KEEWAY 500ATV User manual

Service Manual
500ATV/500ATV-2
4×4

FOREWORD
This service m anual is designed prim arily for
use by certified keeway service center.
technicians in a properly equipped shop and should be kept available for reference. All references to
left and right side of the vehicl e are from the operator's perspective when seated in a norm al riding
position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use,
and shop procedures in order to perform the work safely and corre ctly. Technicians should read the
text and be familiar with service procedures before starting the work. Certain procedures require the
use of special tools. Use only the proper tools as specified.
This m anual contains an introductory de scription of procedures for inspection ，maintenance,
overhaul ，disassembly & assembly ，removal and installation of com ponents and parts,
troubleshooting and service data together with illu strations of our ATV Model 500ATV and
500ATV-2.
CONTENTS
Vehicle
Service Information 1
Vehicle Body, Muffler 2
Inspection & Adjustment 3
Cooling System 4
Removal and Installation of Engine 5
Removal, Inspection and Assemble of Engine 6
Carburetor 7
Front Wheel, Front Brake, Suspension, Steering 8
Rear Wheel, Rear Brake, Suspension 9
Front and Rear Axle 10
Battery, Charging System 11
Ignition System 12
Lighting, Dashboard & Switches 13
Troubleshooting、Circuit Diagram 14
The m anufacturer reserves the ri ght to m ake improvem ents or modifications to the products
without p rior notice. Ov erhaul and m aintenance should be done acco rding to the actual state
and condition of the ATV.

1. SERVICE INFORMATION
1-1
A few Words About Safety ……………1-1 Tightening Torque………………………1-9
VIN Number Engine Number…………1-3 Lubricating oil, and brake liquid ……1-12
Main Data Table………………………1-4 Cables Pipes, Cable Routing ……………1-13
Overhaul Datasheet……………………1-5
A Few Words About Safety
Service Information
The service and repair information contained in this manual is intended for use by qualified,
professional technicians.
Attempting service or repairs without the proper training, tools, and equipment could cause injury to
you or others, It could also damage the vehicle or create an unsafe condition.
This manual describes the proper methods and procedures for performing service, maintenance, and
repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any
person who intends to use a replacement part, service procedure or a tool that is not recommended
by keeway, must determine the risks to their persona l safety and the safe operation of the vehicle.
If you need to replace a part, use genuine KEEWAY parts with the correct part number or an
equivalent part. We strongly recommend that you do not use replacement parts of inferior quality.
For Your Customer is Safety
Proper service and maintenance are essential to the customer is safety and the reliability of the
vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to
the vehicle, or injury to others.
For Your Safety
Because this manual is intended for the professional service technician, we do not provide warnings
about many basic shop safety practices (e.g., Hot parts-wear gloves). If you have not received shop
safety training or do not feel confident about your knowledge of safe servicing practice, we
recommended that you do not attempt to perform the procedures described in this manual.
Some of the most important general service safety precautions are given below. However, we
cannot warn you of every conceivable hazard that can arise in performing service and repair and
procedures. Only you can decide whether or not you should perform a given task, can cause you to
be seriously hurt or killed.
Important Safety Precautions
Make sure you have a clear understanding of all basic shop safety practices and that you are
wearing appropriate clothing and using safety equipment. When performing any service task, be
especially careful of the following:
●Read all of the instructions before you begin, and make sure you have the tools, the replacement
or repair parts, and the skills required to perform the tasks safely and completely.
1

1. SERVICE INFORMATION
1-2
●Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer,
drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy
components. If there is any doubt, put on eye protection.
●Use other protective wear when necessary, for example gloves or safety shoes. Handing hot or
sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt
you, stop and put on gloves.
●Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the
vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use jack
stands.
Make sure the engine is off before you begin any servicing procedures, unless the instruction tells
you to do otherwise. This will help eliminate several potential hazards;
●Carbon monoxide poisoning from engine exhaust, Be sure there is adequate ventilation whenever
you run the engine.
●Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those
areas.
●Injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers
and clothing are out of the way.
Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire
or explosion, be careful when working around gasoline or batteries.
●Use only a nonflammable solvent, not gasoline, to clean parts.
●Never drain or store gasoline in an open container.
●Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts.
Conversion Table
Item Example Conversion
Pressure 200Kpa(2.00kgf/cm2)
33kpa(250mmHg)
1kgf/cm2=98.0665kpa
1kpa=1000pa
1mmHg=133.322Pa=0.133322Kps
Torque 18N· m(1.8kgf-m) 1kgf· m=9.80665N· m
V
olume 419ml 1ml=1 cm3=1cc
1l=1000cm3
Force 12N(1.2kgf)
1kgf=9.80665N

1. SERVICE INFORMATION
1-3
Identification number records
Record the vehicle identification number and engine number in the spaces provided for assistance
when ordering spare parts from your dealer or for reference in case the vehicle is stolen.
Vehicle Identification Number(500ATV): LCXGSTS1~
Vehicle Identification Number(500ATV-2): LCXMSTS1~
Engine Number(Carburetor): XY192
Engine Number（EFI）: XY192-A
NOTE: The vehicle identification number is used to identify your
machine.
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1. SERVICE INFORMATION
1-4
Main Data Table
Item Parameter
Model 500ATV /500ATV-2
Length 2085mm/2285mm
Width 1180mm
Height 1175 mm/1270 mm
Wheel base 1300mm/1500mm
Engine type XY192
Displacement 498.3ml
Fuel type Unleaded gasoline 93octane or above
Mass of whole equipments (Not include driver) 355kg/417 kg
Number of Passengers 1 for 500ATV, 2 for 500ATV-2 (including
driver)
Max. Load 70Kg
Front 25x8-12Tire
Rear 25x10-12
Minimum turning radius 3500mm/4800mm
Starting Electrical starting
Form single cylinder,
four-stroke, water cooling, 4
valves, top camshaft, single equal shaft,
Carburetor type.
Combustion Chamber Type Triangle
Valve Driving Type SOHC /Chain Drive
Bore × stroke 92×75mm (3.62×2.95 in)
Compression ratio 10.2:1
Lubrication Type Pressure and splash lubricating type
Maximal power. 25Kw/6000 rpm(EEC model less than
15kw)
Max. torque 42N.M/4000 rpm(EEC model:24N.M/4000
rpm)
Lowest fuel consuming rate (g/Kw·h) ≤280g/Kw·h
Idling speed (r/min) 1400±100
Starting system Electrical starting/Recoil starting
Ignition type non-touch CDI DC start
Plug type BKR6E(NGK)
Magneto typeever-mag AC motor, ex-rotor flywheel type
Lubricating oil category SAE 15W—40/SF
Engine oil pump type ROTOR type
Oil filter type whole way paper filter element
Carburetor style vacuum film
Engine
Engine oil filter type whole filtering with paper element

1. SERVICE INFORMATION
1-5
Item Parameter
Fuel type higher class than RQ-93
Transmission V-belt with teeth on, auto stepless gear
change, plus gear change cam with change
gear transmission
Gear change type gear lever with hand
Clutch type wet, hoof centrifugal type
Primary speed change ratio (stepless
speed change) 0.8—3.2
Speed change ratio：Total speed reduce ratio
H Gear：2.57 2.056—8.224
LGear：4.39 3.512—14.048
R Gear：3.21 2.568—10.272
Cooling style Closed cooling fluid circulating
Cooling fluid type antifreeze with prevent rust
Out dimension 716 x 516 x 536
Net weight 72.5kg
Output type front and rear shaft output
Engine
Shaft running direction counter-clockwise (from back of engine).
Air Filter type Paper element filter
Type Vacuum Diaphragm type KEIHIN A
W6A
Fuel
Device Carburetor
Diameter of mixing valve 40mm
Type Wet, auto-centrifugal
Clutch Operation mode Automatic (CVT) + Parking & Gear
shifting
Gears Shi ft Low Gear, High Gear & Reverse Gear
Shift
Mode/order
Manual /L-H-N-R
(CVT)
Transmission
Ratio
3.4～0.83
Type Automatic (CVT) + Parking &
Gear shifting
Function Auto-centrifugal
Transmission ratio 0.8~3.2
Final Ratio 1 (16/16, bevel gear)
Secondary
Ratio
2.14 (45/21)
Gearing
Gearbox
Gear
Ratio Gears Low Gear: 2.05(41/20), High
Gear: 1.2(30/25), Reverse Gear: 1.5(30/20)
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1. SERVICE INFORMATION
1-6
Item Parameter
Gearing Gearbox Gear Ratio Total Low Gear: 4.39, High Gear: 2.57,
Reverse Gear: 3.21
Right 40° Steering
device Steering angle
Left 40°
Front Hydraulic
Disc
Brake type
Rear Hydraulic
Disc
Bumper
Device Suspension Swing Arm
Frame type Welded steel tube and plate
Overhaul Datasheet
Lubricating device
Item Standard
Service limit
Volume when replacing 2500ml —
Engine Oil
Capacity Full capacity 12000ml —
Recommended Oil (see original)
●Specially for 4-stroke
motorcycle
SAE-10W-40、20W-50
Substitutes must be used in
the following range.
●API type: SE or SF grade
●SAE type: Choose from
the left chart according to
the environmental
temperature
Gap between
inner
and outer rotors 0.02~0.05mm 0.10mm
Gap between outer
rotor and body 0～0.15mm 0.08mm
Oil pump
Rotor End face gap 0～0.15mm 0.10mm

1. SERVICE INFORMATION
1-7
Fuel Device
Item Parameter
Fuel Tank Capacity Full capacity 22L
Type KEIHIN A
W6A
Main jet 99101-939-1380(#140
Idle jet N424-25B35(#40)
Carburetor
Idle speed 1400±100r/min
Cooling Device
Item Standard
Full Capacity 1000ml
Reservoir tank capacity 300 ml
Coolant capacity
Standard Density 45%
Opening pressure of radiator cap 108kpa(1.1kgf/cm2)
Temperature / valve open 72±2ºC
Temperature/valve full open 88ºC
Thermostat
Overall lift 3.5-4.5mm
Front/Rear Wheel
Item Standard
Service Limit
Vertical 1.0mm 2.0mm Play of wheel
rim Horizontal 1.0mm 2.0mm
Groove —3.0mm
Front
Wheel Tire
Pressure 7±0.2PSI(47±1.5KPa) —
Vertical 1.0mm 2.0mm Play of wheel
rim Horizontal 1.0mm 2.0mm
Groove —3.0mm
Rear
Wheel Tire
Pressure 7±0.2PSI(47±1.5KPa)
—
1

1. SERVICE INFORMATION
1-8
Brake System
Item Standard Service
Limit
Brake lever play 0mm --
Brake disc thickness 4mm 3mm
Brake Pedal Play 0mm
Front brake
Brake disc thickness 4mm 3mm
Battery、Charging System
Item Standard
Model Permanent magnet AC type
Output 3- phase AC
AC magneto
Motor
Charging coil Resistance (20℃) 0.2-0.3Ω
Rectifier Three-phase
annular rectification, Silicon controlled
parallel-connected regulated voltage
Capacity 12V18Ah
Fully charged 12.8V
Terminal point
voltage Insufficient
charge
<11.8V
Standard 0.9A/5~10H
Battery
Charging
current/time Quick 4A/1H
Ignition system
Item Standard
Ignition CDI ignition
Type BKR6E (NGK)
Optional K6RTC
Spark Plug
Spark plug gap 0.6-0.8mm
Ignition timing Max. advanced angle 43°/3500r/min
Ignition Above
200V
Peak voltage
Pulse 150V
Light、Fuse
Headlight 12 V 35 W/35.0 W × 2
Tail/brake light 12 V 5 W/21.0 W × 2
Fuses:
Battery fuse 30A
Main switch fuse 10A
Light fuse 20A
Power output fuse 10A
Fan fuse 10A

1. SERVICE INFORMATION
1-9
Screwing moment of important bolts
Engine：
Sequence
number
Item Thread
diameter mm
Torque
（N·m）
Remark
1CRANKCASE M8×88 25
2 SPARK PLUG M14×1.25 20
3SHIFT CAM/ SECONDARY
SHAFT/SECONDARY SHAFT
M8×32 30
4REAR COVER,BEARING M8×28 25
5 OIL PUMP INSTALLING BOLTS M6×50/M6×45 10
6 UPPER LEFT COVER M6×32 10
7MAGNETO COVER M6×30 10
8 SEAT,MAGNETO M6×25 10
9 COVER,WATER PUMP M6×28 10
10 CYLINDER HEAD/ HOLDER,BEARING/
FRONT COVER,BEARING
M6×22 10
11 SIDE COVER, CYLINDER HEAD/ OIL
STRAINER/ CAMSHAFT/
M6×20 10
12 CVT COVER,LEFT(LOWER) M6×18 10
13 GEAR POSITION SENSOR/ SHEAVE DRUM
ASSY/ HANDLE ASSY
M6×16 12
14 SHEAVE DRUM ASSY /THERMOSTAT/
TEMPERATURE SWITCH
M6×10 12
15 MAGNETO STATOR M5×12 6
16 GEARSHIFT SPRING M14×26 30
17 PRIMARY SHEAVE ASSY M12×160 80
18 CYLINDER M10×78 65
19 CYLINDER M10×70 65
20 HEAD CYLINDER,ASSY M10×190 70
21 DRAIN BOLT M10×16 30
22 SECONDARY SHEAVE ASSY M10×100 80
23 FLANGE,OUTPUT M16 100
24 CRANKSHAFT ASSY M28×1.5 55
25 DRIVE BEVEL GEAR M16 300
26 FLYWHEEL ASSY M16 75
27 IMPELLER ASSY
,WATER PUMP M7 10
28 OIL PIPE,INLET M12×30 35
29 OIL PIPE A/ OIL PIPE B M10×28 35
30 OIL PIPE A/ OIL PIPE B M12×43 35
31 CRANKCASE M6×105 10
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1. SERVICE INFORMATION
1-10
32 CRANKCASE M6×85 10
33 CRANKCASE M6×92 10
34 THERMOSTAT/ TEMPERATURE SWITCH M14×12 30
35 CVT COVER,LEFT(LOWER) M6×12 10
36 COVER,SHIFT SHAFT M6×139 10
37 COVER,SHIFT SHAFT M6×28 10
38 FLANGE,OUTPUT M16 300
M5 4.5—6
M6 8—12
39 Other Bolts
M8 18--25

1. SERVICE INFORMATION
1-11
FRONT, REAR SUSPENSION：
s.q. Item Qty. Thread diameter
mm
Torque
（N·m）
Remark
1 NUT, STABILIZER 2 M10 45～50N.m
2 BOLT, STABILIZER HOLDER 4 M8×16 20～25N.m
3 NUT, FRONT/ REAR AXLE 4 M10 45-50N.m
4 BOLT, FRONT/ REAR AXLE
SUPPORT 8 M8×16 23-25N.m
5 BOLT, STEERING SHAFT 2 M8×55 23-25N.m
6 NUT, STEERING ARM 1 M14 55-62N.m
7 BOLT, HANDLEBAR 4 M8×55 23-25N.m
8 BOLT, ENGINE(NETHER) 2 M12×240 45-50N.m
9 BOLT, ENGINE HOLDER 8 M8×20 23-25N.m
10 BOLT, ENGINE(REAR) 1 M12×145 45-50N.m
11 BOLT, ENGINE REAR BRACKET
AND FRAME 4 M8×16 23-25N.m
12 BOLT, FRONT/REAR DRIVE
SHAFT 8 M8×22 23-25N.m
13 BOLT, FRONT BRAKE MASTER
CYLINDER 4 M8×20 23-25N.m
14 BOLT, REAR BRAKE DISC
GUARD 2 M10×60 45-50N.m
15 BOLT, REAR BRAKE MASTER
CYLINDER 2 M10×20 45-50N.m
16 BOLT, FRONT/REAR BRAKE
DISC 12 M8×16 23～25N.m
17 NUT, BRAKE PEDAL 1 M10×1.25 45～50N.m
18 BOLT, MASTER
CYLINDER.PEDAL BRAKE 2 M6×30 10～12N.m
19 NUT, FRONT/ REAR ARM ANG
FRAME 12 M10×1.25 45～50N.m
20 NUT, FRONT KNUCKLE ANG
FRONT ARM 4 M12×1.25 45-50N.m
21 NUT, REAR KNUCKLE ANG
REAR ARM 4 M10×1.25 45～50N.m
22 BOLT, GEARSHIFT UNIT 2 M8×20 23～25N.m
23 NUT, STEERING TIE-ROD 4 M10×1.25 45～50N.m
24 NUT, FRONT/ REAR SHAFT SET 4 M20×1.5 180～200N.m
25 NUT, FRONT/ REAR SHOCK
ABSORBER 8 M10×1.25 30～35N.m
26 NUT, RIM 16 M10×1.25 30～35N.m
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1. SERVICE INFORMATION
1-12
Specification Tightening moment
M6 8~12N·m
M8 18~25N·m
M10 40~50N·m
Other screws（8.8 grade）
M12 50~60N·m
Specification and usage quantity for fuel
lubricating oil and brake liquid
Category Specification Capacity Remark
Fuel RQ-93or upper grade
lead-free gasoline
22L Content of
fuel box
Lubricating oil（engine,
Gear box）
SAE15W-40/SF 2500ml(change oil)
2600ml(change filter)
Lubricating oil （front
main driver）
First 0.33L/change 0.28
Lubricating oil ( Rear
main driver）
SAE 85W/90 GL-5
First 0.30L/change0.25
Brake liquid GB1083 JG3 1.1L
Engine coolant Distilled water:
Glycol =1:1

1. SERVICE INFORMATION
1-13
Cables, Pipes, Cable Routing
1. L
ightswitch 2. Warning indicator light switch
3. Low beams/High beams turning switch 4. Turning light switch
5. Horn switch 6. Start switch
7. Engine stop switch 8. Starter (choke)
9. Drive select lever 10.Winchswitch
11. 4WD/4WD-Lock 12. 4WD/2WD
13. Throttle lever 14.Mainswitch
15. Auxiliary DC jack (12V 120W/10A)
1

1. SERVICE INFORMATION
1-14

1. SERVICE INFORMATION
1-15
1

1. SERVICE INFORMATION
1-16

2. Vehicle body，Muffler
2-1
Overhaul info……………………………2-1 Left footrest board…………………………2-5
Troubleshooting…………………………2-1 Right footrest board………………………2-6
Front rack………………………………2-2 Rear cover assembly ... ... ... ... .. ... ... ... ...2-7
Front bumper……………………………2-2 Store box cover…………............ ... ... ... ..2-8
Seat……………………………………2-2 Front cover assembly…………............ ... ..2-8
Rear rack………………………….. ... ...2-3Muffler & exhaust pipe…............ ... ... ... ... ..2-10
Rear bumper……………………………2-3 Fuel tank…………………………………2-11
Handlebar cover…………………………2-3 Guard plate…………………………………2-13
Left side panel…………………………...2-4 Visible parts………………………………2-14
Right side panel…………………………2-5
Overhaul Information
Operation Cautions
Warning
Gasoline is highly flammable, therefore smoke and fire are strictly forbidden in the work
place. Special attention should also be paid to sparks. Gasoline may also be explosive
when it is vaporized, so operation should be done in a well-ventilated place.
Remove and Install muffler after it is fully cold.
●This chapter is on the disassembly and installation of rack, visible parts, exhaust pipe,
Muffler and fuel tank.
●Hoses, cables and wiring should be routed properly
●Replace the gasket with a new one after muffler is removed
●After muffler is installed, check if there is any exhaust leakage.
Tightening torque
Muffler Rear Fixing Bolt: 23-25N.m
Muffler Exhaust Pipe Nut: 23-25N.m
Troubleshooting
Loud exhaust noise
●Broken muffler
●Exhaust leakage
Insufficient power
●Distorted muffler
●Exhaust leakage
●Muffler clogged
2

2. Vehicle body，Muffler
2-2
FRONT RACK
Remove
Remove two bolts 1
Remove two bolts 2
Remove two bolts 3
Remove front Rack
Installation
Reverse the removal procedure for
Installation
FRONT BUMPER
Remove
Remove four bolts 4
Remove bumper.
Installation
Reverse the removal procedure for
Installation
SEAT
Remove
Pull upward seat buckle
Lift and push seat backward
Installation
Press upward seat buckle
Press seat forward and down
Note
Make sure that the seat is firmly installed.