KEEWAY 50cc Series User manual
SCOOTER SERVICE MANUAL
KEEWAY 50cc Models
© KEEWAY AMERICA, LLC
SPRING 2008
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If problems cannot be resolved 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 will assist in any way possible.
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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, and adjust accordingly.
Verify proper operation of remote-start system.
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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.
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MAINTENANCE CHART
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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 SPECIFICATIONS
Fastener Torque
DIMENSIONS
Alignment Pins/Dowels
Pin shafts
O-rings
Seals
Bearings
Gaskets
Gears
Sprockets
Chains
ENGINE PARTS ORIENTATION
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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
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POWERTRAIN COMPONENTS
CARBURETOR REMOVAL/INSTALLATION
ENGINE AND COMPONENTS REMOVAL/INSTALLATION
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
CHASSIS
TORQUE SPECIFICATIONS
COMPONENT GUIDE
Front Wheel Assembly
Rear Wheel Assembly
Exhaust Assembly
Front Fork Assembly
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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.
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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-rings, 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.
Table of contents
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