KEEWAY 50cc Models
Contents
1. Procedure Remove inspection cap from fan cover Connect timing light according to manufacturer specific directions Start engine and aim timing light at the timing reference At idle I and F marks should line up This denotes ignition timing of 13 BTDC Idle speed should be approx 2000 RPM refer to tachometer Under Throttle II indicates the advanced mark and should line up with the I reference at 4000 RPM This denotes ignition timing of 28 BTDC If either or both of these indicators are off replace the CDI and MAGNETO together and check again 42 NOTE As part of the initial preparation procedure it is necessary to bring the unit to operating temperature and with a voltmeter connected to the battery proceed to adjust the idle speed until you get a reading of 12 5 12 8 volts at the battery Technical Guide for Keeway 50cc Carburetors Keeway America uses two primary forms of carburetors A mechanical slide type is used on the 50cc units and a constant velocity CV style is used on the 150cc four stroke units This guide will demonstrate the proper method of adjusting these carburetors in efforts to achieve maximum performance and reliability In addition this guide will provide basic trouble shooting skills when dealing with carburetion issues related to rough running or poor performance 50cc units Mechanical slide units are used The throttle cable is connected directly to the throttle slide pullin2. FRONT FORK ASSEMBLY Removal M10x1 25x40 Bolts 77 Bring washer and spacer 9 amp 10 down onto triple clamp stem LH and RH shock absorbers 12 amp 13 CAREFULLY lower race 8 with a hand Stem locknut and seal amp 2 underneath Steel balls 16 will drop into your hand External nut and dust seal 3 amp 4 Upper race 7 Upper steel balls race and cap 5 6 and 16 1 Remove triple clamp and remaining items on stem Slide triple clamp 4 down DO NOT REMOVE 63 Installation Triple clamp washer and spacer 9 10 amp 14 Assemble lower bearing assembly parts 7 8 amp 16 recommend heavy coat of grease and constant pressure to maintain proper fit and position above spacer 9 on triple clamp stem Ensure assembly remains together Slide triple clamp assembly up into frame 20 ensuring proper fit of bearing assembly A rubber mallet may be used Assemble and install upper bearing assembly 5 6 amp 16 1 in the same manner as the lower bearing assembly Again a rubber mallet may be used Install dust cover external thread nut seal and retaining nut 1 2 3 amp 4 LH and RH shock absorbers 12 amp 15 Install M10x1 25x40 bolts 77 NOTE KEEWAY America discourages disassembly of shock absorber assemblies for the purposes of repairing and reinstalling on KEEWAY units Always replace the entire assembly and replace them in pairs 64
3. Installation procedure is the opposite of removal 54 NOTES Coat bushings and shaft ends with grease to ensure proper installation and ensure proper spring pin installation TRANSITION GEAR ASSEMBLY Removal Transition gear assembly Pin 6 Washer 4 Transition gear 3 with bracket 5 intact Tension spring 2 Transition gear shaft 1 Bracket 5 Installation procedure is reverse of removal 55 NOTES Install bracket in proper groove before installing transition gear Ensure proper movement of transition gear 56 VARIATOR CVT ASSEMBLY Removal Fixed face 1 Rollers 6 Spacer 2 Bushing 3 Retaining face 8 Thrust Washer 4 Dampers 7 Movable face 5 Installation procedure is reverse of removal NOTES Before installing retaining face install dampers Ensure free movement of the spacer 57 STARTER CLUTCH ASSEMBLY Removal Clutch gear 1 Rollers spring and bushing 6 7 amp 8 Needle bearing 2 Clutch cover 9 M6 Screws 3 Spring retainer 0 Clutch hub 4 Clutch body 71 Pin 5 Installation procedure is reverse of removal NOTES There should be no play in clutch assembly Ensure proper tension on bolts and spring retainer Clutch gears are directional 58 CHASSIS TORQUE SPECIFICATIONS Front Wheel Fork Axle Nut 1 Fork Legs to Triple Clamp 4 Brake Assembly Mount 2 Handlebar Handlebar to Triple Clamp Frame Engine Bracket Mount 1 R
4. mixture is correct 4 No change in idle noted For issue 1 Set idle airscrew to factory baseline setting Lower idle stop screw until unit is idling at appropriate rate Adjust air mixture screw to smooth idle Repeat vacuum test as outlined above For issue 2 Open the air mixture screw to achieve smooth idle Idle stop screw should be left alone For issue 4 Idle stop screw is adjusted to far open or there is a vacuum leak after the carb slide Quick test for a vacuum leak is to spray WD40 around the intake on the mist setting If the idle changes when this is done there is an intake leak If the idle remains steady adjust as outlined for issue 1 No start Hard start Same adjustment process as 1 but may have to start the unit with the throttle partially open until idle stop screw can be set close to the final setting 44 IMPORTANT NOTE When adjusting the idle air mixture screw to baseline settings DO NOT tighten screw after it seats If the air mixture screw is over tightened one of two things will occur the tapered needle will mushroom and not function or the needle will break off in the carb body ruining the slow circuit 50cc Two Stroke Engine Carburetor Mechanical Carb Air Cleaner Side Mechanical Carb Left Hand Side Mechanical Carb Right Hand Side Mechanical Carb Engine Side Image Number Key 1 Float Bowl Drain Bolt 2 Idle Stop Screw 3 Oiling Port 4 Idle Air Mixture Screw 5 Enrichment Valv
5. PORT opens This allows the combusted gasses to exit the engine ee As the piston continues downward the TRANSFER PORT is now exposed This allows for the compressed mix in the crankcase to expand and enter the cylinder NOTE The intake port remains closed As the piston reaches BDC a new cycle begins air fuel mix entering cylinder through transfer port exhaust bottom of stroke begins new cycle This cycle of the 2 stroke engine translates into a fundamental rotational force inflicted upon the crankshaft known as TORQUE This force is translated to the vehicle s drive wheel via a clutch assembly and drive belt The metric unit of measurement for TORQUE is equal to the unit of force multiplied by the length of the arm that inflicts it which is the Newton meter lb ft standard In order to optimize the efficiency of this engine cycle and maximize TORQUE output the timing of ignition of the compressed air fuel mixture 1s managed by the vehicle s CDI 17 VEHICLE INFORMATION Engine Number The engine number is stamped into the rear of the crankcase as shown in the illustration Fuel Be sure to only use unleaded fuel 90 Octane or better Engine Oil For KEEWAY s oil injection system high quality engine oil is necessary KEEWAY America recommends full synthetic 2 stroke engine oil with the designation suitable for 2 stroke oil injection systems Gear Oil High quality all purpose gear lube SAE 9
6. T07 13 16 Spark plug socket 2 styles shown T08 Impact wrench T9 Impact sockets 17 amp 18mm needed T10 Clutch clamp tool T11 Torque wrench and appropriate sockets Recommend both lbs ft and lbs in 13 ye a UT gt GENERAL INFORMATION TERMINOLOGY Top Dead Center TDC Bottom Dead Center BDC The two absolute maximums of linear piston travel in the internal combustion engine are referred to as TOP DEAD CENTER TDC and BOTTOM DEAD CENTER BDC Note that TDC is at the point farthest from the rotation center of the crankshaft and BDC is the closest point The distance across the piston s sleeve or cylinder is known as CYLINDER DIAMETER The STROKE is the distance the piston travels from TDC to BDC The cylinder s DISPLACEMENT is achieved by calculating the cylinder s volume by multiplying 2 DIAMETER 2 2 STROKE all in centimeters NOTE total engine displacement is achieved by multiplying this number by the total number of cylinders The end measurement is cubic centimeters or cc 14 THE 2 STROKE ENGINE CYCLE The 2 stroke engine differs slightly from the 4 stroke in that it combines its phases or strokes Upon initial inspection the most noticeable difference in overall 2 stroke architecture is the location of the INTAKE PORT Component Guide 5 cylinder transfer port P exaust port intake port p piston connecting rod crankcase c
7. and from the diode trio to the regulator to be distributed The charging coil and pickup function as CDI references for ignition pulse and timing Blue White Green White 200 200 at 20 C 68 F sive 2 NOTE Testing for all resistance is verified on ground side of circuit There is no capacitor in the stator assembly KEEWAY America encourages replacement of the entire magneto assembly when any component is faulty 39 ENGINE COMPRESSION TEST Procedure NOTE Perform initially on cold engine then bring engine to operating temperature and repeat Compare results Disable ignition via the vehicle kill switch remove the spark plug and connect compression tester REQUIRES SPECIAL TOOL TO5 Disconnect vacuum line from fuel petcock valve Open Throttle completely and crank for 6 8 revolutions Record data and repeat procedure 3 times and take the average of total refer to CYLINDER PISTON section of ENGINE COMPONENT FIT TOLERANCE for compression specifications 40 If engine compression is below specifications repeat test procedure placing several drops of oil into combustion chamber JUST BEFORE connecting compression gauge If the compression rises to within range there is excessive wear or damage to the cylinder piston rings or cylinder head gasket Ensure proper valve timing and seat Ensure proper cylinder head gasket seat and seal and proper torque applied to head bolts 41 IGNITION TIMING TEST
8. fashion 43 The 50cc carb also has an automatic enrichment valve mounted on the right side This valve feeds both fuel and air to the engine side of carb slide It is designed to maintain stochiometric metering admitting both fuel and air This valve is an electronic solenoid that moves in or out based on a signal from the stator or the CDI If the unit has no movement the unit has failed and must be replaced Common problems and recommended solutions 50cc and 150cc units Slow idle poor response when warm Adjust idle airscrew in 4 turn increments until idle smoothes out and smooth transition to open throttle is achieved Fast idle Loosen idle stop screw until idling at appropriate rate Adjust idle air mixture screw until smooth even idle is achieved Quick Method for Resetting Unit Idle Set idle air mixture screw to factory baseline setting Run unit until normal operating temperature is reached Adjust idle to appropriate baseline speed using a tach dwell meter Adjust idle air mixture screw until highest idle rpm is reached Turn air mixture screw in or out until idle drops 50 to 100 rpm Adjust idle stop screw to baseline idle Excessive carbon build up on plug excessive smoke at idle on two stroke units Quick test procedure Remove vacuum line to fuel valve when idling 1 If idle goes up mixture is too rich 2 If idle drops and unit stalls mixture is too lean 3 If unit runs rough but continues to idle
9. proper startup procedure to start engine If no start condition continues verify fuel flow by removing plug in overflow hose on carburetor Fuel flow Verify adequate ignition spark by removing spark plug Ignition spark is adequate Ensure sufficient battery charge 31 No fuel flow Verify fuel in tank Verify fuel flow at petcock valve Verify fuel flow at filter Verify clear lines to carburetor Possible lack of gas cap ventilation Possible stuck carburetor float or needle valve Inadequate ignition spark Replace spark plug and once again verify spark If no spark condition remains verify current flow to coil lead If no current to coil lead verify current at vehicle kill switch output If current at output verify current at CDI lead to coil If current at both locations coil is faulty and needs replacement If lack of current exists at either location part is faulty and needs replacement ensure proper battery charge Vehicle should now start If hard start poor idle condition is now present refer to appropriate section above If no start condition remains and spark plug is gas fouled the carburetor s enrichment valve needs replacing From this point if no start condition remains perform an ENGINE COMPRESSION TEST refer to guide for proper procedure and specifications If engine fails to build sufficient compression the most likely causes are a faulty head gasket or a scoured abraded c
10. 0 Break in Duration General guidelines are as follows e Limit break in speed For the first 600 miles do not exceed 4 5 throttle travel Beyond 600 miles run at full throttle e Avoid prolonged idling and try to vary throttle position while riding during the break in period 18 GENERAL SPECIFICATIONS Chassis Front Shock Absorber Rear Shock Absorber Turn Angle Brakes F R Engine Type Intake Cylinder Bore Stroke Displacement Compression Ratio Timing Carburetor Start System Lubrication System Transmission Clutch System Gearshift Gear Range Electrical Ignition Type Spark Plug Generator Fuse FLUID CAPACITY Fuel Tank Engine Oil Tank Gear Oil Spring Oil Damped Spring Oil Damped 48 to left to right Disk Drum 2 Stroke Forced Air Cooling Piston Reed Valve Single 40 0mm 39 6mm 49 8mL 6 9 1 15 BTDC 1500rpm Mechanical Slide Electric and Kick start Remote Start Available Oil Injection Pressure Lubrication Dry Fully Automatic Eccentric Step less CVT 0 86 2 64 CDI BR8HSA A C Magneto 8A 1 38 gal 3 4 oz 19 POWERTRAIN SPECIFICATIONS FASTENER TORQUE Self tapping screws for fan cover assembly Locknuts for fan cover assembly Self tapping screws for air cover Lock nut for air cover Self tapping screw and nut for cylinder head cover vent Locknut for cylinder head cover Locknut for cylinder head Spark plug Intake port bolts Exhaust port bol
11. H Crankcase assembly 2 Middle and output shafts 4 amp 5 Input shaft 3 and middle and and input shaft bearing output shaft bearings Middle shaft bearing output shaft Input shaft oil seal and bearing oil seal and bearing Installation procedure is reverse of removal 32 NOTES Position each bearing with number facing outward and ensure free movement Lightly coat oil seal with oil when installing and ensure proper direction and fit Ensure proper fit and free movement of all gears and pinions Torque bolts in modified star pattern to 8lbs ft DRIVE WHEEL CLUTCH ASSEMBLY Removal Clutch hub retaining pin and woodruff Dampers 20 key 1 11 amp 12 Limiters and pins 21 amp 22 Nut washer and disk 2 7 amp 8 Front cover 23 Clutch shoe assembly 3 Needle bearing 5 Clips 16 Spring seat clip and roller bearing 4 Backing plate 77 13 amp 14 Springs and shoes 18 amp 19 Compression spring and main disk 5 amp 10 53 Rear seat 6 Installation procedure is opposite of removal NOTES When assembling clutch shoe assembly be sure to use new limiters and pins to ensure proper fit and function When installing bearings coat with assembly lube to ensure free rotation and ensure proper positioning of the clip KICK START SHAFT ASSEMBLY Removal Kick start shaft assembly Bushings 1 amp 6 Spring and washer 2 amp 3 Spring pin 5 Kick start shaft 4
12. ICATIONS Fastener Torque DIMENSIONS Alignment Pins Dowels Pin shafts O rings Seals Bearings Gaskets Gears Sprockets Chains ENGINE PARTS ORIENTATION ENGINE COMPONENT FIT TOLERANCE Cylinder Head Valve Cylinder Jug Piston SYSTEM FUNDAMENTALS Kick Start Chain Reaction Fuel Delivery System Brake System Fundamentals Fundamental Front Absorber Theory TROUBLESHOOTING AND PROCEDURES COMMON ISSUES Electric Starter Doesn t Engage or Rotate Only Clicking Noise When Starter Button Is Pressed No Reaction Whatsoever When Starter Button Is Pressed Hard Start Poor Idle Poor Performance No Start Insufficient Power Lack of Acceleration Poor Difficult Handling Instability Soft Brakes or Too Much Lever Travel Hard Brakes or Stiff Lever Feel BATTERY CHARGING SYSTEM FUNDAMENTAL TEST ENGINE COMPRESSION TEST IGNITION TIMING TEST TECHNICAL GUIDE FOR 50cc CARBURETORS POWERTRAIN COMPONENTS CARBURETOR REMOVAL INSTALLATION ENGINE AND COMPONENTS REMOVAL INSTALLATION CHASSIS Cowling Assembly Cylinder Head Assembly Camshaft Rocker Arm Assembly Piston Assembly LH Crankcase Cover RH Crankcase Cover Magneto and Associated Parts RH Crankcase Internals LH Crankcase Cover and Associated Parts Crankcase Assembly Transmission Case Assembly Drive Wheel Clutch Assembly Kick Start Gear Assembly Transition Gear Assembly Variator Assembly Starter Clutch Assembly TORQUE SPECIFICATIONS COMPONENT GUIDE Front Wheel Assembl
13. Piston Pin Guide 12 01mm Piston Pin 12 00mm Pin Guide Tolerance 0 01mm PISTON RING Ring Groove Tolerance first 0 04 0 06mm second 0 02 0 04mm Acceptable Ring End Gap 0 75 3 6mm uniform SYSTEM FUNDAMENTALS KICK START CHAIN REACTION Kick Start Lever 9 Starting Gear 10 Transitional Gear 11 through small on to large Crankshaft Driven Gear 13 Crankshaft 3 Connecting Rod 2 Piston 1 23 FUEL DELIVERY SYSTEM The vehicle s fuel flows by gravity feed into the petcock valve where its flow rate is boosted through vacuum assistance allowing for a steady and potentially constant feed into the carburetor From the petcock to the carburetor the fuel undergoes a double filtration process First the fuel flows through a strainer as it enters the petcock removing any major debris As it exits the fuel travels from the petcock nearly directly into an in line filter removing any residual debris and or sediment before entering the carburetor The vehicle s air supply endures a much shorter process It initially enters through the air filter located on the left hand side of the engine From here it flows through a duct finally mixing with the fuel and undergoing CARBURETION Fuel that enters the carburetor first flows into the float chamber As the fuel level rises so does a float When atmospheric equilibrium is reached the float makes contact with the needle valve
14. SCOOTER SERVICE MANUAL KEEWAY 50cc Models KEEWAY AMERICA LLC SPRING 2008 If problems cannot be resolved or further assistance is needed please feel free to contact us KEEWAY AMERICA LLC 2912 SKYWAY CIRCLEN IRVING TX 75038 214 441 9661 PHONE 214 441 9641 FAX service keeway america com Our support staff will assist in any way possible PRE DELIVERY INSPECTION In order for KEEWAY America to maintain its high standards of quality it is necessary for each dealer to thoroughly inspect each unit before their customer takes delivery INITIAL Wash entire vehicle with warm water and wipe dry with a soft cloth DO NOT USE SOAP OR TERRY CLOTH Inspect paint sheen and decal quality Ensure all fasteners have appropriate torque to include visible body screws axle and exhaust nuts engine and carburetor bolts etc Ensure proper operation of all lock cylinders Verify that a new fully charged battery has been installed Inspect vehicle electrical system including switch and control operations Ensure proper operation and adjustment of levers throttle and rear brake cables Ensure proper front and rear brake operation including fluid level and adjust as needed Verify spark plug gap and adjust accordingly Start engine and bring to operating temperature Check fluid levels and add if necessary Check and adjust idle speed as needed Ensure free travel of both wheels Check tire pressure
15. and adjust accordingly Verify proper operation of remote start system TEST DRIVE Verify proper front and rear suspension for correct damping and travel Ensure proper operation and settings of gauge cluster Verify wheel alignment and adjust accordingly Check for fluid leaks and adjust levels accordingly Verify proper operation and adjustment of all vehicle lights FINAL Wipe down entire vehicle with soft cloth to remove any dust or debris Detail grips seat and tires MAINTENANCE CHART Note Increase maintenance frequency when riding in poor conditions Periodic maintenance table Mile so 4000 f 7500 uwo f is Interval Kilometer 1000 f 6000 12000 18000 f 24000 Storage batey f o ro fo r foo T S E f E Cylinder head nut and exhaust Cylinder head cy linder Spark plug Clean every 00KM 2000 miles ide speedrpm 2 1 Throttle cableplay FP fo o rt f r ES tt Seaoil fo o ot Sooo Soo or S o RS Fugl line Brake hose Brake fluid Replace every 2 years EE EE PS Vehicle body jt andnut Note J inspect clean adjust lubrica orreplace if necessary A adjust C cleans R replace T tighten TABLE OF CONTENTS PREDELIVERY INSPECTION MAINTENANCE CHART PREFACE KEEWAY SERVICE GUIDELINES ELECTRICAL PRECAUTIONS SAFETY GUIDELINES SPECIALTY TOOLS REQUIRED GENERAL INFORMATION Terminology The 2 Stroke Engine Cycle Vehicle Information General Specifications POWERTRAIN SPECIF
16. causing it to close and thereby stop fuel entry until the float level drops again ENRICHMENT When the engine is Enrichment Valve started an electronic ENRICHMENT valve es LE opens allowing a portion of fuel to spray Body ee directly into the carburetor throat This 1 Son makes the air fuel mix richer increasing volatility This makes it easier for the vehicle to start Once the engine is running the enrichment valve gradually closes and the IDLE circuit takes over This allows the air fuel mixture to become leaner which results in optimum combustion efficiency fi pauk i Faig Yi ae ea Le nu ANRT dm ee 1 r pi k z nr Y a on Tii 1 it a Idle Air Screw Sate Jet Main Jet 24 At idle the fuel is sprayed in a fine mist into the carburetor throat by the idle jet Since the throttle body is completely closed air passes through the idle passage and into the throat as well blending with the fuel mist This blending process can be adjusted through the IDLE AIR SCREW As the throttle body is slowly opened a SLOW speed condition begins Under light throttle air begins to flow through the slightly opened throttle body creating small portion of the vacuum needed to trigger the main jet Since vacuum is minimal the idle jet remains active but the main jet operates at minimum capacity At the point of half throttle the throttle body is opened a
17. d into the air fuel mix Due to the intake process of the two stroke engine see The 2 Stroke engine Cycle the oil most effectively lubricates the crankcase by combining with the air fuel charge getting spread throughout by the rotation of the crankshaft Since two strokes are typically air cooled and therefore operate at a much higher temperature the oil also further lubricates as well as acts as an intermediary seal within the combustion chamber As it burns the oil also has a cleaning effect taking with it any significant carbon buildup Refer to THE 2 STROKE ENGINE CYCLE for illustrations further description DISK BRAKE SYSTEM FUNDAMENTALS Hydraulic theory liquid cannot be compressed only displaced Therefore force can be amplified and carried through fluids by application of force to surface in a sealed system 1 Cap 8 Plunger 2 Gasket 9 Tension Spring 3 Fluid Journal 10 Fluid Outlet 4 Dust Boot 11 Return Port 5 Circlip 12 Reservoir 6 Seal 7 Plunger Shaft As the front brake lever is pulled it forces the plunger through the master cylinder reservoir applying force to the brake fluid The fluid is then displaced through the brake line and into the caliper The fluid then forces the caliper s two pistons outward creating a pressure tension between the brake pads and rotor When the brake lever is released a return spring acts to bring the plunger back to its original position creating a suction effect bringing th
18. disengaged completely remove the battery Verifying correct polarity connect slow rate trickle charger Battery should be charged at a rate of 1 5 2 amps and will typically take 4 8 hours for a complete recharge depending on its state Upon completion of charge reinstall battery verifying correct polarity In order to verify properly functioning charging system start vehicle using kick start lever Allow vehicle to reach operating temperature and again connect the digital multimeter in the manner described above A PROPERLY FUNCTIONING CHARGING SYSTEM WILL YIELD A CONSTANT READING OF 12 8 13 2 VOLTS AT THE BATTERY AT IDLE Reading may fluctuate as throttle is increased not to exceed 14 5 volts anything above indicates an overcharge condition and a faulty output from the voltage regulator 36 POWER CIRCUITRY AND PARASITIC DRAW TEST GUIDELINES The parasitic draw test is a procedure used to pinpoint the source of severe voltage draws in electrical systems due to a short in the circuitry Specific Tool Required Digital Multimeter PARASITIC DRAW TEST PROCEDURE Before beginning ensure that electrical system is entirely disabled by verifying that ignition cylinder is in OFF position and keys removed and that the vehicle kill switch 1s in the NO RUN position If the vehicle is equipped with a theft deterrent remote start system please ensure that it 1s disarmed e Disconnect Negative battery terminal e Set multimeter
19. e 6 Intake Slide 7 Vacuum Port 45 POWERTRAIN COMPONENTS CARBURETOR REMOVAL INSTALLATION Removal Remove seat helmet box assembly Remove fuel inlet line Loosen the clamp between carburetor and air box and remove intake duct Remove plug from fuel overflow discharge hose and drain any remaining fuel into a safe container Disconnect enrichment valve pigtail Disconnect throttle cable Remove carburetor mounting bolts and carefully remove carburetor Installation Upon ensuring that all wiring and cables are safely tucked away carefully position carburetor over engine intake runner and start the mounting bolts DO NOT TIGHTEN AT THIS TIME for Flash hurricane and venus models Connect throttle cable and enrichment valve pigtail Ensure that fuel overflow discharge hose plug 1s in place and secure Firmly snug carburetor mounting bolts DO NOT OVERTORQUE Slide intake duct over carburetor throat and tighten clamp Connect fuel inlet line before installing seat helmet box assembly attempt to start the vehicle It will take several seconds as the fuel bowl must fill As the vehicle starts closely inspect all joints to ensure proper fit and seal Install seat helmet box assembly 46 ENGINE COMPONENTS REMOVAL AND INSTALLATION CYLINDER HEAD ASSEMBLY Removal remove cowling prior Cylinder jug and assoc gasket 4 amp 5 Spark plug and cylinder head nuts 3 amp Installation procedure is opposite
20. e fluid back to the reservoir and consequently sucking the caliper pistons back to their original positions NOTE hydraulic theory only works properly in a properly sealed and bled system Air cannot be present or the system will fail 2 Caliper Assembly 1 Bleeder Bolt Dust Cover 2 Banjo Bolt 3 Fluid Path 4 Caliper Body 5 Pistons 6 Guide Bolt Sleeves 7 Piston Seals 8 Piston Dust Covers 9 Brake Rotor 28 FUNDAMENTAL FRONT ABSORBER THEORY This illustration depicts the front fork assembly of this vehicle The triple clamp connects the fork assembly to the vehicle s frame and handlebars An inner shaft is supported by a spring within the outer shaft which is submerged in fluid The spring acts as an absorber to the impacts experienced due to imperfections in the drive surfaces and the occasional pothole or small obstacle The fluid acts as a damper smoothing the spring movement This results in one compound motion of the shaft assembly composed of two strokes compression and rebound This process combines to maintain tire contact with the road as well as to provide a smooth ride Compression When bearing a load from the top of the absorber the inner shaft moves downward and into the outer shaft In an opposite circumstance when the front wheel encounters an imperfection on the road or a minor obstacle the outer shaft moves upward and over the inner shaft In either instance the compression stroke 1s experi
21. ear Shock to Frame 1 Rear Wheel Rear Shock Axle Nut 1 Rear Shock to Swing Arm 1 Engine Exhaust to Engine 2 Expansion Chamber to Engine Engine to Engine Bracket 2 59 41 44lbs ft 27 32Ibs ft 16 21 lbs ft 27 32Ibs ft 28 32Ibs ft 28 32Ibs ft 73 95lbs ft 17 21 lbs ft 13 20lbs ft 8 121bs ft 28 32Ibs ft COMPONENT GUIDE FRONT WHEEL ASSEMBLY Removal Axle locknut 77 Seal bearings and axle shaft bushing 5 6 amp 18 Axle 3 Tire 16 LH Bushing and speedometer gear assembly 4 amp amp Valve stem and cap 2 amp 20 Front wheel assembly Installation procedure is reverse of removal 60 REAR WHEEL ASSEMBLY Removal Locknut Brake shoes and springs 1 amp 2 Rear wheel assembly Tension spring and bushing 3 amp 4 Tire 8 M6x35 Bolt 9 Valve stem and cap 11 amp 12 Brake rocker arm 5 Rear wheel 7 Brake cam 6 Installation procedure is reverse of removal 61 EXHAUST ASSEMBLY Removal Bolts and flange gasket 8 amp 9 Expansion chamber stabilizer bolts washers and grommets 11 12 amp 13 Exhaust assembly 1 Muffler strap insulator and associated bolt 4 6 amp 10 Muffler mounting nuts and gasket 5 amp 5 Installation procedure is reverse of removal assemble exhaust assembly prior NOTE Apply red thread locker to muffler studs before installing mounting bolts to ensure vibration resistance 62
22. ecifications Retaining plate lock bolt Slbs ft Locknuts 8 amp 15 33 40 bs ft NOTES Coat shafts of kick start and transition gears with assembly lube before installing keep transition gear reference aligned with crankshaft and kick start gear reference aligned with contact point at transition gear A brake spring tool is recommended for applying tension to kick start spring USE CAUTION Immediately install retaining plate and lock bolt Install drive belt before installing fixed face CRANKCASE ASSEMBLY Removal remove cylinder Installation head cylinder jug and piston assembly prior LH Crankcase assembly 8 Bolts 1 Camshaft timing chain 6 RH Crankcase assembly 2 Oil seal 5 Dowels and gasket 3 amp 7 Crankshaft assembly 4 Crankshaft assembly 4 Dowels and gasket 3 amp 7 Camshaft timing chain 6 RH Crankcase assembly 2 LH Crankcase assembly 8 Bolts Z Torque 7 8 bs ft Oil seal 5 51 NOTES When installing crankshaft assembly coat LH crankcase bearing with oil then vertically press oil seal into bearing recess place crankshaft gear into camshaft timing chain ensure free movement of crankshaft and connecting rod assembly A rubber mallet may be needed to gently tap the crankcases together Ensure free movement of crankshaft and connecting rod assembly after assembling the crankcase assembly TRANSMISSION CASE ASSEMBLY Gear Splines Ratio Removal Transmission case assembly 1 L
23. enced which means that the spring is being compressed and the fluid is being forced through a one way valve up past the inner shaft At the extreme conclusion of the compression stroke the spring is fully compressed and most if not all of the fluid is now above the inner shaft Rebound Once the compression stroke ends the now compressed absorption spring begins to expand pushing the inner shaft back up and into the displaced fluid The fluid now begins to flow back down through two small one way valves These valves function to increase the damping ability of the fluid during the rebound stroke Once the spring has completely rebounded forcing the fluid back down the tube past the valves the rebound stroke is complete NOTE KEEWAY America discourages disassembly of absorbers for the purposes of diagnosing and repairing KEEWAY vehicles Always replace the absorbers as assemblies and in pairs 29 TROUBLESHOOTING AND PROCEDURES IMPORTANT NOTE before attempting any troubleshooting or repairs please ensure that scooter is placed on the main stand COMMON ISSUES The following compilation describes the most common symptoms and potential solutions in the form of a flow chart Further testing 1s not needed once the problem has been solved ELECTRIC STARTER DOESN T ENGAGE OR ROTATE Verify proper state of battery charge Ensure properly functioning fusible link Ensure proper operation of starter relay Inspect cable con
24. g the slide open The slide is returned by an internal spring Two direct adjustments can be made to these carburetors The idle stop screw controls the closed position of the throttle slide Turning it in tightening raises the slide turning it out loosening lowers the slide The second adjustment is the idle airscrew The carb body is ported to allow airflow AFTER the throttle slide The idle airscrew controls airflow through this port The mixture is enriched when the idle airscrew is turned in clockwise and leaned when the screw is turned out counterclockwise Further adjustments can be made to internal components Those adjustments will be covered in a later bulletin For proper operation and clean running the carb setup of the 50cc units is critical These units should be set with the idle stop screw at the minimum opening possible so that they are running on the idle setscrew almost exclusively for base idle The factory setting for the idle airscrew is 1 2 turns out from seated plus or minus 2 turn Small adjustments should make a LARGE difference in the running of these units at idle For example no more than 2 turn in or out should dramatically affect the idle speed and smoothness If this does not occur the idle stop screw is preventing the throttle slide from closing properly and the unit is running off the main jet circuit This will result in rich running and fouling of spark plugs in rapid
25. ines no blockage collapsing etc Verify proper caliper and piston movement Ensure brake rotor is not damaged or warped Inspect master cylinder plunger and bushing for proper travel as well as signs of excessive wear 35 THE BATTERY In order to troubleshoot the battery the cornerstone of the vehicle s electrical system all vehicle systems must be off Turn voltmeter to DC VOLTS With the alarm disarmed connect the test leads from the digital multimeter to the battery posts red to positive and black to negative alligator clips ideal A properly functioning battery will read a MINIMUM of 12 25 volts Anything below this will require charging see procedure below In situations that the vehicle s starter is the suspected issue and kick start ability has been verified a load test may be conducted on the battery In order to correctly perform this procedure the multimeter must be connected in the manner described above Next with the alarm still disarmed turn the ignition key to the ON RUN position THE VEHICLE KILL SWITCH SHOULD REMAIN IN THE OFF NO RUN POSITION While pressing the vehicle s electric start button observe the change in battery voltage Under load reading should be at or above 10 25 Anything below this indicates that the battery will require charging see procedure below Red Postive Black Negative NOTE Very Polarity Before Testing BATTERY CHARGE PROCEDURE With all vehicle systems
26. l POOR DIFFICULT HANDLING INSTABILITY If turning is difficult Inspect fork bearings and lubricate replace as needed Ensure proper torque is applied to the retaining nut Wheel wobble or hop Inspect wheel bearing for excessive play Ensure that rims are straight and true Ensure proper torque applied to axle nuts Inspect swing arm bushing and ensure no significant wear Ensure proper torque applied to swing arm bushing nut Ensure that swing arm shaft and axle are straight and true If scooter tends to lean Ensure proper alignment of front and rear wheels and ensure that axles are straight and true Ensure that fork and handlebars are straight and true Ensure that swing arm and shaft are straight and true and track properly Inspect front and rear shocks for signs of excessive damage or play 34 SOFT BRAKES OR TOO MUCH LEVER TRAVEL Ensure proper brake fluid level Inspect both pads and shoes for proper travel and excessive wear Ensure absence of air in brake lines Inspect system for leaks Inspect caliper piston seal for signs of aging damage Verify that wear on brake pads and rotor is within limits with no damage or warping Inspect master cylinder reservoir for signs of aging damage HARD BRAKES OR STIFF LEVER FEEL Inspect both pads and shoes for proper travel contamination and excessive wear Inspect all mechanical components of drum brakes and ensure proper fit adjustment Ensure fluid flow through l
27. latile chemical and should be treated with care Never handle near open flame or heat source Keep floor clean and free of debris Avoid fluid spills to minimize the risk of accidents and equipment damage Exhaust fumes are hazardous to your health Never operate engine in closed or poorly ventilated areas BRAKE DUST CONTAINS ASBESTOS Use of a dry brush or compressed air will increase the risk of inhaling asbestos fibers which carries a high risk of damage to the respiratory system AVOID EYE AND PROLONGED SKIN CONTACT with brake cleaner If this occurs immediately and thoroughly flush affected area with water and seek medical assistance Only use DOT approved brake fluid from a sealed container to ensure no moisture absorption Avoid fluid splash overflow onto painted or rubber parts as rapid deterioration can occur BATTERIES CONTAIN ELECTROLYTE SOLUTION Exercise caution and wear protective clothing and eyewear If accidental exposure occurs immediately and thoroughly flush affected area with water and seek medical assistance Please maintain sufficient communication with coworkers to maintain productivity and minimize accident potential 11 SPECIALTY TOOLS REQUIRED TO1 T Driver and socket set 8 10 12 13mm and screwdriver bits needed T02 Flywheel removal tool T03 Valve spring compressor T04 Spanner socket T05 Cylinder compression tester T06 Piston pin removal tool j 12
28. nections to starter solenoid and starter ONLY CLICKING NOISE WHEN STARTER BUTTON IS PRESSED Bypass starter solenoid to ensure proper starter motor operation Check solenoid and wire connections Ensure proper operation of starter relay NO REACTION WHATSOEVER WHEN STARTER BUTTON IS PRESSED Ensure continuity at input and output sides of starter button Bypass starter solenoid to ensure proper starter motor operation Ensure proper operation of starter relay HARD START POOR IDLE OR POOR PERFORMANCE AT SPEED If vehicle is slow to start idles poorly or immediately sputters and dies or if main circuit performance is lacking first verify that there is no restriction or blockage of airflow If condition continues ensure that carburetor is properly tuned see TECHNICAL GUIDE FOR 50cc CARBURETORS for procedure and specifications Inspect carburetor for external leaks or blockage and perform INTAKE LEAK TEST refer to guide for proper procedure 30 Upon completion of properly tuning the carburetor replace the vehicle spark plug If condition continues verify adequate oil flow and ensure proper spark then verify proper ENGINE TIMING refer to guide for proper procedure and specifications if necessary If out of range the MAGNETO ASSEMBLY is most likely sending a faulty reference to the CDI and needs replacement refer to guide for removal installation Recommend replacement of CDI at the same time NO START CONDITION Verify
29. of removal Cylinder head and assoc gasket 7 amp 2 47 PISTON ASSEMBLY Ring End Gap 0 25mm 0 010in minimum Service limit 0 75mm 0 030in Ring Groove Tolerance First 0 04 0 06mm 0 0015 0 002in Second 0 02 0 04mm 0 001 0 00151n Removal remove cowling cylinder head assembly and cylinder jug prior First and second rings J amp 2 Installation procedure is reverse of removal ensure ring gaps are set Pin clips 5 qty 2 according to alignment pins guaranteeing offset of 120 and any Wrist pin 6 markings face up Bearing 7 48 LH CRANKCASE COVER Removal Cable clip and fender bracket 1 amp 2 LH Crankcase cover 3 Dowel and gasket 4 amp 5 Installation procedure is opposite removal NOTE after ensuring proper alignment installation may be facilitated by gently tapping cover into position with a rubber mallet Upon starting all bolts proceed to apply torque in a modified star pattern bringing them all to 8 9Ibs ft 49 LH CRANKCASE COVER AND ASSOCIATED PARTS Removal Nut star washer and fixed face 6 7 amp 5 Drive Belt nut and washer 16 15 amp 14 Spacer and variator assembly 4 amp 5 Clutch hub and drive assembly 2 amp 13 Installation procedure is reverse of removal Spring retainer and kick start gear 10 amp 11 Crankshaft starter and transition gears 3 amp 9 Dowel and gasket 1 amp 2 Torque Sp
30. place spark plug If the spark plug appeared light gray in color this indicates that the engine may be running hot possibly causing detonation or may have poorly maintained and or poor oil quality Inspect vehicle oil Oil meets requirements Verify sufficient flow and operating temperature Temperature is within range Perform ENGINE COMPRESSION TEST refer to guide for proper procedure and specifications Oil does not meet requirements Over full low or burnt dirty oil Perform engine oil change Verify sufficient operating temperature Temperature is too high Inspect for excessive carbon buildup in combustion chamber then perform ENGINE COMPRESSION TEST refer to guide for proper procedure and specifications If the symptom has persisted to this point KEEWAY recommends disassembly of the cylinder head and inspection for proper lubrication verification of carbon buildup and a potentially warped uneven surface Inspect the piston assembly and cylinder jug for the same signs A lubrication issue will denote either blockage in the lines or a bad oil pump Take the appropriate action and reinstall with new gaskets see guide for proper procedure and specifications If the symptom continues beyond this point engine timing is most likely out of range 33 The MAGNETO ASSEMBLY most likely has damaged components and needs replacement refer to guide for removal installation Recommend replacement of CDI as wel
31. pproximately halfway which greatly increases airflow and vacuum pressure to the main jet This triggers a MIDDLE speed condition Under half throttle airflow through the throttle body increases which causes the vacuum pressure on the main jet to increase just enough to take pressure from the idle jet ceasing its fuel spray At this point the main jet is the sole source of fuel spray into the carburetor throat but vacuum is only sufficient for approximately half capacity At this point the air fuel mixture becomes optimal and combustion efficiency is highest a Idle Air Screw Idle Air Screw Throttle Main Jet Main Jet Under a HIGH speed condition the throttle body is opened up all the way allowing maximum airflow This creates the greatest Body vacuum pressure possible resulting in Sali maximum fuel spray from the main jet The iiit air fuel mixture becomes richer to facilitate es m i vite inate ee the faster hotter combustion necessary to SS en support the increased engine speed and l demand Idle Jet eel Main Jet Idle Air Screw LUBRICATION SYSTEM The engine s lubrication system has several functions Lubrication Heat Dissipation Cleansing Rinsing Intermediary Seal Protect Against Wear PROCESS The engine s oil pump located in the RH crankcase 1s gear driven by the crankshaft directly Oil is drawn from the reservoir to the carburetor via the pump where it is injecte
32. rankshaft It provides a direct feed into the CRANKCASE and then moves into the CYLINDER via the TRANSFER PORT The following better describes the process ist Stroke First Half At the beginning of the engine s first intake and compression revolution the piston begins an upward motion in the cylinder which generates pressure in the combustion chamber and creates a vacuum into the CRANKCASE NOTE The piston skirt is blocking the transfer and exhaust ports but is allowing the air fuel mix to enter the crankcase via the intake port 15 Now the piston is reaching TDC completely compressing the air fuel mix in the combustion chamber NOTE The exhaust and transfer ports are still blocked by the piston skirt the intake port is still open but the crankcase has now filled to capacity The spark plug now fires igniting the compressed mixture in the combustion chamber Once the mix has been ignited the following explosion forces the piston back down at a very high rate of speed This generates the power required to perform the workload NOTE All three ports are now closed As this downward motion occurs the air fuel mixture in the crankcase is compressed 16 ist Stroke Second Half combustion 2nd Stroke First Half This is the final and perhaps most Ind Stroke Second Half complicated step in the 2 stroke process exhaust and forced intake As the piston travels downward the EXHAUST
33. s cotter pins etc 4 Please note that all fasteners are metric 5 When reassembling fasteners please snug nuts and bolts in a circular pattern and torque to spec in a diagonal star pattern if applicable 6 Upon completion of assembly double check fastener tension torque and ensure free movement of parts 7 Parts and fasteners should be free of debris prior to measurement Upon assembly use lubricant or thread lock as needed 8 When metal parts are removed and need to be stored for extended periods please apply a heavy coat of lubricant to minimize rust and debris accumulation ELECTRICAL PRECAUTIONS A loose or dangling cable is a tremendous hazard Ensure fasteners are in place and secure Never leave wire exposed especially near any metal surface including nuts and bolts Only lay wire in straight relaxed manner Never stretch twist or sharply bend wire or electrical connectors or loss of conductivity will occur Keep wires away from heat sources and moving parts rotating assemblies to avoid electrical damage Inspect pigtails and connectors before connecting to wire to ensure a clean firm contact When making repairs to wires and connectors please be sure to wrap the new joint in heat shrink tubing This will reinforce the connection and protect it from the elements 10 SAFETY GUIDELINES WARNINGS Use only the appropriate well maintained tool for the task at hand Gasoline is a highly vo
34. to the 25 MILLIAMPS DC mA DC setting Complete circuit between negative cable and battery by placing the multimeter IN SERIES with the POSITIVE test lead connected to the NEGATIVE CABLE and the NEGATIVE test lead connected to the NEGATIVE BATTERY TERMINAL In a properly operating electrical system the multimeter will read well under 50 mA If the draw is greater there is a parasitic draw e Keeping the multimeter connected IN SERIES begin removing components from the loop by disconnecting the pigtails one at a time In some cases such as the instrument cluster it will be necessary to disconnect multiple pigtails in order to accurately remove the component from the loop When the problematic component is removed from the loop the multimeter reading will immediately fall to within acceptable range 37 IMPORTANT NOTE n vehicles with theft deterrent remote start systems unplugging the alarm box will result in an amperage drop THIS DOES NOT NECESSARILY DENOTE A FAULTY ALARM SYSTEM The entire vehicle is powered through the alarm box 38 MAGNETO ASSEMBLY Structure The magneto is composed of the stator assembly star pattern of copper wound spools the charging coil and the magnetic Pickup coil This assembly is located inside the RH crankcase cover behind the cooling fan and flywheel Function The stator acts as the primary charging source for the vehicle s battery Current flows from here to the diode trio
35. ts Carburetor joint locknuts Cooling fan locknuts Flywheel locknut Stator coil locknuts Magneto locknuts Locknuts for RH crankcase cover Locknut for oil pump Locknut for driven clutch assembly Locknut for driven clutch hub RH crankcase locknut Engine pivot bolt LH crankcase cover locknut Self tapping screws for LH crankcase cover vent 20 1 3Nm 9 26 Ibs in 10 12Nm 8 9lbs ft 1 3 Nm 9 26 bs in 10 12Nm 8 9lbs ft 1 3Nm 9 26lbs in 10 12Nm 8 9lbs ft 15 18Nm 71 15lbs ft 15 18Nm 71 15lbs ft 10 12Nm 8 9lbs ft 10 12Nm 8 9lbs ft 10 12Nm 8 9lbs ft 10 12Nm 8 9lbs ft 45 50Nm 33 36lbs ft 6 8Nm 4 6lbs ft 10 12Nm 8 9lbs ft 10 12Nm 8 9lbs ft 5 9Nm 3 7lbs ft 55 60Nm 40 441bs ft 35 38Nm 26 281bs ft 10 12Nm 8 9lbs ft 55 60Nm 41 44lbs ft 10 12Nm 8 9lbs ft 3 6Nm 2 4ibs ft Locknut for fixed drive assembly Kick starter locknut Transmission case cover locknut Transmission case drain nut LH crankcase drain nut LH crank position shaft nut 21 40 60Nm 29 431bs ft 10 12Nm 8 9bs ft 10 12Nm 8 9bs ft 22 25Nm 16 18lbs ft 22 25Nm 16 18lbs ft 18 22Nm 13 16lbs ft ENGINE COMPONENT FIT TOLERANCE REED VALVE CYLINDER HEAD Reed Valve seat clearance A lt 0 2mm overlap B Imm lt 0 05mm CYLINDER PISTON Compression 15545psi Cylinder Inner Diameter 40 005 40 020mm Piston Diameter 39 94 39 955mm Piston Cylinder Tolerance 0 06 0 07mm 22 PISTON PIN
36. y Rear Wheel Assembly Exhaust Assembly Front Fork Assembly PREFACE This service manual serves as KEEWAY America s promise of quality service and technical support for its entire line of vehicles This manual is intended to provide most of the necessary information for the proper service and maintenance of all 50cc scooters KEEWAY 50cc scooters lie on the cutting edge of technology offering such creature comforts as Fully automatic belt driven transmission Forced air cooling system CDI ignition system Electric start with security system remote start capabilities These 50cc scooters are intended to fit the needs of a wide array of potential riders In order to remain familiar with the proper service procedures authorized technicians should periodically review this manual Please understand that this service manual acts as a general guide for KEEWAY s entire line of 50cc 2 stroke scooters Model specific information such as vehicle specifications wiring diagrams and technical service bulletins will follow keeping this guide as complete and current as possible For any questions or concerns not addressed in this service manual or any succeeding documents please don t hesitate to contact KEEWAY America directly KEEWAY SERVICE GUIDELINES 1 Use only genuine KEEWAY parts and use proper lubricants where specified 2 Use only the proper tools for the task at hand 3 Please be sure to replace all washers seals o ring
37. ylinder or piston assembly In the event of either of the latter the head gasket will need replaced at the same time refer to guide for proper procedure and specifications If symptom persists beyond this point verify proper ENGINE TIMING refer to guide for proper procedure and specifications If out of range the CDI has a bad contact internally and needs replacement refer to guide Recommend replacement of MAGNETO ASSEMBLY as well INSUFFICIENT ENGINE POWER LACK OF ACCELERATION In the event that this symptom presents itself the most common issue lies in interference with rear wheel tire rotation To inspect simply spin the rear wheel Wheel rotates freely If wheel has abnormal resistance gets hung up Ensure proper tire pressure Inspect wheel bearing and lubricate replace as needed Ensure proper drive belt tension Ensure proper function of the driven clutch assembly no binding or hang ups Ensure proper tire pressure If proper tire pressure Ensure airflow is free of blockage restriction Verify proper tuning of carburetor refer to TECHNICAL GUIDE FOR 50cc CARBURETORS for proper procedure specifications and replace spark plug If tire pressure is low Inflate to recommended pressure Check for leaks or improper valve stem Ensure airflow is free of blockage restriction Verify proper tuning of carburetor refer to TECHNICAL GUIDE FOR 50cc CARBURETORS for proper procedure specifications and re
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