KEEWAY ARN125, Service And Maintenance Manual

Page 1: ...1 Scooter Service and Maintenance Manual ARN125 150 Copyright KEEWAY INTERNATIONAL DEVELOPMENT CO LTD FEB 2006...

Page 2: ...his manual please fell free to contact with KEEWAY INTERNATIONAL DEVELOPMENT CO LTD 2000 SZENTENDRE U 8 KOZUZO HUNGARY TEL 0036 26 500005 FAX 0036 26 312034 EMAI info keewaymotor com Our engineer are...

Page 3: ...ner assembly Piston assembly Left crankcase cover assembly Right crankcase cover assembly Right crankcase Left crankcase parts assembly Crankcase assembly Transmission case Driven wheel disc clutch as...

Page 4: ...c Electronic ignition part test d Battery charge circuit and testing process for battery charge e Signal system circuit diagram f Various bulbs removal and installation g Inspection process for elect...

Page 5: ...5 A GENERAL INFORMATION...

Page 6: ...DISTANCE THAT PISTON TRAVELS WE USUALLY CALL ONE JOURNEY FROM TOP DEAD CENTER TO BOTTOM DEAD CENTER D WORKING CAPACITY OF THE CYLINDER THE SPACE VOLUME OF PISTON WORKING PATH WHICH PISTON MOVES FROM...

Page 7: ...MP THE TOP DEAD CENTER ADVANCES 35 ENGINE CYCLE ANY FOUR STROKE GASOLINE ENGINE HAS FOUR STROKES WHICH CONSIST OF ONE WHOLE OF CYCLE 1 INLET AIR AND MIXTURED AIR OF OIL ARE ABSORBED INTO INLET CYLINDE...

Page 8: ...STROKE 1 SPARK PLUG INNITES COMPRESSED MIXED GAS OF AIR AND FUEL 2 Burning of mixed gas of air and fuel results in sudden change of temperature and pressure in Burning chamber and then burning gas exp...

Page 9: ...ke fluid with your eyes otherwise wash it with water and see doctor Never touch brake fluid with hands for some long time Never splash brake fluid on the surfaces of oil pait parts and rubber accessor...

Page 10: ...some position where calbe may be clipped when moving g Lay cable along handlebar don t pull it too tight or too loose and never terrer with other parts when ratoating in any position h Lay calbe smoot...

Page 11: ...11 B PRODUCT...

Page 12: ...0 T11 T12 T SHAPE GUIE CYLINDER GUIDE CYLINDER TOOLS 8 10 12 13 SCREWED ROD FOR FLY WHEEL DISASSEMBLAGE TOOLS TO DISASSEMBLE VALVE SPRING DISASSEMBLING TOOLS FOR OIL DRAINAGE CYLINDER PRESSURE GAUGE D...

Page 13: ...13 1 2 3 4 5 6...

Page 14: ...14 7 8 9 10 11 12...

Page 15: ...coil Locknut for magnet motor trigger Locknut for right crankcase cover Oil filter cover cap Locknut for oil pump seperating board Locknut for oil pump sprocket Locknut for oil pump Locknut for oil p...

Page 16: ...gearbox Engine 6 10 x16 2 Left crankcase and left cover Engine 7 8 x14 2 Rignt crankcase and right cover Engine O ring 7NOS S NO Size mm Qty Description Location 1 9 x1 6 2 Inlet and exhast valve pipe...

Page 17: ...NSE28 x15x7 1 Driven disc output shaft Engine 11 HK20 x29x18RS 1 Driven disc output shaft Engine 12 6002 2 Camshaft atmolysis shaft fixing holer Engine PINSHAFT 2NOS S NO Size mm Qty Description Locat...

Page 18: ...E 5 Starting motor drvie gear 9 ENGINE 6 Electricity starter transition gear 54 13 ENGINE 7 Clutch gear 52 ENGINE SPROCKET INFORMATION No No No No Sprocket wheel Sprocket wheel Sprocket wheel Sprocket...

Page 19: ...driver wheel disc and driven wheel disc is towards locknut 4 The side of kick starter gear and transition gear with mark is towards left cover 5 Chain guiding groove is towards chain and column rod of...

Page 20: ...in spring clip Spring clip piston pin piston cylinder gasket pin fan impeller flywheel coil cylinder cover gasket pin Right crankcase cover oil filter oil gauge cam camshaft supporter Right crankcase...

Page 21: ...4 pastern cover 9 Top cowling seal gasket 2 cooling pipe 5 Bottom cowling seal gasket 3 Coil clip 12 Pastern cover 13 Whorl cover screw 6 2N M Whorl cover bolt 7 11N M Cowling screw 10 2N M Cowling bo...

Page 22: ...tmolysis shaft assy mesh Atmolysis shaft assy and atmolysis shaft fixer assy Right against mark T on magneto and correct timing mark on timing gears keep timing scale of timing gears on the same level...

Page 23: ...bearing spring 15 Adusting gasket 16 and atmolysis shaft 17 INSTALLATION Atmolysis shaft and right bearing 12 Adjusting gasket 16 Auto reductor outside ring 14 and ball bearing spring 15 Atmolysis sh...

Page 24: ...24...

Page 25: ...ring and the second one with English Letters are up 3 Never make mistake in positioning the first ring and the second ring 4 Letter IN is towards inlet port and the first ring is dead against oil ring...

Page 26: ...gasket 5 The installation sequence is essentially the reverse of removal Notice 1 When installing left crankcase cover tap it to its proper postion with wood hammer or rubber hammer not metal hammer t...

Page 27: ...w 8 seal ring 4 Trigger assy 7 other bolts Bolt 15 ring crankcase cover 2 Clip holder 20 gasket 1 Bolt 12 Magneto stator 13 nut 22 50N M Magneto bolt 2 7N M Fan bolt 9 11N M Trigger screw 8 6N M Filte...

Page 28: ...ially the reverse of removal Notice oil pump sprocket 11 1 driving gears of oil pump turn flexible 2 when installing oil pump the top arrow of oil pump cover should be towards crankcase bolt 12 3 some...

Page 29: ...daub axes end with little butter keep arrow mark on transition gear dead against crankshaft lineation on kicking start gear dead against rushing point on transition gear carefully pull kicking start s...

Page 30: ...b left crankcase bearing with some little oil and then vertically push the oil into bearing hole cover chain with crankshaft gear crankshaft connecting rod turns freely and feel that axial clearance e...

Page 31: ...nstallation sequence is essentially the reverse of removal Notice 1 Correctly position each bearing the mark of bearing is towards seeable direction and it turns freely without block 2 When installing...

Page 32: ...clutch driving board assy clip circle 16 clutch side board 17 spring 18 clutch mass 19 damper rubber 20 limiter 21 pin shaft 22 driving board bottom holder 23 Installation The installation sequece is...

Page 33: ...l Transition gear shaft assy Fixing pin 6 Adjusting gasket 4 Transition gear assy 3 including 5 Tension spring 2 Transition gear shaft 1 clip 5 installation The installation sequence is the reverse of...

Page 34: ...ole 6 steel bush 3 inner hole bush 4 strap driving brake disc 5 Installation Strap driving brake disc 5 Inner hole bush 4 Steel bush 3 Acentric rolling pole 6 Cushion gasket 7 Pulling FALAN 8 Bush 2 F...

Page 35: ...spring bush 7 and spring 8 Clutch husk 9 Spring retainer 10 Cluch outside circle 11 Remove it if necessary Installation The installation sequence is essentially the reverse of removal Notice 1 There i...

Page 36: ...gear Transition small gear Transition big gear Crankshaft starting driven gear Crankshaft 3 Connecting rod 2 Piston 1 By kicking starter Kicking starter lever Kicking starter shaft 9 Starting gear Tr...

Page 37: ...37 F Lubrication system Rocker arm Camshaft assy Crankshaft assy Oil pump assy Fileter assy...

Page 38: ...lows into oil path hole of cylinder head cover oil splashes out from the two oil holes on cylinder head cover and lubricates rocker arm and rocker shaft then flows back crankcase along two pushing lev...

Page 39: ...he mark on righ crankcase cover 4 Ensure timing reticle of cam sprocket in the same line with joint surface of cylinder head cover 5 Inspect the clearance of inlet valve and exhaust valve inlet valve...

Page 40: ...arm up engine remove spark plug and drop several drops of oil in combustion chamber messure it againe following step ONE with manometer If the pressure in cylinder adds inspect a If cylinder is abrade...

Page 41: ...Valve Valve shaft valve pipe clearance Exhaust 0 030 0 057mm Inner spring 32 3 0 05mm Natural distance of spring Outer spring 35 0 0 05mm Cylinder piston Item Standard A B Cylinder inner diameter 52...

Page 42: ...90 Speed km h For each engine at economic exhaustion speed the ratio ofair against fue is the one of max inlet air against min fuel Manufacturer Type Model Diameter of throat tube Main nozzle Idle noz...

Page 43: ...s installed in the left side of motorcycle Fuel and clean air are mixed into mixed fog gas which is controlled by inlet port and camshaft rocker arm and then goes into combustion chamber Mixed gas for...

Page 44: ...mber of carburetor 2 Condensing oil road When engine starts electronic valve electric condense valve open one part of fuel passes through condensing nozzle hole and goes into throat tube for this mixe...

Page 45: ...plied through main fuel system in this process idle speed oil system does not supply mixed gas for there is negative pressure distributed on throat tube Firstly air flows across air jet copper canal a...

Page 46: ...lve wire is connected correctly 2 Confirm carburetor is intalled correctly and no oil leaking out CARBURETORASSY STEPS FOR REMOVAL 1 Remove 4 screws take out stopper spring and stopper assy 2 Unscrew...

Page 47: ...tes at normal driving temperature 2 Adjust idle speed adjusting screw so that engine rotates at 1600rpm 3 Screw mixture ratio adjusting screw into bottom the strength is not too weight 4 Now engine sh...

Page 48: ...olt for handlebar and supporting under connecting board 1 37 44N m Frame 1 Fixing bolt for frame and engine bracket 45 58N m Fixing bolt for frame and rear absorber 1 Rear wheel rear absorber 2 37 44N...

Page 49: ...middle bush 6 bearing 18 valve port 2 valve cap 20 driving slice 7 gear retainer oil seal 10 gear retainer 12 Installation sequence driving slice 11 gear retainer oil seal 10 gear retainer 12 steel ri...

Page 50: ...lt M6X35 9 Rear brake rocker arm 5 Rear braking camshaft 6 Rear wheel rim 7 valve port 11 valve port cap 12 Installation sequence rear wheel rim 7 valve port 11 valve port cap 12 Rear braking camshaft...

Page 51: ...et assy 6 Muffler assy 1 Decoration cover assy 3 rear decoration cover assy 9 screw 7 Position hole assy 8 Installation sequence Position hole assy 8 Decoration cover assy 3 rear decoration cover assy...

Page 52: ...52...

Page 53: ...owl 11 Handle joint under gasket 10 Upper bearing under steel bowl 6 Under bearing upper steel bowl 7 Frame assy 20 Installation sequence Frame assy 20 Under bearing upper steel bowl 7 Upper bearing u...

Page 54: ...minium outer tube 15 Buffer prick 9 Installation Install piston ring into piston lever Install buffer spring into piston lever Install the above parts assy into inner tube assy Install buffer prick in...

Page 55: ...f upper oil pressure cavity and lower oil pressure cavity piston lever head with piston ring performs tightly with the top end of inner tube buffer bush is assembled in inner tube assy which is to sea...

Page 56: ...on stroke is over Comeback stroke Comeback stroke Comeback stroke Comeback stroke In the comeback stroke compressed damping spring extends to push inner tube back from its bottom when inner tube moves...

Page 57: ...ing liquid in cylinder pressed braking liquid transfers pressure to caliper through braking hose When there is no pressure on braking lever stopper turns back for bearing on rebound from prick spring...

Page 58: ...ig 7 Fig 9 1 Valve anti dust cover 2 Inlet oil bolt 3 Braking liquid path 4 Braking cylinder 5 Oil stopper 6 Long guiding axes 7 Oil seal ring 8 Oil stopper anti dust ring 9 Brake disc Caliper assy Fi...

Page 59: ...container and draw out braking liquid carefully 1 Remove inlet oil bolt and seal gasket 2 Cut off braking hose Put the throat hose of open into container and then draw out braking liquid 3 Disassemble...

Page 60: ...city for front absorber Oil level for front absorber Manufacturer of oil for front absorber ITEM STANDARD Appointed disc brake oil DOT3 or DOT4 Manufacturer for disc brake oil Deepness of brake shoe 6...

Page 61: ...through rectifier to be light and electricity emitted from battery charging coil passes through rectifier to charge Color code of lead of magnet motor and resistances of various coils are the followi...

Page 62: ...62...

Page 63: ...63 Charging system circuit diagram AC circuit diagram...

Page 64: ...64 Electrical start power process table Circuit process Storage battery Fuse Main switch Alarm Stop swtich Start switch Start relay Start motor Connect ground magnet motor...

Page 65: ...ff coil touching off coil touching off coil 3 3 3 3 composite switch composite switch composite switch composite switch a inspect resistance between blue white and green white at 20 inspect its contin...

Page 66: ...lywheel of magnet motor during idle speed during idle speed during idle speed during idle speed Ignition mark F is right against I mark on timing viewing hole and ignate it at 13 ahead of top dead cen...

Page 67: ...l old battery with acidity liquid 2 ensure new battery with full electrolyte to be charged at low temperatrue 3 ensure ventilated pipe of battery not to be blocked or bended ventilated pipe must be sm...

Page 68: ...12V 3 W Heallight installation Install it in the reverse of removal and adjust the focus of headlight Flash light bulb Remove flasher Remove and replace bult 12V 10 W Meter removal Headlight jointing...

Page 69: ...ic components inspection procedure Inspect continuity of the down electric switch with multimeter Main switch Front rear braking switch Horn switch Starting swtich Trans beam swtich Turning switch Lig...

Page 70: ...e battery Time for charge 8 12 hours Capacity 114W at 5000RPM Charger Ignition coil resistance 20 68 F Between black line and black white 2 Lamp line Yellow and green white 2 Adjust the output of rect...

Page 71: ...Green red white Less than 2 Retifying regulator Stable voltage of lighting circuit 13 5 0 2 V DC voltage of battery charge 14 4 0 4 V IGNITION SYSTEM STORAGE BATTERY SPECIFICATION Type C7HSA NGK Spar...

Page 72: ...72 C OTHERS...

Page 73: ...nspect air pressure of tire and correct it if necessary 6 Install battery 7 Inspect the clearance of spark plug and adjust it if necessary 8 Inspect whole electrical system the capability of control s...

Page 74: ...ue of front wheel axes Inspect the performance of left and right handle switch Inspect air Pressure of rear Tire Inspect lighting of headlight Inspect the performance of disc brake at 10 20MM free dis...

Page 75: ...en driving in dusty area 3 Do more maintenance to prolong vehicle when driving in accidented ground Maintenance mileage reading of odometer NOTE 1 NO ITEM 1000Km 4000Km 8000Km 12000Km REMARK 1 Fuel pa...

Page 76: ...ion and keep all oil hoses smooth viii When installing disc brake caliper ensure brake disc between braking shoes Keep tire with normal air pressure Forbid 1 It is forbidden to operate front disc brak...

Page 77: ...handlebar gently 5 Hip sit in the position which doesn t disturb control direction and braking relax hip and slightly bend forward 6 Knee relax knees 7 Feet put tiptoes forward and feet on footboard T...

Page 78: ...Wiring connection of ignition system is not well or open circuit short circuit happens CDI is wrong Charging coil is wrong Touching off coil is wrong 3 use correct start mode to start engine Engine s...

Page 79: ...lement of fuel is not engough Ventilating hole of fuel tank cap is blocked muffler is blocked 5 disassemble and inspect spark plug flooded or there is carbon deposit flooded or there is carbon deposit...

Page 80: ...time and vavle clearance Not corrects Not corrects Not corrects Not corrects something wrong with ignition coil something wrong with the adjustment of valve clearance Correct ignition coil is not asse...

Page 81: ...ution mechanis phase not correct Timing chain is not installed correctly Correct 5 inspect valve spring too loose Valve spring is wrong Normal It is difficult to control 1 If turning is difficult Turn...

Page 82: ...s too hot or clashes Throttle valve is wrong There is carbon deposit on cylinder head or piston head Fuel jet is blocked Cylinder head gives out smoke Carburetor is not adjusted well Valve lever or va...

Page 83: ...deposit CLUTCH SHIFT GEARS Engine librates CLUTCH Crank moves too much It is difficult for scooter to slide at idle speed Clutch is not adjusted correctly Clutch brake pad kit is distorted Kicking st...

Page 84: ...on spring of handle level is damaged Rear wheel rear brake rear shock absorber Rear wheel jumps swings Rear wheel bearing is damaged Tire is bad Rim is distorted Rear wheel bearing is loose Rear wheel...

Page 85: ...mething is wrong with relay Something is wrong with starting motor Press starting button There is no crack noise Starting button is wrong Inspect the voltage of short currentt relay short current rela...