System 1.4.1 Short circuit test Disconnect the grounding wire from the battery and use a voltmeter to connect battery negative lead wire with grounding wire.

  • Page 64: Magneto Charging Coil

    Check continuity between main wiring terminals in the following way: Item (wire color) Judgment Battery (red) and ground of vehicle It is battery voltage. block Ground wire (black) and ground of vehicle There is a lead wire. block Charging coil (white) No power flowing between and ground of vehicle magneto coil and ground...

  • Page 65: Magneto Removal

    1.7 Magneto Removal * Attention Inspection of magneto lighting coil can be performed on the engine. 1.7.1 Inspection Disconnect the 4P connector on the magneto. Use a multimeter to measure impedance value between yellow coil of magneto and ground wire of vehicle block. Standard value：0.4-0.6Ω...
  • Page 66 * Attention There is magnetism on the inner surface of flywheel, ensure there is no bolt on it. Fix the flywheel using a universal non-adjustable spanner and then tighten the locknut. Torque value: 9.0 N· m Install protecting plate on the left side.
  • Page 67 Ignition System 1 Relay 2 Scintillator 3 Battery 4 Igniter 5 High-voltage ignition coil 6. Power lock assembly 7 Voltage regulator...

  • Page 68: Ignition System

    II Ignition System Preparatory data-------------------2.1 CDI assembly--------------2.4 Fault diagnosis--------------------2.2 Ignition coil----------------2.5 Ignition system inspection-------2.3 Trigger----------------------2.6 2.1 Preparatory Data Precautions on operation 1. Ignition system inspection: please perform inspection in the sequence listed in the fault diagnosis table. 2. Ignition system uses electronic-type automatic timing device, which is solidified in the CDI assembly, so it is unnecessary to adjust the ignition time.

  • Page 69: Fault Diagnosis

    2.2 Fault Diagnosis Spark plug not sparking Symptom Possible causes (Determine the cause from 1 in sequence) ① Inner impedance is too small. Use appointed tester to test. ②Crankshaft rpm is too low. ③Tester is disturbed (it is normal when more than one time’s Ignition coil When the high voltage power is too measured voltage is above the basic).

  • Page 70: Ignition System Inspection

    2.3 Ignition System Inspection * Attention • When the spark plug is not sparking, check if components of wiring are loosened or badly contacted and make sure if all the voltage values are normal. • There are many brands of multimeters with different interior impedance.

  • Page 71: Cdi Assembly

    green/white. Min. voltage: higher than 1.7V. * Attention Please do not touch the metal parts of testing probe with your fingers while measuring the voltage, or you will be shocked. Please take care. When the peak voltage measured at connector of CDI assembly is abnormal, take down the protecting plate on the right side of vehicle and remove connector of magneto.

  • Page 72: Ignition Coil

    2.5 Ignition Coil 2.5.1 Removal Remove protecting plate of vehicle block. Remove spark plug cap. Remove primary lead wire of ignition coil. Remove locknut of ignition coil and take out the ignition coil. Install it in the reverse order of removal. *Attention The primary coil is installed with black/white wire connector.

  • Page 73: Trigger

    2.6 Trigger * Attention Trigger inspection can be performed on the engine. Inspection Remove protecting plate of vehicle block. Remove lead-wire connector of trigger. Measure the impedance between blue/white terminal of lead wire at engine side and grounding vehicle block. Standard value: 100-200Ω...
  • Page 74 Starting System 1 Starting relay 2 Scintillator 3 Battery 4 Electronic igniter 5 high-voltage ignition coil 6 Power lock assembly 7 Rectifier 8 Electric horn...

  • Page 75: Starting System

    Starting System Preparatory data-------- 3.1 Fault diagnosis----------3.2 Starting motor-----------3.3 Starting relay------------3.4 3.1 Preparatory Data Precautions on operation Starting motor removal can be performed on the engine. Starting clutch removal refers to removal instruction. Basic data Item Standard Service Limit Length of starting carbon brush 12.5mm 8.5mm Starting idler shaft bushing...

  • Page 76: Fault Diagnosis

    3.2 Fault Diagnosis Starting motor will not run Starting motor runs weakly Starting motor runs but the engine does not •Broken Fuse •Low battery •Defective starting clutch •Low battery •Poor connecting wire contact •Starting motor counter-rotate •Defective ignition switch •Starting motor gear stuck by •Low battery •Defective starting clutch foreign substances...
  • Page 77 Inspect continuity between conducting terminal and brush. Replace it with a new one if abnormality exits. Inspect carbon brush holder for continuity. If there is continuity, replace it. Measure carbon brush length Service limit: replace it when it is shorter than 8.5mm Check rotation smoothness of the needle bearing in the front cover and whether it is loosened when it is pressed in.

  • Page 78: Starting Relay

    3.4 Starting Relay 3.4.1 Actuation Inspection Take down the protecting plate of vehicle block. When the ignition switch is set at “ON” position, press starting motor and a “Click” sound can be heard. “Click” sound indicates normal. No sound: • Check starting relay voltage. •...
  • Page 79 Bulbs/Switches/Instruments 1 Headlamp 2 Instruments 3 Electric horn 4 Left rear turn signal lamp 5 Tail lamp...

  • Page 80: Bulbs/Switches/Instruments

    Bulbs/Switches/Instruments Preparatory data---------------------------------------------------4.1 Fault diagnosis----------------------------------------------------4.2 Headlamp bulb replacement------------------------------------4.3 Front turn signal lamp bulb replacement---------------------4.4 Tail lamp bulb replacement ------------------------------------4.5 Instrument--------------------------------------------------------4.6 Ignition switch---------------------------------------------------4.7 Electric horn------------------------------------------------------4.8 Handle switch----------------------------------------------------4.9 4.1 Preparatory Data Precautions on operation Remove switches from the motorcycle and perform continuity test. All the plastic connectors have pawls on them.

  • Page 81: Headlamp Bulb Replacement

    4.3 Headlamp Bulb Replacement 4.3.1 Removal Screw off with a wrench locknut (1) of headlamp and take down the headlamp. Pull out socket of headlamp adapter and remove the rear cover. Release circlip and take out of the lamp adapter. * Attention When the bulb is lit, keep you hands and inflammable materials some distance away from it.

  • Page 82: Tail Lamp Bulb Replacement

    4.5 Tail Lamp Bulb Replacement 4.5.1 Removal Screw off the two bolts (1). Remove the tail lamp hood. Disconnect wire connector to the tail lamp. While pressing down the tail lamp, rotate it counterclockwise Remove the tail lamp. 4.5.2 Installation Install the tail lamp in the reverse order of removal.

  • Page 83: Ignition Switch And Steering Lock

    4.7 Ignition Switch and Steering Lock 4.7.1 Inspection Remove the headlamp from the cover. Remove ignition switch-wire connector. Inspect continuity of connector terminal. This kind of power lock has electromagnetic anti-theft function. When the switch under the power lock is moved to “OPEN” position, you can insert key into the keyhole above to operate.

  • Page 84: Handle Switch

    4.9 Handle switch Remove protecting plate of steering handle. Screw off mounting bolt on the brake lever and take down the bracket. Remove bracket for the rear brake lever. Remove throttle handle and bolts. Take down throttle handle from the handle and remove the throttle cable. Remove locknut on the handle and take down the handle.

  • Page 85: Chassis Inspection And Maintenance

    Chassis Inspection and Maintenance Tightening Torque of Fastening Part on Chassis Fastening position and part name Tightening Torque (N· m) Oil pump block assembly mounting bolt Front brake cylinder assembly mounting bolt 22-29 Rear brake rocker arm mounting bolt Rear shaft locknut 85-98 Upper bracket assembly mounting bolt 40-60...
  • Page 86 Front Hydraulic Brake Front brake disc diameter：260mm Front brake disc thickness：4.0mm Service limit：3.0 Brake shoe thickness：4 mm Service limit：3mm Mounting torque for Bolt 7 in the diagram： 22-29 N· m 1 Oil pump block assembly 2 Hydraulic brake handle 3 Handle mounting bolt 4 Nut M6 5 Fixing cover 6 Bolt M6×...
  • Page 87 Rear Hydraulic Brake Rear brake disc diameter：240mm Rear brake disc thickness：5.0mm Service limit：4.0 Brake shoe thickness：5mm Service limit：4mm Mounting torque for Bolt 7 in the diagram：22-29 N· m 1 Rear hydraulic brake assembly 2 Bushing Ⅱ 3 Bracket 4 Friction disc assembly 5 Brake cylinder assembly 6 Bolt M8×...

  • Page 88: Braking System

    V Braking System Maintenance instruction--------------------5.1 Fault diagnosis-------------------------------5.2 Front hydraulic disc brake----------------- 5.3 Rear drum brake-----------------------------5.4 5.1 Maintenance Instruction Precautions on operation * Attention • Plea se do not contaminate braking assembly with oil while assembly or disassembly. • Please use specified detergent to clean the braking assembly, or it may reduce braking performance. * Please check braking system before driving your motorcycle.* 5.1.1 Specifications Item...

  • Page 89: Fault Diagnosis

    5.2 Fault Diagnosis Braking System Poor braking performance Brake drags or tight handle 1. Improper brake adjustment 1. Improper brake adjustment 2. Worn braking shoe assembly and brake disc 2. Worn braking shoe assembly and brake disc 3. Braking shoe assembly improperly installed 3.
  • Page 90 Screw off braking cylinder assembly mounting bolt. Remove the braking cylinder assembly from front shock absorber. Remove front shaft. Remove front wheel. Remove brake disc from the front wheel. 5.3.2 Inspection Check if braking shoe assembly and brake disc are worn. Replace them if necessary. Measure braking shoe and brake disc and record the maximum values.

  • Page 91: Rear Hydraulic Brake

    A contaminated braking shoe will reduce braking performance. * Attention • Please do not contaminate braking shoe assembly with oil while assembly or disassembly • Please use specified detergent to clean the braking assembly, or it may reduce braking performance. 5.4 Rear Hydraulic Brake 5.4.1 Removal * Attention...
  • Page 92 5.4.3 Installation Install braking shoe assembly Install rear wheel. Install muffler assembly (24). Install brake pedal assembly (21). * Attention A contaminated braking shoe will reduce braking performance and result in braking failure. Tighten bolt and nut to their specified torque value. Torque value: Rear wheel locknut: 85-98 N·...

  • Page 93: Exterior Parts

    Exterior Parts Attention Do not damage exterior parts during disassembly and assembly. Do not damage the pawls on the exterior parts of the vehicle during assembly or disassembly. Align built-in panel and cover plate to their grooves respectively. Correctly install jaw of each part during combination. Do not damage the fittings during exterior part installation.

  • Page 94: Motorcycle Exterior

    Motorcycle Exterior Disassemble the exterior parts in the following sequence: Seat cushion assembly → Left and right protecting plate assemblies → Left and right tail covers → Left and right hanger → Left and right hanger → ↓ Left and right pedals → Front mudguard brace panel → Front mudguard → Rear mudguard assembly → Rear rail → Rear tail cover connecting board →...
  • Page 95 Front wheel / Front Suspension 1 Front shaft 2 Gear seat assembly 3 Gear seat oil seal 4 Drive plate 5 Bearing 6301 6 Front wheel middle shaft sleeve 7 Front brake disc 8 Front brake disc mounting bolt 9 Front wheel oil seal assembly 10 Front wheel left shaft sleeve 11 Tubeless tyre 12 Front wheel rim...
  • Page 96 Control Assembly N· m Tightening torque of hexagon socket Bolt 2：37-44 N· m Tightening torque of Nut 19：5-9 N· m Tightening torque of Bolt 20：5-9 1 Right rear mirror assembly 2 Left rear mirror assembly 3 Handle gear block 4 Right handle assembly 5 Right combination switch 6 Handle welded assembly 7 Left combination switch 8 Left handle grip...

  • Page 97: Front Fork Assembly

    Front Fork Assembly 1 Steering lever nut 2 Dust cover 3 Upper steel bowl of upper bearing 4 Steel ball 3/16 inch 5 Lower steel bowl of upper bearing 6 Upper steel bowl of lower bearing 7 Steel ball 1/4 inch 8 Lower steel bowl of lower bearing 9 Lower bracket of headlamp 10 Main cable clamp 11 Hexagon socket bolt 8x30 12 Steering...

  • Page 98: Front Wheel/Front Suspension

    assembly 40 Front mudguard right bracket I assembly VII Front Wheel/Front Suspension Preparatory data-----------------7.1 Fault diagnosis------------------7.2 Front wheel----------------------7.3 Control assembly---------------7.4 Front fork assembly------------7.5 7.1 Preparatory Data Precautions on operation Before removing the front wheel, lift and support the bottom of motorcycle with a jack or other available device. The front wheel is off the ground.

  • Page 99: Fault Diagnosis

    7.2 Fault Diagnosis 7.2.1 Heavy Steering Handle Handle bearing damaged Too low tyre pressure Tyre leakage 7.2.2 Wobbly Direction Handle Damaged handle bearing Not enough tyre pressure. Front fork bent, front wheel shaft bent. Distorted and crooked front wheel tyre. 7.2.3 Wobbly Front Wheel Distorted wheel rim Worn front wheel bearing...

  • Page 100: Bearing Replacement

    * Note: Refer to Page 95 of the manual for detailed KW125 Motorcycle front wheel disassembly and assembly diagram. 7.3.2 Inspection 7.3.2.1 Shaft Bow Inspection Place the shaft onto a V block and measure its eccentricity with a dial gauge. Service limit: When the measured value exceeds 0.2mm, replace it.

  • Page 101: Steering Handle

    Install the bearing in the reverse order of removal. Attentions: Lubricate front shaft, gear seat assembly, oil seal (lip), shaft sleeve, bearing 6301-2RS, and middle sleeve. Recommended lubricant is calcium base grease. Install front shaft (3), front wheel, gear seat assembly (5) and Nut M12Χ1.25 (14).

  • Page 102: Front Fork

    Tightening torque: 40-60 N· m 7.5 Front Fork 7.5.1 Removal Support the motorcycle with the middle stand. Remove front wheel. Remove brake caliper and brake pipe clip. Remove front mudguard (1) and reflector (2). Remove the handle. Screw off upper bracket mounting bolt and lower bracket pinch bolt.
  • Page 103 Apply lubricating grease onto the bottom bearing steel bowl and confirm the number of steel balls (23balls). Steering handle shall not be rotated in case of steel ball falling off; then install steering rod. Support the steering handle and apply lubricating grease on to the top bearing steel bowl and confirm the number of steel balls (19 balls).

  • Page 104: Rear Shock Absorber

    Rear Wheel/Rear Suspension 1 Rear shock absorber assembly 2 Rear brake rocker arm 3 Rear shaft 4 Nut M8 5 Sprocket stopper 6 Sprocket 43 teeth 7 Oil seal 8 Rolling bearing 6204-2RS 9 Chain drive sleeve 10 Sprocket hub 11 Sprocket mounting bolt 12 Rear wheel left sleeve assembly 13 Rear wheel buffer...

  • Page 105: Rear Swing Arm

    Rear Swing Arm Side clearance (opening swing arm end) limit value：1.0mm Tightening torque of Nut 3 in the diagram is：70-83 N· m 1 Locking nut M14X1.5 2 Rear swing arm mounting washer 3 Oil seal 4 Rear swing arm shaft 5 Chain protector 6 Rear swing arm welded assembly 7 Chain adjuster 8 Screw M5X12 9 Spacer 2...
  • Page 106 Chain Drive Assembly 1 Sprocket mounting bolt 2 Sprocket hub 3 Chain drive sleeve 4 Rolling bearing 6204-2RS 5 Oil seal 6 Sprocket 43 teeth 7 Sprocket stopper 8 Nut M8 9 Chain 428HG-1× 126 10 Chain guard 11 Boss bolt Tightening torque of Bolt 1 in the diagram is：22-29 N·...

  • Page 107: Rear Wheel/Rear Suspension

    VIII Rear Wheel/Rear Suspension Preparatory data----------------------------------- 8.1 Fault diagnosis-------------------------------------8.2 Rear wheel------------------------------------------8.3 Rear shock absorber/rear swing arm----------- 8.4 Chain drive assembly-----------------------------8.5 8.1 Preparatory Data Precautions on operation Do not contaminate braking shoe ad brake disc with oil. Basic preparatory data Service Standard Item Limit...

  • Page 108: Rear Wheel

    Worn or injured swing arm pivot bush Improper adjustment of drive chain adjuster Bent frame or swing arm 8.2.2 Inflexible Wheel Rotation Incorrect brake adjustment Worn rear bearing Too tight drive chain 8.2.3 Poor Braking Performance Incorrect brake adjustment Worn braking shoe Worn brake drum Incorrect installation of braking shoe 8.2.4 Brake Pedal Inflexible or Slow Return...
  • Page 109 Check and replace rear wheel bearing. 8.3.3 Installation Install the rear wheel in the reverse order of removal and tighten the nut. Rear wheel shaft locknut Tightening torque: 85-98N· m RKV125 Rear Wheel...

  • Page 110: Rear Shock Absorber/Rear Swing Arm

    8.4 Rear Shock Absorber/Rear Swing Arm 8.4.1 Remove Rear Shock Absorber Remove left and right protecting plates, seat cushion assembly and hood. Screw off mounting bolt and cap nut (1) from rear shock absorber. Remove rear shock absorber. 8.4.2 Rear Shock Absorber Inspection Check rear shock absorber rod.

  • Page 111: Chain Drive Assembly

    Check rear swing arm installation shaft. Rotate the shaft on a flat surface or measure it with a dial gauge. If it is bent, replace it. * Attention Don’t attempt straighten bent shaft. Wash in solvent the components for rear swing arm installation shaft.
  • Page 112 8.5.2．Inspection Measure length of 10 chain links. If they cannot meet the specified value, replace the drive chain. Length limit of 10 chain links is 127mm. * Attention: • Stretch the chain by hands and then measure it. • The measuring range is from chain link roller ① to inner side of roller ○...
  • Page 113 Check rear wheel buffer, replace it with a new one if it is worn or damaged. Check wheel bearing. If there is bearing clearance in the wheel hub or rotation of the wheel is unbalanced, replace it with a new one. Check oil seal.
  • Page 114 Seat Cushion Note: Fuel switch shall be at “OFF” position while removing fuel tank. Tightening torque for Bolt 10 in the diagram：5-9 N· m Tightening torque for Bolt 12 in the diagram：5-9 N· m 1 Seat cushion assembly 2 Bolt M8× 20 3 Rear luggage carrier screw I 4 Right rear rail 5 Rear luggage carrier screw II 6 Left rear rail...
  • Page 115 Fuel Tank Assembly Max. capacity of fuel tank：17.5L Tightening torque of Bolt 13 in the diagram：5-9 N· m Tightening torque of Bolt 15 in the diagram：5-9 N· m Note：Fuel switch shall be set at “OFF” position while removing fuel tank. 1 Fuel tank assembly 2 Sensor rubber gasket 3 Screw M5×...

  • Page 116: Fuel Tank/Seat Cushion

    Fuel Tank/Seat Cushion Preparatory data-------------------9.1 Fault diagnosis--------------------9.2 Fuel tank/seat cushion-----------9.3 9.1 Preparatory Data Precautions on Operation Working site for removal shall be away from fire source. Fuel switch shall be set at “OFF” position while removing fuel tank. While installation, tighten bolt and nut to their specified torque. After installation, check if all the components are correctly fixed and work normally.

  • Page 117: Fuel Tank/Seat Cushion

    9.3 Fuel Tank/Seat Cushion 9.3.1 Removal Remove left and right protecting plates (3) and (4). Insert ignition key into the seat lock. Rotate clockwise the key and unlock it. Pull downward and take out the helmet hook. Release the pawl from frame and remove seat cushion (1) .

  • Page 118: Engine Inspection And Maintenance

    Engine Inspection and Maintenance Engine Table of tightening torque for fastening parts used in Fastening position and part name Tightening torque（N· m） Cylinder cap nut M8 25～28 Cylinder cap nut M6 8～12 Cylinder cap bolt 8～12 Cylinder block connecting bend bolt 8～12 Cylinder block connecting nut 8～12...
  • Page 119 Lubricating System Note: When the engine oil pump is removed, clean carefully all the components and purge them with high-pressure gas. During engine oil pump removal and installation, pay attention not to drop anything into the crankcase. 1 Rocker arm 2 Cam mechanism 3 Piston 4 Crankshaft 5 Main shaft assembly 6 Countershaft assembly 7 Filter screen 8 Engine oil pump 9 Filter element assembly...

  • Page 120: Lubricating System

    X Lubricating System Preparatory data--------10.1 Fault diagnosis---------10.2 Oil engine pump-------10.3 10.1 Preparatory Data Precautions on Operation When the engine oil pump is removed, clean carefully all the components and purge them with high-pressure gas. During engine oil pump removal and installation, pay attention not to drop anything into the crankcase. Function of lubricating system: Function of engine lubricating system is to supply lubricating oil to friction surfaces of engine parts so that dry surface friction will turn to liquid friction between plasmids of lubricating oil.

  • Page 121: Oil Pump

    10.3 Oil Pump Oil pump gear 10.3.1 Removal Remove right cover. Take down the engine oil filter and release oil pump mounting screw. Take down oil pump block, drive gear and pump shaft. Oil pump block Screw off the screw Take down pump seat.
  • Page 122 Check clearance between external rotor and oil pump seat. Allowable limit: 0.2mm. 测试规 Check clearance between rotor end faces. Allowable limit: 0.15mm. Flat board Testing gauge...
  • Page 123 10.3.2 Assemble Engine Oil Pump As shown in the following figure: * Attention: After assembly, inner and external rotors shall rotate smoothly and be out of nimbleness. 10.3.2 Installation Install the oil pump in the reverse order of removal.
  • Page 124 Carburetor Attention: Gasoline very dangerous. Fire and smoking are forbidden in working site. When the carburetor is removed, plug the intake pipe side with a cloth in case foreign matters coming in. 1- Upper cover 2- Upper cover seal ring 3- Plunger spring 4- Plunger assembly 5- Lower housing connecting screw 6- Lower housing assembly 7- Seal ring 8- Float assembly 9- Float pin 10- Needle valve core 11- Idle jet 12- Main jet 13- Main nozzle 14- Main foam pipe 15-Mixture screw 16- Mixture screw spring 17-Fixture screw washer 18- Mixture screw seal ring 19-Plunger adjusting screw spring 20- Plunger adjusting...

  • Page 125: Carburetor

    Carburetor Preparatory data--------------11.1 Fault diagnosis--------------- 11.2 Carburetor removal---------- 11.3 Carburetor installation-------11.4 11.1 Preparatory Data Precautions on Operation · Gasoline is very dangerous. Fire and smoking are forbidden in working site. · Pay specially attention to sparks. · Please do not pull and bend wires and cables by force. Distortion and injury may affect operation of cables. ·...

  • Page 126: Removal Of Carburetor

    Clogged oil filter Too high or too low mixed gas concentration Clogged oil pipe Secondary air sucked by the intake system Sticky needle value Improper idle adjustment Improper oil level adjustment Improper oil level adjustment Clogged idle system or enrich valve Too much fuel in engine Too low mixed gas concentration Oil outflow...

  • Page 127: Installation

    11.3.3 Inspection Check if needle valve assembly, needle valve seat and float assembly are worn or broken. If needle valve core is worn or broken, replace it with a new one. If needle valve seat is worn, the main carburetor body shall be replaced.
  • Page 128 Cylinder Head/Valve 1 Limit screw 2 Washer 3 Cylinder cover hood bolt 4 Valve cover 5 O ring 6 Cylinder cover hood bolt 7 Plug 8 O ring 9 Rocker arm shaft 10 Wave spring washer 11 Rocker arm 12 Rocker arm return spring 13 Cylinder cover hood 14 Spark plug assembly 15 Cover nut 16 Washer 17 C-type gasket 18 Cylinder...

  • Page 129: Cylinder Head/Valve

    XII Cylinder Head/Valve Preparatory data-----------------12.1 Valve guide replacement-------------12.5 Fault diagnosis------------------12.2 Valve race fixing and adjustment---12.6 Cylinder head--------------------12.3 Cylinder head installation------------12.7 Valve Inspection---------------- 12.4 12.1 Preparatory Data Precautions on Operation To ensure sealing between cylinder head and cylinder body, there is a great bolt pretension on the cylinder head. Pretension value: 50Nm.

  • Page 130: Fault Diagnosis

    ＿ Valve clearance Intake 0.03-0.05 12.2 Fault Diagnosis Low compression pressure Noisy cylinder head Improperly adjusted valve clearance Improperly-adjusted valve clearance Valve burnt or bent Valve spring hurt Poorly sealed valve race Too high compression pressure Air leakage at cylinder head Too much carbon deposited in the combustion chamber Improperly installed spark plug 12.3 Cylinder Head...
  • Page 131 Measure rocker arm shaft OD. Allowable limit: 11.95mm. Micrometer Measure rocker arm hole ID. Allowable limit: 12.05mm. Clearance between rocker arm and rocker arm shaft Allowable limit: 0.08mm. Screw off the two locknuts and remove the lock washer, cam shaft and C-type gasket. Screw off the three cap nuts and Tester hexagon nuts, remove cylinder head.

  • Page 132: Valve Inspection

    Valve collet Compress valve spring with a valve spring compressor, and remove the valve collet, Remove in sequence spring disc, external and inner valve springs, external valve spring washer and valve. 12.3.2 Disassemble Valve Valve collet Inner valve spring Washer Valve Spring disc External valve...
  • Page 133 Measure the free length of valve inner /external spring. Vernier caliper Allowable limit: Inner spring: 30mm. External spring: 37.8mm. Measure OD of valve stem Micrometer Allowable limit: 4.9mm. Valve reamer Check valve guide. Please eliminate the carbon deposition in the valve guide with a reamer before inspection. Attention: Rotate the reamer in clockwise.

  • Page 134: Valve Guide Replacement

    12.5 Valve Guide Replacement Opener * Attention: When the clearance between valve and valve guide exceeds service limit value, please replace the valve guide. When a valve guide is replaced, surface of valve seat retainer shall be fixed and adjusted. Put the valve guide into the freezing chamber of refrigerator for one hour to freeze it.

  • Page 135: Valve Race Fixing And Adjustment

    12.6 Valve Race Fixing and Adjustment Hackly part Remove hackly and ragged parts on the valve race with a 45° angled milling cutter. Note： Apply a layer of transparent or Prussian blue film onto the valve race so that it can be observed clearly. Remove 1/4 of external edge of valve race with a 32°...

  • Page 136: Cylinder Head Installation

    If contacted place is the higher part of valve, please use a 32° angle plain milling cutter to lower the valve race. High contact face If contacted place is the lower part of valve, please use a 60° angle internal milling cutter to raise the valve race. 32°...
  • Page 137 Cylinder Block and Piston Attention: components shall cleaned before inspection and test, and purged with high-pressure air. 1 Piston 2 Retainer 3 Piston pin 4 Combined oil ring 5 Top ring 6 Second compressing ring 7 Location pin 8 Washer 9 Cylinder cover connecting bent pipe assembly 10 Bolt 11 Cylinder cover connecting bent pipe washer assembly 12 Cylinder block 13 Washer 14 Tensioner assembly 15 Bolt 16 Bolt 17 Screw...

  • Page 138: Cylinder Block And Piston

    XIII Cylinder Block and Piston Preparatory data------------ 13.1 Piston---------------------- 13.4 Fault diagnosis--------------13.2 Cylinder installation----- 13.5 Cylinder block-------------- 13.3 13.1 Service Data Precautions on Operation All the components shall be cleaned before inspection and test, and purged with high-pressure air. Function of cylinder block: Cylinder block provides the space for gas compression, combustion and expansion and guides piston movement.

  • Page 139: Fault Diagnosis

    13.2 Fault Diagnosis Low compression pressure White smoke from exhaust pipe Worn, burnt or broken piston Worn or damaged piston ring Work or damaged cylinder and piston Worn or damaged cylinder and piston Broken washer, air leakage between crankcase and gas Higher compression pressure Noisy piston Damaged cylinder, piston and piston ring...

  • Page 140: Piston

    13.4 Piston 13.4.1 Removal Remove piston pin retainer. * Attention: Please do not drop the retainer into crankcase during removal. Take out piston pin and remove piston. Piston pin ring, piston pin Remove piston ring. Inspect piston, piston pin and piston ring. * Attention: Please do not break or hurt piston ring.
  • Page 141 Measure piston pin hole ID. Allowable limit: 14.04mm. Tester Measure piston pin OD. Allowable limit: 13.96mm. Measure the clearance between piston pin hole and piston pin. Allowable limit: 0.05mm. 90° Measure piston OD * Attention: Measuring position forms a 90° angle with 11mm piston pin, about 11mm below piston skirt.
  • Page 142 Measure the roundness of cylinder inner wall. （internal diameter difference between X direction and Y direction）. Allowable limit: 0.05mm. Measure the cylindricity of inner wall of cylinder. (internal diameter difference of three positions (upper, intermediate and lower) along X direction or Y direction).

  • Page 143: Install Cylinder

    Scrape the washer attached to the crankcase. * Attention: No foreign matters can be dropped into the crankcase. Install piston, piston pin and piston pin retainer. * Attention: “IN” Mark Install with the “IN” mark at the top of piston facing the intake valve.
  • Page 144 Clutch Attention: You don’t have to remove the engine from frame while overhauling clutch. Viscosity and level of engine oil will affect operation of clutch. Please check first engine oil and oil level before inspect clutch. If one of the clutch springs, discs or plates does not work, you shall replace them in pairs.

  • Page 145: Clutch

    XIV Clutch Preparatory data-----------------------------------------------14.1 Fault diagnosis------------------------------------------------ 14.2 Clutch-----------------------------------------------------------14.3 Kick start mechanism---------------------------------------- 14.4 Disassembly of main shaft and countershaft-------------- 14.5 14.1 Preparatory Data Precautions on Operation You don’t have to remove the engine from frame while overhauling clutch. Viscosity and level of engine oil will affect operation of clutch. Please check first engine oil and oil level before clutch inspection.

  • Page 146: Clutch

    Bent or injured gearshift plate Abnormal engine oil and oil level 14.3 Clutch 14.3.1 Removal Screw off the four bolts for separating plate in criss-cross mode. Remove release lever, sleeve, bearing, separating plate and clutch spring. Removed components refer to exploded view. Four-pawl bush Use a special tool to screw off clutch locknut.
  • Page 147 14.3.2 Disassemble Clutch 14.3.3 Inspection Check if there are burs or broken parts on the housing groove of clutch. If there are, fix and adjust with a file. If there is a lot for fix and adjustment, replace it. Check if teeth of pressure plate and center bracket are injured. If they are, replace them.

  • Page 148: Disassemble Main Shaft And Countershaft

    Measure the thickness of friction plate with a vernier caliper. Allowable limit: Replace it when it is below 2.6mm. Thickness 14.4 Disassemble Main Shaft and Countershaft Inspection Check respectively wear of tooth surface and drive pawls. If they are seriously worn or damaged, replace them. Tooth Surface Remove bearing and oil seal on left crankcase.
  • Page 149 * Attention: Hammered-out bearing cannot be reused. Replace it with a new one. Bearing hole, oil seal hole Remove bearing and oil seal with special tools. Remove bearing on right crankcase. Check if bearing is injured. Replace if necessary. * Attention: Hammered-out bearing cannot be reused.

  • Page 150: Reduction Gear

    Reduction Gear 1 Gearshift drum 2 Shift fork 3 Shift fork shaft 4 Main shaft assembly 5 Countershaft assembly XV Reduction Gear Function: Transfer torque Preparatory data----------------15.1 and determinate the final output torque and rotary Fault diagnosis-----------------15.2 speed. Gearshift mechanism----------15.3 Installation----------------------15.4...

  • Page 151: Service Data

    15.1 Service Data Function: Transfer torque and determinate the final output torque and rotary speed. Basic data Unit: mm Shift fork shaft OD 9.98-9.995 9.96 Gearshift mechanism 15.2 Fault Diagnosis Hard to engage gear Difficult gearshift Worn or distorted gearshift fork Clutch is not completely separated.

  • Page 152: Exploded View

    15.3.2 Exploded View 15.3.3 Inspection Before disassembly, gearshift plate shall work flexibly and smoothly. Check if gearshift plate and gearshift shaft assembly are worn. If they are seriously worn, replace them. Check if gearshift locking plate is worn. If it is seriously worn, replace it. Check if gearshift shaft is bent.
  • Page 153 Allowable limit: 9.96mm. Micrometer Measure shift fork hole ID. Allowable limit: 10.05mm. Tester Vernier caliper Measure shift fork thickness. Allowable limit: 4.6mm. Measure OD of gearshift drum Allowable limit: 39.75mm. Measure the width of gearshift drum lock groove. Allowable limit: 6.35mm. Lock groove width...

  • Page 154: Installation

    Remove balance shaft gear Balance shaft gear 15.4 Installation Install it in the reverse order of removal. Crankcase 1 Right crankcase 2 Left crankcase 3 Crankshaft connecting rod assembly 4 Piston pin 5 Bolt 6 Piston...

  • Page 155: Crankcase

    XVI Crankcase Attention: Crankcase is a thin-wall casting part. Avoid impact on it during operation in case it may be distorted or Preparatory data------------ 16.1 broken. Clean carefully all the components Fault diagnosis--------------16.2 before inspection and test and purge them with high-pressure gas.

  • Page 156: Fault Diagnosis

    16.2 Fault Diagnosis Noise Crankcase Engine stops automatically Spare pars falling off or broken in the crankcase Stuck clutch 16.3 Crankcase 16.3.1 Crankcase Removal Screw off starting motor mounting bolts，and remove starting motor. Release starting motor gear chamber cover mounting bolt and remove gear chamber cover.
  • Page 157 Use an electric or pneumatic tool to screw off flywheel locknut. Pull out flywheel assembly (including the star wheel). Remove gear display. Remove cam shaft limit plate and take down cam assembly. Remove bearing locating device. 16.3.2 Exploded View of Cam Assembly Camshaft gear Cam mechanism shaft Cam shaft spring...

  • Page 158: Crankshaft Connecting Rod Assembly

    Right cover Release lever assembly Remove screws, engine oil filter roller cover and its cover washer. Remove washer and location pin. Washer Cover of oil filter roller Location pin Use an electric or pneumatic tool to screw off locknut. Remove oil filter roller and take down the drive gear. Drive chain Screw off engine oil pump screws and remove oil pump assembly.
  • Page 159 Inspection Measure the connecting rod big end left-to-right clearance. Allowable limit: 0.55mm. Measure the connecting rod big end clearance along X-Y Measuring position of C.R big end direction. Allowable limit: 0.05mm. Crankshaft shimmy measurement Allowable limit: 0.01mm. Check if there is abnormal noise and looseness when the crankshaft is rotating.

  • Page 160: Exhaust System Inspection And Maintenance

    Exhaust System Inspection and Maintenance Muffler Assembly Tightening torque of mounting bolt 5 for muffler connector in the diagram：5-9 N· m Dual catalysts are added into the muffler welding assembly in the diagram. Tightening torque of combined screw 6 for muffler protecting plate in the diagram：5-9 N· m 1 Muffler welding assembly 2 Hexagon socket screw 3 Exhaust pipe gasket assembly 4 Muffler tail hood welding assembly 5 Combined screw M6×...

  • Page 161: Emission Control System

    XVII Emission Control System Emission control system guarantee-----------------------------------------17.1 Periodical maintenance instructions/ensure emission standard---------------17.2 Emission control system mechanical function----------------------------17.3 Solutions to Idle exhaust exceeding specified value -------------------- 17.4 17.1 Emission Control System Guarantee 1. The emission control system of the motorcycle is up to the Standard of China Stage III. The company will guarantee it in its effective service life, under normal use and specified maintenance.

  • Page 162: Emission Control System Mechanical Functions

    · If you have any other individual problem, please contact or call your local dealer or service center of KEEWAY Motorcycle Co., Ltd. · Relevant emission specifications: Emission Specifications ≤ 2.0g/km ≤ 0.3g/km Emission standard 0.5 g/km...

  • Page 163: Solutions To Idle Exhaust Exceeding Specified Value (4-Stroke)

    17.4 Solutions to Idle Exhaust Exceeding Specified Value (4-stroke) Perform regular inspection (Repair and maintenance plan) Qualified Qualified Measure Idle exhaust (Note 1) Qualified Adjust carburetor (Note 2) Qualified For Delivery; Disassemble and clean the carburetor Qualified (SJ, MJ, SAJ, MAJ, etc.) Qualified Replace Carburetor Disassemble and repair engine.
  • Page 164 RKV125 Schematic Circuit Diagram...

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