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ATV250
KEEWAY ATV250 User Manual
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act with:
KEEW
A
Y INTERNA
TIONAL
DEVELOPMENT CO.,L
TD
2000 SZENTENDRE U.8 KOZUZO. HUN
GARY
TEL:0036-26-500005
F
AX:0036-
26-312034
EMAI: info@keewaymoto
r
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Table of Contents
Contents
3
General Information
5
Basic Terminology - Engine
6
Dead Center
6
Bore
6
Stroke
6
Engine Work Cycle
7
4-Stroke Engine Work Cycle
7
Suction Stroke
7
Exhaust Stroke
8
Workshop Safety
9
Service Rules
9
Electricals Safety
10
Product
11
Technical Specifications
12
Specified Torque Value
18
Small but Vital Components
19
Bearing
20
Shaft - 2NOS.
20
Washer-6 NOS
21
Information of Gear
21
Chain
22
Engine Removal/Installation
23
Engine Assembly
24
Radiator Assembly
25
Carburetor Intake Pipe Assembly
26
Gearcase/Reverse Gear
27
Cylinder Head Assembly
28
Torque Value
28
Piston Assembly
30
Left Crankcase Cover Assembly
31
Water Pump Assembly
32
Right Crankcase Cover Assembly
33
Spare Parts for Right Crankcase Cover
34
Clutch Assembly
35
Drive Gear Comp Assembly
36
Driven Gear Clutch Comp Assembly
37
Crankcase Assembly
38
Gearbox Assembly
39
Power Flow Chart
40
Lubrication System
41
The Setup of Valve Interval
42
Launch It under the Cold State
42
Engine Cylinder Compression Test
43
If the Pressure of Cylinder Increased
43
If the Pressure of Cylinder Didn’t Increase
43
Some Important Dimensions –Engine
44
Cylinder Head /Valve
44
AIR Filter Assy
45
Carburetor
45
The Curve of Oil Consumption
45
Mixed Air System
46
The Flowing Process of Oil of Carburetor
46
The Process of Oil Entering
47
The Process of Gas Increase Its Concentration
47
Idle Speed
48
Slow Speed
48
High Speed
49
Disassembly and Assembly of the Carburetor
50
Carburetor Assy
50
Step of Disassembly
50
Step of Assembly
50
Step of Adjustment of Carburetor
51
Warning
51
Front Wheel Assy
53
Front Disc Brake Assy
54
Working Rule of Caliper
54
Master Cylinder
54
Brake Tub COMP
55
Checking of Disc Brake
56
Discharging of Oil Pump
56
Step of Letting Air out
56
Taking Apart the Caliper Assy
56
Redirector
57
Upper and Lowers Wing Arm Assy
57
Steering System
59
Rear Wheel, Transmission System Assy
61
Steps of Disassembly
61
Rear Hydraulic Brake Assy
63
Rear Disc Braker
63
Oil Pump Comp
63
Braker Cylinder Comp
64
Overhaul of Rear Hydraulic Brake
65
Disassemble of the Oil Pump
65
Disassemble of Brake Cylinder
65
Steps of the Assembly Are Following
65
Rear Swing Arm Assy
66
Important Tips on Vehicle Assembly
67
Front Wheel/Absorber
68
Rear Wheel
68
Magneto
69
Wiring Diagram
70
Ignition Circuit Test
71
Complex Switch
71
Ignition Loop
71
Test of Timming Ignition
72
The Process of Debugging of Battery
74
Testing of Wiring Diagram
74
Signal System Circuit
75
Battery Charging System Circuit
76
Power Flow Chart of Electric Start
77
Flow of Electric Current
77
Removal and Replacement of Various Lights
78
Disassembly Steps of Front Light
78
Testing Procedure of Electrical Components
79
Power Switch
79
Front Brake Switch
79
Starting Switch
79
Important Specifications
80
Battery Charging System
80
Ignition System
80
Others
81
Pre-Delivery Inspection
82
Check Points
83
Periodical Maintenance
84
Do's and Don'ts
85
Allowed
85
Unallowed
85
Safety Ride
86
The Posture of Drive
86
The Posture of Drive Requires Seven Points
86
Brake Effectively
86
Troubleshooting
87
·Engine Can Not Start or Hard to Start
87
Weak Capability in Idle Speed and Low Speed
91
Badness in High Speed
92
Hard to Operate
92
Malfunction Checking
93
Mixing Air Is Sparse
93
Mixed Air Is Dense
93
Cylinder Head Is Smoking
93
Capability of Driving Is Weak, Waste Oil
94
Too Smoking
94
Donky Motor Slips Hard in Idle Speed
94
Clutch Slips When Speeding
94
Check the Malfunctions
96
Battery Is Empty
96
Starting Motor Do Not Work
96
Low Voltage
96
4
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KEEWAY ATV250 Specifications
General
Brand
KEEWAY
Model
ATV250
Category
Offroad Vehicle
Language
English
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