KEEWAY ATV250, Service And Maintenance Manual

Page 1: ...1 ATV Service and Maintenance Manual Model ATV250 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: ...ase cover Spare parts for right crankcase cover Clutch Drive gear COMP Driven wheel clutch COMP Crankcase Speed gear box g Power flow chart h Lubrication system i The setup of valve interval j Engine...

Page 4: ...ttery charging system circuit h Power flowing chart of electric start i Removal and replacement of various bulbs j Testing procedure of electrical components k Important specifications electrical C Ot...

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

Page 6: ...ton when traveling from TDC to BDC is called displacement Normally displacement is measured in CC cubic centi meter e g 75cc 125cc etc and it varies according to engine type E Torque Torque is a kind...

Page 7: ...energy through con rod 4 Exhaust the gases are expelled 4 stroke engine work cycle A SUCTION STROKE 1 The crankshaft turns in the counter clockwise direction 2 The motion of the crankshaft acts on the...

Page 8: ...s to the crankshaft through connecting rod then the crankshaft speeds up the expanding of mixed air provides power for the engine D Exhaust stroke 1 The air outtake valve opens when the piston goes Th...

Page 9: ...be kept at a safe place out of reach of children Warning Always ensure mutual safety when working with a partner S e r v i c e r u l e s 1 Use only genuine KEEWAY parts and recommended grade of lubric...

Page 10: ...parts or area where they might be pinched between the moving parts 7 Wire harnesses routed along the handlebars should not be pulled tight or have excessive slack or be pinched or interfere with adjac...

Page 11: ...7 B PRODUCT...

Page 12: ...engine Lubrication system Oil pump type Air cleaner Pressure of cylinder Intake valve open close Outtake valve open close Clearence of valve jib intake in cold condition outtake Idle speed Max torque...

Page 13: ...Rear Chassis Front brake Rear brake Volume of tank Oil containing volume of tank Hydraulic spring type Hydraulic spring type 21 7 10 22 11 10 0 43 0 58kg cm 2 6 8Psi 0 43 0 58kg cm 2 6 8Psi Disc Oper...

Page 14: ...M before TDC 320 20 310W 4000RPM D7RTC 0 6 0 7mm 15A 12N9 4B 1 Light Front light high beam dipped beam Tail light brake light Indicator light of machine oil Indicator light of forward gear Indicator l...

Page 15: ...8 10 12 13 Assembly and disassembly tools of stator Assembly and disassembly tools of air valve spring Assembly and disassembly tools of clutch lock nut Pressure chart of cylinder Assembly and disasse...

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Page 17: ...13 11 12...

Page 18: ...rting board Lock bolt of oil pump gear Lock bolt of oil pump Lock bolt of oil pump cover Lock bolt of clutch out ring Lock bolt of righ crankcase Lock bolt of righ and left crankcase Lock bolt of engi...

Page 19: ...5 1 Chain wheel cover Engine 3 15 6 2 4 1 Outtake pipe of pump Engine 4 20 2 5 1 Oil level gauge Engine 5 34 3 4 1 Spring cover oil filter Engine 6 16 2 5 1 Inspective aperture cover Engine 7 9 2 1 Ou...

Page 20: ...ring Engine 11 HK205 32 12RS 1 Driven wheel intake bearing Engine 12 6201 1 Transition shaft gear box cover Engine 13 6203 1 Outtake shaft gear box Engine 14 6005 2RS 1 Outtake shaft gear box cover En...

Page 21: ...il proof asbestos rubber 1 Engine 9 Gear case cover Oi proof asbestos rubber 1 Engine Information of gear Rate of deceleration gear Amount of teeth gear Amount of teeth 2 667 A1 15 A2 40 2 313 B1 16 B...

Page 22: ...hain and the column head of its surface should not be higher than the upper surface of the cylinder 5 The white piston ring is the first one the black is the second during the assembly the hatches of...

Page 23: ...sassemble the muffle air cleaner Disassamble the chain Engine fixed bolt Engine bracket fixed bolt engine bracket COMP engine fixed bolt II bolt rear engine bracket COMP disassemble the engine Steps o...

Page 24: ...der head washer dowel pin Cylinder washer dowel pin Spring circlip piston pin piston Right crankcase Stator Outside parts of right crankcase Starting clutch Starting motor Disassemble right and left c...

Page 25: ...e m b l y D i s a s s e m b l y D i s a s s e m b l y D i s a s s e m b l y Circlip 9 Intake pipe of water pump 11 Outtake pipe of water pump 10 Radiator COMP 14 Assembly Assembly Assembly Assembly op...

Page 26: ...r intake pipe assembl y Disassembly Disassembly Disassembly Disassembly Nut 5 O ring 2 Carburetor COMP 6 Bolt 3 Bakelite washer 4 O ring 2 Assembly Assembly Assembly Assembly opposite of the steps of...

Page 27: ...bearing B10 Outtake bearing COMP B26 Gear bearing comp B6 Drive gear B8 Idle wheel comp B32 Gear shift bearing A36 Assembly Assembly Assembly Assembly Gear shift bearing A36 Idle wheel comp B32 Outtak...

Page 28: ...d Valve pipe B 2 Valve seal comp C 6 Intake and outtake valve C 1 2 Clip of valve C 6 Spring seat of valve C 7 Spring of intake and outtake valve C 4 5 tied tools T04 Adjust cover of valve clearance B...

Page 29: ...ttle fixing oil on it the ploe should roll agilely without any retardarce in the pipe 3 make sure that the close end is gadarene when the spring ofvalve is assembled 4 test if the valve leaks pour coa...

Page 30: ...rings can not be changed 4 Letter IN faces to the intake valve the hatches of the first ring and washer of oil ring 1 faces to the outtake valve he hatches of the second ring and washer of oil ring 2...

Page 31: ...n 2 washer 3 assembly assembly assembly assembly opposite of the steps of disassembl instructions 1 use wooden or rubber hammer to assemble the left cover metallic hammer is forbidden to avoid to do h...

Page 32: ...y Disessembly Bolt 13 Outtake of pipe 15 O ring 16 bolt 5 bolt 14 washer 11 water pump cover 3 water pump seal 4 impeller 2 Whishtring comp 8 water pump body 7 pump bearing 10 O ring 12 assembly assem...

Page 33: ...ase cover assembl y Disassembly Blot 12 Oil lever 1 Sensor 13 Seal ring 2 Bolt 10 Right crankcase cover 6 Magneto stator 11 Washer 5 Assembly Assemble the right crankcase cover opposite to the process...

Page 34: ...et A9 Washer A5 Assembly Assemble the right crankcase cover opposite to the process of disassembly Oil pump chain wheel A3 Instructions Bolt A8 1 The driving gear of oil pump should be rotated agilely...

Page 35: ...nside ring of starting clutch 2 Outside ring of starting clutch 3 Starting clutch block 4 Outside ring of starting clutch 5 Assembly Assembly Assembly Assembly opposite to the steps of the disassembly...

Page 36: ...er 7 Kickstand 11 Roller 5 Oil seal 4 Right drive plate 1 Assembly Assembly Assembly Assembly Right drive plate 1 Roller 5 Oil seal 4 Movable drive plate 6 Damper 7 Kickstand 11 Centrifugal roller 6 S...

Page 37: ...bearing 15 Shockproof rubber 20 Compress spring 4 Circlip 14 Ball bearing 13 Throttle stick 21 Fixing bearing 22 Cover of spring 5 Real drive main plate 10 Seat of drive plate 23 Assembly Oppsite to t...

Page 38: ...en assembling the crank pleae add a little machine oil into the bearing hole of left crankcase then press it into the hole upright and assemble the chain onto the gear of crank the connecting rod shou...

Page 39: ...disassembly Instructions Instructions Instructions Instructions 1 All the bearing should be pressed to the right position the mark on the bearing faces to the direction eyeable The bearing should roun...

Page 40: ...imary driven disk 12 Pressure disk 7 Clutch 8 Intake shaft of gear box 4 Idle shaft of gear box 5 Transation shaft of gear box 6 Idler pulley Rear axle shaft Power flow chart X Outmatic speed down rat...

Page 41: ...37 Lubrication system...

Page 42: ...on the right cover 3 Make sure that the timing carved line of cam chain snap to the critical surface of the cylinder head 4 Check the interval of the intake valve and outtake valve intake valve 0 03...

Page 43: ...t step with the pressure gauge If the pressure of cylinder increased we should check a Whether the cylinder have been abrased b Whether the piston or piston ring have been abrased c Whether the cylind...

Page 44: ...ing 32 3 0 05mm The natural length of springs Outside spring 35 0 0 05mm Cylinder piston Project Standard A B The internal diameter of cylinder 69 005 69 01mm 69 000 69 005mm The diameter of piston 68...

Page 45: ...to the reverse process of dismantlement CARBURETOR The curve of oil consumption 70 Perfect Process Econ state 60 omic cost km 50 area State in fact 40 30 20 30 40 50 60 70 80 90 rate km h For every en...

Page 46: ...he firebox of engine to btub depends on the function of valve intake and lever of cam axle The forming process of mixture air and the illustration of the gas flowing Gas Fuel oil Air Fuel tank Depurat...

Page 47: ...ering in order to avoid that the fuel oil overflow the carburetor On the contrary when the oil surface dropped due to the fuel oil have been consumed the float drives a needle valves to drop then the...

Page 48: ...ne run slowly because the lever plug will rise and make the oil needle up form negative pressure at the main jet and the mixed gas is absorbed out of it It can meet the engine s requirement with the q...

Page 49: ...When the engine have sped up to raise lever plug completely the high speed of engine make the air in throat pipe speed up and it produce big negative pressure around the main jet so that it can absorb...

Page 50: ...the cap of oil needle pull out the oil needle and spring of oil needle 3 turning out the adjust bolt mixed proportion spring washer seal ring 4 turning out the idle adjust bolt and spring 5 take apart...

Page 51: ...down bottom not too rough 4 switch off engine please check whether the connector of air cleaner is leaked or not bolt is tighten or not mouth of air cleaner is blocked or not 5 Ttubing out the mixed...

Page 52: ...director 1 Up and down rockers and frame 8 37 44N m 2 Redirector and up and down rockers 4 37 44N m Handle 1 Fixed nut of the ttubing lever lower part 1 37 44N m 2 Clip seat and fixed nut of frame 2 2...

Page 53: ...el Nut Disassembly Nut 1 Front wheel 2 Cover 3 Dustproof cover 4 Split pin 5 Nut 6 The pump of front disc brake Front hub COMP 7 Outside spacer 8 Dustproof seal 9 Inside spacer 10 Oil seal COMP 25 42...

Page 54: ...ylinder brake cylinder connect with director directly When oil plug push the brake disc under the effect of oil preasure then push brake shoe against brake disc make brake shoe connect surface of brak...

Page 55: ...proof muzzle 2 Oil intake bolt 3 Brake oil channel 4 Brake tub 5 Oil plug 6 Long shaft 7 Seal ring of oil plug 8 Dustproof ring of oil plug 9 brake plate 10 Brake shoe Brake tub COMP Brake tub COMP Br...

Page 56: ...hen put them into the oil pump taking apart the caliper assy should put the cover of brake pipe into one holder then draw out the liquid of brake carfully 1 take apart the bolt In oil and seal washer...

Page 57: ...COMP 22 Right upper rocker jointing COMP Right lower rocker jointing COMP Notice a The method and order of disassembly of right gimbal is the same with the left gimbal and the above order and method b...

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Page 59: ...andle switch 19 Left lever COMP 20 Screw 21 Balance block COMP 22 Grip cover 23 Handle bar jointing COMP 24 Assembly Handle bar jointing COMP Spacer Nut Pin Gimbal COMP A Ttubing pole Seal ring Steeri...

Page 60: ...56...

Page 61: ...of bearing 17 seat of brake clamp 18 Oil seal comp 19 bearing 6008 2RS 20 professional tools Gaine of rear wheel I 21 adjuster of chain 22 Nut 23 rear wheel 24 Bolt I 25 seat of rear wheel 26 Nut 27...

Page 62: ...58...

Page 63: ...e oil pump body the liquid compressed passes the power to the brake tube by the brakeer tube When the pressure disappeares because of the elasticity of the owl spring the piston shrinks back to the st...

Page 64: ...60 digram 7 Diargram 8 dirgram 9 dirgram 10...

Page 65: ...oil in the brake cylinder carfully 3 Disassemble the bolt brake cylinder comp brake shoe spring sheet of the brake shoe 4 Disassemble the oil piston dust seal of the oil piston squre seal ring Steps o...

Page 66: ...spacer II 6 Oil seal of bearing 7 inner bush 8 bearing GB943 20 9 professional tool bolt joining spocket housing comp nut 10 bolt 11 torque link 12 Rear swinging arm comp 13 Steps of assembly rear swi...

Page 67: ...s mark on the tyre should keep the same as the running direction of the wheel 3 The smaller ends of the front and rear absorber should be adown 4 The opening direction of the chain s clip should be o...

Page 68: ...erd driver 58kPa 8psi Air pressure of tyre Free length of front absorber s spring Oil cubage of front absorber Oil level of front absorber Producer of front absorber s oil content standerd driver 58kP...

Page 69: ...ed by electricfication loop is used to electricficate both of them pass through the rectifier The table shows the color code of magneto line and resistances of all kinds loops down blow NO Type of loo...

Page 70: ...66 Wiring diagram...

Page 71: ...ld flash otherwise 2 Cap of spark plug plug replace the spring loop Check if the resistance is around 5 0K or 6 C D I part Not otherwise replace it a Test of C D I part Use C D I working not well inst...

Page 72: ...the flywheel of the magneto Course of slow down F ignition mark snaps the V mark on the stroboscope s inspective hole At 1700RPM ignite at the pocht 15 fortvard the up stop point watch the rev Course...

Page 73: ...later for away from fire Ttub on the electrical switch during electrification Electrification is forbidden if the temperature of electrolyte is higher than 45 Avoid quick electrification Assembly Asse...

Page 74: ...ck the electrifical electrocircuit before change the bad battery Testing of wiring diagram Alternating current produced by magneto is commutated to DC it electrificates autoly according to the battery...

Page 75: ...71 Signal system circuit...

Page 76: ...72 Battery charging system circuit...

Page 77: ...73 Po wer flow chart of electric start Flow of Electric Current battery fuse the power switch the brake switch the starting switch starter relay starting motor grounding magneto...

Page 78: ...bly steps of front light front cover shield with front light comp screw cushion headlight comp tapping screw cover disassembly the front light 12V 18 18W 2 impact the bulb and contrarotate it out of t...

Page 79: ...75 Testing procedure of electrical components Inspect the continuum of the electic seitch hereinafter with multimeter...

Page 80: ...ue white 100 180 item specification capacity 12V 9AH KS proportion 27 full condition of charging 1 220 1 240 1 220 Electrification current 0 25A 0 7A battery hour 8 12 specification 310W 4000RPM magne...

Page 81: ...77 C OTHERS...

Page 82: ...cover the fixing bolt of engine and the front and rear wheel and axle 4 after the engine warm up 5 check the fuel of engine add when be short of 6 inspect the pressure of tire and rectify it 7 set the...

Page 83: ...l axle Check the fasten moment of the engine bolt Check the chains degree of droop 5 20mm Check the pressure of real tyre Check the light of the front lamp Check the function of the front absorber Che...

Page 84: ...hould be check by the seller All of those items had betlerbe checked by the seller Serial NO Item INITIAL SERVICE first week REGUKAR SERVICE every 30 operating days EVERY YEAR 1 Access of oil 2 Contro...

Page 85: ...n wheel driven chain wheel chain should be replaced all 7 Ttubing bearing should be replaced all 8 Keep the aerate tubes no backup curly bend all the tubes should keep expedite 9 Keep air pressure of...

Page 86: ...tiptoes should be forward put feet on the footrest board Basic principle of drive posture is put hand knee foot buttock in correct positions Brake effectively 1 Relax the control bar of oil valve put...

Page 87: ...el goes into the carburetion Fuel filt is jamed Oil tube is jamed Floalter or pin valve of the carburetion is blocked Intake of fuel tank is jamed 2 Ignition test The spark is infirmness Malfunction o...

Page 88: ...dense Spark plug is dry Air cleaner is too dusty Fuel goes into firebox 5 Measure the air pressure Air pressure is too of the cylinder infirmness Air valve seat tooths incorrectly Clearance of air val...

Page 89: ...of carburetion is not enough Without jam 4 Speed up the engine Engine speeds up inadequate a little Mixed air is too sparse or dense Jam of air cleaner Engine speeds up well Flux of full is and check...

Page 90: ...ring loop is fixed in wrong way 8 Check whether the The clutch is slided clutch is skided Loosen of clutch s spring Abration of clutch s rub piece The clutch is not slided 9 Check the engine is too En...

Page 91: ...bility in idle speed and low speed Weak capability in idle speed and low speed Weak capability in idle speed and low speed 1 Check the ignition time and incorrect malfunction of ignition loop Air valv...

Page 92: ...Fuel goes fluently block of oil filter block of filter net block of intake hole of tank 3 Check if muzzle of blocked block of jet of carburetion Carburetion is blocked Expedite 4 Check the physic inc...

Page 93: ...or abration of cylinder head washer jam of throttle hole of fuel cylinder head is bended or broken adjust the carburetion wrongly malfunction of cylinder or piston Mixed air is dense Mixed air is den...

Page 94: ...Clutch slips when speeding Clutch slips when speeding Clutch slips when speeding Clutch slips when speeding adjusting the clutch wrongly abration of clutch grind spring of clutch centrifugal block is...

Page 95: ...91 malfunction of tyre wheel slopes excessive wheel is screwed wrongly...

Page 96: ...heck the uninterrupted capability of discontinuous relay malfunction of discontinuous relay Open circuit Open circuit Open circuit Open circuit continuity continuity continuity continuity is abnormal...

Page 97: ...or battery electrification and the clutch is detached press down the start loop button and start motor works Front light is dark grounding weakly malfunction of rectifier malfunction of light or batte...