2006-2012 Keeway Superlight 125 150 Scooter Service & Repair Manual

1 Motorcycle Service and Maintenance Manual Superlight125/150 Copyright: KEEWAY INTERNATIONAL DEVELOPMENT CO.,LTD. FEB.2006

2 If you have any problems can not fnd the solution in this manual, please fell free to contact with: KEEWAY INTERNATIONAL DEVELOPMENT CO.,LTD 2000 SZENTENDRE U.8 KOZUZO. HUNGARY TEL:0036-26-500005 FAX:0036-26-312034 EMAI: info@keewaymotor.com Our engineer are very glad to give you the necessary assistance and help.

3 CONTENTS A GENERAL INFORMATION 1. BASIC TERMINOLOGY——ENGINE 2. ENGINE TYPES — 4 STROKE & 2 STROKE ENGINE ， WORK CYCLES/ILLUSTRATIONS 3. WORKSHOP RULES SERVICE RULES ELECTRICALS SAFETY B PRODUCT 1. LIST OF SPECIAL SERVICE TOOLS 2. ENGINE & TRANSMISSION a) SPECIFIED TORQUE VALUES-ENGINE b) SMALL BUT VITAL COMPO c) ENGINE REMOVAL/INSTALLATION d) ENGINE DISMANTLING/ASSEMBLY e) SUB ASSEMBLIES f) GEAR TRAIN/GEARS POWER FLOW CHART g) POWER FLOW CHART h) LUBRICATION SYSTEM i) ENGINE COMPRESSION TESTING PROCEDURE j) SOME IMPORTANT STANDARD DIMENSIONS-ENGINE 3. OIL—FUEL SYSTEM – AIR FILTER/CARBURETOR —CARBURETOR —CARBURETOR REMOVAL/INSTALLATION/ADJUSTMENT 6. MOTORCYCLE a) FASTEN TORQUE—MOTORCYCLE BODY b) SUB ASSEMBLIES (i.) CHAIN COVERCHAIN GEARREAR GEAR ASSY. (ii.) REAR ARM ASSY (iii.) FRONT GEAR ASSY (iv.) FRONT SHOCK ABSORBER (v.) TURNING SYSTEM c) BRAKE —HOW TO WORK —BRAKE TEST d) IMPORTANT POINT e) IMPORTANT SIZE 7. ELECTRIC WORK/ELECTRITY a) MAGNETO b) CIRCUIT DRAWING c) CIRCUIT TEST ABOUT ELECTRIC IGNITION PAGE

4 d) BATTERY CIRCIUT AND TEST PROCESS ABOUT STORAGE CELL e) CIRCUIT ABOUT SIGNAL SYSTEM f) ALL LAMPS REMOVAL AND INSTALLATION g) CHECK PROCESS ABOUT ELECTRIC ELEMENT h) MAIN ELECTRIC PARTS SPECIFICATION C. OTHERS 4. CHECKING BEFORE OPERATION/CHECKED POINT 5. ENGAGEMENT 6. YES AND NO 7. SAFETY DRIVE (i.) DRIVE POSE (ii.) SAFETY BRAKE 8. FAULT CHECK

5 A GENERAL INFORMATION

6 BASIC TREMS OF ENGINE A. DEAD CENTER THE DEAD CENTER IS THE TWO LIMITED POLES OF POSITON, WHICH PISTON MOVES IN LINE UP AND DOWN POSITION. THE TOP DEAD CENTER－WHICH IS FAREAT AWAY FROM THE ROTATION CENTER OF CRANKSHAFT. THE BOTTOM DEAD CENTER － WHICH IS NEAREST AWAY FROM THE ROTATION CENTER OF CRANKSHAFT. B. THE DIAMETER OF THE CYLINDER THE INNER DIAMETER OF THE CYLINDER IS CALLED CYLINDER DIAMETER. C. STROKE THE STROKE IS CALLED THE LENGTH OF PISTON WALKING PATH. ONE STROKE IS THAT PISTON MOVE FROM THE TOP DEAD CENTER TO THE BOTTOM DEAD CENTER. D. THE WORKING VOLUME OF THE CYLINDER THE SPACE VOLUME OF PISTON WORKING PATH WHICH THE PISTON MOVE FROM THE TOP DEAD CENTER TO THE BOTTOM DEAD CENTER IS CALLED THE WORKING VOLUNE OF THE CYLINDER. USUALLY THE UNIT OF CYLINDER WORKING VOLUME IS CC(CM³). SUCH AS 75CC, 125CC, AND CHANGE ALONG WITH THE ENGINE MODEL CHANGE. E. TORQUE TORQUE IS THE FORCE OF WHIRLING ROTATING. WHEN WE LOOSEN OR SCREW NUTS/ SCREWS, WE PUT THE TORQUE ON IT. IN ORDER TO DRIVE THE WHEELS, THE ENGINE PUT THE TORQUE ON THE WHEELS; APPLY LARGER FORCE WHEN CLIMBING SLOPE. THE TORQUE IS EQUAL THAT THE FORCE MULTIPLIES THE ARM OF FORCE. THE UNIT OF TORQUE IS KILOGRAM POWER/METER. F. IGNITION TIMING IN ORDER TO CONTROL THE BURNING OF BURNING ROOM, IGNITION IS TIMING. THE IGNITION TIMING OF THE ENGINE QJ162FMJ CHANGE AS FOLLOW: WHEN ‘F’ IS AT 1400RMP, THE TOP DEAD CENTER ADVANCES 15°. WHEN II IS AT 4000RMP, THE TOP DEAD CENTER ADVANCES 35°.

7 Engine cycle ANY FOUR-STROKE ENGINE HAS FOUR STROKES; THE FOUR STROKES CONSIST OF ONE CYCLE. 1.INLET: AIR-FUEL MIXTURE GOES INTO CYLINDER. 2.COMPRESSION: AIR-FUEL MIXTURE AIR COMPRESSED IN CYLINDER. 3.POWER: WHEN STARTING THE ENGINE, GAS BURNS AND EXPANDS, PUSH THE PISTON MOVING DOWN, THROUGH CONNECTING ROD BRING ALONG THE CRANKSHAFT TO OUTPUT MECHANICAL ENERGY. 4.EXHAUST: THE EXHAUST GAS IS EXPELLED FROM THE CYLINDER . THE WORKING CYCLE OF FOUR-STROKE ENGINE A. INLET STROKE 1.THE CRANKSHAFT TURNS CLOCKWISE. DIRECTION 2.THE CRANKSHAFT BRING ALONG THE POSTION MOVING DOWN THROUGH CONNECTING ROD. 3.WHEN PISTON MOVES FROM THE TOP DEAD CENTER TO THE BOTTOM CENTER, THE INLET VALVE OPENS, AND AIR-FUEL MIXTURE GOES INTO CYLINDER. B. COMPRESSION STROKE 1.THE CRANKSHAFT REVOLVES CONTINUALLY, BRING ALONG THE PISTON TO MOVE FROM THE TOP DEAD CENTER TO THE BOTTOM DEAD CENTER. 2.AIR-FUEL MIXTURE IS COMPRESSED INTO THE NARROW SPACE OF THE CYLINDER HEAD AND PISTON DEAD CENTER, WHICH IS CALLED COMBUSTION CHAMBER. C. POWER STROKE

8 1.SPARK PLUG LIGHTS COMPRESSED AIR-FUEL MIXTURE. 2.THE MIXTURE OF AIR-FUEL BURNING CAUSE THE MUTATION OF TEMPERATURE AND PRESSURE OF THE COMBUSTION CHAMBER AS THE BURNING GAS EXPANDS. 3.THE FORCE WORKING ON THE PISTON PASSES ON TO THE CRANKSHAFT THROUGH CONNECTING ROD, AND ACCELERATE THE MOVING OF CRANKSHAFT. BURNING GAS EXPANDS AND SUPPLIES POWER TO ENGINE. D. EXHAUST STROKE 1.WHEN THE PISTON IS PUSHED TO THE BOTTOM OF ITS STROKE BY BURNING GAS, THE EXHAUST VALVE OPENS. 2.ROTATE CRANKSHAFT BECAUSE OF INERTIA, AND PUSH PISTON TO MOVE UPTO THE CYLINDER HEAD. 3.ALONG WITH PISTON TOWARDS CYLINDER COVER MOVING, BURNING GAS IS PUSHED OUT BY THE EXHAUST VALVE. WHEN PISTON ARRIVE AT THE TOP OF STROKE, THE EXHAUST VALVE CLOSES. .

9 Working cycle of two-stroke engine A: Scavenging Piston (1) move downward and press the mixed gas in the crankcase (2), and this movement will go on, air intake open, and from here (intake (3)), mixed gases enter cylinder. Note: the compression that mixed gases being compressed in crankshaft case is primary compression, and in cylinder is second compression. B: Compression Piston move upward, and intake and exhaust port closing, at the same time, mixed gases in the cylinder are compressed. When piston moves upward, the compression in the crankcase became lower, reed valve opens, and new mixed gases enter into crankcase. C: Power Spark plug (7) ignites mixed gases compressed in cylinder, gases will expand due to burning, and produce great pressure to push piston move downward. As a result, mechanism energy is output by connecting rod ‘s effect to crank shaft. D: exhaust When piston continually moves downward, exhaust gate open, exhaust gas flows out, and the air pressure becomes lower, and at some point, air intake opens, new mixed gases enters into cylinder. In the two-stroke working circulation, there are processes being finished at the same time. For example: 1. Intake gas and exhaust gas 2. When the gas in the cylinder is compressed, new mixed gases enter into crankshaft case 3. At the same time of compression stroke, mixed gases and gas in the crankshaft case are also compressed.

10 Warning Don’t use the tool that is easy to be damaged, it may hurt you Warning Gasoline is easy to burn, at some situation, it may lead to explode, don’t smoke or produce spark. Warning Keep floor clean and neat, avoid oil overflowing to floor, it may hurt you Warning Don’t start engine in the place where air can’t flow well, since harmful gases may be produced by engine. Warning Don’t use dry brush to clean some parts such as brake hub. This may make you inhale asbestos and lead to cancer. Warning There is vitriol in the battery, protect your eye, skin and cloth, once you contact it, use water to clean, and to see doctor. Battery should be put in the place, which children can’t contact Warning Cooperate with your company and guarantee each other’s security. Warning Avoid brake liquid contacting eyes, once happen, use water to clean and see a doctor Don’t contact brake liquid for a long time Avoid brake liquid splash into painting matter Don’t use superfluous liquid, which is exposed in the air, because brake liquid absorb water from atmosphere and damage its character. Service rules 1. Please use KEEWAY genuine parts, and use accommodating lubrication in pointed place 2. Use special or universal tool. 3. When reassembling, use new sealed washer, o ring, oil seal , clip, and pin, etc. 4. Use metric bolt and nut 5. When assembling bolt and nut , firstly tighten big diameter or central bolt and nut. Secondly tighten bolt and nut with diagonal 6. After assembly, check bolt’s and nut’s tightening degree with torque wrench, check if parts can move freely. 7. Before measuring, oil and dirt should be removed; when assembly, make parts lubricated by lubrication. 8. When parts are removed and need be reserved for a long time, please put some lubrication on the surface so that it won’t be rusted.

2006-2012 Keeway Superlight 125 150 Scooter Service & Repair Manual

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