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KEEWAY 50cc Series User Manual

KEEWAY 50cc Series
64 pages
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SCOOTER SERVICE MANUAL
KEEWAY 50cc Models
© KEEWAY AMERICA, LLC
SPRING 2008

Table of Contents

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KEEWAY 50cc Series Specifications

General IconGeneral
Cooling SystemAir-cooled
Fuel SystemCarburetor
IgnitionCDI
Front SuspensionTelescopic fork
Front BrakeDisc
Rear BrakeDrum
Tires Front120/70-12
Tires Rear130/70-12
Width700 mm
TransmissionAutomatic
Engine TypeSingle-cylinder, 2-stroke

Summary

PRE-DELIVERY INSPECTION

TEST DRIVE

Verify proper front and rear suspension for correct damping and travel.

MAINTENANCE CHART

SAFETY GUIDELINES

SPECIALTY TOOLS REQUIRED

POWERTRAIN SPECIFICATIONS

FASTENER TORQUE

List of torque specifications for various fasteners on the scooter.

ENGINE COMPONENT FIT/TOLERANCE

TROUBLESHOOTING AND PROCEDURES

COMMON ISSUES

The following compilation describes the most common symptoms and potential solutions in the form of a flow chart.

NO-START CONDITION

Troubleshooting steps for when the engine fails to start.

INSUFFICIENT ENGINE POWER/LACK OF ACCELERATION

Troubleshooting steps for insufficient engine power or lack of acceleration.

POOR/DIFFICULT HANDLING/INSTABILITY

Guidance for diagnosing and fixing handling issues such as steering difficulty or wheel wobble.

BRAKE SYSTEM ISSUES

Troubleshooting for soft brakes, stiff brakes, and lever travel.

THE BATTERY

BATTERY CHARGE PROCEDURE

Step-by-step guide for charging the vehicle's battery.

POWER CIRCUITRY AND PARASITIC DRAW TEST GUIDELINES

PARASITIC DRAW TEST PROCEDURE

Procedure for identifying excessive voltage draws in electrical systems.

MAGNETO ASSEMBLY

ENGINE COMPRESSION TEST

IGNITION TIMING TEST

Technical Guide for Keeway 50cc Carburetors

Common problems and recommended solutions

Troubleshooting common carburetor issues like slow idle or fast idle.

POWERTRAIN COMPONENTS

ENGINE COMPONENTS REMOVAL AND INSTALLATION

LH CRANKCASE COVER

LH CRANKCASE COVER AND ASSOCIATED PARTS

CRANKCASE ASSEMBLY

TRANSMISSION CASE ASSEMBLY

DRIVE WHEEL CLUTCH ASSEMBLY

KICK START SHAFT ASSEMBLY

TRANSITION GEAR ASSEMBLY

VARIATOR/CVT ASSEMBLY

STARTER CLUTCH ASSEMBLY

CHASSIS

TORQUE SPECIFICATIONS

Lists torque specifications for various chassis components.

COMPONENT GUIDE

REAR WHEEL ASSEMBLY

EXHAUST ASSEMBLY

FRONT FORK ASSEMBLY

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