KEEWAY RKV125, Instruction And Maintenance Manual

Page 1: ...Two wheel Motorcycle RKV125 Instruction and Maintenance Manual KEEWAY MOTORCYCLE CO LTD ...

Page 2: ...mbly 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 Steeri...

Page 3: ...cating 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 Adj...

Page 4: ...paratory 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 ...

Page 5: ... 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...

Page 6: ... 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...

Page 7: ...se 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 assem...

Page 8: ... 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 ra...

Page 9: ...t 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...

Page 10: ...annot 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 al...

Page 11: ... Name Remarks Special socket wrench Clutch holder Flywheel extractor Feeler gauge Bearing puller Bearing installer Oil seal remover Puller handle Piston pin puller Piston ring pliers Spark plug socket wrench Clutch thickness measurement Cylinder bore tester Dial gauge Dial gauge V block Micrometer Valve guide remover Valve guide installer Valve clearance adjuster Valve spring remover Valve guide r...

Page 12: ...Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Handle Figure 1 11 Figure 1 12 Pliers Piston ...

Page 13: ...Figure 1 13 Figure 1 14 Figure 1 15 Figure 1 16 Figure 1 17 Figure 1 18 Figure 1 19 Figure 1 20 Figure 1 21 Figure 1 22 ...

Page 14: ... Socket wrench Micrometer Magnetic stand V block Dial gauge Vernier caliper Spring clamp ring pliers Hammer screwdriver Front fork oil seal installer Front fork seal driver Steering nut wrench Figure 1 27 Figure 1 28 Figure 1 29 Figure 1 30 Figure 1 31 Figure 1 32 Figure 1 33 Figure 1 34 Figure 1 35 Figure 1 36 Figure 1 37 Figure 1 38 1 General tools used for chassis overhaul Continued Table 1 26 ...

Page 15: ...Figure 1 31 Figure 1 32 Figure 1 33 Figure 1 34 Figure 1 35 Figure 1 36 2 Special tools for chassis overhaul Front fork seal driver Figure 1 37 3 Steering nut wrench Figure 1 38 ...

Page 16: ...l components Special tools and their pictures for electrical component test are listed in Table1 39 and 1 40 Table 1 39 Name Remarks Multimeter Ignition tester Figure 1 41 Figure 1 42 Continued Table 1 40 Figure 1 41 Figure 1 42 ...

Page 17: ...ess tyre 100 80 17 Air cleaner Dry Rear tubeless tyre 130 70 17 Drive Train Clutch type Wet multi plate friction type Fuel tank capacity 17 0 5L Gear shift pattern Five speed left foot control Performance Carburetor type PD26JS Transmission Chain drive Idle speed rpm 1 400 100rpm min Electrical Battery capacity type 12V dry charged type Max torque 9 2N m 7 000rpm Max power 8 2kW 9 000rpm Max magne...

Page 18: ...RKV125 ...

Page 19: ... if magneto flywheel or trigger coil looses Loosen drain screw of carburetor and check if there is oil flowing out from overflow pipe Refuel gasoline Check compression pressure in the cylinder Check oil in the fuel tank Compression pressure in the cylinder is normal Check ignition power supply Check if wires in the ignition system are shorted or broken Check if CDI igniter fails Non contact batter...

Page 20: ...gine can continue to run when it is started Carburetor is clogged inside or float is too high Carburetor starter i e cranking enrichment system fails 1 Check leakage at external connection parts of engine 2 Check valve timing 3 Check tightness between valve and valve seat 4 Check if valve clearance is too small 5 Check if piston ring is stuck inside the ring groove or of less elasticity 6 Check we...

Page 21: ... low or the gasoline has been stored for a too long time 2 Check if engine runs at a high speed for a very long time or overloaded Check cooling system Air cooling the engine Check if radiator plates are covered by mud greasy oil or sand Clean Check if cooling fan or wind scooper is damaged forced air cooled engine Check and solve it Use an ignition timing lamp to check ignition timing of engine Y...

Page 22: ...f Carburetor starter i e cranking enrichment system works normally 3 Check if float of carburetor is too low Mixture ratio of air fuel is normal Check if exhaust of cylinder and exhaust muffler is clogged due to carbon deposition Check lubricating system Air fuel concentration is too low 2 stroke engine lubricating system 4 stroke engine lubricating system 1 Check if fuel switch is perfect 2 Check...

Page 23: ...cessively worn 4 Check if conical surfaces of driving wheel and mobile friction wheel is excessively worn or worn to groove 5 Check if conical surface of driven wheel and mobile driven wheel are excessively worn or worn to groove 6 Check if raceway on the inner end face of friction wheel is excessively worn or pitted due to crush 1 Check if fuel supply system is smooth 2 Check if carburetor air cl...

Page 24: ...on ring and cylinder Re adjust carburetor idle speed Check if idle jet is too big Check if throttle control cable can pull flexibly in the cable jacket and if throttle spring is too soft 1 Check CDI igniter 2 Check if magneto flywheel or trigger coil looses Engine has idle speed after adjustment Engine has no idle speed after adjustment Air adjusting screw of carburetor or throttle adjusting screw...

Page 25: ...e Air pressure too low Air pressure normal Gas up as specified Check if fuel tank fuel switch delivery pipe or carburetor leaks oil Exclude as practical situations Check mixture ratio Mixture ratio of air fuel is normal Air fuel concentration is too high Air fuel concentration is too low Check if idle speed of engine is too high 1 Check if air cleaner is clogged 2 Check if float of carburetor is t...

Page 26: ...ace Check if contact area between braking shoe and friction disc is worn terribly Repair or replace clutch shoe Refill engine oil Check if viscosity of engine oil in the crankcase is too low or the oil is badly contaminated Replace engine oil 1 Check if adjusting screw for clutch push rod is properly adjusted 2 Check if pinch bolt for clutch spring is loosing 3 Check if braking shoe of clutch is b...

Page 27: ... cam shaft separation push rod and other components of clutch control mechanism are excessively worn No i No No Yes Yes Yes 4 stroke engine exhaust muffler gives off blue white smoke Check if engine oil level in the crankcase exceeds the upper limit line Too much engine oil in the crankcase bleed surplus oil and decline oil level to upper limit line 1 Check if cylinder piston or piston ring is ove...

Page 28: ...hole is excessively worn 3 Check if shift fork is deformed 4 Check if fork shaft is distorted or over worn Drum type brake fails Check if clearance of brake handle bar is within 10mm 20mm or clearance of brake pedal within 20mm 30mm range Re adjust Separate cable of brake rocker arm from brake control cable Move rocker arm by hands Brake rocker arm rotates freely but there is resistance feeling fr...

Page 29: ...e and check if meshing depth of each gear meets requirement Enough meshing depth Insufficient meshing depth 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 the upper limit line of tank meantime check if oil leaks at br...

Page 30: ... charge Resistance is less than standard Charging coil is shorted Resistance is infinitely great Resistance meets the standard Charging coil or its output wires are shorted 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 Connect connectors of magneto lead wire harness to the cables of the whole ...

Page 31: ...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 Replace charging coil Battery runs down quickly Wire from rectifier or rectification regulator or battery to ignition switch is shorted 1 Check if electrolyte in the battery is enough 2 Check ...

Page 32: ... starter button and the click from starter relay cannot be heard After short circuit starting motor does not run Push starting button and a click from starting relay can be heard Disassemble the connector of starter relay from cables of the whole vehicle connect the two hatching wires from relay coil to negative and positive terminals of battery with two pieces of wires Use a screwdriver or a piec...

Page 33: ...heck if armature coil is broken or shorted 1 Check if contact inside clutch switch is poorly contacted 2 Check if starter button contact is poorly contacted 3 Check if rectifier diode is damaged 4 Check if neutral gear switch works abnormally 5 Check if wiring of electrical starter system is broken or shorted Check if starting button contact is poorly contacted Grasp brake handle and check if brak...

Page 34: ...heck if it is on state Check if starter button contact is poorly contacted Disassemble starter motor and make the following inspections 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 Starter relay contact is burnt or injured Yes Yes No No Turn on ignition switch press horn button...

Page 35: ...of rectification regulator from cables of the whole vehicle Lights are lit Lights are not lit Short circuit inside rectifier Disassemble headlamp assembly and check if the bulb is burnt Electric horn sounds loudly and turn signal light is lit Electric horn does not sound and turn signal light is not lit Normal power supply from battery Use a piece of wire to touch quickly positive and negative ter...

Page 36: ...e of wire to short circuit power line and output line of lighting switch Wiring from magneto or ignition 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 is poorly contacted Wiring from lighting switch to lamp is broken or shorted Yes No No Yes ...

Page 37: ... density of electrolyte in the battery is too low check if pole plates inside the battery are vulcanized or broken Separate conductors of rectification regulator from cables of the whole vehicle Measure and check with an Ohmmeter if wirings between lighting and charging coil of magneto and regulator are broken Set multimeter on 0V 20V DC voltage measure the voltage between the wire from connector ...

Page 38: ...e cables of the whole vehicle Check brightness of light Headlamp light recovers after separation Headlamp light is still dim after separation Stable voltage of rectification regulator is too low Check if charging coil of magneto and wirings in the charging system are shorted Electric horn sounds loudly Turn signal lamp is bright Electric horn sounds hoarse Turn signal lamp is dim Battery is low or...

Page 39: ... if power of bulb in the lighting system is up to the requirement Replace the bulb 1 Check if headlamp switch and side lamp switch is poorly contacted 2 Check if connectors and earth wire are poorly contacted Replace bulb ...

Page 40: ...ound with a voltmeter No voltage display No voltage display Grounding wire of lamp holder is of poor contact or bulb of turn signal lamp is badly contacted with lamp holder Power line to the lamp holder is broken Take down the turn signal lamp cover and check if the bulb is burnt Replace turn signal lamp bulb Power line on the troubled side is broken or grounding wire of lamp holder is poorly cont...

Page 41: ...ntact of turn signal lamp is poor contacted Check if there is power output from power input line of turn signal lamp switch by lamp test Test lamp is on Test lamp is off Power line of turn signal lamp is broken or shorted Wire from ignition switch to scintillator or from scintillator to turn signal lamp switch is shorted or broken Turn signal lamp is on after short circuit Turn signal lamp is stil...

Page 42: ...e 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 connect non power terminal terminal to button of horn with ground wire Power line between ignition switch and electric horn is broken Electric horn sounds after connection Inner contact of horn is poorly contacted or the wire from horn to button is broken Adjust vol...

Page 43: ...mp is not lit after short circuit Brake lamp is lit after short circuit Use a screwdriver or a piece of wire to touch quickly power line of brake lamp switch and grounding wire and check sparks Brake lamp switch is not properly adjusted or its inner contact is not well contacted Spark at touch No spark at touch Wire from brake lamp switch to brake lamp is broken or shorted Power line from ignition...

Page 44: ...nsion 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...

Page 45: ...all type Ignition time BTDC15 1 1400 100rpm Frame Clearance of front brake handle 10 20mm Clearance of rear brake pedal 20 30mm Pneumatic pressure unit of tyre Kpa Specification Tyre pressure RKV125 Front wheel 100 80 17 210 10kPa Rear wheel 130 70 17 210 10kPa Torque Front shaft locknut 55 62 N m Rear shaft locknut 85 98 N m ...

Page 46: ...ion of looseness of bolts at all positions I I I I I I Torque wrench Check if gearbox leaks oil I I I I I I Common tool Spark plug inspection and replacement I I R R I Common tool Gearbox oil replacement I Once every 5000KM Common tool Lubrication of all the places on the vehicle L L Lubricant injector 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 ...

Page 47: ...e 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 hig...

Page 48: ...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 pollute...

Page 49: ...rk 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 re...

Page 50: ...e 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...

Page 51: ...stment 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 Attentio...

Page 52: ...le 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 eng...

Page 53: ...ained 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 lea...

Page 54: ...arance 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...

Page 55: ...ncy 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 ...

Page 56: ...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 tig...

Page 57: ... 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 loosene...

Page 58: ...ening parts used in electric system Fastening position and fastening part name Tightening torque N m Starting motor clutch cover bolt Starting motor clutch locknut Rectifier bolt High voltage coil pinch bolt Flywheel locknut Vehicle block protecting plate bolt 12 95 5 0 9 0 5 0 9 0 ...

Page 59: ...Charging system 1 Starting relay 2 Scintillator 3 Battery 4 Electric igniter 5 High voltage ignition coil 6 Power lock assembly ...

Page 60: ...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 plea...

Page 61: ...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...

Page 62: ...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 ba...

Page 63: ...tion 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 ...

Page 64: ...self Attention Do not touch the metal part of multimeter probe with your finger Check with a multimeter If impedance values measured by different multimeters are not the same it perhaps the inspection is not correct When impedance value between terminals is abnormal replace voltage regulator 1 6 Magneto Charging Coil Attention Inspection of magneto charging coil can be performed on the engine Insp...

Page 65: ...aced 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 conic...

Page 66: ...magnetism on the inner surface of flywheel ensure there is no bolt on it Fix the flywheel using a universal non adjustable spanner and then tighten the locknut Torque value 9 0 N m Install protecting plate on the left side ...

Page 67: ...Ignition System 1 Relay 2 Scintillator 3 Battery 4 Igniter 5 High voltage ignition coil 6 Power lock assembly 7 Voltage regulator ...

Page 68: ... 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 Ch...

Page 69: ...high voltage wire is not good Inferior CDI assembly after items are tested and proved abnormal or spark plug no sparking High voltage power is normal spark plug no sparking Inferior spark plug or secondary leakage of the ignition coil Bad ignition coil Charging coil No high voltage power supply Inner impedance is too small Use appointed tester to test Crankshaft rpm is too low Tester is disturbed ...

Page 70: ...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 shoc...

Page 71: ...dicates 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 conn...

Page 72: ...rminals 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...

Page 73: ...emove 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 ...

Page 74: ...Starting System 1 Starting relay 2 Scintillator 3 Battery 4 Electronic igniter 5 high voltage ignition coil 6 Power lock assembly 7 Rectifier 8 Electric horn ...

Page 75: ...e 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 ...

Page 76: ...wer 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 assemb...

Page 77: ...le 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 A...

Page 78: ...age 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 ...

Page 79: ...Bulbs Switches Instruments 1 Headlamp 2 Instruments 3 Electric horn 4 Left rear turn signal lamp 5 Tail lamp ...

Page 80: ... 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...

Page 81: ...mp 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 Re...

Page 82: ...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 ...

Page 83: ...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...

Page 84: ...rew off mounting bolt on the brake lever and take down the bracket Remove bracket for the rear brake lever Remove throttle handle and bolts Take down throttle handle from the handle and remove the throttle cable Remove locknut on the handle and take down the handle ...

Page 85: ...unting bolt Rear shaft locknut Upper bracket assembly mounting bolt Front shaft locknut Front shock absorber mounting bolt Rear shaft locknut Rear shock absorber top nut Rear shock absorber bottom nut Seat cushion mounting bolt Fuel tank mounting bolt Gasoline switch mounting bolt Protecting hood mounting bolt Sprocket mounting bolt Rear swing arm shaft nut 5 9 22 29 5 9 85 98 40 60 55 62 37 44 85...

Page 86: ...it 3mm D Mounting torque for Bolt 7 in the diagram 22 29 N m 1 Oil pump block assembly 2 Hydraulic brake handle 3 Handle mounting bolt 4 Nut M6 5 Fixing cover 6 Bolt M6 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 ...

Page 87: ...2 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 ...

Page 88: ... 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...

Page 89: ...aminated 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 ...

Page 90: ... 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 b...

Page 91: ...icator 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 Atte...

Page 92: ...taminate 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...

Page 93: ...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 ...

Page 94: ... 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 D...

Page 95: ... seat assembly 3 Gear seat oil seal 4 Drive plate 5 Bearing 6301 6 Front wheel middle shaft sleeve 7 Front brake disc 8 Front brake disc mounting bolt 9 Front wheel oil seal assembly 10 Front wheel left shaft sleeve 11 Tubeless tyre 12 Front wheel rim ...

Page 96: ...on 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 bol...

Page 97: ...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 b...

Page 98: ...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 position Item Standard value mm Service Limit mm Front wheel shaft Curvature 0 2 Front wheel Wheel shimmy Longitudinal 2 0 Transversal Within 1 0 2 0 Tightening torque Tools Upper br...

Page 99: ...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 Scr...

Page 100: ...er 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 ...

Page 101: ...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 han...

Page 102: ...crew 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 remo...

Page 103: ...e 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 Tight...

Page 104: ... 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 B...

Page 105: ... 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 ...

Page 106: ...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 A Tightening torque of Bolt 1 in the diagram is 22 29 N m B Drive chain specification 428HG 1 126 ...

Page 107: ...tion Do not contaminate braking shoe ad brake disc with oil Basic preparatory data Item Standard Value mm Service Limit mm Rear wheel Shimmy Longitudinal 2 0 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 ...

Page 108: ...f 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...

Page 109: ...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 ...

Page 110: ... 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 ...

Page 111: ...ivot 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 ...

Page 112: ...itions 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 and its side plate 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 rep...

Page 113: ... 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 i...

Page 114: ... 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 ...

Page 115: ...nk 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 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 E Note Fuel switch shall be set at OFF position while removing fue...

Page 116: ...e 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 consum...

Page 117: ...on 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 cu...

Page 118: ...rew Closing bolt Right side cover bolt Front left cover bolt Coil screw Clutch separating disc bolt Clutch locknut Filter screen cover bolt Tensioner pinch bolt Drive gear locknut Drive sprocket bolt Engine oil pump screw Ratchet upper and lower baffler screw Spark plug 25 28 8 12 8 12 8 12 8 12 50 55 10 15 8 12 8 12 8 12 8 12 8 12 6 8 45 50 8 12 8 12 50 60 18 22 8 12 8 12 18 22 Components that ca...

Page 119: ...ountershaft assembly 7 Filter screen 8 Engine oil pump 9 Filter element assembly 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 ...

Page 120: ...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 Item Standard Service Limit Engine oil capacity Oil replacement 1 0 0 1L Engine overhaul 1 3 0 1L Oi...

Page 121: ...unting screw Take down oil pump block drive gear and pump shaft Screw off the screw Take down pump seat Remove the screw and take down pump cover Disassemble oil pump Check radial clearance between inner rotors Allowable limit 0 2mm Oil pump block Testing gauge Screw Oil Pump Screw Oil Pump Oil pump gear ...

Page 122: ...Check clearance between external rotor and oil pump seat Allowable limit 0 2mm Check clearance between rotor end faces Allowable limit 0 15mm 测试规 Testing gauge Flat board ...

Page 123: ...gine Oil Pump As shown in the following figure Attention After assembly inner and external rotors shall rotate smoothly and be out of nimbleness 10 3 2 Installation Install the oil pump in the reverse order of removal 塞 ...

Page 124: ...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 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 ...

Page 125: ...ide 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 wor...

Page 126: ... 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 plung...

Page 127: ...ce 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 ...

Page 128: ...sting 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 ...

Page 129: ...ith piston to hold high temperature and high pressure fuel gas It accomplishes air intake and exhausting operation with valve mechanism Basic Data Unit mm Item Standard Service Limit Cylinder cover flatness 0 03 0 05 Valve Valve guide Valve clearance Intake 0 03 0 05 Exhaust 0 03 0 05 Valve stem OD Intake 4 97 4 98 4 9 Exhaust 4 96 4 97 4 9 Valve guide ID Intake 5 5 012 5 1 Exhaust 5 5 012 5 1 Cle...

Page 130: ...ace 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 12 3 1 Removal Screw off the ten locknuts and remove cylinder cover Remove cylinder cover hood Screw off two locknuts and remove the rocker arm return spring and rocker arm shaft Cylinder cover Bolt Cylinder cover hood Rocker arm Bolt...

Page 131: ...t 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 Micrometer Tester Cylinder head Lock washer C type gasket Bolt ...

Page 132: ... 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 then push the sandpaper to grind in figure of 8 way Valve collet Valve Washer Inner valve spring Valve collet Valve ...

Page 133: ...se 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 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 Vernier caliper Valve reamer Tester Micrometer r ...

Page 134: ...h 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 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 clock...

Page 135: ... clearly Remove 1 4 of external edge of valve race with a 32 angle milling cutter Remove 1 4 of bottom of valve race with a 60 angle milling cutter Remove the milling cutter and check the places processed 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 Standard valve race width Intake 1 0mm Exhaust 1 0mm Ha...

Page 136: ... and cutting please apply some polishing agent on the surface of valve Polish the valve 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...

Page 137: ... 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 Attention All the components shall be cleaned before inspection and test and purged with high pressure air ...

Page 138: ...shaft 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 Cylinder ID 57 57 01 57 10 Cylindricity 0 005 0 05 Roundness 0 004 0 05 Flatness 0 02 0 05 Piston OD measuring point 56 987 56 977 8mm at the bo...

Page 139: ...on pressure Noisy piston Too much carbon deposited in the combustion chamber Damaged cylinder piston and piston ring Worn piston pin hole and piston pin 13 3 Cylinder Block 13 3 1 Cylinder Block Removal Screw off cylinder block mounting bolt Remove cylinder block together with cam follower 13 3 2 Cylinder Block Inspection Inspect wear of cylinder inner wall If it is seriously worn replace it Remov...

Page 140: ...deposited carbon inside the piston ring Install the piston ring Measure the clearance between piston ring and piston ring groove Allowable limit Top ring 0 09mm Second ring 0 09mm Remove piston ring and install all the piston rings onto bottom of cylinder Attention Compress piston rings into the cylinder with piston head Measure the joint clearance between piston rings Allowable limit 0 5mm Piston...

Page 141: ...0 angle with piston pin about 11mm below piston skirt Allowable limit 56 93mm Inspect wear and scratch on inner wall of cylinder 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 17m...

Page 142: ...mm Check flatness of cylinder surface Allowable limit 0 05mm Measure Connecting rod small end ID Allowable limit 14 06mm 13 4 2 Installation of piston Install location pin Apply engine oil evenly on each piston ring and piston Install piston to its place with bevel upward Attention Piston shall not be scratched and piston ring shall not be broken When the piston ring is installed it can rotate fre...

Page 143: ...iner Attention Install with the IN mark at the top of piston facing the intake valve 13 5 Install Cylinder Install washer and location pin onto the crankcase Apply evenly engine oil on inner wall of cylinder piston and piston ring Install carefully the piston ring into the cylinder Attention Do not hurt piston ring IN Mark Cylinder Location pin Washer ...

Page 144: ... assembly 12 Driven friction plate 13 Center bracket 14 Sleeve 15 Thrust washer 16 Housing assembly 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 p...

Page 145: ...asic 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...

Page 146: ...utch spring Removed components refer to exploded view Use a special tool to screw off clutch locknut 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 Remove spline washer Remove housing assembly Install clutch in the reverse order of removal Four pawl bush wrench Universal fi...

Page 147: ...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 ...

Page 148: ...6mm 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 Remove bearing and oil seal on left crankcase Check if bearing and oil seal are injured Replace if necessary Drive pawl Thickness Tooth Surface ...

Page 149: ...ce 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 Bearing hole oil seal hole ...

Page 150: ...Shift fork shaft 4 Main shaft assembly 5 Countershaft assembly XV Reduction Gear Preparatory data 15 1 Fault diagnosis 15 2 Gearshift mechanism 15 3 Installation 15 4 Function Transfer torque and determinate the final output torque and rotary speed ...

Page 151: ...ock 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...

Page 152: ...ng 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 Remove gearshift fork Measure shift fork OD Shift fork...

Page 153: ... Allowable limit 10 05mm 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 Micrometer Tester Vernier caliper Lock groove width ...

Page 154: ...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 Balance shaft gear ...

Page 155: ...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 Item Standard Allowable limit 0 5 5 Tools Universal fixer C...

Page 156: ...rew 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 ...

Page 157: ... Remove bearing locating device 16 3 2 Exploded View of Cam Assembly Measure cam bush ID Allowable limit 14 10mm Measure cam height Allowable limit 32 5mm 16 3 3 Crankcase Right Cover Removal Screw off mounting bolt and take down the crankcase right cover Remove clutch release lever assembly from the right cover Tester Cam shaft spring Cam mechanism shaft Camshaft gear Cam Bolt Right cover ...

Page 158: ... pump assembly 16 4 Crankshaft Connecting Rod Assembly Removal Remove left crankcase Remove washer and location pin Remove drive gear Remove the crankshaft connecting rod assembly from the right crankcase Attention Please do not hurt washer and closing surface Release lever assembly Right cover Washer Cover of oil filter roller Drive chain Locknut Oil filter roller Oil pump Location pin Crankshaft...

Page 159: ...ection 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 gearshift mechanism on the crankcase Measuring position of C R big end Crankshaft bearing ...

Page 160: ...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 ...

Page 161: ...otorcycle 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 maint...

Page 162: ...ur 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 w...

Page 163: ...etor Disassemble and repair engine Valve Leak Piston Worn Combustion chamber clean For Delivery Qualified Qualified 合格 Qualified Qualified Qualified Qualified 17 4 Solutions to Idle Exhaust Exceeding Specified Value 4 stroke 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 Qualified ...

Page 164: ...RKV125 Schematic Circuit Diagram ...