KEEWAY ATV300 User manual

1
CONTENTS
GENERAL INFORMATION
1.Information…
……
……………………………………..…….…2
22
2
2.Maintenance………………………………………
..
.…..6
3.EngineRemoval&Installation……
……
………………...…..13
ENGINE
4.LubricationSystem………...…………………………15
5.FuelSystem…………………………………………….19
6.CylinderHEAD&CylinderValve………...……….…..30
7.Cylinder&Piston……………………………………..46
8.V-Beltdrivingsystem…………………………………54
9.ACG&Startonewayclutch……………...…………..67
10.CoolingSystem……………...……………………..76
CHASSIS
1
1
.Steering
Suspension…………
..
………................
84
1
2
.Front
Wheel&
BrakeSystem……………
...
……….
90
13.RearWheel&BrakeSystem…………………….….95
14.ElectricalSystem…………………………………..97
15.TroubleShooting…………………………………..107

2
1. INFORMATION
1.1 SAFTY
1.2 NOTES
1.3 SPECIFICATION
1.4 SERIAL NUMBER
1.5 TORQUE VALUE
1.1 SAFETY
GASOLINE
Gasoline is extremely flammable and is explosive under certain condition. Do
not smoke or allow sparks or flames in your work area.
● CARBON MONOXIDE
Never run the engine in a closed area. The exhaust contains poisonous carbon
monoxide gas that may cause loss of consciousness and lead to death.
● BATTERY ELECTROLYTE
The battery electrolyte contains sulfuric acid. Protect your eyes, skin and
clothing. If you contact it, flush thoroughly with water and call a doctor if
electrolyte gets in your eyes.
● HOT PARTS
Engine and exhaust pipe become very hot and remain hot for one hour after the
engine is run. Wear insulated gloves before handling these parts.
● USED ENGINE/GEAR OIL
Used engine oil and gear oil may cause skin disease if repeatedly contact with
the skin for long periods.
Keep out of reach of children.
1.2 NOTES
All information, illustrations, directions and specifications included in this
publication are base on the latest product information available at the time of
approval for printing.
reserves the right to make changes at any time without notice and without
incurring any obligation whatever .
No part of this publication may be reproduced without written permission.
1.3 SPECIFICATION ENGINE
Type
4 Stroke ，
Single Cylinder, Water cooled
Displacement
264
c.c.
Bore and Stroke
71 mm x 6
6.8
mm

3
SUSPENSION
Front
Double A
-
Arm & Adjustable Shocks
Rear
Double A
-
Arm & Adjustable Shocks
BRAKES
Front
Hydraulic Disc*2
Rear
Hydraulic Disc*
2
TIRES
Front
2
5
x8
-
1
2
Rear
2
5
x10
-
12
PRESSURE 【 psi ( kgf/cm 2 ) 】
Front
8
(0.
58
)
Rear
9
(0.
65
)
COLORING
Specifications subject to change without notice.
Compression
10.
5
:1
O
utput
Power
14KW/6000rpm
Maximum Torque (Nm/rpm)
22.3 Nm / 5500
rpm
Carburetor
Vacuum film
Ignition
TC
I
Starting
El
ectric
Lubrication
15W
-
40
Transmission
Au
tomatic (C.V.T. V
-
belt
+ Shafts
)
CHASSIS
Overall Length
2170mm
Overall Width
1200
mm
Overall Height
1210mm
Wheel base
1275mm
Ground Clearance
260
mm
Dry Weight
330
kg
Fuel Tank Capacity
1
3
L

4
1.4 SERIAL NUMBER
Vehicle Identification Number (VIN) and Engine No. are used for registration. When you
order parts or need special service, these numbers can help you receive the best service from
our Authorized Dealers.
We recommend copying your vehicle identification date in your operation and
maintenance manual and on a sheet that you should keep in a safe place, separately from
the vehicle.
The VIN No. A is stamped on the central frame tube, to view the number ,remove the
inspection cap at the central of the leg guard; the ENGINE No. B is engraved on the left side
of crankcase, A is VIN plate jointed on the right side of tail frame.
VIN NO. ：
：：
：
ENGINE NO. ：
：：
：
A( VIN NO.)
B (ENGINE NO.)

5
1.5 TORQUE VALUES
FRAME
● Handlebar upper holder bolt
24 N.m (17.7 lbf.ft)
● Throttle housing cover screw
4 N.m (2.9 lbf.ft)
● Steering shaft nut
50 N.m (36.9
lbf.ft)
● Steering shaft holder bolt
33 N.m (24 lbf.ft)
● Wheel rim bolt
18 N.m (13.3 lbf.ft)
● Tie rod lock nut
35 N.m (25.8 lbf.ft)
● King pin nut
40 N.m (29 lbf.ft)
● Handlebar lower holder nut
40 N.m (29.5 lbf.ft)
● Front wheel bolt
24 N.m
(17.7 lbf.ft)
● Front axle castle nut
40
-
60 N.m (30
-
45 lbf.ft)
● Front brake arm nut
4 N.m (3.0 lbf.ft)
● Rear brake arm nut
7 N.m (5.2 lbf.ft)
● Rear axle castle nut
40
-
60 N.m (30
-
45 lbf.ft)
● Rear wheel bolt
24 N.m (17.7 lbf.ft)
● Exhaust muffler mounting bolt
30 N.m (22.1 lbf.ft)
● Engine hanger bolt
30 N.m ( 22 lbf.ft)
● Rear axle holder bolt
90 N.m (65 lbf.ft)
● Swing arm pivot nut
90 N.m (65 lbf.ft)
● Rear shock absorber mounting nut
45 N.m (33 lbf.ft)
STANDARD
● 5 mm bolt and nut
5 N.m (3.5 lbf.ft)
● 6 mm bolt and nut
10 N.m (7.2 lbf.ft)
● 8 mm bolt and nut
22 N.m (16 lbf.ft)
● 10 mm bolt and nut
35 N.m (25 lbf.ft)
● 12 mm bolt and nut
55 N.m (40 lbf.ft)
ENGINE
● Cylinder head nut
28 N.m (20.7 lbf.ft)
● Spark plug
12 N.m (8.9 lbf.ft)
● Cylinder head bolt
20 N.m (14.8 lbf.ft)
● Alternator bolt
8 N.m (5.9 lbf.ft)

6
2. MAINTENANCE
2.1 MAINT
ENANCE DATA
2.8 IDLE SPEED
2.2 MAINTENANCE SCHEDULE
2.3 FUEL TUBLE
2.
9
BRAKE SYSTEM
2.4 THROTTLE OPERATION
2.1
0
WHEELS AND TIRES
2.5 THROTTLE CABLE AJUSTMENT
2.1
1
STEERING SYSTEM
2.6 AIR CLEANER
2.1
2
TOE
-
IN
2.7 SPARK PLUG
2.1 MAINTENANCE DATA
SPECIFICATION
SPARK PLUG
SPARK PLUG GAP
0.6
-
0.8 mm
RECOMMENDED SPARK PLUGS
NGK
DR8EA
THROTTLE LEVER FREE PLAY
2
-
5
mm
IDLE SPEED
1500 ± 100 rpm
BRAKE LEVER FREE PLAY
15
-
25 mm
TORQUE VALUES
SPARK PLUG
12
-
19 N.m
TIE
-
ROD LOCK NUT
35
-
43 N.m
ENGINE OIL
1.
2
Liter (1.
0
Liter for change)
GEAR LUBRICATION OIL
750cc (650cc for change)

7
2.2 MAINTENANCE SCHEDULE
To keep the performance good, the motorcycle should be checked and maintained at certain
interval. The meanings of capital in following table are:
I: Inspection, including check, clean, lubricate, refuel, repair or replacing if necessary.
A: Adjusting C: Cleaning R: Replacing T: Tightening
Maintenance
period
Items
Odometer (km) 里程数
里程数里程数
里程数
300 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
Everyday
check
before
riding
Crankcaselube
R
R
R
R
R
R
R
I
Lube filter
C
C
C
C
Air filter
Clean filter every 2000~3000 km. change it when necessary
Spark pl
ug
Initial 1000km and Clean every 3000~4000km change it when necessary
Valve gap
A
A
A
A
Cam chain
A
A
A
A
Carburetor
I
I,C
I,C
I,C
Gas filter
R
Brake system
I
I
I
I
I
I
I
I
I
I
I
I
I
Driving chain
I
I
I
Fasteners
T
T
T
Coolent
A
A
A
A
A
I
Gearbox oil
I
R
R
R
Battery
I
* When the mileage is over the highest on the table, please perform according to the period set
on the table
* Driving on dust place, it is recommended to clean it frequently.

8
2.3 FUEL TUBE
Inspect the fuel lines for deterioration,
damaging or leakage and replace if necessary.
2.4 THROTTLE OPERATION
Inspect for smooth throttle lever full opening and
automatic full closing in all steering positions.
Inspect if there is no deterioration, damage or kink
in the throttle cable, replace it if necessary.
Check the throttle lever, free play is 2 —
——
— 5 mm at the
tip of the throttle lever.
Disconnect the throttle cable at the upper end.
Lubricate the cable with commercially lubricant to
prevent premature wear.
2.5 THROTTLE CABLE ADJUSTMENT
Slide the rubber cap of the adjuster off the throttle
Housing, loosen the lock nut and adjust the free play
of the throttle lever by turning the adjuster on
the throttle housing. Inspect the free play of the
throttle lever.
2.6 AIR CLEANER
Please remove the four hooks, and then disassemble
two screws inside the air cleaner case.
Pull out the air filter element from the air cleaner case.
Washing the element in non-flammable solvent, squeeze
out the solvent thoroughly.
Let it dry.
Soak the filter element in gear oil and then squeeze
out the excess oil.
Install the every component into air cleaner in the reverse
order of removal.
Note: for more detail please check chapter 5-10
Throttle

9
2.7 SPARK PLUG
This spark plug is located at the front of the engine.
Disconnect the spark plug cap and unscrew
the spark plug.
Check the condition of spark plug electrodes wear.
Change a new spark plug if the electrodes and
insulator tip appear unusually fouled or burned.
Discard the spark plug if there is apparent wear
if the insulator is cracked or chipped.
The spark plug gap shall keep in 0.6-0.8mm
With the sealing washer attached, thread the
spark plug in by hand to prevent crosses threading.
Tighten the spark plug with 12-19 N.m
2.8 IDLE SPEED
Connect an engine speed meter.
Warm up the engine, 10 minutes are enough.
Turn the idle-speed adjust screw B on the carburetor
to obtain the idle speed. “Turn in” (clockwise) will
get higher speed. “Turn out” (counter clockwise) will
get lower speed.
IDLE SPEED: 1500±100 rpm
2.9 BRAKE SYSTEM
Inspect the front brake lever and cable for excessive
play or other damage.
Replace or repair if necessary.
Measure the free play of the brake lever at the end of the
brake lever.
The standard of free play is 5-15 mm.
The parking brake is shown on the picture. The position
of parking Off is on the left side. Turn parking brake to
right side is parking on
Brake handle
Parking Brake

10
Inspect the rear brake lever and cable for excessive
play or other damage.
Replace or repair if necessary.
Measure the free play of the rear brake lever at the
end of the lever.
The standard is 5-15 mm.
The second method to adjust brake level is under the
driver seat and rear brake component.
Because the brake system is different, ones need to adjust it
to reach a proper brake level.
2.10 WHEELS AND TIRES
Inspect the tire surfaces for cuts, nails or other
sharp objects.
Check the each tire surface at cold tire condition.
*The standard of tire pressure is 8(0,6до1,0) psi ( kgf/cm 2 )
2.11 STEERING SYSTEM
Check the free play of the steering shaft with the front
wheels, turned straight ahead.
When there is excessive play, inspect the tie-rod,
kingpin bushing and ball joint.
Parking BRAKE Adjustabie nut

11
STEERING SHAFT HOLDER BUSHING
Remove the front fender first.
Remove the steering shaft holder and check the
steering shaft bushing for wears or damage.
If the bushing is worn or damaged, please change a new
one.
Grease the steering shaft bushing and install the parts
in the reverse order of removal.
Torque: steering shaft holder bolt: 33 N.m (24 lbf.ft)
2.12 TOE-IN
Keep the vehicle on level ground and the front
wheels facing straight ahead.
Mark the centers of the tires to indicate the axle
center height.
Measure the distance between the marks.
Carefully to move the vehicle back, let the wheels
turn 180 degree, so the marks on the tires are aligned
with the axle center height.
Measure the distance between the marks.
Calculate the difference in the front and rear
measurements.
Toe-in: 5±10mm

12
If the toe-in is out of standard, adjust it by changing
the length of the tie-rods equally by turning the tie-rod
while holding the ball joint.
Tighten the lock nuts.
Torque: 35-43 N.m

13
3. ENGINE REMOVE AND INSTALLATION
3.1 REPAIR CONDITION
3.3 ENGINE INST
ALLATION
3.2 ENGINE REMOVAL
3.1 ENGINE SHALL BE REMOVED IN THE CONDITIONS OF NECESSARY
REPAIRMENT OR ADJUSTMENT TO THE TRANSMISSION AND
COMBUSTION SYSTEM ONLY
3.2 ENGINE REMOVAL
Before removing engine, you need to remove all of components such as seat, front and
back fender, fuel tube, exhaust pipe, carburetor cable and drive shafts …
……
… etc. You can then
see three hanger bolts which have screwed on engine.
Loosen these three hanger bolts. You have succeeded to remove this engine.
There are some pictures to describe main step of removing engine.
Disconnect the wire connectors. There are three
connectors for carburetor auto-choke, starter motor
and generator respectively.
Remove the drive Shafts.

14
3.3 ENGINE INSTALLATION
The Engine installation is essentially in the reverse order of removal.
The torque of engine hanger bolt is 30 N.m
Route the wires and cable in reverse order properly.

15
4. LUBRICATION SYSTEM
4
-
1 Mechanism Diagram
4-2 Precautions in Operation
4-3 Troubleshooting
4-4 Engine Oil
4
-
5 Engine Oil Strainer Clean
4-6 Gear Oil
4-1 Mechanism Diagram

16
4-2 Precautions in Operation
General Information:
This chapter contains maintenance operation
for the engine oil pump and gear oil replacement.
Specifications
Engine oil quantity Disassembly: 1200 c.c.
Change: 1000c.c.
Oil viscosity SAE 10W-40 (Recommended King serial oils) 單位
單位單位
單位 :mm
Gear oil Disassembly: 750c.c.
Change: 650c.c.
Gear oil viscosity SAE 10w- 40
(Recommended SYM Hypoid gear oils)
Torque value
Torque value oil strainer cap 1.5~3.0kgf-m
Engine oil drain bolt 1.9~2.5kgf-m
Gear oil drain bolt 1.0~1.5kgf-m
Gear oil join bolt 1.0~1.5kgf-m
Oil pump connection bolt 0.8~1.2kgf-m
4-3 Troubleshooting
Low engine oil level Low oil pressure
Oil leaking Low engine oil level
Valve guide or seat worn out Cylinder head gasket damage
Piston ring worn out Piston ring worn out
Dirty oil
No oil change in periodical
Cylinder head gasket damage
Piston ring worn out
Items
Standard (mm)
Limit (mm)
Oil pump
Inner rotor clearance
0.15
0.20
Clearance between outer rotor and body
0.15~0.20
0.25
Clearance between rotor side and body
0.04~0.09
0.12

17
4-4 Engine Oil
Turn off engine, and park the ATV in flat
surface with main stand.
Check oil level with oil dipstick.
So not screw the dipstick into engine as
checking.
If oil level is nearly low level, fill out
recommended oil to upper level.
Oil Change
Caution
Drain oil as engine warmed up so that makes sure
oil can be drained smoothly and completely.
Place an oil pan under the ATV, and remove oil
drain bolt.
After drained, make sure washer can be re-used.
Install oil drain bolt.
Torque value ： 1.9~2.5kgf-m
4-5 Engine Oil Strainer Clean
Drain engine oil out.
Remove oil strainer and spring.
Clean oil strainer.
Check if O-ring can be re-used.
Install oil strainer and spring.
Install oil strainer cap.
Oil strainer cap
Torque value ： 1.5~3.0kgf-m
Add oil to crankcase (oil viscosity SAE 10W-40)
Recommended using King serial oil.
Engine oil capacity: 1000c.c. when replacing
Install dipstick, start the engine for running
several minutes.
Turn off engine, and check oil level again.
Check if engine oil leaks. O-ring Oil strainer
Drain bolt

18
4-6 Gear Oil
Gear Oil Change
Remove oil join bolt.
Remove drain bolt and drain gear oil out.
Install the drain bolt after drained.
Torque value: 1.0~1.5kgf-m
Make sure that the drain bolt washer can be
re-used.
Add oil to specified quantity from the join hole.
Gear Oil Quantity: 650c.c. when replacing
Make sure that the join bolt washer can be
re-used, and install the bolt.
Start engine and run engine for 2-3 minutes.
Turn off engine and make sure that oil level is
in correct level.
Make sure that no oil leaking.
Gear oil drain bolt
Gear oil join bolt

19
5. FUEL SYSTEM
5-1 Mechanism Diagram
5-2 Precautions in Operation
5-3 Trouble Diagnosis
5-4 Carburetor Remove / Install
5-5 Air Cut-Off Valve
5-6 Throttle Valve
5-7 Float Chamber
5-8 Adjustment of Idle Speed
5-9 Fuel Tank
5-10 Air Cleaner
5-1 Mechanism Diagram

20
5-2 Precautions in Operation
General Information
Warning
Gasoline is a low ignition point and explosive materials, so always work in
a well-ventilated place and strictly prohibit flame when working with
gasoline.
Cautions
●
●●
● Do not bend off throttle cable. Damaged throttle cable will make
unstable drive-ability.
●
●●
● When disassembling fuel system parts, pay attention to O-ring
position, replace with new one as re-assembly
●
●●
● There is a drain screw in the float chamber for draining residual
gasoline.
●
●●
● Do not disassemble air cut valve arbitrarily.
Specification
ITEM
UA2
5A
Carburetor diameter
I.D. number
Fuel level
Main injector
Idle injector
Idle speed
1
5
00 ± 100rpm
Throttle handle clearance
2~5
mm
Pilot screw
Tool
Special service tools
Vacuum/air pressure pump
Fuel level gauge