KEEWAY ATV250 Installations- und Benutzerhandbuch

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

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.

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

1. Technical specifications

2. Special service tools

3. Engine and transmission

a) Specified torque value

b) Small but vital component /Nondirectional fitment-parts of engine

c) Engine removal /installation

d) Engine assembly

e) Radiator assembly

f) Engine removal /installation

Intake pipe of carburetor /Gear case/Cylinder head /Piston/Left crankcase cover / Water

pump/Right crankcase cover/Spare parts for right crankcase cover/ Clutch/Drive gear

COMP/Driven wheel clutch COMP/Crankcase/Speed gear box

g) Power flow chart

h) Lubrication system

i) The setup of valve interval

j) Engine cylinder compression test

k) Some important dimensions-engine

Fuel –air system - Air filter/Carburetor assy

- Mixed air ( air burning) system

- Disassembly and assembly of the carburetor

4. Chassis group

a) Specified torque value – chassis

b) Sub assembly – chassis

(i) Front wheel assy

(ii) Front disc brake assy

(iii) Redirector, upper and lower swing arm assy

(iv) Steering system

(v) Rear wheel, transmission system assy

(vi) Rear hydraulic brake assy

(vii) Rear swing arm assy

c) Important tips on vehicle assembly

d) Important dimensions of vehicle

5. Electricial /electronics

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

f) Signal system circuit

g) Battery charging system circuit

h) Power flowing chart of electric start

i) Removal and replacement of various bulbs

j) Testing procedure of electrical components

k) Important specifications -electrical

C Others

1. Pre-delivery inspection (P.D.I)/check points

2. Periodical maintenance

3. Do’s and don’t’s

4. Safety ride

(i) Riding posture

(ii) Effective braking

5. Trouble shooting

GENERAL INFORMATION

B a s i c t e r m i n o l o g y - E ng i n e

.Dead center

Either of the two limits in the cylinder at which the

piston changes its moving direction.

TDC ------- top dead center(the upper limit of the piston

movement)

BDC------- bottom dead center(the lower limit of the

piston movement)

B. Bore

Bore is the internal diameter of the cylinder block

C. Stroke

The length of the piston travel is called the stroke.

When piston moves from TDC to BDC, it is one stroke.

D. D.

D. Displacement

The volume swept by piston when traveling from TDC to BDC is

called displacement. Normally displacement is measured in

CC( cubic centi-meter) e.g. 75cc, 125cc etc. and it varies

according to engine type.

E. Torque

Torque is a kind of twisting or turning force. When we loosen

or tighten the screws or bolts, we impart the torque to them.

The engine imparts torque to the wheels to drive them, and

imparts more torque when it climbs. The produce of strength and

the arm of force equal to the torque, and its unit is kilogram-meter.

F. 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: 150。When it is 5000RPM.

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、Power : after spark, mixture explodes and expand to push dam

piston, thus crankshaft output machanical energy through con-rod.

4、Exhaust : the gases are expelled

4 - s t ro k e e n g i n e w o r k c y c l e

A：

：：

：SUCTION STROKE

1、The crankshaft turns in the counter clockwise direction

2、The motion of the crankshaft acts on the con-rod to pull the

piston down.

3、As the piston moves from TDC to BDC, the intake valve

opens and air-fuel mixture is drawn into cylinder

B：

：：

：Compression stroke

1、The crankshaft continues running, and brings the

piston goes from the BDC to the TDC by the connecting rod.

2、The mixing air is pressed into a narrow room between the

cylinder head and the top of piston which is called firebox.

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.

3. The power forced on the plug transfers to the

crankshaft through connecting rod, then the crankshaft

speeds up, the expanding of mixed air provides

power for the engine.

D：

：：

：Exhaust stroke

1、The air outtake valve opens when the piston goes

The bottom of the process.

2、The revolvable crankshaft pushes the piston towards the

cylinder head because of inertia.

3、Then the piston goes towards the cylinder head, the

burning gas is pushed out from air outtake valve, the

air outtake valve closes when piston reach the top end

of process.

Wo r k s h o p s a f e t y

Warning

Never use worn-out Tools which may slip and

cause injury to you.

Warning

Do not smoke or allow flames or spark near

petrol which is highly explosive as well as

inflammable.Work in a well ventilated area.

Warning

Do not spill oil on the workshop floor as one

may slip and get injuried.Always keep it neat

and clean.

Warning

Never run the engine in an enclosed or

badly-ventilated area for a long time because the

exhaust contains poisonous gas.

Warning

Never use dry brush or compressed air to clean

brake assembly/components because inhaled

airborne asbestos fibres may cause cancer or

respiratory disease.

Warning

The battery electrolyte contains sulphuric

acid.Protect your eyes,skin and clothing.In

case of contact,flush thoroughly with water

immediately & call a doctor.Electrolyte

should be kept at a safe place out of reach

of children.

Warning

Always ensure mutual safety when working

with a partner.

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.

3. Install new gaskets,O rings,oil seals,clips,split pins and so on,while reassemblying.

4. Use only Metric nuts and bolts(MKS system).

5. When tightening nuts or bolts,start first with larger diameter or centre ones.Then tighten the

others to the specified torques diagonally (criss-cross pattern).

6. After reassemblying,checking all nuts & bolts for proper tightening by torque wrench,check free

operation and also movement of the moving components.

7. Clean parts before measurement and get rid of oil,if any.Lubricate working parts lightly by oil

while assembly.

8. When engine and transmission components are dismantled and kept for a longer period,coat the

mating surface with a lubricant to prevent rusting and cover them,to avoid dust.

Electricals safety

1. A loose wire harness can be a safety

hazard.After clamping,check each wire to be

sure it is secure.

2. Don’t curve clamps towards welds.

3. 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.

4. Route wire harnesses and cables to avoid

frame ends or sharp edges.

5. Route wire harnesses to avoid the projected

ends of bolts and screws.

6. Keep wire harnesses and cables away from the

hot parts or area where they might be pinched

between the moving parts.

7. Wire harnesses routed along the handlebars

should not be pulled tight or have excessive

slack or be pinched or interfere with adjacent

or surrounding parts in all steering positions.

8. Check that the wire harnesses are not twisted

or kinked.

9. Ascertain that there is a damage of connector

cover,and if its terminal is opened

excessively,before connection.

10. Protect wires and harnesses with tape or a tube

if they contact a sharp edge or corner.

11. After repairing wire harnesses,wrap with

protective tape or replace them.

12.Don’t bend or twist the control

cables.Damaged control cables will not

operate smoothly and may stick or bind .

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