KEEWAY CRUISER 250 MOTORBIKE Workshop Repair Manual
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Keeway Cruiser
- - 1 - -
Keeway Cruiser
Service Manual
Keeway Cruiser
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CONTENT
PREFACE .........................................................................................................................................................................- 8 -
GENERAL INFORMATION ............................................................................................................................................... - 9 -
Motorcycle VIN number ..........................................................................................................................................- 9 -
Engine Number........................................................................................................................................................- 9 -
SPECIFICATION ............................................................................................................................................................ - 10 -
CRUISER ...................................................................................................................................................................... - 11 -
SPECIAL REMOVAL TOOLS ........................................................................................................................................... - 16 -
1．
．
．Tool list for engine removal and inspection refer to table 1-1, 1-2........................................- 16 -
2．
．
．Tools for chassis refer to Table 2-1, 2-2............................................................- 19 -
3．
．
．Tools for electric refer to table 3-1, 3-2. ...........................................................- 21 -
SERVICE INFORMATION ...........................................................................................................................................- 21 -
Safety ......................................................................................................................................................................- 22 -
Carbon monoxide...................................................................................................................................................- 22 -
TORQUE VALUE OF THE FASTENER............................................................................................................................... - 22 -
TROUBLESHOOTING .................................................................................................................................................... - 23 -
Engine will not start or hard to start .....................................................................................................................- 23 -
Engine lacks power ................................................................................................................................................- 24 -
Poor performance (idle and low speed).................................................................................................................- 25 -
Poor performance (high speed) .............................................................................................................................- 26 -
Poor charging (battery discharging or over charging).........................................................................................- 27 -
No spark at spark plug...........................................................................................................................................- 28 -
Over heating ...........................................................................................................................................................- 30 -
Clutch Slipping ......................................................................................................................................................- 30 -
Clutch Dragging ....................................................................................................................................................- 31 -
INSPECTION/ADJUSTMENT......................................................................................................................................- 32 -
Service information ...............................................................................................................................................- 32 -
Schedule Maintenance Guide ...............................................................................................................................- 34 -
Engine oil/Filter.....................................................................................................................................................- 35 -
Engine oil filter clean ............................................................................................................................................- 37 -
Oil filter replacement .............................................................................................................................................- 38 -
Valve clearance adjustment Guide ........................................................................................................................- 39 -
Idle speed................................................................................................................................................................- 42 -
Inspection/Adjustment of throttle ..........................................................................................................................- 42 -
Air cleaner..............................................................................................................................................................- 43 -
Spark plug ..............................................................................................................................................................- 45 -
Battery ....................................................................................................................................................................- 47 -
Carburetor ..............................................................................................................................................................- 50 -
Ignition timing .......................................................................................................................................................- 50 -
Engine Compression..............................................................................................................................................- 50 -
Engine oil ...............................................................................................................................................................- 51 -
Primary Drive chain ..............................................................................................................................................- 52 -
Free play of front & rear brake .............................................................................................................................- 52 -
Keeway Cruiser
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Brake Fluid ............................................................................................................................................................- 53 -
Headlight ................................................................................................................................................................- 53 -
Clutch .....................................................................................................................................................................- 54 -
Front & Rear shock absorber ................................................................................................................................- 54 -
Bolts/Nut/Fastener.................................................................................................................................................- 55 -
Rim/Tire .................................................................................................................................................................- 55 -
Steering, bearings and handlebar .........................................................................................................................- 56 -
1. BRAKE...................................................................................................................................................................- 58 -
1.1 SERVICE INFORMATION ......................................................................................................................................... - 61 -
1.1.1 Specification..................................................................................................................................................- 61 -
1.2 TROUBLESHOOTING .............................................................................................................................................. - 62 -
1.3 FRONT DISC BRAKE .............................................................................................................................................. - 63 -
1.3.1 Removal .........................................................................................................................................................- 63 -
1.3.2 Inspection ......................................................................................................................................................- 64 -
1.3.3 Installation ....................................................................................................................................................- 65 -
1.4 REAR DISC BRAKE ................................................................................................................................................ - 66 -
1.4.1 Removal .........................................................................................................................................................- 66 -
1.4.2 Inspection ......................................................................................................................................................- 67 -
1.4.3 Installation ....................................................................................................................................................- 68 -
2. BATTERY/CHARGING SYSTEM............................................................................................................................- 69 -
2.1 SERVICE INFORMATION ................................................................................................................................... - 69 -
2.2 TROUBLESHOOTING .............................................................................................................................................. - 71 -
2.3 BATTERY ............................................................................................................................................................... - 71 -
2.3.1 Battery removal .............................................................................................................................................- 71 -
2.3.2 Charging .......................................................................................................................................................- 73 -
2.4 CHARGING SYSTEM............................................................................................................................................... - 74 -
2.4.1 Short circuit Test Procedure .........................................................................................................................- 74 -
2.4.2 Inspection for an under charging condition ................................................................................................- 74 -
2.5 REGULATOR/RECTIFIER......................................................................................................................................... - 75 -
2.5.1 Wire harness terminal inspection .................................................................................................................- 75 -
2.5.2 Rectifier Inspection .......................................................................................................................................- 75 -
2.6 INSPECTION OF STATOR WINDINGS......................................................................................................................... - 76 -
2.7 MAGNETO REMOVAL ............................................................................................................................................. - 76 -
2.7.1 Removal .........................................................................................................................................................- 76 -
2.7.2 Installation ....................................................................................................................................................- 77 -
3. IGNITION SYSTEM .................................................................................................................................................- 79 -
3.1 SERVICE INFORMATION ......................................................................................................................................... - 79 -
3.2 C.D.I. .................................................................................................................................................................... - 80 -
3.3 IGNITION COIL....................................................................................................................................................... - 81 -
3.3.1 Removal .........................................................................................................................................................- 81 -
3.3.2 Primary coil inspection .................................................................................................................................- 81 -
3.3.3 Secondary coil ...............................................................................................................................................- 82 -
3.4 PICKUP COIL .......................................................................................................................................................... - 82 -
Keeway Cruiser
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4. STARTING SYSTEM ................................................................................................................................................- 84 -
4.1 SERVICE INFORMATION ......................................................................................................................................... - 84 -
4.2 TROUBLESHOOTING .............................................................................................................................................. - 85 -
4.3 START MOTOR ....................................................................................................................................................... - 85 -
4.3.1 Removal .........................................................................................................................................................- 85 -
Caution: .................................................................................................................................................................- 85 -
4.3.2 Removal .........................................................................................................................................................- 85 -
4.3.3 Inspection ......................................................................................................................................................- 86 -
4.3.4 Assembly ........................................................................................................................................................- 87 -
4.3.5 Installation ....................................................................................................................................................- 87 -
4.4 STARTER RELAY..................................................................................................................................................... - 87 -
4.4.1 Operation Inspection ....................................................................................................................................- 87 -
4.4.2 Voltage of starter relay inspection ................................................................................................................- 88 -
4.4.3 Operation inspection.....................................................................................................................................- 88 -
5. BULBS/SWITCHES/SPEEDOMETER.....................................................................................................................- 89 -
5.1 SERVICE INFORMATION ......................................................................................................................................... - 89 -
5.2 TROUBLESHOOTING .............................................................................................................................................. - 89 -
5.3 HEADLIGHT BULB REPLACEMENT ......................................................................................................................... - 89 -
5.3.1 Removal .........................................................................................................................................................- 89 -
5.3.2 Installation ....................................................................................................................................................- 90 -
5.4 FRONT TURN SIGNAL BULB REPLACEMENT............................................................................................................ - 90 -
5.4.1 Removal .........................................................................................................................................................- 90 -
5.4.2 Installation ....................................................................................................................................................- 90 -
5.5 T AILLIGHT BULB REPLACEMENT............................................................................................................................ - 90 -
5.5.1 Removal .........................................................................................................................................................- 90 -
5.5.2 Installation ....................................................................................................................................................- 91 -
5.6 SPEEDOMETER....................................................................................................................................................... - 91 -
5.7 IGNITION SWITCH .................................................................................................................................................. - 91 -
5.7.1 Inspection ......................................................................................................................................................- 91 -
5.7.2 Ignition switch replacement .........................................................................................................................- 92 -
5.8 HORN..................................................................................................................................................................... - 92 -
5.9 HANDLE SWITCHES................................................................................................................................................ - 93 -
5.9.1 Removal .........................................................................................................................................................- 93 -
5.9.2 Installation ....................................................................................................................................................- 93 -
6. BODY REMOVAL PROCEDURE ............................................................................................................................- 95 -
7. FRONT WHEEL/FRONT SUSPENSION .................................................................................................................- 96 -
7.1 SERVICE INFORMATION ......................................................................................................................................... - 99 -
7.2 TROUBLESHOOTING .............................................................................................................................................. - 99 -
7.2.1 Steering handlebar is hard to turn ...............................................................................................................- 99 -
7.2.2 Steering wobbling........................................................................................................................................- 100 -
7.2.3 Front wheel wobbling .................................................................................................................................- 100 -
7.2.4 Front wheel is hard to rotate ......................................................................................................................- 100 -
7.2.5 Front shock absorber noise ........................................................................................................................- 100 -
Keeway Cruiser
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7.3 FRONT WHEEL..................................................................................................................................................... - 100 -
7.3.1 Removal .......................................................................................................................................................- 100 -
7.3.2 Inspection ....................................................................................................................................................- 101 -
7.3.3 Bearing replacement ...................................................................................................................................- 102 -
7.4 STEERING HANDLEBAR ....................................................................................................................................... - 103 -
7.4.1 Removal procedure .....................................................................................................................................- 103 -
7.4.2 Assembly ......................................................................................................................................................- 103 -
7.5 FRONT FORK ........................................................................................................................................................ - 103 -
7.5.1 Removal procedure .....................................................................................................................................- 103 -
7.5.3 Assembly ......................................................................................................................................................- 104 -
8. REAR WHEEL/REAR SUSPENSION....................................................................................................................- 105 -
8.1 SERVICE INFORMATION ....................................................................................................................................... - 108 -
8.2 TROUBLESHOOTING ............................................................................................................................................ - 108 -
8.2.1 Twist or warp of rear wheel ........................................................................................................................- 108 -
8.2.2 Rear shock absorber too soft ......................................................................................................................- 108 -
8.3 REAR WHEEL ....................................................................................................................................................... - 109 -
8.3.1 Removal .......................................................................................................................................................- 109 -
8.3.2 Inspection ....................................................................................................................................................- 109 -
8.3.3 Assembly ......................................................................................................................................................- 109 -
8.4 REAR SHOCK ABSORBER/REAR SWING ARM ........................................................................................................ - 110 -
8.4.1 Removal ....................................................................................................................................................... - 110 -
8.4.2 Assembly ...................................................................................................................................................... - 110 -
8.4.3 Swing arm removal ..................................................................................................................................... - 111 -
8.4.4 Rear swing arm inspection ......................................................................................................................... - 111 -
8.5 DRIVING CHAIN................................................................................................................................................... - 112 -
8.5.1 Removal ....................................................................................................................................................... - 112 -
8.5.2 Inspection .................................................................................................................................................... - 113 -
Stretch................................................................................................................................................................... - 113 -
8.5.3 Slack of the driven chain ............................................................................................................................ - 113 -
8.5.4．
．
．Assembly................................................................................................................................................... - 114 -
9. LUBRICATION SYSTEM....................................................................................................................................... - 115 -
9.1 SERVICE INFORMATION ....................................................................................................................................... - 117 -
9.2 TROUBLESHOOTING ............................................................................................................................................ - 117 -
9.3 OIL PUMP ............................................................................................................................................................. - 118 -
9.3.1 Removal Procedure ..................................................................................................................................... - 118 -
9.3.2 Assembly ......................................................................................................................................................- 120 -
10. CARBURETOR .....................................................................................................................................................- 120 -
10.1 SERVICE INFORMATION ..................................................................................................................................... - 122 -
10.2 TROUBLESHOOTING........................................................................................................................................... - 122 -
10.3 CARBURETOR REMOVAL .................................................................................................................................... - 123 -
10.3.1 Removal .....................................................................................................................................................- 123 -
10.3.2 Carburetor disassemble ............................................................................................................................- 124 -
10.3.3 Inspection ..................................................................................................................................................- 126 -
Keeway Cruiser
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10.4 ASSEMBLY ......................................................................................................................................................... - 126 -
11. FUEL PUMP .........................................................................................................................................................- 127 -
12. CYLINDER HEAD/VALVE ..................................................................................................................................- 129 -
12.1 SERVICE INFORMATION ..................................................................................................................................... - 129 -
12.2 TROUBLESHOOTING........................................................................................................................................... - 130 -
12.3 CYLINDER HEAD................................................................................................................................................ - 130 -
11.3.1 Removal procedure....................................................................................................................................- 130 -
12.4 CAMSHAFT INSPECTION..................................................................................................................................... - 132 -
12.5 V ALVE................................................................................................................................................................ - 135 -
12.6 V ALVE CLEARANCE INSPECTION AND ADJUSTMENT........................................................................................... - 135 -
12.9 ASSEMBLY ......................................................................................................................................................... - 137 -
13. CYLINDER/PISTON .............................................................................................................................................- 138 -
13.1 SERVICE INFORMAION ....................................................................................................................................... - 139 -
13.2 TROUBLESHOOTING........................................................................................................................................... - 140 -
13.3 CYLINDER ......................................................................................................................................................... - 140 -
13.3.1 Removal .....................................................................................................................................................- 140 -
13.3.2 Cylinder inspection ...................................................................................................................................- 140 -
13.4 PISTON............................................................................................................................................................... - 141 -
13.4.1 Removal .....................................................................................................................................................- 141 -
13.5 PISTON INSTALLATION ....................................................................................................................................... - 145 -
13.6 CYLINDER INSTALLATION.................................................................................................................................. - 146 -
14. CLUTCH/TRANSMISSION..................................................................................................................................- 147 -
14.1 SERVICE INFORMATION ..................................................................................................................................... - 147 -
14.2 TROUBLESHOOTING........................................................................................................................................... - 147 -
14.3 CLUTCH ............................................................................................................................................................. - 147 -
14.3.1 Removal .....................................................................................................................................................- 147 -
14.3.2 Inspection ..................................................................................................................................................- 148 -
14.3.3 Installation ................................................................................................................................................- 150 -
14.4 TRANSMISSION .................................................................................................................................................. - 150 -
13.4.1 Removal .....................................................................................................................................................- 150 -
14.4.2 Inspection ..................................................................................................................................................- 150 -
14.4.3 Installation ................................................................................................................................................- 152 -
15. CRANKCASE ........................................................................................................................................................- 153 -
15.1SERVICE INFORMATION ...................................................................................................................................... - 153 -
15.2 TROUBLESHOOTING........................................................................................................................................... - 154 -
15.3 CRANKCASE ...................................................................................................................................................... - 154 -
15.3.1 Removal of left & right crankcase side covers .........................................................................................- 154 -
15.4 ASSEMBLY ......................................................................................................................................................... - 156 -
16. CRANKSHAFT AND TRANSMISSION GEAR ..................................................................................................- 157 -
16.1 SERVICE INFORMATION ..................................................................................................................................... - 159 -
16.2 CRANKSHAFT .................................................................................................................................................... - 159 -
Keeway Cruiser
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16.2.1 Removal .....................................................................................................................................................- 159 -
16.2.2 Inspection ..................................................................................................................................................- 160 -
16.3 INSTALLATION ................................................................................................................................................... - 161 -
16.4 MAIN SHAFT AND COUNTER SHAFT REMOVAL ................................................................................................... - 161 -
16.5 INSPECTION ....................................................................................................................................................... - 162 -
16.6 MAIN SHAFT & COUNTER SHAFT ASSEMBLY...................................................................................................... - 163 -
17. EXHAUST EMISSION SYSTEM .........................................................................................................................- 164 -
18. REMOVING THE ENGINE FROM THE MOTORCYCLE .................................................................................- 166 -
19. ENGINE ASSEMBLY ..........................................................................................................................................- 173 -
CAM SHAFT REMOVAL ............................................................................................................................................. - 216 -
ROCKER ARM REMOVAL .......................................................................................................................................... - 217 -
Keeway Cruiser
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PREFACE
This Service Manual describes the technical features and servicing procedures for the
Keeway Cruiser.
Service information contains the necessary safety precautions for all operations stated in
this manual. Read them carefully before any operation is started.
Inspection/adjustment describes the inspection/ adjustment procedures, safety rules and
service information for each part, starting from periodic maintenance.
Contents after section 1 give instructions for disassembly, assembly and adjustment of the
engine, body and electrical system.
Most sections start with an assembly or system illustration and Troubleshooting for the
section. The subsequent pages give detailed procedures for the section.
Caution:
The information and contents included in this manual may be different from the
motorcycle in case specifications are changed.
Keeway motor Co., Ltd.
Keeway Cruiser
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General Information
Motorcycle VIN number
VIN (vehicle identification number) is engraved on the steering head pipe.
Engine Number
Engine number is engraved on the crankcase of the engine.
Keeway Cruiser
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Specification
Model Cruiser Engine Type
Air cooled 4-stroke,
SOHC engine
Overall length 2250 mm Fuel Type
92#/95# unleaded
Petrol
Overall width 880 mm
Cylinder
arrangement
2-v configuration
Overall height 1110 mm Bore*Stroke (mm) 49*66
Wheel base 1550 mm Displacement 250 ml
Front
wheel
86 Starter type Electric start
Rear
wheel
93 Cooling Type Air cooled
Net weight (kg)
Total 179
Front wheel
110/90-16
Lubrication Type
Forced pressure & wet
sump
Rear wheel
Tires
120/90-16
Air Cleaner Paper element, wet
Fuel capacity 13.5±0.2L
Max. Speed 100km/h
Clutch
Type
Wet
At
disasse
mbly
1.6L
Engine oil capacity
At
replace
ment
1.3L
Transmission
Transmissi
on
Chain drive
Idle-rpm 1400±100rpm/min
Battery
Capacity
12V-9AH Max. Torque 18.7N.m/5750rpm
Generator
Type
2v49FMN Max. Power 14.3kW/8500 rpm
Spark Plug NGK CR6HSA
Perfo
rman
ce of
engin
e
Compression 9.4: 1
Gap of
spark plug
0.7-1.0mm
Diameter of front
disc brake (mm)
φ270 mm
Electric
Ignition
Type
Battery Ignition
Brake
Diameter of rear
disc brake (mm)
φ220 mm
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What's Included?
Lifetime Access
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Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$52.99
This Workshop Repair Service Manual is specifically designed to detail the technical features and servicing procedures for the Keeway Cruiser 250 motorbike. It contains essential service information along with safety precautions for all operations mentioned in the manual.
The manual covers inspection and adjustment procedures, including safety rules and service information for each part, beginning from periodic maintenance. Additionally, it provides instructions for disassembly, assembly, and adjustment of the engine, body, and electrical system.
