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KEEWAY TX200 Service Manual
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KEEWAY TX200 Service Manual

KEEWAY TX200 Service Manual

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TX200 Service Manual
KEEWAY Motor Corporation Ltd.
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Summary of Contents for KEEWAY TX200

  • Page 1 TX200 Service Manual KEEWAY Motor Corporation Ltd. - 1 -...

  • Page 2: Table Of Contents

    Contents Contents................................- 2 - Preface ..............................- 5 - Preparing ..............................- 6 - Inspection/Adjustment ........................... - 17 - 1 Brake ................................- 30 - 1.1 Maintenance Instructions ......................... - 30 - 1.2 Failure Diagnosis ..........................- 30 - 1.3 Front Fluid Brake ..........................
  • Page 3 7 Starting System ............................71- 7.1 Preparing ............................. 71- 7.2 Failure Diagnosis ..........................72- 7.3 Starting motor ............................72- 7.4 Starting Relay ............................74- 8 Lithts/ Switches / meters ..........................75- 8.1 Preparing ............................. 76- 8.2 Failure Diagnosis ..........................76- 8.3 Headlight bulb replacement .........................
  • Page 4 14.5 Disassembly of Main&Counter Shafts ................... 116. 15 Speed transmisson system ........................119. 15.1 Preparing ............................119- 15.2 Failure Diagnosis ..........................119- 15.3 Gear Shifting Mechanism ........................ 120- 15.4 Installation ............................122- 16 Crankcase ..............................124- 16.1 Preparing ............................124- 16.2 Failure Diagnosis ..........................

  • Page 5: Preface

    Preface This manual is an introduction to the maintenance of TX200. Preparing Documents include all the contents needed, so read it carefully before operation. Inspections introduce how to check and maintain your motorcycle, which needs to be done regularly. After the first chapter, the manual will explain parts of the engine, entire motorcycle, electrical parts, and how to disassemble and reassemble these parts.

  • Page 6: Preparing

    Preparing Documents General safety Maintenance rules Specification table Failure diagnosis General Safety Carbon monoxide Start the engine in a well ventilated place, not a confined one. Note Exhausted gas contains poisonous carbon monoxide, which may cause people unconscious and even death. Do use the exhaust removal system when starting the engine in a confined place.

  • Page 7: Maintenance Rules

    Maintenance rules In the maintenance of this bike, metric tools should be used as much as possible; otherwise, the bike will be damaged using the improper tools. Clean up the dirt of the parts or the assembly parts before removing or opening the motorcycle shield in the maintenance work to prevent dirt falling into the engine, chassis or braking system.
  • Page 8 The length of bolts or screws is different for different assemblies and shields, so bolts and screws should be correctly mounted. If there is confusion, you can put the bolt into the hole to see if it is appropriated. To install the oil seal, first fill the oil seal groove with the grease lubricant, then check whether the seal is smooth, otherwise it will damage the oil seal.

  • Page 9: Specifications

    TX200-A Specifications Off-road type QJ200GY-AOff-road type Q J 1 6 4 F M L Model Engine type 2100 Fuel type Above 90# White gasoline Length mm Width mm Cylinders 1090 Bore*Stroke 63.5mmx62.2mm Height mm Engine Wheel base mm 1365 Swept volume...
  • Page 10 Specifications (TX200 Street type QJ200GY-AStreet Model Engine type Q J164FML type >90# White Length mm 2100 Fuel type gasoline Width mm Cylinders Cylinders Height mm 1090 Bore*Stroke Bore*Stroke Engine Wheel base mm 1365 Swept volume Swept volume Forward Electric/kick 45.9kg...
  • Page 11 Failure diagnosis Hard to start hard or can not start Failure diagnosis Adjustment and inspection Source of trouble Loosen the bolt of the carburetor No petrol in the petrol tank to check whether there is enough Oil pipe of carburetor plugs up fuel Oil pipe of float chamber plugs up Enough fuel for...
  • Page 12 Unsmooth rotation（under speed） Failure diagnosis Adjustment and inspection Source of trouble Start the engine Air filter plugs up lightly Bad petrol Engine speed enough Pipeline of the Evaporative Emissions Control rise engine speed System plugs up Vent-pipe plugs up Adjust the electronic spark Bad automatic choke timing Cracked vacuum module for the carburetor...
  • Page 13 Unsmooth rotation（especially low speed） Failure diagnosis Adjustment and injection Source of trouble Adjust ignition time Bad CDI Normal Abnormal Bad trigger Adjust the bolt to change the oil level of the carburetor Mixed gas is too thin (loosen the screw) Well Bad adjustment adjusted...
  • Page 14 Unsmooth rotation（especially high speed） Failure diagnosis adjustment and inspection Source of trouble Adjust ignition time Bad CDI Normal Abnormal Bad trigger Insufficient petrol in the petrol tank Petrol filter plugs up Normal Abnormal Pipeline of the Evaporative Emissions Control System plugs up Bad automatic oil-control ring Carburetor plug up Unblocked...
  • Page 15 Bad battery（over discharged or overcharged） Failure diagnosis Adjustment and inspection Source of trouble Start the engine and measure the battery voltage Life of the battery is over Voltage don’t The voltage rises to the normal rise level and is back to original Bad battery after switch off the bike Check whether the voltage adjuster is...
  • Page 16 Spark plug cannot jump Failure diagnosis Adjustment and inspection Source of trouble Change a new spark plug No jump spark or Intense Old spark plug is bad little jump spark spark Check the spark plug Loose spark plug cap tight loose Check whether the CDI plug is loose or not...
  • Page 17 Inspection/Adjustment Preparing information Cylinder pressure Check list for periodical maintenance Gear oil Engine oil/Oil filter screen Gear oil change Petrol filter Drive chain Cable accelerator inspection/adjustment Front/Rear travel clearance Air cleaner Front brake shoe wear Spark plug Headlight Battery Clutch Carburetor Front/Rear suspension system Electronic spark timing...

  • Page 18: Specification

    Specification Engine Idling speed 1400±100rpm/min Plug gap gauge 0.5-0.7mm Oil capacity 0.5L BR8ES/F10KC Spark plug type Cylinder compression 1.1-1.3Mpa/1400rpm pressure Duration of ignition BTDC12°（+/-）1° 1400±100rpm Frame Front brake lever free 10-20mm stroke Rear brake pedal free play 10-20mm Specification Tire pressure 90/ 90-19 Front 225kpa...
  • Page 19 Check list for periodical maintenance maintenance Every Every Every Every Every mileage and time every 1000 3000 6000 12000 14500 300 KM Using tools Check item 3mon 6mont 12month 1month 15months Air filter Common tools Petrol filter Common tools Oil filter Common tools Engine oil replacement Change oil every 1500KM...

  • Page 20: Engine Oil Filter

    Valve, cylinder—-excessive wear of the cylinder，replace the old ones. Please go to KEEWAY dealer for inspection on a regular basis. The bike should be adjusted regularly to ensure the best driving Status. In the table, suppose the bike works 1000KM per month.

  • Page 21: Petrol Filter

    Oil capacity：0.5L Check the oil leakage when the engine operates at its idling speed. Check the oil capacity again. Petrol filter Fuel pipe deterioration and damage inspection If there is any deterioration, damage, fuel leaks and other phenomena, it should be replaced。 Warning！...

  • Page 22: Spark Plug

    Spark plug Spark Remove the spark plug plug Check the burning, pollution, carbon distribution of the plug In the above condition, use the spark plug cleaner or steel brusher. Cylinder head Check spark plug gap gap：0.5-0.7mm spark plug clearance *Note When installing the plug, first install it by hand and then use the spark plug box (socket) spanner to make it tight...
  • Page 23 Charging state（closed circuit voltage）inspection Open the cushion Open the air filter cap, remove the battery connector wires. Measure the voltage between battery terminals Full charge：13.1V Under charge：12.3V *Note Charge state examination must use a voltmeter operation. Charge Connection method： Connect the battery charger positive pole and battery positive pole together. Connect the battery charger negative pole and battery negative pole together.

  • Page 24: Idle Speed Adjustment

    Carburetor Idle speed Adjustment *Note Idle adjustment made Screw for implementation of the engine warm-up adjusting state. idle speed Implement after warm-up of the engine Connect the engine rotation meter after running the engine Adjust the screw of the cable accelerator to rotating velocity Idle speed：1400±100rpm/min Adjust the idling adjusting screw when idle speed is unstable or unsmooth after oiling lightly.

  • Page 25: Gear Oil Replacement

    —Piston ring damage —Piston ring wear —Piston, cylinder wear and tear When compression pressure is too high, check the Combustion chamber and too much carbon distribution at piston head. Gear oil Inspection *Note Stop on smooth, level ground, turn the ignition OFF remove the key.Use the center stand to park the scooter and allow the engine to cool.

  • Page 26: Front Light

    bearings. Remove the bushing. Remove the drive chain and bolt of the chain wheel from the chain wheel seat. Check whether the drain chain and chain wheel exceed Limits size. Front/Rear braking free path Front braking free path Measure the front braking free path at the point of the brake lever.

  • Page 27: Front/Rear Suspension System

    Adjustment Loosen the adjusting screw of the front light in order to adjust the optical axis. Clutch Start the engine and increase its speed gradually to check the clutch. If the motorcycle fails to go and the engine stops, you should check the clutch block.

  • Page 28: Tire Specifications

    Rim/Tire Check whether the tire or rim has crack, screw or any other damage. Check the tire pressure. *Note Check the tire air pressure when it is cold. Standard air pressure Unit：Kpa Specification Tire pressure 90/90-19 QJ200GY-AOff-road Front wheel 110/90-17 type Rear wheel 100/80-17...

  • Page 29: Rear Fluid Brake

    Front fluid brake Rear fluid brake Brake shoe Yoke plate bushing Rear fluid brake assembly - 29 -...

  • Page 30: Maintenance Instruction

    1 Brake Maintenance instruction------------------------1.1 Failure diagnosis------------------------1.2 Front fluid brake--------------------------1.3 Rear fluid brake--------------------------1.4 Maintenance instruction Operation notes *Note •Parts of the braking system should not be polluted when installing or removing. •Use the required cleaner to prevent affecting the function of the braking system. *Check the brake before riding* 1.1.1Specifications Items...

  • Page 31: Abnormal Noise

    1. Improper adjustments for the brake 1. Improper adjustments for the brake 2. Brake shoe wears 2. Brake shoe wear 3. Improper installation for the brake shoe 3. Improper installation for the brake shoe 4. Polluted brake shoe Abnormal noise 1.

  • Page 32: Installation

    Measure the thickness of the brake shoe. If the thickness of the brake disc and shoe is smaller than the Measuring thickness maintenance value or polluted by oil, they should be replaced. Available limits: Brake shoe 3.0 mm Brake shoe 1.3.3 Installation Install front wheel.
  • Page 33 Note：The brake disc cannot be removed unless it is be heated. *Note •Brake shoe replacement. •Mark the replaced shoe for the next use Remove the follow parts from the rear wheel Rear brake： 1. Rear fluid brake assembly 2. Brake shoe assembly 3.
  • Page 34 Don’t let oil stains pollute the shoe. If the shoe is polluted by oil stains, you should us special cleaner to clean it up *Note If there is oil stains on the brake shoe, the performance of the brake will go bad. - 34 -...
  • Page 35 bracket for front mudguard rear rear reflector mounting pad rear mudguard front lower mudguard R e a r l a m p left front fender rear air guide sleeve left fender left foot board left rear fender left front right rear fender right foot board left decorated...

  • Page 36: Body Panel

    2 Body panel Following the follow sequence to tear down the body Rearview mirror→ front air guide sleeve → instrument bracket → instrument → rear air guide sleeve → front mudguard → cushion→ left and right front decorated fender → left and right fender → left and right fender junction plate → cover at the end→...
  • Page 37 Front wheel/Front suspension（TX200 Off-road type） - 37 -...

  • Page 38: Front Wheel

    Front wheel TX200（Off-road type） front rim tire fluid brake disc mounting bolt Front axle front wheel left sleeve front axle oil seal rolling bearings rolling bearings odometer pinion stand middle front front axle oil seal assembly wheel sleeve Front brake disc...

  • Page 39: Front Wheel/Front Suspension

    3 Front wheel/Front suspension Preparing -----------------------3.1 Failure diagnosis-------------------------3.2 Front wheel-------------------------3.3 Steering control---------------------------3.4 Front fork-------------------------3.5 3.1 Preparing Notes Before removing the front wheel, you should use jack to let it float above the ground and it cannot be rotated. Pay attention that no oil stains sticking to the brake shoe while operating. Entire motorcycle standards Standard Measuring position...

  • Page 40: Front Wheel

    Bearings of the steering handle are broken Not enough tire air pressure Bent front fork Bent front tire 3.2.3 Shimmy of front wheels Deformed tire Loose front wheel bearings Bad tire 3.2.4 Difficulty of turning the wheel Trouble of the wheel and bearings 3.2.5 Abnormal noise of front absorber Loose bolts of the parts of absorber 3.3 Front wheel...

  • Page 41: Spoke Inspection

    Horizontal：Replace if it is above 2mm. Middle front 3.3.2.3 Front wheel bearings inspection wheel bushing Remove the bushing from the front wheel, and take down the oil seal. front axle oil seal Windage Windage Check the rolling condition of bearings. If the bearings cannot roll, wear or loose, replace new ones.
  • Page 42 •after installing the axle, rotate the wheel, and confirm Whether the drive axle of the speedometer rotate or not Install and tighten the front axle. *Note：TX200（Off-road type）, TX200（Street type）disassembly/assembly drawing in page 41. Torque force\ Front axle 100-113 N·m...

  • Page 43: Steering Handle

    3.4 Steering handle 3.4.1 Removing Fixing bolt Remove the steering handle jacket and back Handle stand mirror. Remove the front brake lever and left lever. Take down the throttle stand and right lever. Take down the accelerator cable. Steering lever Take down the left side grip.
  • Page 44 3.5.3 Installation Tools: Fixing bolt spanner Turn the front fork to confirm its rounding. Loosening is not allowed. Steps： Install the steering handle Install the front absorber Install the front wheel Rear Wheel/Rear Suspension（TX200 Off-road type） - 44 -...
  • Page 45 Rear wheel/Rear suspension（TX200 Street type） - 45 -...
  • Page 46 Rear absorber/rear rocker 1. weld assembly of the rear rocker2.inner steel sleeve 3.spacer 4.rear rocker cap 5.screw M14 6.rear rocker cap 7.rear rocker axle 8.Chain protective block 9.chain cover 10.bolt M6X12 11.screw M5X12 12.spacer 2 13.bolt M8X50 14.chain tensioner 15.nut M8 16.fixing bolt M6X16 17.bushing 18.chain jacket 19.spacer 1 20.bolt M6X16 21.chain adjustor subassembly - 46 -...

  • Page 47: Rear Wheel/Rear Suspension

    4 Rear wheel/Rear suspension Preparing documents-----------------4.1 Failure diagnosis-----------------4.2 Rear wheel-----------------4.3 Rear wheel/ Rear rocker----------4.4 Drive drain-----------------4.5 4.1 Preparing documents Notes No oil stains sticking to the brake shoe and disc. Preparing standards Item Standard Available limits（mm） value （mm） Vertical Amplitude of fluctuation of the rear wheel Horizontal Tightening torque force...

  • Page 48: Rear Wheel

    Elastic fatigue of the spring 4.3 Rear wheel Rear rocker 4.3.1 Removing Loosen the rear axle screw Remove the rear axle screw and take down the chain. Take down the rear axle Take the rear wheel Rear axle 4.3.2 Inspection 4.3.2.1 Axle bent inspection Put the axle on the V-pedestal and measure the eccentricity ratio with dial indicator...
  • Page 49 TX200（Off-road type）rear wheel chain fluid brake mounting bolt chain mounting bolt rear brake disc bearing bushing rear wheel left sleeve rear axle rolling bearings rear wheel hub rear wheel pressure oil seal board TX200（Street type）rear wheel 1.tire 2.screw M16 3.rear wheel platen 4.fluid brake disc mounting bolt 5.rear brake disc 6.dust ring 7.rolling bearing 6203-2RS 8.middle sleeve assemblies 9.rear rim 10.inflating valve 11.valve...
  • Page 50 15.dust ring assemblies 16.rear wheel sleeve 17.chain wheel mounting bolt 18.chain pulley seat 19.chain wheel 20.chain 21.screw M12 22. rear axle - 50 -...

  • Page 51: Rear Absorber/Rear Rocker

    4.4 Rear absorber/rear rocker 4.4.1 Rear absorber removing Remove the body fender Remove the rear mud guard Fixing screw Remove the tool box Remove the air fifer Remove the rear absorber fixing screw Take down the rear absorber 4.4.2 Installation Install the rear absorber.

  • Page 52: Drive Chain

    4.5 Drive chain 4.5.1．Removing Put the motorcycle on the ground. Remove the shift lever rocker, side cover, drive chain. Remove the rear wheel, chain fender and drive chain 4.5.2．Inspection Clean the drive chain and put it into the kerosene to clean up the dust. Take out the chain of the kerosene and make it dry.
  • Page 53 4.5.3 Adjustment of the relaxation degree of the drive chain Place the motorcycle on a flat ground and keep it upright ○ Check the degree of relaxation of the drive chain a ，the degree is between 10-20mm. Adjust the relaxation degree if it is not accord with the standard.

  • Page 54: Charging System

    rectifier flame battery lighter ignition alternator coil Charging system - 54 -...

  • Page 55: Battery/Charging System

    5 Battery/Charging system Preparing documents------5.1 Failure diagnosis--------5.2 Battery------------------5.3 Charging system-------5.4 Voltage current adjustor--5.5 Alternator charging coil---5.6 Alternator lighting coil-5.7 Removing alternator------5.8 5.1 Preparing Notes *Note 1. Battery charge and discharge can be repeated use, its life span can be shortened and performance decreases after discharging.

  • Page 56: Failure Diagnosis

    Preparing standards Item Specifications Capacity/Type 12V-9AH/dry cell voltage Full charge 13.1V （20℃） Obligatory 12.3V(not working 1h) Battery charge Charging current standard：0.9A，rapid：9A Charging time standard：10-15h，rapid：30min capacity 100W/8000rpm Magnetor Coil impedance（20℃） White-White 0.5-10Ω type Full wave rectifier Voltage adjuster Battery charging voltage 14.5V±0.4V/5.000rpm Tightening torque force value Tools...

  • Page 57: Battery

    5.3 Battery 5.3.1 Battery removing 电瓶的安 Mounting position Open the cushion of battery Remove the left fender 装位置 First remove the negative wire and then the positive Take out the battery Warning！ When removing the positive terminal, the tools should not be contacted with the bracket.

  • Page 58: Charging System

    *Note ••Except emergencies, you should not use emergency charge •Measure the voltage for every other 30 minutes Charging current：standard0.4A emergency：4.0A Charging time：standard：10-15h emergency：30min Charging completes：open-circuit voltage：above12.8V 5.4 Charging system 5.4.1 Short circuit test Remove the batter ground wire, and connect the voltmeter between the negative terminal and ground wire. Turn off the switch and check whether it is short circuit.

  • Page 59: Voltage And Current Adjustor

    Item（wiring Judgments color） 5.5 Voltage and current adjustor Between Battery （red）and GND With battery voltage 1.5.1 Main wiring inspection of the body Between GND Remove the adjustor’s 6p plug. wire（black）and With wiring GND of the body Check the conducting state of the Between charging No connection between the terminals of the main wiring.

  • Page 60: Alternator Charging Coil

    •Different multimeter will show differently, so use the same multimeter while checking. Replace the voltage adjustor when the resistance value between the terminals is abnormal. 5.6 Alternator charging coil *Note Check the alternator charging coil on the engine. Check Remove the 4p connector of the alternator. Measure resistance value between the white coil and the body Standard value：0.6-1Ω（20℃）...
  • Page 61 Remove the flywheel using the flywheel remover. Remove the solid key. Remove the connector of the alternator wiring. Remove the alternator stator. 固定 螺母 5.8.2 Installation Install the stator on the body of the engine. Connect the alternator terminator. Clean up the taper part of the bent axle and flywheel Install the solid key of the flywheel into the bent axle.

  • Page 62: Ignition System

    rectifier flame battery lighter ignition alternator coil MAIN SW SPARK PLUG FUSE BL/W R/W BL/W IGNITION COIL MAGNETO BATTERY 点火系统 Ignition system - 62 -...

  • Page 63: Preparing

    6 Ignition system Preparing system--------6.1 Ignition coil---------6.5 Failure diagnosis---------6.2 Trigger---------------6.6 Ignition system checking--6.3 Charging coil---------6.7 CDI group-----------------6.4 6.1 Preparing Notes 1. Checking the ignition system following the sequence listed in the table of failure diagnosis. 2. The ignition system is solidified in the CDI group and you don’t have to adjust the ignition time. 3.
  • Page 64 Voltmeter Multimeter 6.2 Failure diagnosis Spark plug unable to jump Abnormal situations Source of trouble (confirming in order) ① The inner resistance is too small and it should be tested by required tester ② Low rotation speed of the bent axle ③...

  • Page 65: Checking The Ignition System

    6.3 Checking the ignition system Multimeter * Attention •When there is no spark on the spark plug, check whether there is loose wiring or poor contact of all components, and make sure all voltage values are normal. •There are various kinds of multimeters with different internal impedances and different test values.

  • Page 66: Charge Coil

    6.3.2 Charge coil *Attention Install the spark plug in the cylinder head and carry out the measuring when the compression pressure is normal. Remove the 4p and 2p joints of CDI group, connect the high-voltage shunt between the charge coil with short wiring 2p end(red/white end) and 4p end (Black end).

  • Page 67: System Check

    Remove the 4p joints of CDI group, connect the peak-voltage current divider black between the trigger with wiring 4p end 黑 (blue / white end) and 4p end (black end). Press the starting motor or step on the 蓝/白 Red/White actuating lever to measuring the peak voltage of the trigger.
  • Page 68 Checking item Testing end Standard value（20℃） Main switch Red--red/white Breakover when the main switch is “OFF” Trigger Red—car body ground 100-200Ω Primary coil of the ignition coil Black/white--black 0.4Ω（+/-）10％ Secondary coil of the ignition coil Black--spark plug cap（without 4.5-5.5KΩ（+/-）10％ the spark plug） 6.5 Ignition coil 6.5.1 Unload Unload the body cover.

  • Page 69: Trigger

    the spark plug cap. Standard value：8-11KΩ（20℃） If the impedance value is within the range of the standard value, it is fine. If the impedance is “∞”, there is wire break in the coil. Remove the spark plug cap, measure the impedance value between a side wire and the negative end.
  • Page 70 rectifier flame battery lighter ignition alternator coil BRAKE SWITCH BRAKE SWITCH BATTERY RELAY STARTOR MOTOR STARTER SWITCH 启动示意图 Schematic diagram of starting - 70 -...

  • Page 71: Starting System

    7 starting system Preparing---------------7.1 Failure diagnosis---------------7.2 Starting motor--------------7.3 Starting relay------------7.4 7.1 Preparing Notes for operation The unloading of the starting engine could be carried out on the engine. Refer to the method of unloading when unloading the engine. Preparation standard item Standard value Service limits...

  • Page 72: Failure Diagnosis

    7.2 Failure diagnosis Activation failure Weak rotating force starting motor is rotating of the starting motor well while the engine is not •Burnt out fuse ·Low storage battery •Broken starting clutch •Low storage battery •Poor contact of connecting line •anticlockwise revolution of the starting motor •Broken main switch •The gear of the starting motor is •Low storage battery...
  • Page 73 7.3.3 Check Check other component assembling. Replace for a new one when there is wear, fragment or burning loss in the surface. Clean the metal powder on the surface of the commutators. Electric brush Conduction check between all interfaces of 电刷...

  • Page 74: Starting Relay

    between the electric brush and the armature, pay attention please. The labial part of the oil seal should not be damaged by the installation shaft, pay attention please. Install new packing rings on the front cover. Pair the screw of the motor shell with the one of the front cover during installation.
  • Page 75 must be in accordance with specification. Continuity check and examination of the wires when the voltage between the ends of the starting motor iszero. 7.4.3 Examination of the ground loop of the starting relay Remove the adaptor of the starting relay. Conduction examination between the grey wire at the end of conductor joint and the ground strap connection of the body.

  • Page 76: Preparing

    8.1 Preparing Matters need attention on operation Conduction examination of the switch (The switch could be removed from the motorcar before being examined) 8.2 Failure diagnosis The bulb can not light up when the main switch is turned to “on”. ·The bulb is broken.

  • Page 77: Front Turn Light Bulb Replacement

    8.4 Front turn light bulb replacement 8.4.1 Unloading Unscrew the setscrew of the turn light. Remove the bulb outlet from the lamp. 8.4.2 Installation Install the bulb in the opposite order of removal. adjusting screw 8.5 Taillight/Number plate lamp/Rear turn signal light bulb replacement 8.5.1 Unloading Remove the screw to unload the lampshade of the taillight.

  • Page 78: Meters

    8.6 Meters Meter panel Remove the rearview mirror. Remove the protective guard of the handlebar, pull up the waterproof connector. Remove the screw. Remove the meter housing to unload the meter. Install the speedometer in the opposite order of removal. 8.7 Main switches 4.7.1 Examination Remove the apron plate.

  • Page 79: Horn

    8.8 Horn Examination Remove the wires of the speaker. light Connect the speaker to the storage battery. blue If there is sound, it is working. 淡蓝 Yellow/red Red/white 红/白 黄/红 蓝 blue 棕 brown 8.9 Handle switches 橙 orange 绿/黑 绿/白 Green/white Remove the apron of the steering gear arm.
  • Page 80 schematic wiring diagram - 80 -...
  • Page 81 - 81 -...
  • Page 82 Inspection and maintenance of the engine Engine fastener torque value table Fastening parts and fasteners Name Tightening torque（N·m） cylinder head nut 25～28 Rocker arm shaft support bolt 15～20 Cylinder double end bolt 10～17 CMFLR Cam Follower shaft standing bolt 18～23 Flywheel locking screw nut 30～40 Filter spring blind nut...

  • Page 83: Lubracation System

    Lubrication system Attention ： After unloading the oil pump, all the components must be carefully washed, and the surface of the components should be blown clean with high pressure gas. Don’t let foreign matter fall into the crankcase during the unloading and installation of the oil pump.

  • Page 84: Preparation Standard

    Preparing-----------10.1 Failure diagnosis-----------10.2 Oil pump-------------10.3 10.1 Preparing Matters need attention on operation： After unloading the oil pump, all the components must be carefully washed, and the surface of the components should be blew clean with high pressure gas. Don’t let foreign matter fall into the crankcase during the unloading and installation of the oil pump. Use of the lubrication system：...

  • Page 85: Oil Pump

    No oil pressure or low oil pressure Normal consumption of oil Oil leak Oil line block Oil filter 10.3 Oil pump 10.3.1 Unloading Remove the right cover, unload the oil filter, unscrew the set screw of the oil pump, and remove the driver gear and the oil pump shaft.
  • Page 86 oil pump seat Operating limit: 0.25mm Test calliper Examine end clearance of rotors. Operating limit: 0.15mm - 86 -...

  • Page 87: Assembling The Oil Pump

    10.3.2 Assembling the oil pump As the following picture shows: oil pump gear 机油泵座 oil pump body snap spring inner rotor oil pump cover oil pump shaft outer rotor oil pump carrier sheet blot *Attention： After assembling, inner and outer rotors should rotate smoothly without stagnation. 10.3.2 Assembling In the opposite order of unloading Carburetor...
  • Page 88 Attention：Gasoline is very dangerous, fireworks is strictly prohibited workplace. After disassembling of the carburetor, block the intake manifold with cloth in case of the entering of foreign matter. 1-roof cover 2-roof cover airproof 3- plunger spring 4-plunger piston component 5-lower casing coupling screw 6-lower casing component 7- sealing ring 8-float component 9-float pin 10-needle valve 11-idle metering jet 12-main entering jet 13-mian jet 14-mian foam pipe 15-mixing ratio screw 16-mixing ratio screw spring 17-mixing ratio screw spacer 18- mixing ratio screw sealing ring 19- plunger adjusting...

  • Page 89: Preparing

    Preparing-------------11.1 Failure diagnosis-------------11.2 Disassembling of the Carburetor ---------11.3 Assembling of the Carburetor---------11.4 11.1 Preparing Matters need attention on operation ·Gasoline is very dangerous, fireworks is strictly prohibited in workplace. ·Pay special attention to sparks. ·Forcibly pulling and bending of wires is not allowed. Distortion and damage will affect the wires.

  • Page 90: Remove Carburetor

    Oil level maladjustment oil volume maladjustment Blockage in the idling system or the electric enrichment valve Excessive fuel in the engine too thin gas mixture Outflow due to excessive oil oil jet blockage Secondary air suction in the inspiration system needle valve blockage Fuel deteriorate low oil level...

  • Page 91: Carburetor Installation

    Change the needle valve for a new one if there is any wear or damage. Change the carburetor body for a new one if there is any wear or damage in the needle valve seat. Change the float tongue piece for a new one if there is any wear and tear.

  • Page 92: Cylinder Head/Valve

    Installation is carried out in the opposite order of unloading. Cylinder head/Valve Attention: The cylinder cover bears large bolt preload to ensure seal between the cylinder cover and the cylinder body. Preload value: 50 Nm 1 cylinder cover hood 2 bolt 3 spark plug 4 cylinder head gasket 5 cylinder...
  • Page 93 12.Cylinder head/ Valve Preparing-------12.1 valve guide pipe replacement ----12.5 Failure diagnosis---12.2 valve seating ring correction ----12.6 Cylinder head-----12.3 cylinder head installation ------12.7 Valve examination-----12.4 12.1 Preparing Matters need attention on operation For air tightness between the cylinder head and the cylinder body, the head bears tremendous bolt pretightening force.

  • Page 94: Cylinder Head/ Cylinder Vavle

    internal diameter of the Inlet/outlet 12-12.018 12.05 rocker clearance between the rocker Inlet/outlet 0.012-0.038 0.08 shaft and the rocker hole 12.2 Failure diagnosis Low compression pressure abnormal sound in the cylinder head Maladjustment of the valve Maladjustment of the valve clearance Valve burning or bending valve spring damage Bad air tightness in the valve seat...

  • Page 95: Cylinder Head

    Valve push Remove the valve push rod. rod bracket Unscrew the screws in the cylinder head and unload the push rod bracket. Measure the external diameter of the rocker shaft. Allowable limit: 11.95mm Cylinder cover screw Measure the internal diameter of the rocker shaft. Allowable limit:：12.05mm。...
  • Page 96 Valve lock clamp Compress the valve spring with valve spring compression instrument. Remove the valve lock clamp. Remove the spring plate, inner and outer valve spring, the spring shim of the outer valve and the valve one by one. - 96 -...
  • Page 97 12.3.2 Valve disassembling valve lock clamp inner valve spring gasket valve spring plate outer valve spring valve oil seal Ruler Test calliper - 97 -...
  • Page 98 12.4 Valve examination Vernier caliper Clean the carbon deposit on the cylinder head. Measure the flatness of the junction surface of the cylinder head. Allowable limit：0.05mm. Place the crocus paper on the panel when the flatness of the junction surface of the cylinder head exceeds the allowable limit.

  • Page 99: Remove Valve Guide

    12.5 Remove valve guide Screwdriv *Attention Displace the valve guide if the clearance between the valve and the valve guide exceeds the allowable limit. After displacement, correct the surface of the valve gate seat ring. Place the valve guide in the freezing Chamber of the fridge for an hour.
  • Page 100 12.6 Repair and maintenance of the valve seat ring Use the milling cutter of 45°cutting angle to eliminate coarse or bumpy places. Note： Smear the valve seat ring with a transparent or Prussian blue layer to make it easily seen. Use a milling cutter of 32°cutting angle to remove 1/4 of the outer part of the valve seat ring.

  • Page 101: Cylinder Head Installation

    12.7 Cylinder heads installation Installation is carried out in the opposite order of unloading. *Attention： Install the valve spring with the end with smaller spring pitch pointing to the combustion chamber. In the installation the valve lock clamp, use valve spring compression instrument to compress the spring.

  • Page 102: Cylinder Block And Piston

    13.Cylinder block and piston Attention: components should be cleaned and dried with high-pressure air before test. 1 bolt 2 cylinder body 3 spacing piece 4 piston 5 piston pin 6 locating pin - 102 -...

  • Page 103: Preparing

    Preparing -----13.1 piston------------13.4 Failure diagnosis----13.2 installation of the cylinder ---13.5 Cylinder block-------------------13.3 13.1 Preparing Matters need attention on operation All components must be cleaned before examination and dried with high-pressure air. Function of the cylinder body: The cylinder provides a space for the air to compress combust and expand, and direct the movement of the piston.

  • Page 104: Failure Diagnosis

    Internal diameter of the small end of the 15.010-15.018 15.06 connecting rod Clearance between the connecting rod and 0.010-0.024 0.10 the piston pin Internal diameter of the cam follower hole 12.01-12.018 12.05 Cam Follower External diameter of the camshaft 11.986-11.994 11.93 Cam Follower Clearance between the cam follower hole...
  • Page 105 13.3.3 Disassembling the cam follower Tester Measure the internal diameter of the cam follower. Allowable limit：12.05mm。 Measure the external diameter of the cam follower. Micrometer Allowable limit：11.93mm. Measure the clearance between the cam follower hole and the camshaft. Allowable limit：0.08mm。 - 105 -...

  • Page 106: Piston

    13.4 Pistons Retaining ring for piston 13.4.1 Unloading *Attention： Remove the retaining ring for piston pin. Don’t allow the retaining ring fall into the crankcase during unloading. Remove the piston pin and unload the piston. Remove the piston ring. Examine the piston, the piston pin and the piston ring. *Attention: don’t break off or damage the piston ring.
  • Page 107 Tester Measure the internal diameter of the piston pin hole. Allowable limit：15.04mm。 Measure the external diameter of the piston pin. Allowable limit：14.96mm。 Measure the clearance of the piston pin hole and the piston pin. Allowable limit：0.02mm。 90° Measure the external diameter of the piston. *Attention: The angle between the measuring point and the 11mm piston pin is 90 degree.
  • Page 108 Measure the circular degree of the cylinder inwall. （internal diameter difference between X direction and Y direction）. upper Allowable limit：0.05mm。 Measure the cylindricity of the cylinder inwall. middle （internal diameter difference between X direction and Y direction at upper, middle and lower parts of the cylinder ） 。 lower Allowable limit：0.05mm。...

  • Page 109: Cylinder Block Installation

    ring glove after installation. Chip the adherent spacers to the crankcase away. *Attention： Don’t allow foreign matter fall into the crankcase. Install the piston, piston pin and retaining ring of piston pin. The “In” mark *Attention： Install the piston with the “IN” at the piston head pointing to the valve.
  • Page 110 Clutch Attention: It is not necessary to unload the engine during examination of clutch. The viscosity of the engine oil and the oil level will affect the operation of the clutch. Make sure to examine the oil and oil lever before examination. If any of the clutch spring, disk or plate doesn’t work, displace it.
  • Page 111 Foot actuating mechanism Attention: Check if there is any spring force reduction or damage in the foot start return spring or retchet wheel on operation. Check if there is any wear of damage in the start retchet wheel. 1 recoil start shaft 2 recoil start ratchet wheel 3 ratchet spring 4 ratchet counter vane module 5 recoil start gear 6 spring retainer...

  • Page 112: Clutch/Foot Starting System

    14 Clutch/ Foot starting system Preparing-------14.1 Foot starting system-----14.4 Failure diagnosis---14.2 main shaft/counter shaft disassembling ---14.5 Clutch-------------------14.3 14.1 Preparing Matters need attention on operation It is not necessary to unload the engine during the overhaul of the clutch. The viscosity of the oil and the oil level of the engine will influence the operation of clutch. Thus they have to be examined before the overhaul of the clutch.

  • Page 113: Clutch

    14.3 Clutch adjusting bolt 14.3.1 Unloading Unscrew four bolts on the split disc in the direction of diagonal cross. Remove the disengaging rod, the shaft housing, the bearing, the split disc and the clutch spring. Please refer to the exploded view for removing components.

  • Page 114: Assembling The Clutch

    14.3.2 Assembling the clutch 1 adjusting bolt 2 push rod 3 bearing 4 split disc 5 pressure spring 6 center bearing bracket 7 primary plate 8 driven plate 9 locknut 10 sliding key gasket 11 pressure plate 12 shell widgets 14.3.3 Examination Center bearing Pressure plate...

  • Page 115: Foot Starting System

    Measure the thickness of the wearing piece with a slide caliper. Allowable limit: Displace it below 2.6mm. Thickne 14.4 Foot starting system Foot starting mechanism modules Unloading Remove the foot starting mechanism components from the right crankcase. Main shaft modules examination Counter shaft modules Examine the elasticity of return spring and...
  • Page 116 14.5 Disassembling of main shaft & counter shaft main shaft modules Counter shaft modules - 116 -...
  • Page 117 Examination Examine the wear of tooth surface and driving pawl of the gear. If damaged seriously or injured, displace it. Tooth surface Driving pawl Remove the bearing and oil seal of the left crankcase. Check if there is any damage in the bearing or the oil seal. If Bearing oil seal there is, displace it.

  • Page 118: Speed Control System

    Note： Installation of the crankcase is in the opposite order of unloading. Speed control system Function: Transmitting torque moment, determine final output torque t ti 1 shift drum 2 shift fork 3 fork shaft 4 main shaft module 5 counter shaft module 6 recoil foot starting module - 118 -...

  • Page 119: Speed Transmisson System

    15 Speed transmission system Preparing-----------------15.1 Failure diagnosis-----------------15.2 Shift mechanism-----------------15.3 Installation---------------------15.4 15.1 Preparing Function： Transmitting torquemoment, and determine the final output torque and rotating speed. Preparation standard unit: mm external diameter of shifting fork shaft 11.97-12 11.95 Internal diameter of shifting fork shaft 12-12.018 12.05 Shift mechanism...

  • Page 120: Gear Shifting Mechanism

    15.3 Gear Shifting mechanism 15.3.1 Unloading Remove the shift shaft combination. Remove the bolt and shift locating plate. Remove the bolt, locking arm and springs. Remove the locating plunger. Refer to the exploded view for removing components. Locking arm Shift shaft combination 15.3.2 Disassembling ocking arm ocking arm spring...
  • Page 121 Unscrew mould assembling bolt to separate the crankcase. *Attention： Don’t damage the gasket and the mould assembling surface. shifting fork shaft Remove the left tank body. Pull out the shifting fork shaft. Remove the shifting fork. shift drum shifting fork Measure the external diameter of the shifting fork shaft.

  • Page 122: Installation

    Measure the external diameter of the shift drum. Allowable limit：35.75mm。 Measure the width of the hinge slot of the shift drum. Allowable limit：7.3mm。 Width of the hinge slot Balance shaft gear Remove the gear of the balance shaft. 15.4 Installation Installation is in the opposite order of unloading.

  • Page 123: Crankcase

    Crankcase Attention: The crankcase is thin-section casting thus has to avoid shock on operation in case of deformation and fracture. All components must be cleaned and dried with high-pressure air before test. The lubricant in the crankcase should released before operation.

  • Page 124: Preparing

    16 Crankcase Preparing-----------------16.1 Failure diagnosis----------------16.2 Crankcase-------------------16.3 16.1 Preparing Matters need attention on operation The crankcase is thin-section casting thus has to avoid shock on operation in case of deformation and fracture. All components must be cleaned and dried with high-pressure air before test. The lubricant in the crankcase should be released before operation.
  • Page 125 starting motor 16.3 Crankcase 16.3.1 Unloading crankcase Unscrew the standing bolt of the starting motor. bolt Unload the starting motor. gear room cover Unscrew the standing bolt in the gear room cover of the starting motor. Remove the cover of the gear room. Remove the electric starting gear, the needle bearing and the gasket.
  • Page 126 Use electric or air-powered instrument to unscrew the flywheel locknut. Pull out flywheel modules (including star wheel). Flywheel modules Camshaf t retainer Remove the gear monitor. Remove the camshaft limiting plate. Remove the cam modules. Bearing locating Remove the gear locating equipment. device Gear monitor...
  • Page 127 16.3.3 Unloading the right rear cover of bolt the crankcase Unscrew the binding bolt. Unload the right cover of the crankcase (the right cover for short in the picture) Remove clutch release lever components from the right cover right cover. release lever components right cover Remove bolts, rotor cover of oil filter and the...

  • Page 128: Crankshaft&Connecting Rod

    Use electric or air-powered instrument locknut 主动齿轮 to unscrew locknuts. Remove the oil filter rotor, unload the oil filter rotor driving gear. Unscrew the screws of the oil pump, unload oil pump component. driving gear oil pump driving 16.4 Crankshaft & Connecting rod gear Crankshaft &...
  • Page 129 Measure the shimmy of the crankshaft. Allowable limit ：0.01mm。 Check if there is any abnormal sound or looseness of the crankshaft bearing on revolution. If there is, displace the crankshaft components. *Attention： Install the Crankshaft & Connecting bar to the crankcase with gear shift mechanism together.
  • Page 130 Muffler 1. exhaust mainfold subassembly 2.acorn nut M6 3.vent-pipe protective shield 4.bolt M6X20 5.Clamp component 6.bolt M6X20 7.gasket 6 8.rubber gasket 9.bolt M6X12 10.bull bar components of muffler 11.gasket 6 12.bolt M8X40 13.muffler component 14.gasket 8 15.screw nut M8 16.bolt M5X10 17.

  • Page 131: The Exhaust Emission System

    17 The exhaust emission system Exhaust emission system warranty-------------17.1 Regular maintenance notes/guarantee of discharge standard --------17.2 17.1 Exhaust gas discharge control system warranty 1. The exhaust gas discharge system of this motorcycle is in conformity with the revision of EC/97/24/5/I and 2003/77/EC B stage by EU.
  • Page 132 The use is requested to carry out regular check, adjustment or maintenance according to the scheduled time to ensure normal emission. ·If other problems occur, please contact KEEWAY distributors or KEEWAY service center for help. ·Relevant discharge provisions are shown as follows：...