KEEWAY RKV125 Instructions for use

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

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 CDIAssembly................................................................................................................................................. 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

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

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

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.

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.

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.

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

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.

Identification of motorcycle
1. Frame number ①labeled 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 ①is 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.