KEEWAY 50cc Series Service Manual Download

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SCOOTER SERVICE MANUAL

KEEWAY 50cc Models

Summary of Contents for 50cc Series

Page 1: ...SCOOTER SERVICE MANUAL KEEWAY 50cc Models KEEWAY AMERICA LLC SPRING 2008...

Page 2: ...or further assistance is needed please feel free to contact us KEEWAY AMERICA LLC 2912 SKYWAY CIRCLE N IRVING TX 75038 214 441 9661 PHONE 214 441 9641 FAX service keeway america com Our support staff...

Page 3: ...etor 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...

Page 4: ...eration 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 FIN...

Page 5: ...5 MAINTENANCE CHART...

Page 6: ...RICAL PRECAUTIONS SAFETY GUIDELINES SPECIALTY TOOLS REQUIRED GENERAL INFORMATION Terminology The 2 Stroke Engine Cycle Vehicle Information General Specifications POWERTRAIN SPECIFICATIONS Fastener Tor...

Page 7: ...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 P...

Page 8: ...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 Gea...

Page 9: ...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 auth...

Page 10: ...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 trem...

Page 11: ...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 an...

Page 12: ...OLS REQUIRED T01 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 pi...

Page 13: ...13 T07 13 16 Spark plug socket 2 styles shown T08 Impact wrench T9 Impact sockets 17 18mm needed T10 Clutch clamp tool T11 Torque wrench and appropriate sockets Recommend both lbs ft and lbs in...

Page 14: ...er 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 cy...

Page 15: ...direct feed into the CRANKCASE and then moves into the CYLINDER via the TRANSFER PORT The following better describes the process At the beginning of the engine s first revolution the piston begins an...

Page 16: ...e 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 d...

Page 17: ...eaches BDC a new cycle begins 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 d...

Page 18: ...s 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 90 Break in Du...

Page 19: ...39 6mm Displacement 49 8mL Compression Ratio 6 9 1 Timing 15 BTDC 1500rpm Carburetor Mechanical Slide Start System Electric and Kick start Remote Start Available Lubrication System Oil Injection Press...

Page 20: ...11 13lbs ft Intake port bolts 10 12Nm 8 9lbs ft Exhaust port bolts 10 12Nm 8 9lbs ft Carburetor joint locknuts 10 12Nm 8 9lbs ft Cooling fan locknuts 10 12Nm 8 9lbs ft Flywheel locknut 45 50Nm 33 36lb...

Page 21: ...m 29 43lbs ft Kick starter locknut 10 12Nm 8 9lbs ft Transmission case cover locknut 10 12Nm 8 9lbs ft Transmission case drain nut 22 25Nm 16 18lbs ft LH crankcase drain nut 22 25Nm 16 18lbs ft LH cra...

Page 22: ...ALVE CYLINDER HEAD Reed Valve seat clearance A 0 2mm overlap B 1mm Cylinder Head Surface Clearance 0 05mm CYLINDER PISTON Compression 155 5psi Cylinder Inner Diameter 40 005 40 020mm Piston Diameter 3...

Page 23: ...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 Tra...

Page 24: ...ocated 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...

Page 25: ...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 approximately halfway which greatly increases air...

Page 26: ...nkcase is gear driven by the crankshaft directly Oil is drawn from the reservoir to the carburetor via the pump where it is injected into the air fuel mix Due to the intake process of the two stroke e...

Page 27: ...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 p...

Page 28: ...28 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...

Page 29: ...ters 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 is experienced which means that the spring is being...

Page 30: ...r 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...

Page 31: ...w hose on carburetor Fuel flow Verify adequate ignition spark by removing spark plug No fuel flow Verify fuel in tank Verify fuel flow at petcock valve Verify fuel flow at filter Verify clear lines to...

Page 32: ...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...

Page 33: ...ure Oil does not meet requirements Over full low or burnt dirty oil Perform engine oil change Verify sufficient operating temperature Temperature is within range Perform ENGINE COMPRESSION TEST refer...

Page 34: ...ssive 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 n...

Page 35: ...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...

Page 36: ...ssing 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...

Page 37: ...et multimeter 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 a...

Page 38: ...In 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 thro...

Page 39: ...e vehicle s battery Current flows from here to the diode trio and from the diode trio to the regulator to be distributed The charging coil and pickup function as CDI references for ignition pulse and...

Page 40: ...vehicle kill switch remove the spark plug and connect compression tester REQUIRES SPECIAL TOOL T05 Disconnect vacuum line from fuel petcock valve Open Throttle completely and crank for 6 8 revolutions...

Page 41: ...ustion 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 va...

Page 42: ...ng 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 sho...

Page 43: ...hrottle 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...

Page 44: ...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 t...

Page 45: ...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...

Page 46: ...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 ca...

Page 47: ...VAL AND INSTALLATION CYLINDER HEAD ASSEMBLY Removal remove cowling prior Spark plug and cylinder head nuts 3 7 Cylinder head and assoc gasket 1 2 Cylinder jug and assoc gasket 4 5 Installation procedu...

Page 48: ...5 0 002in Second 0 02 0 04mm 0 001 0 0015in Removal remove cowling cylinder head assembly and cylinder jug prior First and second rings 1 2 Pin clips 5 qty 2 Wrist pin 6 Bearing 7 Installation procedu...

Page 49: ...and gasket 4 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...

Page 50: ...ing retainer and kick start gear 10 11 Crankshaft starter and transition gears 3 9 Dowel and gasket 1 2 Installation procedure is reverse of removal Torque Specifications Retaining plate lock bolt 8lb...

Page 51: ...before installing fixed face CRANKCASE ASSEMBLY Removal remove cylinder head cylinder jug and piston assembly prior Bolts 1 RH Crankcase assembly 2 Dowels and gasket 3 7 Crankshaft assembly 4 Camshaf...

Page 52: ...cases together Ensure free movement of crankshaft and connecting rod assembly after assembling the crankcase assembly TRANSMISSION CASE ASSEMBLY Gear A1 A2 B1 B2 Splines 15 42 13 40 Ratio 2 8 3 077 Re...

Page 53: ...all gears and pinions Torque bolts in modified star pattern to 8lbs ft DRIVE WHEEL CLUTCH ASSEMBLY Removal Clutch hub retaining pin and woodruff key 1 11 12 Nut washer and disk 2 7 8 Clutch shoe assem...

Page 54: ...nd 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 star...

Page 55: ...r 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 ge...

Page 56: ...56 NOTES Install bracket in proper groove before installing transition gear Ensure proper movement of transition gear...

Page 57: ...ixed face 1 Spacer 2 Retaining face 8 Dampers 7 Rollers 6 Bushing 3 Thrust Washer 4 Movable face 5 Installation procedure is reverse of removal NOTES Before installing retaining face install dampers E...

Page 58: ...3 Clutch hub 4 Pin 5 Rollers spring and bushing 6 7 8 Clutch cover 9 Spring retainer 10 Clutch body 11 Installation procedure is reverse of removal NOTES There should be no play in clutch assembly Ens...

Page 59: ...Assembly Mount 2 16 21lbs ft Handlebar Handlebar to Triple Clamp 1 27 32lbs ft Frame Engine Bracket Mount 1 28 32lbs ft Rear Shock to Frame 1 28 32lbs ft Rear Wheel Rear Shock Axle Nut 1 73 95lbs ft...

Page 60: ...L ASSEMBLY Removal Axle locknut 17 Axle 3 LH Bushing and speedometer gear assembly 4 8 Front wheel assembly Seal bearings and axle shaft bushing 5 6 18 Tire 16 Valve stem and cap 2 20 Installation pro...

Page 61: ...oval Locknut Rear wheel assembly Tire 8 Valve stem and cap 11 12 Rear wheel 7 Brake shoes and springs 1 2 Tension spring and bushing 3 4 M6x35 Bolt 9 Brake rocker arm 5 Brake cam 6 Installation proced...

Page 62: ...ets 11 12 13 Exhaust assembly 1 Muffler strap insulator and associated bolt 4 6 10 Muffler mounting nuts and gasket 5 15 Installation procedure is reverse of removal assemble exhaust assembly prior NO...

Page 63: ...nal nut and dust seal 3 4 Upper steel balls race and cap 5 6 and 16 1 Slide triple clamp 14 down DO NOT REMOVE Bring washer and spacer 9 10 down onto triple clamp stem CAREFULLY lower race 8 with a ha...

Page 64: ...r fit of bearing assembly A rubber mallet may be used Assemble and install upper bearing assembly 5 6 16 1 in the same manner as the lower bearing assembly Again a rubber mallet may be used Install du...

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KEEWAY 50cc Series, Service Manual

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