Two-wheel Motorcycle RKV125

Instruction and Maintenance Manual

KEEWAY MOTORCYCLE CO., LTD.

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 Contents
Contents. ......................................................................................................................................................................... 2
Preface ............................................................................................................................................................................ 5
Preparatory Data ..................................................................................................................................................... 6
Inspection/Adjustment .......................................................................................................................................... 44
Inspection and Maintenance of Electric System ........................................................................................................... 58
I Battery/Charging System .................................................................................................................................... 60
1.1 Preparatory Data ............................................................................................................................................. 60
1.2 Fault Diagnosis ............................................................................................................................................... 61
1.3 Storage Battery ............................................................................................................................................... 62
1.4 Charging System ............................................................................................................................................. 63
1.5 Voltage-current Regulator ............................................................................................................................... 63
1.6 Magneto Charging Coil .................................................................................................................................. 64
1.7 Magneto Removal ........................................................................................................................................... 65
II Ignition System ................................................................................................................................................... 68
2.1 Preparatory Data ............................................................................................................................................. 68
2.2 Fault Diagnosis ............................................................................................................................................... 69
2.3 Ignition System Inspection ............................................................................................................................. 70
2.4 CDI Assembly................................................................................................................................................. 71
2.5 Ignition Coil .................................................................................................................................................... 72
2.6 Trigger ............................................................................................................................................................ 73
III Starting System ................................................................................................................................................... 75
3.1 Preparatory Data ............................................................................................................................................. 75
3.2 Fault Diagnosis ............................................................................................................................................... 76
3.3 Starting Motor................................................................................................................................................. 76
3.4 Starting Relay ................................................................................................................................................. 78
IV Bulbs/Switches/Instruments ............................................................................................................................... 80
4.1 Preparatory Data ............................................................................................................................................. 80
4.2 Fault Diagnosis ............................................................................................................................................... 80
4.3 Headlamp Bulb Replacement ......................................................................................................................... 81
4.4 Front Turn Signal Lamp Bulb Replacement ................................................................................................... 81
4.5 Tail Lamp Bulb Replacement ......................................................................................................................... 82
4.6 Instrument ....................................................................................................................................................... 82
4.7 Ignition Switch and Steering Lock ................................................................................................................. 83
4.8 Electric horn ................................................................................................................................................... 83
4.9 Handle switch ................................................................................................................................................. 84
Chassis Inspection and Maintenance ............................................................................................................................ 85
V Braking System................................................................................................................................................... 88
5.1 Maintenance Instruction ................................................................................................................................. 88
5.2 Fault Diagnosis ............................................................................................................................................... 89
5.3 Front Hydraulic Brake .................................................................................................................................... 89
5.4 Rear Hydraulic Brake ..................................................................................................................................... 91
VI Motorcycle Exterior ............................................................................................................................................ 94

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 VII 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 ............................................................................................................................................. 107
8.3 Rear Wheel ................................................................................................................................................... 108
8.4 Rear Shock Absorber/Rear Swing Arm ........................................................................................................ 110
8.5 Chain Drive Assembly ...................................................................................................................................111
IX Fuel Tank/Seat Cushion .................................................................................................................................... 116
9.1 Preparatory Data ........................................................................................................................................... 116
9.2 Fault Diagnosis ............................................................................................................................................. 116
9.3 Fuel Tank/Seat Cushion ................................................................................................................................ 117
Engine Inspection and Maintenance ........................................................................................................................... 118
X Lubricating System ........................................................................................................................................... 120
10.1 Preparatory Data ......................................................................................................................................... 120
10.2 Fault Diagnosis ........................................................................................................................................... 120
10.3 Oil Pump ..................................................................................................................................................... 121
XI Carburetor ......................................................................................................................................................... 125
11.1 Preparatory Data ......................................................................................................................................... 125
11.2 Fault Diagnosis ........................................................................................................................................... 125
11.3 Removal of Carburetor ............................................................................................................................... 126
11.4 Installation .................................................................................................................................................. 127
XII Cylinder Head/Valve ......................................................................................................................................... 129
12.1 Preparatory Data ......................................................................................................................................... 129
12.2 Fault Diagnosis ........................................................................................................................................... 130
12.3 Cylinder Head ............................................................................................................................................. 130
12.4 Valve Inspection.......................................................................................................................................... 132
12.5 Valve Guide Replacement ........................................................................................................................... 134
12.6 Valve Race Fixing and Adjustment ............................................................................................................. 135
12.7 Cylinder Head Installation .......................................................................................................................... 136
XIII Cylinder Block and Piston ................................................................................................................................ 138
13.1 Service Data ................................................................................................................................................ 138
13.2 Fault Diagnosis ........................................................................................................................................... 139
13.3 Cylinder Block ............................................................................................................................................ 139
13.4 Piston .......................................................................................................................................................... 140
13.5 Install Cylinder ........................................................................................................................................... 143
XIV Clutch................................................................................................................................................................ 145
14.1 Preparatory Data ......................................................................................................................................... 145
14.2 Fault Diagnosis ........................................................................................................................................... 145
14.3 Clutch.......................................................................................................................................................... 146

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 14.4 Disassemble Main Shaft and Countershaft ................................................................................................. 148
XV 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 ........................................................................................................................................... 156
16.3 Crankcase.................................................................................................................................................... 156
16.4 Crankshaft Connecting Rod Assembly ....................................................................................................... 158
Exhaust System Inspection and Maintenance ............................................................................................................. 160
XVII Emission Control System ................................................................................................................................. 161
17.1 Emission Control System Guarantee .......................................................................................................... 161
17.2 Periodical Maintenance Instructions ........................................................................................................... 161
17.3 Emission Control System Mechanical Functions ....................................................................................... 162
17.4 Solutions to Idle Exhaust Exceeding Specified Value (4-stroke)................................................................ 163

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 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.

Check and adjustment contains main aspects for inspection and adjustment, safety of
the vehicle, performance and maintenance of each component. This shall be started
from the time of periodical inspection.

The parts following Chapter One demonstrate the main point of disassembly,
installation and check of electrics parts, finished vehicle, engine and other components.

System diagrams, breakdown drawings, fault diagnosis, maintenance and other

explanatory contents are presented before each part.

Note:

For any pattern and structure change of the motorcycle, or any difference between the
product and pictures, drawings and instructions in the manual, the product shall prevail.
The product is subject to changes without prior personal notice.

KEEWAY MOTORCYCLE CO., LTD.

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 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.

It is necessary to run the engine in an open area. To run the engine in an enclosed site, ventilation system shall be
used.

Gasoline

Operate in well-ventilated site. No fire or smoking is allowed in operation site and gasoline storage place.

Storage Battery

Battery shall be away from spark, fire and smoking places since it may emit explosive gases. Keep it in
well-ventilated condition while charging.

Battery has sulphuric acid (electrolyte) in it, which will cause burns when it touches skin or eyes. Please wear
protective clothing and mask.

-- If the electrolyte splashes to skin, please flush it with water immediately.

-- If the electrolyte gets into eyes, flush immediately with water for over 15 minutes and call physician.

Electrolyte is poisonous. If swallow by mistake, please drink plenty of water, milk and milk of magnesia (a kind of
laxative antacid) or vegetable oil and call physician. Keep it out of reach of Children.

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 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.

Plastic parts may age and deteriorate, which are apt to be damaged by
solvent or oil. Check before re-installation and replace if necessary.

To loose component with many assembling units, it shall start from

external to internal and loosen smaller assemblies first. The
complicated assemblies such as transmission case shall be put in
proper assembling order for easy assembly in the future.

Pay special attention to the key fitting position before disassembly.

The components that are not used any more shall be replaced on time
before disassembly.

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 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.

Installation of rubber hose (fuel, vacuum, or coolant): insert its end

into bottom of connector so that there is enough room for the hose
clamp to grip the connector. Install the rubber or plastic dust cover
back to its originally designed position

Disassembly of ball bearing: use a tool to push against one or two

(internal and external) bearing races. If the force works only on one
bearing race (whatever internal or external), it may be damaged when
the bearing is disassembled, in which case, it must be replaced

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 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;

Wiring of cable shall be away from heat source or places where

cable may be clipped while moving;

Prevent the cable from being pulled too tightly or slacking too

much when the cable is wired along the handle pipe. The cable

shall not be affected by any neighbored components at any

turning position;

The cable shall be wired smoothly and shall not be knotted or

twisted;

Check if the sheath of connector is damaged and if the connector

is over stretched before butt joint connection;

If cable runs around the closed angle or the corner, please protect

it with tape or hose;

Tie the cable with adhesive tape reliably when it is repaired;

The controlling cable shall not be bent or twisted. Broken

controlling cable will result in non-flexible control.

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 Identification of motorcycle

1. Frame number ① labeled as: *LBBK6910?????????*, as shown

in Figure 1-1.

Figure 1-1

2. Frame nameplate is riveted at frame Position ②, as shown in Figure 1-1. Words on the nameplate are as described
in Figure 1-2.

Figure 1-2

3. Serial number of engine ① is marked on the housing of

crankcase, as shown in Figure 1-3.

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.
3. While re-assembling, new washers, O rings, cotter pins and locking plates shall be renewed.
4. While tightening bolt or nut, please first fasten bolts of large-diameter or internal bolts; and then tighten gradually
to the specified torque in diagonal order. Those with special requirements are excluded.
5. Clean the removed components with cleaning liquid. Lubricate all the sliding surfaces before assembly.
6. After assembly, check that all the components are correctly installed and operated.
7. Remove dirt and oil before measurement; apply recommended lubricant at lubricating positions at assembly.
8. When the engine and transmission system are disassembled/assembled and to be stored for a long time, please
apply some lubricant on the surface of the components to avoid rust and dust deposition.

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 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.
1. Tools used for engine overhaul
Specially designed tools are required for smooth assembly and disassembly of some components on the engine.
Special tools and pictures for engine component assembly and disassembly are listed in Table 1-1 and Table 1-2.
Table 1-1
Name Remarks
Special socket wrench Used for disassembly/assembly of flywheel bolt, Figure 1-3
Clutch holder Figure 1-4
Flywheel extractor Figure 1-5
Feeler gauge Figure 1-6
Bearing puller Figure 1-7
Bearing installer Figure 1-8
Oil seal remover Figure 1-9
Puller handle Figure 1-10
Piston pin puller Figure 1-11
Piston ring pliers Figure 1-12
Spark plug socket wrench Figure 1-13
Clutch thickness measurement Figure 1-14
Cylinder bore tester Figure 1-15
Dial gauge Measuring inner diameter of piston pin, Figure 1-16
Dial gauge, V-block Measuring valve stem deflection, Figure 1-17
Micrometer Measuring OD of valve stem, Figure 1-18
Valve guide remover Figure 1-19
Valve guide installer Figure 1-20
Valve clearance adjuster Figure 1-21
Valve spring remover Figure 1-22
Valve guide reamer Figure 1-23
Crankcase remover Figure 1-24
Continued Table 1-2

Figure 1-3 Figure 1-4

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 Figure 1-5 Figure 1-6

Figure 1-7 Figure 1-8

Figure 1-9 Figure 1-10

① Handle

Figure 1-11 Figure 1-12 ① Pliers ② Piston

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 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

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 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 Figure 1-29
Micrometer Figure 1-30
Magnetic stand, V-block Figure 1-31
Dial gauge Figure 1-32
Vernier caliper Figure 1-33
Spring clamp ring pliers Figure 1-34
Hammer screwdriver Figure 1-35
Front fork oil seal installer Figure 1-36
Front fork seal driver Figure 1-37
Steering nut wrench Figure 1-38
（1）General tools used for chassis overhaul
Continued Table 1-26

Figure 1-27 Figure 1-28

Figure 1-29 Figure 1-30

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 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

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 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

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 Specifications (RKV125)

Model RKV125 Engine type KW157FMI-2B

90# or higher unleaded

Overall Length 2090mm Fuel
gasoline

Overall Width 830mm Number of cylinders 1

Overall height 1,060mm Bore*stroke 57.0×48.8

Wheelbase 1,330mm Displacement 125cc

Engine
Front axle 56 Starting mode Electric
Weight (kg)
Rear axle 79 Cooling mode Air cooled
(Dry weight)
Total 135 Force-feed and splash
Lubricating mode
Front lubrication
100/80-17
tubeless tyre
Tyre
Rear Air cleaner Dry
130/70-17
tubeless tyre
Wet multi-plate friction
Clutch type Fuel tank capacity 17±0.5L
type
Drive Train

Gear shift
Five-speed left foot control Carburetor type PD26JS
pattern

Transmission Chain drive Idle speed-rpm 1,400±100rpm/min

Performance

Battery Max. torque 9.2N·m/7,000rpm

12V dry-charged type
capacity/type
Max. power 8.2kW/9,000rpm
Max. magneto
120W
load
Compression ratio 10.6 : 1
Electrical

Spark plug NGK DR8EA

Top speed 100km/h
Spark plug
0.6-0.7mm
clearance Diameter of front
Braking system

φ260mm
brake disc

Ignition type C.D.I ignition Diameter of rear

φ240mm
brake disc

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 RKV125

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 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.

No Yes

Perform spark-over test

Clean deposited carbon

Spark is weak between electrodes or no spark at all. Strong blue or violet spark leaps between electrodes

Screw off spark plug cap, perform high-voltage wire spark over test Use an ignition timing lamp to check ignition timing of engine

No Yes

Strong blue spark leaps Weak or no spark 1. Check CDI igniter 2. Loosen drain screw of

Check if magneto carburetor and check

flywheel or trigger coil if there is oil flowing

Check spark plug and cap
looses. out from overflow pipe

Yes No
Check ignition Check if wires in
Check if Check if
power ignition coil is the ignition system Check compression
CDI igniter
supply. shorted or are shorted or pressure in the Check oil in
fails.
broken. broken. cylinder. the fuel tank.

Non-contact battery ignition system Non-contact magneto ignition system

Compression Compression Yes No

1. Check electric quantity 1. Check if ignition pressure in pressure in

the cylinder
of battery; 2.Check if power supply coil is the cylinder
is low. Refuel
low-voltage circuit is shortened or broken; 2. is normal.
gasoline
broken or shorted; 3 Check if trigger coil is
Check if trigger coil is shorted or broken.
shorted or broken.

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 1. Check leakage at 1. Check if breather on
external connection parts the fuel tank cap is
of engine; 2.Check valve clogged; 2. Check if
timing; 3. Check fuel filter and fuel
tightness between valve switch are clogged; 3.
and valve seat; 4. Check Check if fuel switch
Remove if valve clearance is too works normally; 4.
spark plug small; 5.Check if piston Check if oil intake of
and check. ring is stuck inside the carburetor is clogged;
ring groove or of less 5. Check if carburetor
elasticity; 6. Check wear float is too high.
and tear of piston ring
and cylinder.

Electrodes of spark plug are dry.

Electrodes of spark plug are wet.

Check overflow of carburetor Drop a little gasoline into the cylinder for a trial start.

Yes No

1. Check if there is Check if air filter

foreign substance is clogged.
Engine can
between needle valve
Engine stalls when it continue to run
and valve seat of
runs a very short when it is started.
carburetor float and it
time.
cannot be closed; 2.
Check if the conical
Carburetor
surface of needle valve of
Carburetor is starter (i.e.
carburetor float is worn
clogged inside or cranking
into a step form; 3. Check
float is too high. enrichment
if the float is broken; 4.
system) fails.
Check if float is too low.

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 Symptom: Engine Overheats Diagnosis procedures

Engine Overheats

Check improper operation method

Yes No
.

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
Check if radiator plates are covered by mud, greasy oil or sand,

Yes No

Clean Check if cooling fan or wind scooper is damaged

(forced air cooled engine)

Yes No

Check and solve it Use an ignition timing lamp to

check ignition timing of engine

No. Yes

1. Check CDI Check if clutch slips.

igniter. 2. Check if
magneto flywheel
or trigger coil
looses.
Yes No

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 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 black and when the Skirt section of insulating part is brown. Skirt section of insulating part is

engine runs at middle or low speed, exhaust muffler gives white and engine generates an

off black smoke or explodes, acceleration capability is interval, carburetor has backfire
Mixture ratio of air/fuel is normal.
poor, idle speed is unstable and the engine is apt to stall; and engine power is not enough.

but it runs normally at high speed.,

Air/fuel concentration is too high. Check if exhaust of cylinder Check lubricating Air/fuel concentration is
and exhaust muffler is clogged system too low
due to carbon deposition.
1. Check if air cleaner is
clogged; 2. Check if Carburetor 1. Check if fuel
starter (i.e. cranking enrichment switch is perfect; 2.
system) works normally; 3. 2-stroke engine 4-stroke engine Check if carburetor
Check if float of carburetor is too lubricating system lubricating system float is too high; 3.
low. Check if the jets and
channels in the
1. Check if there is 1. Check if there is enough carburetor are
engine oil in the oil engine oil in the crankcase; clogged.
tank; 2. Check if 2. Check if viscosity of
engine oil pump engine oil in the crankcase
works normally; 3. is too low or the oil is badly
Check if delivery contaminated; 3.Check if
pipe is clogged. engine oil filter is clogged;
4. Check if engine oil pump
works normal; 5. Check if
lubricating pipe is clogged.

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 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; 3. Check if the middle spacers
in the hub are missed or short.
Air pressure too low Air pressure normal

Check if valve core leaks Remove spark plug and block the screw hole of spark plug with a
or tyre is broken. finger. Press starter button or kick starter pedal.

Finger can feel strong air blasting out Finger cannot feel strong air blasting out.
and meantime make a pitpat sound

Compression pressure in the cylinder is not enough.

Compression pressure in the cylinder is normal.

1. Check leakage at external

Start engine and accelerate gradually and connection parts of engine;
observe variation of engine RPM. 2.Check valve timing; 3. Check if
valve clearance is too small; 4.
Check tightness between valve
and valve seat; 5.Check if piston
Engine RPM rises as accelerator enlarges Engine RPM does not increase as accelerator enlarges
ring is broken or stuck inside the
ring groove or of less elasticity; 6.
1. Check if clutch slips; 2. Check if Use an ignition timing lamp to check Check wear and tear of piston
transmission belt is excessively worn; 3. ignition timing of engine ring and cylinder.
Check if the centrifugal roller of driving wheel
Yes No
is excessively worn; 4. Check if conical
surfaces of driving wheel and mobile friction
1. Check if fuel supply system is smooth; 1. Check CDI
wheel is excessively worn or worn to groove;
2. Check if carburetor, air cleaner and igniter. 2. Check if
5. Check if conical surface of driven wheel
exhaust muffler are clogged; 3. Check if magneto flywheel
and mobile driven wheel are excessively worn
vacuum diaphragm of plunger valve on or trigger coil
or worn to groove; 6. Check if raceway on the
carburetor is cracked or broken; 4. Check looses.
inner end face of friction wheel is excessively
if height of carburetor float is proper.
worn or pitted due to crush.

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 Symptom: Poor idle speed of engine

Diagnosis procedures

Poor idle speed

Engine has no idle speed. Higher idle speed Unsteady idle speed

Check compression pressure in cylinder Pull throttle valve of carburetor by hand Use an ignition timing lamp to
and see if it is completely closed. check ignition timing of engine

Yes No Y N
Insufficient compression
pressure in cylinder Compression pressure

in cylinder is normal. Check if Check if Check if 1. Check CDI

throttle control clearance
idle jet is igniter. 2. Check
1. Check leakage cable can pull of
at external Re-adjust carburetor too big. if magneto
flexibly in the electrodes
connection parts idle speed.
cable jacket in spark flywheel or
of engine; 2.Check and if throttle plug is too
trigger coil
valve timing; 3. spring is too small.
Check if valve looses.
Engine has no idle soft
clearance is too Engine has idle speed
speed after
small; 4. Check after adjustment. adjustment
tightness between
Yes No
valve and valve
seat; 5.Check if
Air adjusting screw Check if carburetor idle
piston ring is Adjust electrode Check
of carburetor or
broken or stuck jet, idle oil path and air
throttle adjusting clearance. mixture ratio
inside the ring path are clogged
screw is improperly
groove or of less of mixed gas.
adjusted.
elasticity; 6. Check
wear and tear of No Yes
piston ring and
cylinder. Check if float is too high. Clean and dredge.

Yes No

Adjust float to 1. Check if carburetor insulator is cracked; 2. Check

standard height. if connecting and fixation nut on carburetor looses; 3.
Check if negative pressure hose on fuel switch is
broken; 4. Check if leaf valve leaks air.

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 Symptom: Too much fuel consumption by the engine Diagnosis procedures

Too much fuel consumption

Check operation method

Yes No

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. Wheels rotate freely.
used is correct.

1. Check braking Check tire pressure

drag; 2. Check if
bearings of wheels
are over worn or
Air pressure too low Air pressure normal
injured; 3. Check if
middle spacers in
the hub are missed Gas up as specified. Check if fuel tank, fuel switch, delivery pipe
or shorter. or carburetor leaks oil.

Yes
No

Exclude as practical situations, Check mixture ratio.

Mixture ratio of air/fuel is normal. Air/fuel concentration is too low.

Air/fuel concentration is too high.

Check if idle speed of engine is too high. 1. Check if air cleaner is 1. Check if carburetor

clogged; 2. Check if float is clogged inside; 2.

Yes No Check if float is too
of carburetor is too low;
3. Check if main jet of high.
Check and adjust Use an ignition timing lamp to
carburetor is too big.
check ignition timing of engine
carburetor.

Yes No

Check if transmission belt Check ignition system.

of clutch slips.

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 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.
No Yes
No Yes

Check if braking shoe Clean greasy

Check if throttle cable can pull
Re-adjust is excessively worn. dirt
flexibly in the cable jacket.

No Yes
No Yes

Check if contact area between Replace the

Clean, lubricate or Check if engine oil level in whole set of
braking shoe and friction disc
replace the crankcase is too low. clutch shoe.
is less than 70％.

Yes No No Yes

Refill engine Check if viscosity of engine oil in the Check if contact area Repair or
crankcase is too low or the oil is
oil. between braking shoe replace clutch
badly contaminated
and friction disc is worn shoe.
Yes No terribly.

Replace 1. Check if adjusting screw for clutch

engine oil. push rod is properly adjusted; 2. Check if
pinch bolt for clutch spring is loosing; 3.
Check if braking shoe of clutch is burnt or
excessively worn; 4. Check if elasticity of
clutch spring is enough; 5. Check if the
contact end face between driven hub,
pressure plate and braking shoe is over
worn. 6. Check if splines on clutch driven
and drive hubs are worn into zigzag form.

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 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

Yes No

Too much engine oil in the crankcase, bleed surplus oil Start engine and run it at high speed; screw off

and decline oil level to upper limit line. oil ruler and check if oil filler smokes.

No Yes

Check if clearance between valve 1. Check if cylinder, piston or

and valve guide is too big. piston ring is over worn; 2.
Check if elasticity of piston ring
Yes No is not enough or stuck in the ring
groove; 3. Check if openings of
Check if valve or valve guide is over worn. Valve oil seal is piston ring are staggered with
damaged. each other.

Symptom: Incomplete separation of clutch Diagnosis procedures

Incomplete separation of clutch

Check if clearance of clutch handle bar is within 10mm-20mm.

No Yes
i
Re-adjust Check if adjusting screw for clutch push rod is properly adjusted

No Yes
.
Check if elasticity of clutch spring is even. Re-adjust

Yes No

Check if splines on clutch active and drive hubs are worn into zigzag form Replace the whole set of clutch
spring.
Yes No

Repair or replace 1. Check if clutch driven plate is warping and distorted;

2. Check if separation cam shaft, separation push rod and other
components of clutch control mechanism are excessively worn.

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 Symptom: Difficult gearshift on transmission Diagnosis procedures

Difficult gearshift on transmission

Start engine and check if idle is too high.

Yes No

Re-adjust Check if the operation is harmonious at gearshift.

Yes No

Check if clutch is completely separated. Improve operation method.

No Yes

Check if gearshift box is distorted and shift lever is deformed or over worn. 1. Check if clearance of clutch handle bar is

No Yes within 10mm~20mm; 2. Check if elasticity of

clutch spring is even; 3. Check if splines on
clutch active and drive hubs are worn into
Replace 1. Check if groove of gearshift camshaft is
zigzag form; 4. Check if clutch driven plate is
over worn or injured; 2. Check if shift fork
warping and distorted; 5. Check if
hole is excessively worn; 3. Check if shift
components of clutch control mechanism are
fork is deformed; 4. Check if fork shaft is
excessively worn.
distorted or over worn.

Symptom: Drum-type brake fails Diagnosis procedures

Drum-type brake fails.

Check if clearance of brake handle bar is within 10mm~20mm

or clearance of brake pedal within 20mm ~ 30mm range.

No Yes

Re-adjust Separate cable of brake rocker arm from brake control cable. Move rocker arm by hands.

Brake rocker arm rotates Rocker Arrow on the indicating board Arrow on the indicating board of cam
freely but there is resistance arm turns of cam aims at or exceeds“▽” does not align to the“▽” mark on
feeling from brake handle. inflexibly mark on hub cap. hub cap.
. 制动凸轮上指示牌上的箭头未对准制
动毂盖上的“▽”标记
1.Check if there is oil adhered to
Brake control cable Movable parts of 1. Check if crown face of brake cam
brake cam rusts or is over worn; 2. Check if brake shoe the surface of brake shoe
does not pull flexibly in
is stuck by foreign friction disc is over worn; 3. Check if friction disc; 2.Check if contact
the jacket.
substances. bore of brake hub is excessively area between braking shoe and

worn. friction disc is less than 70％

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 Symptom: Transmission jumps of gear Diagnosis procedures

Transmission jumps of gear

Check if spring of position wheel is broken or of insufficient elasticity.

Yes No

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.
forms great roundness; and if corresponding gear end groove is worn or like a
horn mouth.
No Yes
Yes No
1. Check if fork hole and fork shaft are over Replace fork.
Replace Check if spline gear of main shaft worn; 2. Check if matching clearance
and counter shaft, or spline
gear between fork pin and cam groove of shift
groove of sliding gear is over
gear shaft is big. 3. Check if transmission is
worn.
correctly installed.

Symptom: Hydraulic disc brake fails Diagnosis procedures

Hydraulic disc brake fails

Check brake liquid level in the liquid tank of main brake pump

Brake liquid level is lower than lower limit line of tank. Brake liquid level is higher than lower limit line of tank.

Refill brake liquid to If there is sponge-like feeling while operating brake handle.
the upper limit line of
tank, meantime, No Yes
check if oil leaks at
brake caliper, brake
hose and hose
Check if brake shoe has been worn to the limit mark and brake disc is over worn. Air contained in the
connector. hydraulic brake system.
Yes No

Replace brake shoe 1. Check if piston surface of main brake pump and cylinder wall surface are
and brake disc. over worn or injured; 2.Check if piston cup of main brake pump is damaged,
cracked or aged; 3. Check if sealing ring of brake caliper is damaged,
cracked or aged; 4.Check if piston surface of brake caliper and cylinder wall
surface are over worn or injured.

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 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. Resistance is infinitely great.

Charging coil is shorted. Connect connectors of magneto lead wire harness to the Charging coil or its
cables of the whole motorcycle; break off connectors of rectifier
output wires are
or regulator to cables of the whole vehicle.
shorted.

Measure with an Ohmmeter on the resistance in the connectors

between output wires from charging coil, and check if the result

is in accordance with the resistance of the charging coil itself.

Yes No

Set multimeter on 0V~20V DC voltage, measure the Wire from magneto to rectifier or wires
voltage between connector to the battery wire terminal among rectification regulators are not well
(usually a red or red/white wire) and the ground. connected or broken.

No voltage display Voltage displays

Wire from connector to Check with an Ohmmeter if rectifier or

battery is broken. rectification regulator fails.

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 Symptom: Battery runs down quickly Diagnosis procedures

Battery runs down quickly

Check if braking lamp is always on.

Yes No

Adjust or replace braking Set ignition switch to “OFF” position, disconnect negative wire from battery, and then

lamp switch. put negative probe of ammeter onto the negative pole terminal and positive probe on

the negative wire to check current leakage.

Leaking current is smaller than specified. Leaking current is bigger than specified (usually
It shall be no more than 1mA).

Check if charging coil of magneto is shorted.

Wire from rectifier or rectification

regulator or battery to ignition switch
Yes No is shorted.

Replace charging coil 1. Check if electrolyte in the battery is enough.

2. Check if density of electrolyte in the battery is
too low
3. Check if plates in the battery are vulcanized
or shorted.

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 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.

Battery is low or the wire terminal Grasp brake handle bar (autoscooter), or shift
connected with battery is poorly transmission into neutral, or grasp clutch handle
contacted. bar, push starter button.

Push starter button and the click from starter Push starting button and a click from
relay cannot be heard. starting relay can be heard.

Disassemble the connector of starter relay from cables of Use a screwdriver or a piece of thick wire to
the whole vehicle; connect the two hatching wires from connect battery terminal on the starter relay with
relay coil to negative and positive terminals of battery with starter relay terminal.
two pieces of wires.

After connection, the After connection, After short circuit, After short circuit,
starter motor does not starter motor works. starting motor runs starting motor does
run either and no click normally not run.
sound can be heard from
starter relay.

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 Disassemble starter motor and
Coil in starter coil Check wiring in electrical Contact of
make the following
is broken or 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.
Striding Motorcycle Autoscooter 3. Check if armature
commutator is over worn.
4. Check if armature coil is
broken or shorted.

1.Check if contact inside clutch Grasp brake handle and check

switch is poorly contacted; if braking lamp is on.
2. Check if starter button contact is
poorly contacted;
3. Check if rectifier diode is
damaged; Yes No
4. Check if neutral gear switch works
abnormally;
5. Check if wiring of electrical starter Check if starting button Inner contact of brake lamp switch is
system is broken or shorted. contact is poorly contacted poor contacted or matched wire is
broken.

Yes No

Repair or replace Wiring of electrical starting system

starter button. is broken or shorted.

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 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 to starter motor is poorly contacted.
badly contacted.

No Yes

Remove the starter motor lead wire and battery connecting

Check if starter button
wire from starter relay, press starter button; when starter
contact is poorly
relay gives a click sound, measure with an ohmmeter
contacted.
resistance between battery terminal on the relay and starter
motor terminal and check if it is on state.

Yes No

Disassemble starter motor and make the Starter relay contact is

following inspections： burnt or injured.
1. Check if the carbon brush is over worn;
2. Check if carbon brush spring is broken or
weak.
3. Check if armature commutator is over worn,
burnt, or injured, or contaminated.

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 Symptom: All the lights are not on Diagnosis procedures

All the lights are not on

AC power supplied lighting system DC 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.
output from lighting coil of magneto by lamp test method.

Electric horn sounds loudly Electric horn does not sound

Test lamp is not lit Test lamp is lit. and turn signal light is lit. and turn signal light is not lit.

Start engine and separate Normal power Use a piece of wire to touch
connectors of rectification regulator supply from quickly positive and negative
from cables of the whole vehicle. battery terminal of battery to check spark.

Lights are lit. Lights are not lit No spark at touch Spark at touch

Short circuit inside Battery is out 1. Check if fuse is burnt;

rectifier of power. 2. Check wiring between

battery and ignition switch
Disassemble headlamp assembly for short circuit and break
and check if the bulb is burnt. 3. Check if ignition switch is
broken or shorted.

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 Yes No

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

Yes No

Use a piece of wire to short circuit power line and Wiring from magneto or ignition
output line of lighting switch. switch to lighting switch is broken
or shorted.

Lamp is lit after short circuit. Lamp is still not lit after short circuit.

Inner contact of lighting switch Wiring from lighting switch to lamp

is poorly contacted. is broken or shorted.

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 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.

1. Check if the connector to the battery is poorly Separate conductors of rectification regulator from
contacted; cables of the whole vehicle. Measure and check with
2. Check if electrolyte in the battery is not enough. an Ohmmeter if wirings between lighting and
3. Check if density of electrolyte in the battery is charging coil of magneto and regulator are broken.
too low; check if pole plates inside the battery are
vulcanized or broken.
No Yes

Set multimeter on 0V~20V DC voltage, measure the Connect well the

voltage between the wire from connector to battery broken wire.
terminal (usually a red or red/white line) and the
ground.

No voltage display Voltage displays

Wiring from connector to Check if regulator malfunctions.

battery is broken.

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 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.
ohmmeter if resistance between lead wire section output
from magneto lighting coil is smaller than the standard.

Yes No

Electric horn sounds hoarse.

Turn signal lamp is dim.
Lighting coil is Start engine and limit its RPM. Separate
shorted. conductors of rectification regulator from the
cables of the whole vehicle. Check brightness of
Battery is low or the connection
light.
position between ignition switch
and battery is badly contacted.

Headlamp light recovers Headlamp light is still

after separation. dim after separation.
Electric horn sounds
loudly. Turn signal lamp
Stable voltage of Check if charging coil of is bright.
rectification regulator is magneto and wirings in the

too low. charging system are shorted.

Yes No

Check and solve Disassemble headlamp assembly and check if

problem. the bulb glass black or yellowish-green.

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 No Yes

Check if power of bulb in the lighting Replace the bulb.

system is up to the requirement.

Yes No

1. Check if headlamp switch Replace bulb.

and side-lamp switch is poorly
contacted;
2. Check if connectors and
earth wire are poorly
contacted.

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 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. on.

Take down the turn signal lamp Take down the turn signal lamp Press horn button and
cover and check if the bulb is burnt. cover and check if the bulb is burnt. check

Yes No Yes No

Electric horn
Measure the voltage
Replace Replace Separate connectors
Electric horn does not sound
between power line contact of turn signal lamp,
turn signal turn signal or sounds
sounds loudly
of lamp holder and the measure and check hoarse.
lamp bulb. lamp bulb.
ground with a voltmeter. with an ohmmeter if

turn signal lamp switch

Power supply from
works on faulty side. Battery is
battery is normal.
low.

No voltage display No voltage display Yes No

Take down the turn signal
lamp cover and check if
Power line on Inner contact the bulb is burnt.
Grounding wire of lamp Power line to
the troubled side of turn signal
holder is of poor the lamp
is broken or lamp is poorly
contact or bulb of turn holder is
grounding wire contacted.
signal lamp is badly broken.
of lamp holder is
contacted with lamp poorly
holder. No Yes
contacted.

Slide turn signal lamp switch and short circuit it with a piece of Replace turn signal lamp

wire or a screwdriver two lugs of scintillator. bulb and check if regulator

works normally.

Turn signal lamp is still off after short circuit.

Turn signal lamp is still on after short circuit.

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 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.

Inner contact of turn signal lamp is Check if there is power output from power input line of
poor contacted. turn signal lamp switch by lamp test

Test lamp is on Test lamp is off

Power line of turn signal lamp Wire from ignition switch to

is broken or shorted. scintillator or from scintillator to
turn signal lamp switch is shorted
or broken.

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 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.
to ignition switch is broken or shorted.

Pull out power line from power terminal of electric horn; touch
the power line quickly with ground wire to check spark.

Spark at touch No spark at touch

Connect power line of horn, use a screwdriver to Power line between ignition switch
connect non-power terminal (terminal to button) and electric horn is broken.
of horn with ground wire.

Electric horn sounds after connection. Electric horn does not sound after connection.

Inner contact of horn is poorly Adjust volume and tune of horn.

contacted or the wire from
horn to button is broken.

Horn does not work after adjustment.

Horn works normally after adjustment.

Horn is damaged. Horn is improperly adjusted

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 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.

Yes No

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. Brake lamp is lit after short circuit.

Use a screwdriver or a piece of wire to touch Brake lamp switch is not

quickly power line of brake lamp switch and properly adjusted or its
grounding wire and check sparks. inner contact is not well
contacted.

Spark at touch No spark at touch

Wire from brake lamp Power line from ignition

switch to brake lamp is switch to brake lamp switch
broken or shorted. is broken or shorted.

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 Inspection/Adjustment

Preparatory standard Compression pressure of cylinder

Periodic maintenance schedule chart Engine oil

Engine oil/filter Replacement of engine oil

Steering stem bearing and handle fixation Drive chain slackness

Throttle cable adjustment Front/rear brake clearance

Air cleaner Headlamp

Spark plug Clutch

Battery Front/rear suspension system

Carburetor Bolt/nut/fastening part

Ignition timing Tyre specification

Wheel rim/tyre

Preparatory Standard

General
Warning!
• Before running the engine, please make sure the area you are working in is well ventilated. You shall never
run the engine in an enclosed site. Gas exhausted from the motorcycle contains carbon monoxide, which may
lead to loss of consciousness and result in death.
• Under certain conditions, gasoline is highly volatile. Work in well-ventilated site. Fire and smoking are
forbidden in working site or gasoline storage place.

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 Specifications
Engine

Idle speed 1400±100rpm/min

Spark plug clearance 0.6-0.7mm
Spark plug type NGK DR8EA
Combustion chamber Ball type
Ignition time BTDC15°±1° 1400±100rpm

Frame

Clearance of front brake handle 10-20mm

Clearance of rear brake pedal 20-30mm
Specification Tyre pressure

Pneumatic pressure unit of tyre： Front wheel 100/80-17 210±10kPa

Kpa RKV125
Rear wheel 130/70-17 210±10kPa

Front shaft locknut 55-62 N·m

Torque
Rear shaft locknut 85-98 N·m

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 Periodic Maintenance Schedule

Every Every Every Every Every Every

300 1000 3000 6000 12000 14500
Mileage and KM KM KM KM KM KM
interval Tools
New One three Six Twelve Fifteen
Vehicle month months months months months
Items
* Air cleaner I C C R C Common tool
* Gasoline filter I I R Common tool
* Engine oil filter C C C Common tool
Engine oil replacement R Once every 1000KM Common tool
Tyre pressure gauge,
Tyre pressure I I I I I I
air inflator
Densimeter,
Battery inspection I I I I I I
multimter
Actuating clearance
I I I I I I Common tool
inspection
Inspection of steering
I I I Common tool
handle bar looseness
Shock absorber actuating
I I I Common tool
inspection
Inspection of looseness of
I I I I I I Torque wrench
bolts at all positions
Check if gearbox leaks oil I I I I I I Common tool
Spark plug inspection and
* I I R R I Common tool
replacement
* Gearbox oil replacement I Once every 5000KM Common tool
Lubrication of all the
L L Lubricant injector
places on the vehicle
Muffler I I I I I I Common tool
* Ignition timing I I I I I I Timing light
* Carburetor A I A A A A Tachometer,
* Idle exhaust gas inspection A I A A A A CO HC analyzer
* Throttle inspection I I I I I Common tool
Fuel hose inspection I I I I I Common tool
Light instrument and
I I I I I I Visual multimeter
electric apparatus
Main stand and side stand I I I Common tool
Shock absorber I I I I Common tool
* Torque of engine bolt I I I I I Torque wrench
Front/rear brake I I I I Common tool
Drive chain I I I I A Common tool
Clutch I I I I Common tool
* Valve I I I I I Feeler gauge

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 Expected Inspection
1 Ignition system -- perform maintenance inspection on obvious and continuous ignition malfunctions,
engine on fire, overheated back burning and others.
2 Carbon deposit removal -- obvious underpowered, get rid of carbon deposit at cylinder head, piston head
and air exhaust system.
3 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.
I— Inspect A—Adjust R—Replace C—Clean L—Lubricate

Note: 1.“*” for items involved in exhaust gas, which meets regulations of China Environmental Protection Agency.
Normal maintenance shall be performed according to specifications on the user’s manual; unauthorized repair and
adjustment are forbidden. We will not be responsible for the results.
2. You shall clean more frequently the air cleaner to extend its service life when your motorcycle is used on
sand-gravel roads or in severely polluted environment.
3. More frequent servicing may be required when the motorcycle is often driven at high speed or travels a long
distance.

Engine Oil/Filter

Engine oil level

*Attention
• Motorcycle shall stand on the flat ground while checking engine oil
level.
•Inspect engine oil level when the engine has run for 2~3mintues or
stopped for 2~3minutes.

Check engine oil level

When the engine oil level sensor alarms, refill engine oil to its upper limit.

Engine oil replacement

* Attention
When the engine is warmed up, replace engine oil. The oil can flow
out easily.

Shut down engine.

Screw off the drain plug at the bottom of crankcase (1) to drain engine
oil.

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 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.

Throttle Cable Adjustment

*Attention
Adjust properly engine idle before
adjustment of throttle cable clearance.

Check clearance of throttle cable, clearance

shall be 3-5mm.
If the clearance is not up to the specified,
adjust it.

Adjust clearance of throttle cable.

Procedures:
Loosen locknut (1).
Rotate adjusting nut (2) inward or outward till it achieves specified clearance.
Rotate inward to increase clearance; rotate outward to reduce clearance.
Tighten locknut.
When the clearance is adjusted, rotate handle leftward and rightward to make sure idle of engine does not change.

Air Cleaner

Replace air cleaner.

Take down the left protecting plate.

Take air cleaner cover.
Take out filter element and filter guide of air cleaner.

Check if filter element is polluted or injured. If necessary,

replace it with a new one.
Clean air filter element.
Thoroughly and gently wash filter element with detergent.
Never use gasoline oil as cleaning agent, it may cause fire.
Please do not twist filter element in case the foam material is damaged.
Apply engine oil onto the filter element and then compress surplus engine oil so that the filter element is wet but not
dropping oil.

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 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. On the other hand, rotation of engine
without filter element may affect the carburetor and the carburetor will not work normally afterwards, which may
result in overheated engine. Install filter element guide, filter element, air cleaner housing cover, stop valve assembly
and left protecting plate.

Spark Plug

Disconnect lead wire of spark plug cap.

Remove spark plug with a spark plug wrench or other applicable tools.

Inspection
．If the insulator is cracked or damaged;
．If electrodes are worn;
．Combustion condition and color
—Light grey color means excellent combustion condition.
—Pale color indicates that ignition system fails or lean fuel/air mixture.
—Wet appearing or dark carbon deposition means higher fuel/air mixture.
If the above-mentioned appears, please remove them with spark plug cleaner or
wire brush. If necessary, replace the spark plug.
Spark plug visual inspection
If the insulator is cracked or worn, please replace it with a new one.

Spark plug clearance inspection

Clearance: 0.6-0.7mm

* Attention
Reinstall the spark plug into the cylinder head and tighten it with the specified torque.
Tightening torque: 18N.m
Screw the spark plug into the cylinder head first with fingers, and then tighten it with spark plug wrench.

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 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; or it will result in short
circuit sparks, which may ignite gasoline and damage battery. It is dangerous!

Install the battery in reverse order of removal.

Warning!
To avoid short circuit, please connect positive (+) lead wire
first, then the negative (-) lead wire.
During the whole motorcycle adjustment, please do not
disconnect the battery, which may result in interior component
damage of the whole vehicle.

Battery charging (circuit voltage) inspection

Open the seat cushion and take down the right protecting plate.
Disassemble the battery from the battery case (1).
Disconnect the battery negative (-) lead wire first and then the
positive (+) lead wire.
Remove the battery.
Measure the battery voltage using a voltmeter.
Fully charged: 13.1V
Undercharge: 12.3V (battery not work for one hour)
* Attention
Voltmeter shall be used for charging inspection.

Charging
Connection method: Positive pole of battery charger is connected
to battery positive lead wire; Negative pole of battery charger is
connected to battery negative lead wire.

Warning!

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 • 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
• Battery quick recharging is not recommended except in case of emergency.
• After recharging, wait at least 30minutes and then measure the battery voltage.

Recharging current: Standard: 0.3A

Quick recharging: 3.0A
Recharging time: Standard: 10-15hours
Quick recharging: 30minutes
After recharging: Open circuit voltage: over 12.8V

Carburetor

Idle speed adjustment

*Attention
Perform idle speed adjustment when the engine is warm.

Warm up the engine and then adjust idle speed.

Run the engine and connect engine tachometer.
Adjust the throttle cable lock-screw to specified RPM.
Idle speed RPM: 1400±100rpm/min
If idle speed RPM is unsteady, or idle speed is not smooth
when gently raise engine speed, adjust idle speed adjusting
screw again.

Ignition Timing
*Attention
Inspect ignition system when the ignition timing is incorrect.
Warm up the engine for 3~5 minutes
Stop the engine and connect the timing light to lead wire of
spark plug.
Remove timing hole cap.
Start engine and idle it.
Inspect ignition timing.
If symbol “F” aligns with the mark on the right crankcase, it indicates that the ignition timing is correct. Increase
engine speed and check if Symbol “F” begins to move.

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 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.
Causes for low pressure:
. Valve improperly adjusted
. Valve leaks air.
. Worn piston ring or cylinder
Causes for high pressure:
. Carbon deposition in combustion chamber or on piston
Stop engine and remove spark plug and spark plug cap.

Engine oil

Engine oil level inspection

* Attention
During engine oil inspection, please do not tighten engine oil
ruler.
Oil level inspection. Stop the motorcycle on the flat ground
with its middle stand and stand the vehicle vertically.
When engine oil is consumed continually, you shall inspect oil
level regularly and refill to proper position if necessary.
Engine oil volume: 0.8L for oil replacement
1.1L for engine overhaul
If engine oil level is too high, operation of engine and clutch will be affected；
Too low engine oil level will result in overheated engine and premature component wear.
Refilling engine oil of poor quality or different types or brands
will reduce lubrication effects.

Remove engine oil ruler when the engine stops. Dry the oil on
the ruler with a piece of clean cloth.
Stand the engine on a horizontal plane and put the engine oil
ruler into the engine. Do not tighten the ruler.
Take out the engine oil ruler and inspect oil level.
If oil level is lower or approaches the lower limit, add
recommended oil to the upper limit mark.

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 * 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.
After drainage, inspect and clean engine oil filter.
Be sure that filter screen, spring, O ring and drain plug are
perfect and then put them back onto the engine.

* Attention
Oil should be changed when the engine is warm. Place the
engine on the side stand.
Make sure all the engine oil is completely and quickly drained.
When the drain plug is removed, engine oil filter and spring
will be ejected.

Tighten the drain plug.

Add recommended engine oil into the crankcase.
Install engine oil leveler. Start the engine and let it run for
2~3minutes at idle.
Stop the engine and check if engine oil level is at upper limit
mark in a few minutes.
Stand the engine vertically on the ground to check oil level.
Make sure no oil leaks.

Drive Chain Slackness

Stand vertically the motorcycle on the flat ground and check

drive chain slackness ○

a.

Drive chain slackness: 10-20mm

If the drive chain does not meet the specification, adjust it.
Adjust drive chain slackness:

Screw off rear shaft nut and lock-nuts of adjusters on both drive
chains.
Rotate uniformly both adjusters till the drive chains gain
normal slackness.

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 * 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.
Clearance: 10-20mm

Brake pedal clearance

Measure brake pedal clearance.
Clearance: 20-30mm.

If the clearance measured does not meet the specified value,

adjust it.

Adjust clearance of brake pedal.

Screw in or screw off adjuster.
If the adjuster is screwed in, clearance is decreased; if screwed
out, clearance is increased.
Adjust till the clearance is up to the specification.
After adjustment, brake does not drag.

Headlamp

Remove mounting screw (1) of cowling.

Remove cowling (3), headlamp hood and headlamp.
Pull out headlamp holder and remove the reflector. Release the
circlip and take out lamp adapter.
* Attention
When the bulb is lit, keep your hands and inflammable
materials with some distance away from it. If lighting bulb is
hot, touch it when it cools down.

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 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 luminous flux of bulb.
If oil is adhered to the bulb, clean it with a cloth moistened
with alcohol or highly volatile rubber solution.

Install headlamp assembly.

Clutch

Check clearance of clutch cable.

Clearance: 10-15mm.
Adjust clearance of clutch cable.
First loosen lock nut (1).
Screw in or screw off adjuster (2) till clearance meets the
specified value.
Finally tighten the locknut.

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 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.
Check if components on the rear shock absorber are
loosened or injured.
Lift and support the rear wheel and swing the wheel to
check if engine suspension bushing is loosened.

Bolt/Nut/Fastening Part

Inspect bolts, nuts and fastening parts at every part of the

motorcycle for looseness.
If it is loose, tighten it to specified torque.

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 Wheel Rim/Tyre

Check if there is crack, nails and similar sharp objects, and other injuries on the tyres.
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.
Check if lock nut of rear shaft is loosened.
If loosened, tighten it to specified torque.

Tightening torque: Front shaft lock nut 40-60 N·m

Rear shaft lock nut 85-98 N·m

Steering Stem Bearing and Handle Fixation

Move the left and right handle and check if lead wires disturb it.
Rotate front wheel and confirm handle can move smoothly.
If the handle does not move smoothly and is loosened, check steering
stem bearing.

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 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 12

Starting motor clutch locknut 95
Rectifier bolt 5.0
High-voltage coil pinch bolt 9.0
Flywheel locknut 5.0
Vehicle block protecting plate bolt 9.0

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 Charging system

1. Starting relay 2. Scintillator 3. Battery 4. Electric igniter 5 High-voltage ignition coil

6. Power lock assembly

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 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. Performance of a battery is usually reduced after about
2-3 years’ run. Voltage of the performance-reduced (capacity drops) battery can be resumed, but the voltage will run
down quickly while loading.
2. Overcharging of battery: Usually overcharging is demonstrated by the battery itself. If short circuit occurs inside
the battery, there will be no voltage or very low voltage on the terminals of the battery. Adjuster fails: it indicates too
high voltage on the battery, the life-span of the battery will be shortened.
3. When the battery is not be used for a long period, it will self-discharge and its capacitance will drop. The battery
should be recharged every three months.
4. Charging system inspection: please perform inspection in the sequence listed in the fault diagnosis table.
5. If there is current going through the electric part, please do not remove the connector, or the voltage will be very
high and electronic components inside the voltage adjuster will be damaged. Set ignition switch at “Off” position and
then begin your operation.
6. It is not necessary to inspect maintenance-free (dry-charged type) battery. You don’t need to add electrolyte and
distilled water for it.
7. Inspect the entire electric load.
8. Quick charging is forbidden except in emergency.
9. During quick recharging, the battery must be removed from the motorcycle and recharged.
10. While battery is exchanged, please do not use liquid-feeding battery.
11. A voltmeter shall be employed to check recharged battery.

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 Preparatory Standard
Item Specification
Capacity/type 12V dry-charged type
Voltage Fully recharged 13.1V
Battery （20℃） 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

Voltage Type Full-wave rectification

regulator Battery recharging voltage 14.5V±0.4V/5.000rpm

Tightening torque Tools

Rectifier bolt 5.0 N·m Universal non-adjustable spanner
High-voltage coil pinch bolt 9.0 N·m Flywheel remover
Flywheel locknut 5.0 N·m Testing device
Vehicle block protecting plate bolt 9.0 N·m Multimeter

1.2 Fault Diagnosis

No power Unstable power

Battery over discharged Lead wire of battery is poorly contacted.
Lead wire of battery is not connected. Discharging system is of poor contact.
Fuse is broken. Lighting system is of poor contact or short circuit.
Power switch is poorly contacted.

Low voltage Poor charging system

Battery is poorly recharged. Wire connector is of poor contact, short circuit or short line.
Poor contact. Defective voltage and current adjuster
Poor charging system Magneto does not work well.
Bad voltage and current adjuster

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 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; or it will result in
short circuit sparks, which may ignite gasoline and damage
battery. It is dangerous!
During the whole motorcycle adjustment, please do not
disconnect the battery, which may result in interior component
damage of the whole vehicle
Install the battery in the reverse order of removal.

*Attention
To avoid short circuit, please connect positive (+) lead wire first, then the negative (-) lead wire.
Battery charging (circuit voltage) inspection
Open the battery cover and remove battery pressure plate assembly.
Disconnect lead wire of the battery connector.
Measure voltage between terminals of the battery
Fully charged: 13.1V
Undercharged: 12.3V (battery does not work for 1hour)

* Attention
A voltmeter shall be employed to check recharged battery.

1.3.2 Charging
Connection method: positive pole of battery charger is
connected to battery positive lead wire; Negative pole of
battery charger is connected to battery negative lead wire.

Warning!
• 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
• Battery quick recharging is not recommended except in case of emergency.
• After recharging, wait at least 30minutes and then measure the battery voltage.

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 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. Set the switch at OFF position and check if it is shorted.

* Attention
Positive lead wire of multimeter is connected to negative lead
wire of battery.

If abnormality found, check if there is short circuit on ignition switch and main wiring.

1.4.2 Charging state inspection

While inspection, battery shall be fully charged and a multimeter be used for the test.
Warm up the engine and then install fully charged battery onto the
motorcycle.
Connect voltmeter between terminals of the battery.
Remove the main fuse and connect ammeter between the two terminals.
Start engine and slowly raise RPM. Measure limited voltage and current.

Limited voltage/rpm: 14-15V (5.000rpm)

If limited voltage is beyond the specified range, check voltage regulator.
Inspect limited voltage in lighting system.

* Attention
Set multimeter to position of AC voltage

1.5 Voltage-current Regulator

1.5.1 Loop inspection on main wiring terminals

Disconnect the 6P plug on the voltage-current regulator.

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 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
block
Between charging
coils (while 1 and There is resistance between
white 2) coils

1.5.2 Voltage-current regulator inspection

When main wiring terminal is normal, check if plug of voltage-current regulator is of poor contact and measure
impedance value between terminals of voltage-current regulator itself.
* Attention
Multimeter
• Do not touch the metal part of multimeter probe White1 Red/white Red Black White2
+
with your finger.
- Unit: MΩ
• Check with a multimeter. If impedance values
White1 No No 0.1~3 10~90
measured by different multimeters are not the same,
red/white No No 0.1~3 No
it perhaps the inspection is not correct.
When impedance value between terminals is Red 0.1~3 No 1.2~5 0.1~3
abnormal, replace voltage regulator. Black No No No No
White2 60~80 No No 0.1~3

1.6 Magneto Charging Coil

* Attention
Inspection of magneto charging coil can be performed on the engine.

Inspection
Disconnect the 6P connector on the magneto.
Use a multimeter to measure impedance value between white coil of magneto and vehicle block.
Standard value: 0.5-10Ω (20℃)
If measured value exceeds the standard, the magneto coiling shall be replaced.

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 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 (20℃)
If measured value exceeds the standard, the magneto coiling shall be replaced.

1.7.2 Removal
Remove vehicle block protecting plate.

Remove protecting plate of engine on the left side.

Remove flywheel locknut.

Use a flywheel remover to take down the flywheel.
Remove the fixation key.
Disconnect lead-wire connector of magneto.
Remove stator of magneto.

1.7.3 Installation
Install the magneto stator onto the engine box.
Connect lead-wire connector magneto.

Clean crankshaft and conical part of flywheel.

Make sure the fixation key is installed into the key slot on the crankshaft.
Align the groove on the flywheel to the fixation key on the crankshaft.

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 * 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.

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 Ignition System

1 Relay 2 Scintillator 3 Battery 4 Igniter 5 High-voltage ignition coil

6. Power lock assembly 7 Voltage regulator

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 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.
3. Ignition system inspection: please perform inspection in accordance with the sequence listed in the fault diagnosis
table.
4. Ignition system CDI shall not be dropped and hung, or heavily knocked (this is also the main reason for its failure).
Pay special attention to this while removing it.
5. Most of the ignition system problem due to poor contact of sockets. Please check first if parts of the connector are
well contacted.
6. Check if heat value of spark plug is proper. Improper spark plug may result in unsmooth engine running or burn of
spark plug.
7. The maximum voltage is taken to introduce inspection items in this Part. Inspection methods for impedance value
of ignition coil are also recorded and judged.
8. Check ignition switch according to the continuity test table.
9. Remove magneto and stator on operation instructions.

Preparatory data
Item Standard Value
Spark plug Standard NGK DR8EA
Spark plug clearance 0.6-0.7mm
Primary coil 0.4Ω±10％
Ignition coil impedance value（20℃） With spark plug cap 8-11KΩ
Secondary coil
Without spark plug cap 3-5.5KΩ
Impedance value of trigger（20℃） 100-200Ω
Impedance value of charging coil（20℃） 600-800Ω
Ignition coil primary peak voltage 300V
Trigger voltage Higher than 1.7V

Tools
Accessory for voltmeter with maximum range
Multimeter

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 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).
low.
④Wiring of ignition system is poorly contacted.
⑤Ignition coil is no good.
⑥Charging coil is bad. (Peak voltage measurement)
①Tester is wrongly connected.
②Poor ignition switch.
③Connector of CDI assembly is poorly contacted.
④Ground wire for CDI assembly is shorted or poorly contacted.
While no high-voltage power supply,
⑤ Poor charging coil (Peak voltage measurement).
Secondary high voltage power is sporadic.
⑥ Defective trigger (Peak voltage measurement).
side voltage
⑦ Connector of high voltage wire is not good.
⑧ Inferior CDI assembly (after items ①-⑦ are tested and proved
abnormal or spark plug no sparking)
High-voltage power is normal, spark ①Inferior spark plug or secondary leakage of the ignition coil.
plug no sparking. ② Bad ignition coil.
①Inner impedance is too small. Use appointed tester to test.
②Crankshaft rpm is too low.
No high-voltage power supply ③Tester is disturbed (it is normal when more than one time’s
Charging coil measured voltage is above the basic).
④Charging coil is bad. (when items ①-③ are proved normal)
No high-voltage power supply or ①Defective ignition coil.
high voltage power is sporadic. ②Defective charging coil.
①Inner impedance is too small. Use appointed tester to test.
②Crankshaft rpm is too low.
When high-voltage power supply is
③Tester is disturbed (it is normal when more than one time’s
too low.
Trigger measured voltage is above the basic).
④Trigger is bad. (when items ①-③ are proved normal)
No high-voltage power supply or ①Bad ignition coil.
high voltage power is sporadic. ②Bad trigger.

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 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. The values they measured are not the same.

Connect a high-voltage shunt or an ammeter with input impedance

higher than 10MΩ 10CV to the multimeter.

2.3.1 Primary voltage of ignition coil

If an old spark plug is removed and replaced with a good one, ground it with engine.

* Attention
Test when wirings of all the circuits are correct.
Normal cylinder compression pressure means to test
with spark plug installed on the cylinder head.

Connect lead wire of ignition coil; a shunt is connected between

the terminal (black/white) of primary coil and the grounding
vehicle block.
Press starting motor button or kick starting pedal to measure
primary peak voltage of ignition coil.
Min. voltage: over 95V.

*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.

2.3.2 Trigger
* Attention
Inspect when spark plug is installed on the cylinder head and
compression pressure is normal.

Disconnect connector 4P and 2P from CDI assembly. A

peak-voltage shunt is indirectly connected to the 4P connector
(black terminal) and 2P wiring-terminal connector of trigger
(blue/white terminal). Press starting motor button or kick pedal
level to measure primary peak voltage of trigger.

Connecting method: positive (+) to blue/white, negative (-) to

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 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.
Trigger (blue/white) is connected with a shunt.
• When the measured voltage at CDI assembly terminal is
abnormal, but measured voltage at magneto terminal is
normal, it indicates that the connector is of poor contact or wiring is broken.
• When measured results at both sides are abnormal, the trigger is damaged. Please refer to items listed in Diagnosis
Table and check.

2.4 CDI Assembly

2.4.1 System Inspection

System inspection
Remove CDI assembly and check components related to the
ignition system at wiring terminal.

2.4.2 Inspection
Remove CDI assembly and check if connectors are loose or corrosive.

Item Measuring terminal Standard Value（20℃）

Main switch Red—Red/White On continuity when main switch is
“OFF”.
Trigger Blue/White-White/Green 100-200Ω
Primary coil of ignition Black/White—Black 0.4Ω±10％
coil
Secondary coil of Black—spark plug cap（not including spark 3-5.5KΩ±10％
ignition coil plug）

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 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.

2.5.2 Primary coil inspection

Measure the impedance between terminals of primary coil.
Standard value: 0.4Ω±10% (20℃)
Impedance value within the range is good.
Impedance value “∞” indicates broken wire inside the coil. The
coil shall be replaced.

2.5.3 Secondary coil

Attached with the spark plug, and measure the impedance
between lead-wire side of spark plug cap and terminal.
Standard value: 8-11KΩ (20℃)
Impedance value within the range is good.
Impedance value “∞” indicates broken wire inside the coil.
Remove the spark plug cap and measure impedance value
between primary side lead-wire of ignition coil cap and
negative terminal.
Standard value: 3-5.5KΩ±10% (20℃)

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 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 (20℃)
If measured impedance value is beyond the range, please
replace the magneto.

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 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

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 III 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 8.3mm
Starting idler shaft OD 7.94mm

Tightening torque
Starting motor clutch cap bolt 12 N·m
Starting motor clutch locknut 95 N·m

Tools
Locknut wrench
Universal un-adjustable wrench

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 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
•Defective braking switch
•Defective starting relay
•Poor connecting wire contact
•Defective starting motor

3.3 Starting Motor

3.3.1 Removal
* Attention
Before removing starting motor, the ignition switch must be set at
“OFF” position. Disconnect battery grounding wire and then turn
on the power supply to check if starting motor runs to confirm
your operation is safe.

First remove the lead-wire clip of starting engine.

Remove starting motor pinch bolt and take down the starting motor.
Roll up the rubber waterproof jacket and remove starting motor connector.

3.3.2 Disassembly
Disassemble housing screw, front cover, motor housing and other
parts.

3.3.3 Inspection
Inspect other component assemblies.
Replace with a new one when there is surface partial friction,
injuries or burn.
The commutator shall be cleaned when there is metal particles
adhered to its surface.
Inspect for continuity between contact surfaces of other
assemblies.
Confirm the discontinuity of armature shaft among surfaces of commutator.
Inspect for continuity of starting motor housing.
Confirm the continuity between conducting terminal and starting motor housing.

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 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.
If there is abnormality, replace it with a new one.
Check the oil seal for wear and injury.

3.3.4 Assembly
Apply lubricating grease on the oil seal in the front cover.
Install brush onto the carbon brush holder.
Apply lubricating grease on movable parts at both ends of
brush shaft.
Press brush into its holder and install front cover of electrodes.

* Attention
• There should be no hurt on the contact surface of brush and
armature. Take care.
• Installation shaft of armature cannot hurt lip of oil seal. Take care.

Install a new O ring onto the front cover.

Align and install the boss of motor housing to the recess of front cover.
Tighten housing screws.

* Attention
When assembling housing and front cover, armature can work as a magnet to easily pull the front cover up; and then
gently press it down to complete the assembly.

3.3.5 Installation
Install lead wire of starting motor and be sure to install the dust seal.
Check if the O ring is damaged and replace it if necessary.
Apply some engine oil onto the O ring and then install the starting motor
Install rear brake wire clip.

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 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.
• Check starting relay ground wire loop.
• Inspect starting relay actuation.

3.4.2 Starting relay voltage inspection

Lift and support the main stand. Measure the voltage between
negative pole (green/yellow) of starting relay connector and
vehicle ground wire.
Set ignition switch at “ON” position and catch the brake lever. Battery voltage shall meet the specified.
When there is no voltage at wire terminal of starting relay, inspect braking switch continuity and lead wire.

3.4.3 Starting relay ground loop inspection

Remove starting relay connector.
Inspect continuity between black wire of connector terminal
and vehicle ground wire.
When the starting button is pressed, continuity between black
wire of connector and vehicle ground wire shall be fine.
If there is no continuity, inspect starting button continuity and
lead wire.

3.4.4 Actuation Inspection

Connect starting relay with battery and connect terminal of
starting motor with multimeter.
Connect fully charged battery between black wire and
green/yellow wire of relay. A “tap” sound of operation can be
heard on the relay and resistance displayed by multimeter is zero.

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 Bulbs/Switches/Instruments

1 Headlamp 2 Instruments 3 Electric horn 4 Left rear turn signal lamp 5 Tail lamp

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 IV 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. Release clamping of the pawl before removal. Align pawl to its hole
when it is reinstalled.
While trouble shooting electric faults, please check continuity of electric component as current flowing over it.
Confirm state of battery before any inspection, including battery voltage.

4.2 Fault Diagnosis

“ON” lamp of Ignition switch is not on.

• Bulb burnt.
• Defective switch.
• Poor contact of connector or broken wire.
• Low battery power or no voltage.

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 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. Lighting bulb is
hot; touch it when it cools down.

4.3.2 Installation
Install the new bulb, adapter and headlamp rear cover.
Tighten the new bulb into the socket.

Avoid touching bulb glass with your bare hands during installation and staining it with oil, which may affect
transparency, service life and luminous flux of bulb.

If oil is adhered to the bulb, clean it with a cloth moistened with alcohol or highly volatile rubber solution.

Install headlamp assembly.

4.4 Front Turn Signal Lamp Bulb Replacement

4.4.1 Removal
Disconnect wire to turn signal lamp.
Screw off self-tapping screw (2) on the turn signal lamp.
Remove the bulb socket from the lamp.
Remove the bulb from lamp adapter.

4.4.2 Installation
Install the bulb in the reverse order of removal.

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 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.

* Attention
While installing tail lamp, be sure that sealing washer on the
tail lamp hood is in good condition and correct position.

4.5.3 Tail lamp bulb replacement

4.5.3.1 Removal
Screw off mounting bolts on the tail lamp hood.
Remove tail lamp hood (3) so that tail lamp bulb can be removed.
Remove the tail lamp bulb from lamp adapter (2).

4.5.3.2 Installation
Install the tail lamp bulb in the reverse order of removal.

4.6 Instrument

Remove rear mirror.

Take down the handle hood and pull out waterproof connector.
Remove the bolts.
Remove odometer assembly.
Remove the instrument.
Install the instrument orderly in the reverse order of removal.

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 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. When the switch
under the power lock is moved to “SHUT” position, the keyhole above
is closed. You can use “key handle switch” to resume it to “OPEN”
position and the keyhole above is open.

“ ”(OFF) position: All the circuits are broken.

“ ”(ON) position: Ignition circuit is switched on and engine can be
started.
“ ”(Stop) position: Turn the key counterclockwise to “ ”position,
lock cylinder protrudes, lock the handle pipe.

4.7.2 Ignition switch replacement

Remove the headlamp.
Screw off the mounting bolts and remove the ignition switch holder.
Remove the mounting bolts and replace ignition switch.

4.8 Electric horn

Inspection
Disconnect wire to the electric horn.
Connect lead wire of horn with the battery. When the electric horn sounds, it
indicates the horn is in good condition.

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 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.

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 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 5-9
Front brake cylinder assembly mounting bolt 22-29
Rear brake rocker arm mounting bolt 5-9
Rear shaft locknut 85-98
Upper bracket assembly mounting bolt 40-60
Front shaft locknut 55-62
Front shock absorber mounting bolt 37-44
Rear shaft locknut 85-98
Rear shock absorber top nut 37-44
Rear shock absorber bottom nut 22-29
Seat cushion mounting bolt 22-29
Fuel tank mounting bolt 5-9
Gasoline switch mounting bolt 5-9
Protecting hood mounting bolt 5-9
Sprocket mounting bolt 22-29
Rear swing arm shaft nut 70-83

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 Front Hydraulic Brake

A Front brake disc diameter：260mm

Front brake disc thickness：4.0mm

B
Service limit：3.0
Brake shoe thickness：4 mm
C
Service limit：3mm
Mounting torque for Bolt 7 in the diagram：
D
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 M6×23 7 Front hydraulic brake mounting bolt 8 Front hydraulic brake assembly 9 Washer
10 Oil hose mounting bolt 11 Brake hose assembly 12 Brake cylinder assembly 13 Brake shoe assembly

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 Rear Hydraulic Brake

A Rear brake disc diameter：240mm

Rear brake disc thickness：5.0mm

B
Service limit：4.0
Brake shoe thickness：5mm
C
Service limit：4mm

D 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 M8×16 7 Sealing ring 8 Hex. Flange head bolt 9 Brake hose assembly 10 Oil cup assembly
11 Collar 12 Oil hose 13 Protecting spring 14Brake switch assembly 15 Oil pump block assembly
16 Bolt M6×20 17 Nut M6 18 Lever 19 Draw-bar 20 Cotter pin 2.5×25 21 Mounting bolt 22 Bolt M6×12

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 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 Standard Value (mm) Service Limit (mm)

Front brake disc thickness 4.0 3.0

Front brake shoe thickness 4 3

Front brake disc diameter φ260 -

Rear brake shoe thickness 5 4

Rear brake disc diameter φ240 -

5.1.2 Tightening Torque Value

Front wheel shaft locknut 55-62 N·m Front brake cylinder assembly mounting bolt 22-29 N·m
Rear wheel shaft locknut 85-98 N·m

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 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. Braking shoe assembly improperly installed
4. Braking shoe assembly and brake disc contaminated

Noisy Braking
1. Braking shoe assembly and brake disc are worn.
2. Braking shoe assembly and brake disc are contaminated

5.3 Front Hydraulic Brake

5.3.1 Removal
* Attention
• Replace braking shoe assembly.
• If a braking shoe assembly will be used
again, please mark it on the side before
removal so as to re-install it to its original
place.

Remove from right handle and front shock

absorber the following assemblies.
Front brake:
1. Hydraulic brake handle (7)
2. Oil pump block assembly (5)
3. Braking hose assembly (4)
4. Braking cylinder assembly (6)
5. Hydraulic brake disc (2)
Note: Detailed breakdown drawing refers to P85.

* 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.

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 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.
Specifications
KW125 Front brake disc diameter φ260mm
Front brake disc thickness 4.0mm
* Attention
• Micrometer shall be used for the measurement.

Measure the thickness of braking shoe.

If brake disc and braking shoe are contaminated by grease or
their thickness is smaller than service limit, replace them.

Service limit: Braking shoe: 3mm

Brake disc: 3mm
Note:
Braking shoes shall be replaced in pairs.

5.3.3 Installation
Install brake disc and front wheel.
Install front brake hose assembly and brake cylinder assembly.
Please do not contaminate braking shoe and brake disc with oil.

* Attention
A contaminated braking shoe will reduce braking performance and result in brake failure.

Tighten bolt and nut to their specified torque value.

Torque value:
Oil pump block assembly mounting bolt 5-9 N·m
Front brake cylinder assembly mounting bolt 22-29 N·m

Do not contaminate braking shoe with oil.

If a braking shoe is polluted by oil, clean it with brake cleaner.

*Attention

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 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
• Replace braking shoe.
• If a braking shoe assembly will be used again, please
mark it on the side before removal so as to re-install it
onto its original place.
Remove the following rear brake assembly from the rear
wheel:
1. Bolt M6Χ35 (23)
2. Rear brake rocker arm (1)
3. Nut M6 (22)
4. Rear indicator
5. Rear brake return spring
6. Rear brake cam shaft (2) 7. Braking shoe assembly (12) 8. Braking shoe return spring (8)
9. Tyre 3.00-18 (18) 10. Rear wheel (9) 11. Rear shaft locknut (6)_

Note: Detailed exploded view refers to P86.

5.4.2 Inspection
Check if braking shoe assembly and brake drum are worn. Replace them if necessary.
Measure braking shoe thickness and brake drum ID and record the maximum values.

* Attention
• Micrometer shall be used for the measurement.
Measure the thickness of braking shoe and the inner diameter of brake drum.
If the braking shoes are contaminated by oil or their thickness is smaller than service limit, replace them.

Braking shoes shall be replaced in pairs.

Diameter of rear brake disc φ240mm

Thickness of rear brake disc 5mm
Service limit: Braking shoe 4mm
Brake disc 4mm

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 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·m

Do not contaminate braking shoe with oil.

If a braking shoe is polluted by oil, clean it with brake
cleaner.

Rear brake:
1. Rear brake disc (5) 7. Rear wheel damper (10)
2. Locking nut M14×1.5 (1) 8. Bearing spacer (8)
3. Rear wheel rim (7) 9. Left shaft sleeve assembly (11)
4. Brake disc mounting bolt M6×16 (4) 10. Washer φ16×φ32×2 (9)
5. Rolling bearing 6302-2RS (3) 11. Tubeless tyre 130/70-17 (6)
6. Front wheel oil seal assembly (2) 12 Rear shaft M14×1.5×292

* Attention
A contaminated braking shoe will reduce braking performance

Note: Detailed breakdown drawing refers to P86.

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 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.

1 Right cowling installation plate 2 Cowling installation plate 3 Left cowling installation plate 4 Right decorative
panel II 5 Right decorative panel I 6 Left decorative panel I 7 Left decorative panel II 8 Right tail cover
9 Left tail cover 10 Decorative panel for left protecting plate 11 Left protecting plate 12 Decorative panel for right
protecting plate 13 Right protecting plate 14 Tail cover bracket 15 Rear mudguard II 16 Rear mudguard I
17 Front part of rear mudguard II 18 Front part of rear mudguard 19 Left decorative panel for front mudguard
20 Right decorative panel for front mudguard 21 Front mudguard

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 VI 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 → Tail lamp → Tail lamp support

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

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 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

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 Control Assembly
A Tightening torque of hexagon socket Bolt 2：37-44 N·
m
B Tightening torque of Nut 19：5-9 N·
m

C Tightening torque of Bolt 20：5-9N·

m

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
9 Left handle assembly 10 Left handle 11 Handle mounting bolt 12 Nut M6 13 Bolt M6×25 14 Fixed
cover 15 Adjusting screw tube 16 Slotted nut 17 Left rear mirror holder 18 Clutch cable jacket 19 Rear mirror
assembly 20 Hexagon socket bolt M6×35 21 Throttle cable assembly 22 Clutch cable assembly 23 Stop valve
wire clamp 24 Choke cable assembly 25 Brake pedal mounting bolt 26 Spring retainer 10 27 Bushing
28 Brake pedal welded assembly 29 Bolt M6×40 30 Nut M6 31 Brake pedal return spring

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 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
handle upper holder 13 Bracket lower washer 14 Upper bracket assembly 15 Bolt M6×16 16 Bushing
17 Rubber bush 18 Stem bolt 19 Lower bracket assembly 20 Combination bolt M6×12 21 Wire clamp
22 Nut M6 23 Side reflector assembly 24 Washer 10 25 Bolt M10×16 26 Cable clip 27 Combination bolt
M6×16 28 Location pin 29 Hexagon socket set screws with flat point M4×6 30 License plate bracket
31 Right front shock absorber assembly 32 Left front shock absorber assembly 33 Front mudguard bracket I
assembly 34 Front mud guard bracket II assembly 35 Bolt M6×15.2 36 Hexagon socket bolt M6×16 37 Front
license plate mounting bolt M10×1.25×30 38 Hexagon socket bolt M6×30 39 Front mudguard right bracket II

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 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. Take care not to rotate the wheel reversely.
Attention: Please do not let oil contaminate braking shoe, braking shoe assembly and brake disc.

Basic data of the motorcycle as a whole

Measuring Standard Service
Item
position value(mm) Limit(mm)
Front
wheel Curvature 0.2
shaft
Front Wheel
Longitudinal 2.0
wheel shimmy
Transversal Within 1.0 2.0

Tightening torque Tools

Upper bracket assembly mounting bolt 40-60 N·m Bearing remover

Front wheel shaft locknut 55-62 N·m Locknut wrench
Front shock absorber mounting bolt 37-44 N·m

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 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
Defective front tyre

7.2.4 Difficult Rotation of Wheel

shaft or bearing seat fault
Braked

7.2.5 Noisy Front Shock Absorber

Friction sound of shock absorber protecting
plate.
Loosened bolts on the shock absorber.

7.3 Front Wheel

7.3.1 Disassembly
Attention:
Stand the motorcycle reliably.
Screw off speedometer mounting bolts and remove speedometer
cable.
Screw off front shaft locknuts.
Remove front shaft (1), take down bearing seat assembly (2) and
front wheel.
Screw off bolts and remove front mudguard and lead wire of odometer.
Remove front brake hose.
Remove oil seal assembly (8) and bearing (3) with an oil seal remover and a bearing remover respectively.

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 * 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.

7.3.2.2 Wheel Shimmy Inspection

Place the wheel onto a precise support and check its
amplitude of shimmy.
Rotate the wheel with your hands and read out shimmy
amplitude.
Service limit:
Longitudinal: replace it when it is over 2.0mm
Transversal: replace it when it is over 2.0mm.

7.3.2.3 Front Bearing Inspection

Remove front shaft (1) and brake disc (10).
Remove left shaft sleeve (9) of front wheel.
Remove oil seal assembly (8).
Remove bearing (3).

Inspect rolling of bearing.

If bearing does not roll, roll smoothly or unsteadily, or
bearing is worn or loosened, replace it with a new one.

7.3.3 Bearing Replacement

Remove front shaft, front wheel and left shaft sleeve and
middle shaft sleeve (4) of front wheel.
Remove oil seal assembly (8) and bearing (3) with an oil seal
remover and a bearing remover respectively.

Note: Removed bearing shall be replaced with a new

bearing.
Apply some lubricating grease on the bearing at installation.
And then press the bearing in with bearing installer.
* Attention
• The bearing must be pushed in parallel.

7.3.4 Installation

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 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).
Gear seat assembly shall be halved at
installation.
If odometer gear seat assembly does not
align and lock the front shaft, the odometer
gear seat will be distorted.
Install front brake assembly to the front
brake disc.
Tighten front shaft.

* Note: Refer to Page 95 of the manual

for detailed KW125 Motorcycle front
wheel disassembly and assembly diagram
Front wheel locknut tightening torque: 55-62 N·m

7.4 Steering Handle

7.4.1 Removal
Remove left and right rear mirror assemblies (1) and
(2).
Open the fixed cover
Remove left handle assembly (10) of front brake.
Remove balancer assemblies (3) and (20).
Remove left and right combination switches (5) and
(7).
Remove left handle grip assembly (8), throttle
control handle (3) and steering handle upper holder
mounting bolt (hexagon socket bolt M8X25) (13).
Take down steering handle upper holder (17).
Remove steering handle assembly (6).

7.4.2 Installation
* Note: Refer to Page 96 of the manual for KW125 Motorcycle steering handle disassembly and assembly
diagram.
Install the steering handle in the reverse order of removal.
Top bracket assembly mounting bolt

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 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.

Remove headlamp bracket.

Remove the front fork.

Tools:
Steering handle welded assembly mounting bolt wrench.
Locknut wrench
Special remover for bearing steel bowl

* Attention:
Clean the opening part of protecting plate of motorcycle block with a cloth.
Upper and lower bearing steel bowls shall be removed with special bearing steel bowl remover.

7.5.3 Installation

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 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).
Apply lubricating grease on the top holder race.
Swing steering handle left and right to have steel balls
closely fit.

Tools:
Locknut wrench
Rotate the front fork left and right to be sure of its
smoothness and there shall be no looseness.

Procedures：
Install it in the reverse order of removal.
Before installing the front fork, tighten pinch bolt first.
Make sure that end of inner fork pipe is parallel and level with handle head.
Tighten lower bracket pinch bolt (25), bolt (15) and steering stem pinch bolt (18).

* Note: Refer to Page 97 of the manual for KW125 Motorcycle front fork disassembly and assembly diagram.

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 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 14 Bearing spacer
15 Tubeless tyre 130/70-17 16 Rear brake disc 17 Hydraulic brake disc mounting bolt M6×16
18 Rolling bearing 6302-2RS 19 Front wheel oil seal assembly 20 Locking nut M14×1.5

Rear Shock Absorber

1 Cap nut M10×1.25 2 Rear shock absorber mounting gasket 3 Rear shock absorber assembly
4 Washer 12 Bolt M10×1.25×40

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 Rear Swing Arm

A Side clearance (opening swing arm end) limit value：1.0mm

B 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
10 Chain adjuster plate 11 Nut M8 12 Rear hydraulic brake wire clip 13 Screw M6X12
14 Intermediate spacer 15 Rear swing arm bush 16 Dust ring assembly

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 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 1

Tightening torque of Bolt 1 in the

A
diagram is：22-29 N·m
Drive chain specification：
B
428HG-1×126

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 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
Value（mm）
（mm）
Rear
wheel Longitudinal 2.0
Shimmy
Transversal 2.0

Tightening torque
Rear shat locknut 85 - 98 N·m
Rear shock absorber top nut 37 - 44 N·m
Rear shock absorber bottom nut 37 - 44 N·m

8.2 Fault Diagnosis

8.2.1 Shimmy Rear Wheel

Distorted wheel rim
Worn rear bearing
Troubled tyre

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 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

Incorrect brake adjustment
Worn or contaminated brake drum
Incorrect installation of braking shoe

8.2.5 Noisy Brake

Worn braking shoe
Worn brake drum
Contaminated braking shoe
Contaminated brake drum

8.3 Rear Wheel

8.3.1 Removal
Stand the motorcycle steadily and rear wheel is off the ground.
Remove rear brake pedal assembly (1).
Remove muffler assembly (2).
Screw off rear wheel adjuster.
Take down the brake rod from brake arm.
Remove connector and spring on the brake arm.
Remove brake pin, washer, rear wheel buffer and brake
nut.
Remove torque linked arm from rear drum brake.
Screw off drive chain adjuster (20).
Remove rear shaft locknut (21) and rear shaft (4).
Move forward rear wheel. Remove the drive chain from
the rear drive sprocket.
Remove the rear wheel.

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 8.3.2 Inspection

8.3.2.1 Wheel Shimmy Inspection

Rotate the wheel by hands and measure its eccentricity
with a dial gauge.

Service limit:
Longitudinal: Replace it when the measured value
exceeds 2.0mm.
Transversal: Replace it when the measured value
exceeds 2.0mm.

When rear wheel shimmy exceeds service limit, rear wheel

bearing is loosened, which results in wobbly rear wheel.
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

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 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. If the rod is bent or damaged, please replace
rear shock absorber assembly.
Check fatigue of spring. If it is, replace rear shock absorber assembly.

8.4. Install Rear Shock Absorber

Install the rear shock absorber in the reverse order of removal.
Install upper locknut and lower mounting bolt on the rear shock absorber
Tighten them to specified torque.

Locknut
Tightening torque: 37-44 N·m

8.4.4 Remove Rear Swing Arm

Remove rear wheel.
Remove bolt and drive chain cover.
Screw off the lower mounting bolts on the shock absorber at both sides.
Screw off swing arm pivot nut (3) from the frame.
Remove rear swing arm shaft (2) and rear swing arm assembly (1).

Note: Refer to Page 106 for detailed disassembly and assembly diagram.

8.4.5 Rear Swing Arm Inspection

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 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
to straighten
bent shaft.

Wash in solvent the components for rear swing arm installation

shaft.
Check sleeve assembly (7) and intermediate sleeve (5) of rear
swing arm.
If they are damaged, replace them.

8.4.6 Install Rear Swing arm

Install the rear swing arm in the reverse order of removal.
Apply lubricating grease on to pivot bush.
Install rear swing arm sleeve assembly (15) and intermediate sleeve (14).
Install rear swing arm assembly (6).
Install rear swing arm onto the frame and insert
rear swing arm shaft.
Install and tighten rear swing arm shaft nut to
specified torque.
Install lower mounting bolt on rear shock
absorber.
Install drive chain cover.
Install the two connecting bolts.
Install rear wheel.

Install rear swing arm nut

Tightening torque: 70-83N·m

8.5 Chain Drive Assembly

8.5.1．Removal
Stop the motorcycle on the flat ground and stand it steadily.
Remove gearshift pedal connecting parts, drive chain cover
and drive sprocket.
Remove rear wheel, rear shock absorber, chain cover and
drive chain.

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 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 ○
11 .

• Measure length of 10 chain links.

• Measure length of 10 chain links for 2-3 times at different
positions.

Clean drive chain. Immerse it into kerosene and brush the

dust on it as possible as one can.
Take the cleaned chain from kerosene and dry it in the air.

Inspect roller ① and its side plate ②. If it is damaged or

worn, replace the drive chain.
Lubricate drive chain. Drive chain lubricant can be purchased
from the local dealer.

Inspect rigidity of drive chain. If it is rigid, you can clean,

lubricate or replace it.

Check driving sprocket and driven sprocket.

If 1/4 of the gear teeth are worn , replace the sprocket; so

does with bent teeth.

Check rear brake. If it is cracked or worn, replace it.

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 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. If it is worn or broken, replace it with a new one.

8.5.4．Installation
Install it in the reverse order of removal.
Install drive chain, chain cover, rear left shock absorber, rear wheel and drive sprocket cover.

Adjust slackness of drive chain and clearance of brake pedal.

If slackness of drive chain is too small, engine and other important components will work overload.

Keep the slackness of drive chain in specified limit range.

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 Seat Cushion

A Note: Fuel switch shall be at “OFF” position while removing fuel tank.
B Tightening torque for Bolt 10 in the diagram：5-9 N·m
C 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

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 Fuel Tank Assembly

A Max. capacity of fuel tank：17.5L

B Tightening torque of Bolt 13 in the diagram：5-9 N·m
D Tightening torque of Bolt 15 in the diagram：5-9 N·m
Note：Fuel switch shall be set at “OFF” position while
E
removing fuel tank.

1 Fuel tank assembly 2 Sensor rubber gasket 3 Screw M5×22 4 Screw M5×10 5 Damper 6 Bolt M6×35
7 Washer 8 Fuel tank installation shaft sleeve 9 Fuel tank installation gasket 1 10 Fuel tank installation gasket
2 11 Oil hose 4.5×8.5 1 clip Ф8 13 Oil hose 5×9×600 14 Fuel tank switch assembly 15 Nut M6
16 Sensor assembly 17 Protecting plate installation gasket 18 Carbon canister

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 IX 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.

Basic data
Item Standard Service limit

Fuel tank capacity 17 17.5

Tightening torque
Cushion mounting bolt 22-29 N·m
Fuel tank mounting bolt 5 - 9 N·m

9.2 Fault Diagnosis

Reducing Fuel Level

Natural consumption
Oil leakage

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 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) .
Remove connector from lead wire of oil level
sensor.

Fuel switch shall be set at “OFF” position.

Disconnect fuel hose and carbon canister connecting hose.
Remove bolt, washer, damper and fuel tank.

Remove the fuel tank from the frame.

Note:
Refer to P115 and P116 for detailed disassembly and
assembly diagram.

9.3.1 Installation
Install the tank in the reverse order of removal.

Installation torque:
Seat cushion mounting bolt 22-29 N·m
Fuel tank mounting bolt 5 - 9 N·m

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 Engine Inspection and Maintenance

Table of tightening torque for fastening parts used in Engine

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
Flywheel locknut 50～55
Valve clearance adjuster 10～15
Gearshift changeover contact screw 8～12
Closing bolt 8～12
Right side cover bolt 8～12
Front left cover bolt 8～12
Coil screw 8～12
Clutch separating disc bolt 6～8
Clutch locknut 45～50
Filter screen cover bolt 8～12
Tensioner pinch bolt 8～12
Drive gear locknut 50～60
Drive sprocket bolt 18～22
Engine oil pump screw 8～12
Ratchet upper and lower baffler screw 8～12
Spark plug 18～22
Components that cannot be reused:
Please be sure to use new paper pad, sealing ring, O ring, cotter pin, circlip, retainer and so on while
installing or assembling components.

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 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

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 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. It is used to reduce wear of component, cool components of higher
heat, absorb impact from bearing and other parts, weaken noise, increase tightness between
piston ring and cylinder wall, clean and take away impurities from surface of component, etc.

Basic data
Service
Item Standard
Limit

Engine oil Oil replacement 1.0±0.1L ＿

capacity Engine overhaul 1.3±0.1L ＿
Radial clearance between inner and external Less than
0.2
rotors 0.15
Oil pump rotor Clearance between external rotor and pump
0.15-0.18 0.2
block
Clearance of rotor end face 0.08-0.12 0.15

10.2 Fault Diagnosis

Reducing engine oil Engine burnt

Natural consumption No oil pressure or too low oil pressure
Oil leakage Clogged oil way.

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 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.

Oil Pump
Screw

Screw
Oil Pump

Remove the screw and take down pump cover.

Disassemble oil pump.

Testing gauge

Check radial clearance between inner rotors

Allowable limit: 0.2mm.

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 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

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 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
塞
Install the oil pump in the reverse order of removal.

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 Carburetor

Attention: Gasoline is 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
screw

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 XI 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.
·When the carburetor is removed, plug the intake pipe side with a cloth in case foreign matters coming in.
·When the carburetor has not been used for more than one month, the gasoline inside the float must be drained. Since
gasoline inside the float may deteriorate, which will clog idle nozzle and idle may become dangerous.

Function of carburetor：Carburetor is one of the key parts for oil supply system of the engine. Its
working performance has direct effect on engine stability and power and economical indexes.
Carburetor can atomize gasoline into tiny oil drops and then mix them with certain amount of
air. Depending on different working conditions of engine, carburetor can form combustible
mixed gas of various concentrations and supply to the engine so that normal and continuous
rotation of engine is guaranteed.

Basic data Unit: mm

Item Standard Value

Main nozzle A07
Main jet 173
Idle jet 42.5
Needle A08-3

11.2 Fault Diagnosis

Poor starting Difficult start, stalling after start, unstable idle

No fuel in carburetor Clogged carburetor

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 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 Clogged oil nozzle
Secondary air sucked by fuel system Clogged needle valve
Degraded fuel Too low oil level
Improper work of enrich valve Clogged fuel system
Clogged idle system or choke system Improper work of plunger
Secondary air sucked by the intake system

Too high mixed gas concentration Intermittent spark while acceleration

Improper work of enrich valve Too low mixed gas concentration
Improper work of needle valve
Too high oil level
Oil outflow from carburetor
Clogged airway
Dirty air cleaner

11.3 Removal of Carburetor

11.3.1 Removal
Remove the locknut between carburetor and bakelite washer.
Remove carburetor assembly.

11.3.2 Disassemble Carburetor

Screw off upper cover and remove sealing ring, plunger spring and plunger assembly on it.
Screw off lower housing connecting screw and remove lower housing assembly and sealing ring.
Remove float assembly, float pin and needle valve core.
Remove idle jet, main jet, main nozzle and main foam pipe.
Remove mixture screw, mixture screw spring, mixture screw washer and mixture screw sealing ring.
Remove plunger adjusting screw and plunger adjusting screw spring.

For details, refer to breakdown diagram in P125.

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 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.
If the tongue plate of float is worn, replace it.
Check if oil needle of carburetor is worn or broken. If it is,
replace it and main nozzle together.
Check if idle jet, main jet or main nozzle is worn, broken or
contaminated. If it is, replace it.
Check if plunger is worn. Replace it if necessary.
Check carburetor itself and fuel pipe. If they are dirty, clean it
according to the user’s manual.

11.4 Installation

Assembly
Install idle jet, main jet, main nozzle and main foam pipe.
Install float, float pin and needle valve core.
Install upper and lower housing sealing rings, lower housing assembly and lower housing connecting screw.
Install mixture screw washer, mixture screw sealing ring, mixture screw spring and mixture screw. Put the mixture
screw on to the housing body.
Install plunger adjusting screw spring and plunger adjusting screw.
Install plunger spring and plunger assembly.
Install top cover sealing ring and top cover.

Installation
Install the carburetor in the reverse order of removal.

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 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
cover nut 19 Copper washer 20 Round pin 21 Locknut 22 Adjusting screw 23 Valve collet 24 Valve spring
upper retainer 25 Valve spring 26 Valve rod sealing assembly 27 Valve guide 28 Valve spring lower retainer
29 O ring 30 Rubber air intake assembly 31 Stud 32 Nut 33 Clamp assembly 34 Carburetor assembly
35 Cylinder cover 36 Elastic round pin 37 Cam shaft 38 Cam shaft sprocket 39 Lock washer 40 Bolt 41
Cylinder cover plug 42 Exhaust valve 43 Timing chain assembly 44 Inlet valve 45 Nut 46 Stud 47
Cylinder cover sealing washer 48 Right chain guide plate assembly 49 Sealing washer 50 Chain guide plate bolt
51 Left chain guide plate

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 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.
All the components shall be cleaned before inspection and test, and purged with high-pressure air.
Function of cylinder head: Cylinder head is used to seal cylinder and form a combustion chamber with piston to
hold high-temperature and high-pressure fuel gas. It accomplishes air intake and exhausting operation with valve
mechanism.

Basic Data Unit : mm

Service
Item Standard Limit
Cylinder cover flatness 0.03 0.05
Intake 0.03-0.05 ＿
Valve clearance
Exhaust 0.03-0.05 ＿
Intake 4.97-4.98 4.9
Valve stem OD
Exhaust 4.96-4.97 4.9
Valve
Intake 5 -5.012 5.1
Valve guide Valve guide ID
Exhaust 5-5.012 5.1
Intake 0.02-0.042 0.08
Clearance between valve stem and valve guide
Exhaust 0.03-0.052 0.10
Valve race width Intake/Exhaust 0.7 1.5
Valve 38.8 37.8
Clearance
spring
Rocker arm shaft OD Intake/Exhaust 11.980-11.988 11.95
Rocker arm
Rocker arm hole ID Intake/Exhaust 12-12.012 12.05
Valve
Clearance between rocker arm shaft and rocker arm
Valve guide Intake/Exhaust 0.012-0.032 0.08
hole

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 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

Bolt
12.3.1 Removal
Screw off the ten locknuts and remove cylinder cover. Cylinder cover

Bolt
Cylinder cover hood

Return spring
Remove cylinder cover hood.
Screw off two locknuts and remove the rocker arm, return spring
and rocker arm shaft.

Rocker arm
Rocker arm shaft

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 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
hexagon nuts, remove cylinder head. Tester

C-type gasket

Cylinder head

Bolt Lock washer

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 Compress valve spring with a valve spring compressor, and remove the valve collet, 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
spring
Valve oil seal

Ruler
12.4 Valve Inspection

Clean carbon deposition on the cylinder cover.

Measure flatness of junction surface of cylinder cover
Allowable limit: 0.05mm.
If flatness of junction surface of cylinder cover exceeds the
service limit, put a piece of fine sandpaper on the flat plate and
fit the sandpaper with junction surface of cylinder cover; and Metering gauge
then push the sandpaper to grind in figure of “8” way.

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 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. r

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. Please do not rotate

the reamer in counterclockwise.

Tester

Measure valve guide ID.

Allowable limit: Intake/Exhaust: 5.5mm.
Clearance between valve and valve guide
Allowable limit: Intake Valve: 0.08m.
Exhaust valve: 1.0mm.

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 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.
Heat with electric furnace or oven the cylinder head to
100-150℃. Opener
Fix the cylinder head and remove the valve guide from upper
side of cylinder head with a special valve guide remover.

Install a new O ring onto the new valve guide.

Install the valve guide from the top of cylinder head.
* Attention: Please do not hurt cylinder head while
installing valve guide.

Valve reamer

When the valve guide is inserted, fix and adjust it with a valve
guide reamer.
* Attention: When a reamer is used to cut, please apply
some amount of cutting lubricant onto it.
Rotate the reamer in clockwise direction.

Remove carbon deposited in combustion chamber and valve

and clean thoroughly intake and exhaust valves. Valve seat contact surface
Inspect width of contact surface of valve seat (width of valve
race)
Allowable limit: intake/exhaust: 1.6mm.

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 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°angle

milling cutter.

32°

Remove 1/4 of bottom of valve race with a 60°angle milling

cutter.
Remove the milling cutter and check the places processed.

60°

Grind and cut valve race with a 45°angle precise milling cutter
till it gains a proper width.
All the dents and ragged parts must be removed.
1mm

Standard valve race width: Intake: 1.0mm

Exhaust: 1.0mm

45°

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 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°
Grind and cut valve race with a 45°angle precise milling cutter till it
meets the required specification. Low contact
After completion of valve race grinding and cutting, please apply face
some polishing agent on the surface of valve. Polish the valve
60°
gently.

12.7 Cylinder Head Installation

Install the cylinder head in the reverse order of removal.

* Attention：
While installing valve spring, the end with short spring links heads combustion chamber.
While installing valve collet, please compress valve spring with a valve spring compressor and install the valve
collet.
While installing valve, please apply appropriate amount of engine oil on the surface of valve stem, and then install it
into valve guide.

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 Cylinder Block and Piston

Attention: All the

components shall be
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

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 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. It also transfers part of heat in the cylinder to
surrounding coolant.

Function of piston:
Piston can bear the pressure generated by combustion of mixed combustible gas in the cylinder and transmit the
pressure to connecting rod to drive crankshaft to rotate.
It forms a combustion chamber with cylinder head.
It works as a slide valve to compress regularly fresh mixed gas from crankcase into cylinder and exhaust combustion
gas from the cylinder.

Basic data Unit: mm

Item Standard Value Service Limit

ID 57-57.01 57.10
Cylindricity 0.005 0.05
Roundness 0.004 0.05
Flatness 0.02 0.05
56.987-56.977
Piston OD(measuring point) 56.93
(8mm at the bottom of piston skirt)
Piston pin hole ID 14.002-14.008 14.04
Piston pin OD 13.994-13.997 13.96
Cylinder
Clearance between piston and piston pin 0.005-0.014 0.05
Top ring 0.020-0.060
Clearance between piston ring and ring groove
Second ring 0.020-0.060
Top ring 0.25-0.35
Joint clearance of piston rings Second ring 0.20-0.35
Oil ring 0.20-0.70
Connecting rod small end ID 14.010-14.018 14.06
Clearance between linkage rod and piston pin 0.013-0.024 0.10

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 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

Too much carbon deposited in the combustion chamber Damaged cylinder, piston and piston ring
Worn piston pin hole and piston pin

Cylinder block
13.3 Cylinder Block

13.3.1 Cylinder Block Removal

Screw off cylinder block mounting bolt.
Remove cylinder block (together with cam follower).

Mounting bolt

13.3.2 Cylinder Block Inspection

Inspect wear of cylinder inner wall. If it is seriously worn,
Location
replace it.
pin
Remove washer and location pin.

Washer

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 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.
Remove deposited carbon inside the piston ring.

Piston
Testing gauge
Install the piston ring.
Measure the clearance between piston ring and piston ring Push
groove.
Allowable limit: Top ring: 0.09mm.
Second ring: 0.09mm.

Piston ring

Remove piston ring and install all the piston rings onto bottom
of cylinder. Testing gauge
* Attention: Compress piston rings into the cylinder with
piston head.
Measure the joint clearance between piston rings.
Piston ring
Allowable limit: 0.5mm.

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 Measure piston pin hole ID.
Allowable limit: 14.04mm.

3 Tester

1
2
Measure piston pin OD. 3
Allowable limit: 13.96mm.
Measure the clearance between piston pin hole and piston pin.
Allowable limit: 0.05mm.

Measure piston OD 90°

* Attention: Measuring position forms a 90° angle with 11mm
piston pin, about 11mm below piston skirt.
Allowable limit: 56.93mm.

Inspect wear and scratch on inner wall of cylinder. Testing gauge

* Attention: Measure cylinder ID at three positions, i.e.
upper, intermediate and lower positions. The position forms
a 90°angle with piston pin.
Allowable limit: 57.1mm.
Measure the clearance between cylinder and piston. Take the
maximum clearance as standard.
Allowable limit: 0.17mm.

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 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).
Allowable limit: 0.05mm.

Check flatness of cylinder surface. Ruler

Allowable limit: 0.05mm.

Testing gauge Cylinder

Connecting rod small end ID

Measure Connecting rod small end ID.
Allowable limit: 14.06mm.

Top ring
13.4.2 Installation of piston
Install location pin.
Apply engine oil evenly on each piston ring and piston. Install Second ring
piston to its place with bevel upward.
* Attention: Oil ring
Piston shall not be scratched and piston ring shall not be
broken.
When the piston ring is installed, it can rotate freely in the
piston ring groove.

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 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:
Install with the “IN” mark at the top of piston facing the intake “IN” Mark
valve.

13.5 Install Cylinder

Install washer and location pin onto the crankcase.

Location pin

Washer

Apply evenly engine oil on inner wall of cylinder, piston and piston ring.
Install carefully the piston ring into the cylinder.

Cylinder
* Attention: Do not hurt piston ring.

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 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.

1 Nut 2 Cross recessed adjusting screw 3 Thrust washer 4 Plane needle bearing 5 Locknut 6 Bearing seat
7 Lock washer 8 Bolt combination assembly 9 Pressure plate 10 Clutch spring 11 Friction disc assembly
12 Driven friction plate 13 Center bracket 14 Sleeve 15 Thrust washer 16 Housing assembly

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 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.

Function：Clutch and driven wheel constitutes a continuously variable transmission

Basic data Unit: mm

Clutch Braking shoe thickness 2.9-3 2.6

14.2 Fault Diagnosis

Tight clutch release lever Clutch slips at acceleration Transmission jumps gear
Clutch cable injured, twisted or contaminated No clearance on clutch release lever Weak or broken brake pad arm return spring
Injured clutch lifter Worn clutch disc Injured brake pad arm
Faulty clutch lifter bearing Weak clutch spring Worn or injured gearshift cam
Sticky clutch lifter

Gearshift difficult Clutch not released or motorcycle drags when clutch released
Incorrect clutch adjustment Too big clutch release lever clearance
Bent gearshift spindle Warped clutch plate
Injured gearshift cam Faulty clutch push rod

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 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.
wrench
Remove locknut and washer.
Remove clutch center bracket.
Remove clutch drive and driven friction plates.
Remove clutch pressure plate.
Removed components refer to exploded view.

Universal fixer

Remove spline washer.

Remove housing assembly.
Housing assembly

Install clutch in the reverse order of removal.

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 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.

Measure the free length of pressure spring.

Allowable limit: replace it if it is below 29.7mm.

Free Length

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 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
Remove bearing and oil seal on left crankcase. Surface
Drive pawl
Check if bearing and oil seal are injured. Replace if necessary.

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 * Attention:
Hammered-out bearing cannot be reused. Replace it with a
new one.
Remove bearing and oil seal with special tools. Bearing hole, oil seal hole

Remove bearing on right crankcase.

Check if bearing is injured. Replace if necessary.
* Attention:
Hammered-out bearing cannot be reused. Replace it with a
new one.
Remove bearing and oil seal with special tools.

Main shaft and countershaft combination

* Attention: Apply each gear and shaft with lubricating grease evenly at combination.
Make sure there is no stuck after combination.

Note:
Install the crankcase in the reverse order of removal.

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 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

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 15.1 Service Data

Function: Transfer torque and determinate the final output torque and rotary speed.

Basic data Unit: mm

Gearshift mechanism Shift fork shaft OD 9.98-9.995 9.96

15.2 Fault Diagnosis

Hard to engage gear Difficult gearshift

Worn or distorted gearshift fork Clutch is not completely separated.
Broken shift fork guide pin Defective transmission pull spring
Worn gear pawl Worn gearshift drum lock groove

Automatic gearshift
Connecting pawl is worn and its edge turns round.
Weak transmission unit return spring.
Spline gear of spline shaft and spline groove of sliding gear are worn, which result in a greater axial force during
operation of gears.
Worm gearshift drum and shift fork.

15.3 Gearshift Mechanism

15.3.1 Removal
Remove gearshift shaft assembly.
Remove the bolt on the upper baffle plate
of ratchet, the ratchet upper baffle plate
and gearshift ratchet gear ring.
Remove the bolt on lower baffle plate of
ratchet, the ratchet lower baffle and the
ratchet, etc.
Removed parts refer to exploded view. .

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 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. If it is over bent, replace it.
Check if return spring is weakened. If necessary, replace it.
Screw off closing bolt.
Disassemble crankcase.
*Attention: Please do not hurt washer and closing surface.
Remove left case block.
Pull out shift fork shaft.
Remove gearshift drum. Shift fork shaft
Remove gearshift fork.

Gearshift drum
Shifting fork

Measure shift fork OD.

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 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

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 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

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 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.
Crankcase--------------------16.3 Drain the lubricating oil from
crankcase before working on it.

16.1 Preparatory Data

Precautions on Operation
Attention: Crankcase is a thin-wall casting part. Avoid impact on it during operation in case it may be
distorted or broken.
Clean carefully all the components before inspection and test and purge them with high-pressure gas.
Drain the lubricating oil from crankcase before working on it.

Function of crankcase: Crankcase is the force bearing part of engine. It is mainly used to
support crankshaft, clutch, transmission, cylinder block and cylinder head. It bears impact from
combustion and inertia force from movement of crankshaft connecting rod; and forms a partial
enclosed space (for air and oil).
Suspension hole is set on the crankcase, which can be connected with the suspension hole in the vehicle block so that
the engine can be linked together with frame and other parts.

Basic data Unit: mm

0
Item Standard Allowable limit
.
5
5

Tools
Universal fixer Clutch spring compressor
Screwdriver rod Socket wrench
uide rod Bearing screwdriver

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 16.2 Fault Diagnosis

Noise in the 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.
Remove starting motor gear, needle bearing and washer.

Screw off bolts on left front cover and left rear cover of
crankcase.
Remove left front cover and left rear cover.

Remove starting motor idle gear.

Remove washer and location pin.

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 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

Cam

Measure cam bush ID.

Allowable limit: 14.10mm.
Measure cam height
Allowable limit: 32.5mm.

Tester

16.3.3 Crankcase Right Cover Removal

Bolt
Screw off mounting bolt and take down the crankcase right
cover.

Remove clutch release lever assembly from the right cover. Right cover

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 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.
Locknut

Oil filter
roller
Oil pump

Crankshaft connecting
16.4 Crankshaft Connecting Rod Assembly rod assembly

Drive gear
Removal
Location pin
Remove left crankcase.
Remove washer and location pin.
Remove drive gear.
Washer
Remove the crankshaft connecting rod assembly from the right
crankcase.
* Attention: Please do not hurt washer and closing surface.

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 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.
If there is, replace the crankshaft.

* Attention:
Install together crankshaft connecting rod assembly and Crankshaft bearing
gearshift mechanism on the crankcase.

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 Exhaust System Inspection and Maintenance

Muffler Assembly

A Tightening torque of mounting bolt 5 for muffler connector in the diagram：5-9 N·m
B Dual catalysts are added into the muffler welding assembly in the diagram.

C 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 M6×10 6 Spring washer 8 7 Exhaust pipe protecting plate

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 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.
2. Scope of Guarantee
1> Emission control system function guarantee
The company guarantees that the system meets regular or irregular exhaust emission inspection carried out by
relevant government authorities within 15,000km drive.
3. The guarantee article is not applicable to the following situations, but local dealers or service departments of the
company are still willing to provide maintenance service for the customers at a reasonable price.
1> Not performing regular maintenance according to the time and traveled distance specified by the company
2> Users not performing regular inspection, adjustment or maintenance at local dealer or service center of the
company, or unable to provide evidence of maintenance record
3> Overloading or improper use
4> Remounting the motorcycle, removing original spare parts or install extra devices on to the vehicle at will
5> Using the motorcycle as a racing vehicle or driving on the roads not suitable for it
6> Damages because of typhoon, flood or other natural disasters; or injuries or trouble caused by gross negligence,
traffic accident or subject to impact by external objects
7> Stopping use for a long time without regular maintenance
8> Odometer is damaged and no prompt repair; or the odometer is artificially altered, stopped or replaced
9> Please come to the inspection station every three months for regular exhaust gas inspection
·The new motorcycle delivered by the company has passed noise inspection and is up to EPA Standard.

17.2 Periodical Maintenance Instructions

·To reduce environment pollution, it is required by the country that all the motor vehicles manufactured by each
company shall meet the regulations of emission standard of air pollutants. Besides the production process is up to the
regulations of emission standard of air pollutants, the company is also devoted to purifying air and reducing air
pollution.
·Strict inspection is performed on the motorcycle delivered from the company; all the specifications can meet the
regulations of emission standard of air pollutants. Due to different situations the users are in, we make the following
regular inspection table relating to exhaust emission. To ensure normal gas exhaust, please inspect, adjust or repair

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 your motorcycle in the specified time intervals.
·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 CO HC NOX
Emission standard ≤ 2.0g/km ≤ 0.3g/km 0.5 g/km

※ The latest version shall prevail when emission standard is updated.

·The motorcycle that does not perform regular inspection in local dealer or service center of the company may be
prohibited to use. The company will not be responsible for that. Please have your motorcycle inspected whenever
necessary to keep it in best condition.
Note: ① You shall clean more frequently the air cleaner to extend service life of the engine when your
motorcycle is often used on sand-gravel roads or in severely polluted environment.
② More frequent servicing may be required when the motorcycle is often driven at high speed or travels a
long distance.
Pay attention to the followings to ensure standard emission
1> Please use only 92 or 95 unleaded gasoline.
2> Please use only specified type of engine oil.
3> Please service your motorcycle according to your periodical maintenance table.
4> Emission control system is forbidden to be adjusted or replaced (including spark plug use, idle speed adjustment,
ignition timing, carburetor adjustment, etc.).
5> Attentions:
·Improper ignition system, charging system or fuel system will have great effect on muffler, so please go to your
local dealers or service center of the company for inspection, adjustment or maintenance when you encounter it.
·Please use only 92 or 95 unleaded gasoline, or the muffler device (four-stroke system) may be injured.
6> Emission control system of the motorcycle meets national standard. If you have to replace any component of the
system, please use the spare parts made by KEEWAY Motorcycle Co., Ltd. and ask your local dealer or service
center to replace it for you.

17.3 Emission Control System Mechanical Functions

General introduction
The emission control system is based on four-stroke single cylinder engine and carburetor. It uses air intake device
and keep excellent exhaust gas level; Activated carbon canister is used for vaporized waste gas process.
※ Air intake device
Guide air into exhaust pipe and CO and HC of incomplete combustion will be reacted into harmless gas.
Classification Equipment Constituted Part Desired Function
Emission control system Catalytic device Catalytic converter Oxidize CO, HC and NOX.

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 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.

• Valve (Leak) Qualified
• Piston (Worn) 合格

• Combustion chamber (clean)

Note 1: Measure according to the idle speed measuring procedures.

Note 2: Adjust with lock screw engine rpm to the specified and measure idle CO/HC.

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 RKV125 Schematic Circuit Diagram

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