KEEWAY ATV250 Service And Maintenance Manual
  1. Manuals
  2. Brands
  3. KEEWAY Manuals
  4. Offroad Vehicle
  5. ATV250
  6. Service and maintenance manual
KEEWAY ATV250 Service And Maintenance Manual

KEEWAY ATV250 Service And Maintenance Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

ATV Service and
Maintenance Manual
Model: ATV250
C o p y r i g h t :
K E E WAY I N T E R N AT I O N A L D E V E L O P M E N T C O . , LT D .
FEB.2006
1

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ATV250 and is the answer not in the manual?

Questions and answers

Related Manuals for KEEWAY ATV250

Summary of Contents for KEEWAY ATV250

  • Page 1 ATV Service and Maintenance Manual Model: ATV250 C o p y r i g h t : K E E WAY I N T E R N AT I O N A L D E V E L O P M E N T C O . , LT D .
  • Page 2 If you have any problems can not fnd the solution in this manual, please fell free to contact with: KEEWAY INTERNATIONAL DEVELOPMENT CO.,LTD 2000 SZENTENDRE U.8 KOZUZO. HUNGARY TEL:0036-26-500005 FAX:0036-26-312034 EMAI: info@keewaymotor.com Our engineer are very glad to give you the necessary assistance and help.
  • Page 3 C O N T E N T A. General information 1. Basic terminology- Engine 2. Engine types-4 stroke engine work cycle/illustrations 3. Workshop safety Service rules Electricals safety B Product Technical specifications Special service tools Engine and transmission a) Specified torque value b) Small but vital component /Nondirectional fitment-parts of engine c) Engine removal /installation d) Engine assembly...
  • Page 4 a) Magneto（A.C.G） b) Wiring diagram c) Ignition circuit test d) The relational matters of the battery e) The process of debugging of battery Signal system circuit g) Battery charging system circuit h) Power flowing chart of electric start Removal and replacement of various bulbs Testing procedure of electrical components k) Important specifications -electrical C Others...
  • Page 5 GENERAL INFORMATION...
  • Page 6 The timing of ignition. The ignition is timed in order to control the combustion in the firebox. The timing ignition of ATV250 engine 。 changes as follows: 15...
  • Page 7 Engine work cycle Each 4-stroke petrol engine has the following 4 processes the completion of these 4 processes is termed as one cycle of the engine work. 1、 Suction: air and fuel mixture is sucked inside the cylinder 2、 Compression: air and fuel mixture is being compressed in cylinder 3、...
  • Page 8 C： ： ： ： Power stroke 1. Spark plug lights the compressed air- fuel mixture. 2. The combustion of air-fuel mixture causes the the temperature and the pressure increase in the firebox, the air expands, the power forces the piston to push the protuberance down.
  • Page 9 S e r v i c e r u l e s 1. Use only genuine KEEWAY parts and recommended grade of lubricants at specified parts and points. 2. Use right/proper (general and special) tools at right place.
  • Page 10 Electricals safety A loose wire harness can be a safety hazard.After clamping,check each wire to be sure it is secure. Don’t curve clamps towards welds. Secure wire bands to the frame at the designated locations.Tighten the wire bands (strap) so that the insulated surfaces can contact the wire wirenesses.
  • Page 11 PRODUCT...
  • Page 12 Te c h n i c a l s p e c i f i c a t i o n s Item Parameter ATV250 Total length 1950mm Total width 1100mm Total height 1110mm Seat height 840mm Wheelbase 1290mm Front wheel...
  • Page 13 Two levels gear case Gear speed-down rate First level 2.667（40/15） Second level 2.313（37/16） Max speed Manufacturer/type of carburetor KEEWAY-Wenling-China，vacuum chaff type Carburetor Identify NO. PD31 Diameter of throat pipe 31mm Size of main muzzle #294 Size of idle speed muzzle...
  • Page 14 Item Parameter Specs Ignition system Electric Timing ignition ‘F’ mark ±2 1500RPM before TDC 10 ‘Ⅱ’Full advance ±2 3500RPM before TDC 32 Alternator（magnetic electrode） 310W@4000RPM Spark plug D7RTC Clearance of spark plug 0.6~0.7mm fuse battery 12N9-4B-1 Front light （ high beam/dipped beam） Light 12V 18/18W Tail light/brake light...
  • Page 15 The tools are indispensable to install or dischange the engine down blow: Code of tools “T”shape sleeve Sleeve （7、8、10、12、13） Assembly and disassembly tools of stator Assembly and disassembly tools of air valve spring Assembly and disassembly tools of clutch lock nut Pressure chart of cylinder Assembly and disassembly tools of piston pin Assembly and disassembly tools of spark plug...
  • Page 16 ① ② ③ ④ ⑤ ⑥...
  • Page 17 ⑦ ⑧ ⑨ ⑩ ○ ○...
  • Page 18 S p e c i f i e d t o r q u e v a l u e Torque（ （ （ （ N.m） ） ） ） Name Lock bolt of chain tension pole 10-12 Lock bolt of chain tensioner 10-12 Lock bolt of cylinder head 25-28...
  • Page 19 S m a l l b u t v i t a l c o m p o n e n t Dowel pin-16NOS. S.NO. Size (mm) Qty. Description Location φ10×15.5 Cylinder head and body Engine φ10×14 Crankcase and cylinder body Engine φ10×14 Right and left crankcase...
  • Page 20 Bearing S.NO. Code Qty. Description Location 6303 Transition shaft-speed gear box cover Engine HK15×28×15 Idle shaft-speed gear box cover Engine 6205 Intake shaft- speed gear box cover Engine 62/22 Transition shaft-left crankcase Engine HK15×28×15 Idle shaft-left crankcase Engine 6302 Intake shaft-left crankcase Engine 6306 Left crank-left crankcase...
  • Page 21 Washer-6 NOS S.NO. Gasket Type Qty. Location Cylinder head Steel Engine Cylinder body Oil-proof asbestos rubber Engine Crankcase Oil-proof asbestos rubber Engine Right cover of crankcase Oil-proof asbestos rubber Engine Left cover of crankcase Oil-proof asbestos rubber Engine Chain tensioner Oil-proof asbestos rubber Engine Speed gear box cover...
  • Page 22 I n f o r m a t i o n o f c h a i n g e a r gear gear gear gear Amount of teeth Amount of teeth Amount of teeth Amount of teeth position position position position Drive chain wheel of left crank shaft...
  • Page 23 E n g i n e r e m o v a l / i n s t a l l a t i o n Steps o f a ssembly ： Steps o f disa ssembly : Front and rear luggage COMP Assembly engine Seat、Front fender、Rear fender、Footrest Engine bracket COMP, engine bracket fixed bolt, engine...
  • Page 24 E n g i n e a s s e m b l y Disassembly： ： ： ： Assembly： ： ： ： Radiator/cooling water pipe/intake pipe of carburetor Assemble left crankcase /Assemble speed gear box cover Gear shaft box/reverse gear Assemble speed gear box Left cover/water pump/outside of left crankcase Crank /Assemble right and left crankcase /Starting motor...
  • Page 25 R a d i a t o r a s s e m b l y D i s a s s e m b l y D i s a s s e m b l y D i s a s s e m b l y D i s a s s e m b l y ：...
  • Page 26 C a r b u r e t o r i n t a k e p i p e a s s e m b l y Disassembly Disassembly： ： ： ： Disassembly Disassembly Nut（5） O ring（2） Carburetor COMP（6） Bolt（3）...
  • Page 27 G e a r c a s e / R e v e r s e g e a r Disassembly Disassembly Assembly Assembly Disassembly Disassembly Assembly Assembly outtake chain wheel（B29） Gear shift bearing（A36） Rocker （A23） Idle wheel comp（B32） Bearing（A26）/Display of gear （A5）/feeler of Outtake bearing comp(B26）/gear bearing comp(B6）...
  • Page 28 C y l i n d e r h e a d a s s e m b l y Disassembly ： Assembly Assembly： ： ： ： Assembly Assembly Cylinder head Timing tensioner（A-15）/Chain wheel cover（B-7）/ Valve cap（B-10、11） Valve pipe（B-2） Snap to the“T”mark of the magneto （in the cylinder head comp, at the TDC of the Valve seal comp（C-6）...
  • Page 29 Istructions Istructions Istructions Istructions： ： ： ： 1.The valve should be rubbed evenly before assembly， the rubbing lines of the valve and valve seat should be even after rubbing. 2.when assembling the valve， check the vale pole and adda little fixing oil on it， the ploe should roll agilely without any retardarce in the pipe.
  • Page 30 P i s t o n a s s e m b l y Disassembly: The first ring The second ring Washer of oil ring （1） washer of oil ring（2） gasket of oil ring piston Assembly： ： ： ： Opposite to the steps of disassembly Instructions：...
  • Page 31 L e f t c r a n k c a s e c o v e r a s s e m b l y Disassembly： ： ： ： Left crankcase cover Front cover of the engine（6） real cover of the engine（9） Left crankcase cover（1）...
  • Page 32 W a t e r p u m p a s s e m b l y Disessembly Disessembly： ： ： ： Disessembly Disessembly Bolt（13） Outtake of pipe（15）/O ring（16） bolt（5）/bolt（14）/washer（11） water pump cover（3）/water pump seal（4） impeller （2）/Whishtring comp（8） water pump body（7）/pump bearing（10）/O ring（12） assembly assembly：...
  • Page 33 R i g h t c r a n k c a s e c o v e r a s s e m b l y Disassembly： ： ： ： （ ） Blot Oil lever（1） （ ） Sensor Seal ring（2） （...
  • Page 34 S p a r e p a r t s f o r r i g h t c r a n k c a s e c o v e r Disassembly： ： ： ： Circlip（B4） Cover of oil filter net （A11） Bolt（A20） Lock nut（B9）...
  • Page 35 C l u t c h a s s e m b l y Disassembly Disassembly： ： ： ： Disassembly Disassembly Big gear COMP of starting clutch（1） Inside ring of starting clutch（2）/Outside ring of starting clutch（3）/Starting clutch block（4） Outside ring of starting clutch（5） Assembly Assembly ：...
  • Page 36 D r i v e g e a r C O M P a s s e m b l y Disassembly: Disassembly: Assembly: Assembly: Disassembly: Disassembly: Assembly: Assembly: Nut（2） /Washer（14） Right drive plate（1） Impeller（6） Roller（5）/Oil seal（4） （6）/Damper（7）/Kickstand（11） Collar（2）/Belt（15） Movable drive plate Right grive plate COMP Centrifugal roller（6）...
  • Page 37 Dr i v e n g e a r c l u t c h C O M P a s s e m b l y Disassembly： ： ： ： Disassembly of the dirve plate comp of clutch： ： ： ： Driven wheel COMP Cover of spring（6）...
  • Page 38 a s s e m b l y C r a n k c a s e Disassembly： ： ： ： Circlip（11）/Piston pin（12）/Piston comp（26） Bolt 15/Bolt 16/Gear 5 Right crankcase comp（3）/Left crankcase comp（12）/Dowel pin（13） Crankcase comp（4）/Chain（27） （ ） Damper /Stud bolt Damper（1）/Stud bolt /Oil seal（16）/Damper（17）...
  • Page 39 a s s e m b l y G e a r b o x Disassembly： ： ： ： Gear box comp Left crankcase comp（24） Screw（19）/Gear box cap cmop（20）/Washer（21、23） Rear axle（13） Idle shaft（4 ）Transmition bearing（5） Idle shaft comp（1）Transmition bearing（6） Rear axle shaft（12） Idle shaft （4）...
  • Page 40 Power flow chart From the engine： ： ： ： Piston(1) Connecting rod(2) Crankshaft(3) Primary driven disk(12) Pressure disk(7) Clutch(8) Intake shaft of gear box(4) Idle shaft of gear box(5) Transation shaft of gear box(6) Idler pulley Rear axle shaft X－Outmatic speed-down rate Y－Junior speed-down rate（4015）...
  • Page 41 L u b r i c a t i o n s y s t e m...
  • Page 42 T h e s e t u p o f v a l v e i n t e r v a l Launch it under the cold state 1、Take down a rubber cover on the worm wheel body 2、Let the mark “T” on the flywheel be in the same level with the mark on the right cover. 3、Make sure that the timing carved line of cam chain snap to the critical surface of the cylinder head.
  • Page 43 E n g i n e c y l i n d e r c o m p r e s s i o n t e s t The first step: 1.Start the engine ,so that the temperature reaches to the temperature of going normally ； 2.Take down the spark plug, and connect the manometer；...
  • Page 44 Some important dimensions –engine Cylinder head /valve Project Standard The pressure of the cylinder 12±1kg/cm Intake 0.03~0.05mm The valve interval Outtake 0.05~0.06mm Intake 36.63 The height of cam of the camshaft Outtake 31.6 Intake 5975~5990 mm Valve poles Outtake 5955~5.970 mm Intake 6.000~.012mm Valve...
  • Page 45 4、 Reinstallate all the parts according to the reverse process of dismantlement. C A R B U R E T O R The manufacturer KEEWAY The curve of oil consumption Type China Model...
  • Page 46 M i x e d a i r ( a i r b u r n i n g ) s y s t e m The flowing process of mixtual gas ： ： ： ： The fuel oil flow out from the fuel tank depends on its gravity through the entering oil switch,at last flow into the carburetor.
  • Page 47 1、 、 、 、 The process of oil entering The fuel oil flows into the float room of carburetor from fuel tank depend on one's own gravity.The float room communicates with the atmosphere by balance pipe of carburetor ,in order to guarantee that the pressure in the float room is the same as pressure of the atmosphere.The float rises with the...
  • Page 48 3、 、 、 、 Idle speed After starting the engine, the channels of oil concentrating will close and concentration of mixed gas become less, then the fuel oil was absorbed into throat pipe through idle speed hole and transit hole. The other parts of fuel oil was absorbed into throat pipe through mixed proportion...
  • Page 49 6、 、 、 、 high speed When the engine have sped up to raise lever plug completely, the high speed of engine make the air in throat pipe speed up, and it produce big negative pressure around the main jet so that it can absorb more mixed gas .

  • Page 50: Carburetor Assy

    Disassembly and assembly of the carburetor Disassembly 1) Take apart the seat of ATV and front or rear fender 2) keep the control switch of oil “off” 3) pull out the oil pipe ,in with pliers 4) loosen clip ring between carburetor and air cleaner 5) pull out the plug at the end of oil pipe, out.
  • Page 51 4) turning mail hole tightly 5) put needle valve and floater into seat of needle valve together, hook of needle valve is put on the tongue of floater 6) put the pin into seat of floater, floater pin go through the floater and floater in order 7) check the high in the range 13+_1mm,please adjust the tongue of floater if it is not correct 8) setting up the under cover body 9) setting up the idle,adjust bolt, spring, mixed proportion .adjust bolt , spring,washer and seal ring(as usual should put...
  • Page 52 S p e c i f i e d t o r q u e v a l u e Subject Total Value of fixed torque Front wheel/Front shock absorber Redirector and front wheel nut 70~83N.m Front wheel and bolt of front hub 37~44N.m Front shock absorber, frame and bolt of rocker 37~44N.m...
  • Page 53 F r o n t w h e e l a s s y Disassembly： Assembly： Nut（1） 、Front wheel （2） 、Cover（3） The fixing bolt of front wheel, Front hub Dustproof cover 4） 、Split pin 5） 、Nut（6） Inside bearing（61905-2RZ） Special tools The pump of front disc brake、Front hub COMP（7）...
  • Page 54 F r o n t d i s c b r a k e a s s y Working rule of caliper. disc brake:： ： ： ： Liquid can not be compressed easily, so the power can be transfer through it. Master cylinder When the brake handle is compressed, the lever plug of master cylinder will move in the compressed direction, when rubber bowl A...
  • Page 55 图 7 Diagram 7 Brake tub COMP Brake tub COMP Brake tub COMP Brake tub COMP Dustproof seal of airproof muzzle 2. Oil intake bolt 3. Brake oil channel 4. Brake tub 5. Oil plug Diagram 9 6. Long shaft 7.
  • Page 56 Checking of disc brake Notice 2) break brake pipe, put the open end of throat pipe into 1) don not touch the liquid with bare hands for a long the holder then draw out the liquid time 3) take apart the bolt, caliper, brake shoe, spring of brake 2) please clean with water and ask for doctors once the liquid of disc brake spatter into eyes shoe...
  • Page 57 R e d i r e c t o r ， ， ， ， U p p e r a n d l o w e r s w i n g a r m a s s y Disassembly： Assembly：...
  • Page 59 S t e e r i n g s y s t e m Disassenbly： Assembly： Protecting sleeve COMP（1） 、Bolt（2） Handle bar jointing COMP Spacer 、Nut 、Pin Fixing plate（3）Pilot lamp COMP（4）Up handle cover （5） Gimbal COMP A 、 Ttubing pole Stay up line（6）...
  • Page 61 R e a r W h e e l , t r a n s m i s s i o n s y s t e m a s s y Steps of disassembly： steps of assembly： stay up line、pump of rear disc brake comp. Adjuster of chain、gaine of rear wheel I、...
  • Page 63 R e a r h y d r a u l i c b r a k e a s s y Rear disc brakeer（ （ （ （ disc） ） ） ） Principle of disc breacker：liquid can’t be compressed，so power can be past by a go-between of liquid。...
  • Page 64 digram 7 Diargram 8 dirgram 9 dirgram 10...
  • Page 65 Overhaul of rear hydraulic brake Instrutions： (4)Disassemble the oil piston, dust seal of the oil 1．Don’t touch the brake liqucd directly. piston,squre seal ring. 2．Once brake liqucd splashescnto eyes, wash them Steps of the assembly are following： ① by cold water and see the doctor. Bellow compressed air into the brake cylinder at the 3．Don’t let brake liqucd splashes on the part painted , opening of the interface, push the oil piston out of the...
  • Page 66 R e a r s w i n g a r m a s s y Steps of disassembly： Steps of assembly： stay up line、pump of rear disc brakeer comp、transmission rear swinging arm comp comp bearing（GB943/20） 、inner bush、oil seal bearing nut、bolt、rear absorber comp spacer I、spacer II nut（1）...
  • Page 67 I m p o r t a n t t i p s o n v e h i c l e a s s e m b l y 1． The seal side of the wheel bearing should be outside 2．...
  • Page 68 I m p o r t a n t d i m e n s i o n s o f v e h i c l e Front wheel/absorber content standerd Air pressure of tyre driver 58kPa（8psi） Free length of front absorber’s spring Oil cubage of front absorber Oil level of front absorber Producer of front absorber’s oil...
  • Page 69 M a g n e t o （ （ （ （ A C G ） ） ） ） Configuration： ： ： ： ATV’s magneto is made up by stator and rotor. Type of stator’s loop: star model. Assembly of stator ： ： ： ： Stator with 12loops: 12 loops are for lighting and electrification.
  • Page 70 W i r i n g d i a g r a m...
  • Page 71 I g n i t i o n c i r c u i t t e s t For any corn of C.D.I we can always check each b.The resistance between the gihg voltage lead part step by step according the processed down and sub loop should be -7.5±1K , including the below.
  • Page 72 Test of timming ignition 1.Remove the cap of ignition inspection. 2.Join the stroboscope according to the instruction of the manufacturer. 3.Start the engine and aim the stroboscope to the ignition mark on the flywheel of the magneto. •Course of slow down: “F”ignition mark snaps the “V”...
  • Page 73 T h e r e l a t i o n a l o f m a t t e r s o f t h e b a t t e r y Full accumulation:1.220-1.240. Proportion Term of electrification：＜1.220. Use densimeter to check the battery.
  • Page 74 T h e p r o c e s s o f d e b u g g i n g o f b a t t e r y Disassemble the battery from the body tie anode and cathode of battery to the red（＋） 、 black（－） leads of the debugger.
  • Page 75 S i g n a l s y s t e m c i r c u i t...
  • Page 76 B a t t e r y c h a r g i n g s y s t e m c i r c u i t...
  • Page 77 P o w e r f l o w c h a r t o f e l e c t r i c s t a r t Flow of Electric Current battery fuse the power switch the brake switch the starting switch starter relay starting motor...
  • Page 78 R e m o v a l a n d r e p l a c e m e n t o f v a r i o u s l i g h t s （ （ （ （ front light） ） ） ） Disassembly steps of front light：...
  • Page 79 Te s t i n g p r o c e d u r e o f e l e c t r i c a l c o m p o n e n t s Inspect the continuum of the electic seitch hereinafter with multimeter...

  • Page 80: Ignition System

    I m p o t a n t s p e c i f i c a t i o n s - e l e c t r i c a l Battery charging system item specification capacity 12V-9AH（KS） full 1.220-1.240 proportion（27℃）...
  • Page 81 OTHERS...
  • Page 82 P r e - d e l i v e r y i n s p e c t i o n （ （ （ （ P. D . I ） ） ） ） / c h e c k p o i n t s It is very important to do thoroughly inspection before delivery.
  • Page 83 C h e c k p i o n t s Check the function of Check the fuction of the ignition switch the combinatorial switch Check pressure of front tyre Check the fasten moment Check the fasten moment Check the pressure of front wheel axle of the engine bolt of real tyre...
  • Page 84 P e r i o d i c a l m a i n t e n a n c e The table show the schedule of the regular maintenance according to the process. At the end of the dtep,check test,lubricate, maintain.
  • Page 85 D o ’s a n d d o n ’ t ’s Allowed Unallowed 1、 Disassemble and install by professional tools 1、 The brake toe abrations rear to the abration mark, aontinuing using is unallowed. 2、 Install oil seal by professional tools 2、...
  • Page 86 S a f e t y r i d e The posture of Drive What kind of driving posture can be regarded as the good driving posture? 1. helpful to the driver to gather information necessary for the driving accurately. 2 .Driver and motor are the one.
  • Page 87 6. After stopping you put your feet on the ground. The front shock absorber restores to the original state after the vehicle stops. Tro u b l e s h o o t i n g ·Engine can not start or hard to start （check whether ignition switch is in the position of opening）...
  • Page 88 not adjusted The engine can not start -Jam of carburetion Appropriately -Ignition in advance or lag -Mixed air is too sparse or dense 4.Disassemble and check spark plug Spark plug is wet -Airproof valve of carburetion is too tight -Seep of carburetion -Mixed air is too dense Spark plug is dry -Air cleaner is too...
  • Page 89 the ground by hard -Brake resistance -Abration or ruin of wheel bearing The wheel runs freely -The wheel bearing need be lubricated -Drive chain is too tight 2.Check the pressure of The pressure is too low tire -Seep of tire -Malfunction of tire’s air valve Pressure is normal...
  • Page 90 oil character not enough -Oil level is too low -Pollution of oil In good condition 7.Check the time of ignition Incorrect -Malfunction of C.D.I -Malfunction spring loop Correct -Spring loop is fixed in wrong way 8.Check whether the The clutch is slided clutch is skided -Loosen of clutch’s spring...
  • Page 91 10. Check the pressure of the cylinder the pressure valve seat tooth’s incorrectly is low -clearance of air valve is narrow The pressure is normal -abration of cylinder and piston ring -ruin of cylinder head washer -incorrect of air intake phase 11.
  • Page 92 5. Check if the carburetion blocked -block in oil duct of carburetion Is blocked -block of carburetion muzzle Expedite ·Badness in high speed Badness in high speed Badness in high speed Badness in high speed reasons possible reasons possible reasons possible reasons possible 1.
  • Page 93 -rocker or bracket bends -front or real absorber looses or Malfunction checking •fuel system •c c c c ylinder head ylinder head ylinder head ylinder head –malfunctions of cylinder head or assembly engine can’t start –carburetion without oil valve will effect the capability of the engine. –tank without fuel Those problems can be checked by testing of air –jam of oil filter...
  • Page 94 –jam of tank assembly hole –pressure of cylinder is low –jam of oil tube –intake leaks capability of driving is weak, waste oil capability of driving is weak, waste oil capability of driving is weak, waste oil capability of driving is weak, waste oil –jam of fuel supply system –jam of fuel system –malfunction of carburetor...
  • Page 95 –malfunction of tyre –wheel slopes excessive –wheel is screwed wrongly...
  • Page 96 Check the malfunctions • light light light/ / / / electrification system of battery light electrification system of battery electrification system of battery electrification system of battery • electric start system electric start system electric start system electric start system Battery is empty Battery is empty starting motor do not work...
  • Page 97 –malfunction of light or battery electrification and the clutch is detached, press down the start loop button, and start motor works. Front light is dark –grounding weakly –malfunction of rectifier –malfunction of light or battery electrification loop...

Table of Contents

Save PDF