KEEWAY ARN125 Installation and user guide

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Scooter Service and Maintenance Manual
ARN125/150
C o p y r i g h t :
K E E WAY I N T E R N AT I O N A L D E V E L O P M E N T C O . , LT D .
FEB.2006

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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:[phone]
FAX:[phone]
EMAI: [e-mail]
Our engineer are very glad to give you the necessary assistance and
help.

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CONTENTS
Perface
A General knowledge
1. Basic term-----engine
2. Engine type—4 STROKE ENGINE，WORK CYCLES/ILLUSTRATIONS.
3. Safety for repair shop
4. Electric safety
B PRODUCT
1. Technical parameter
2. Special service tools
3. Engine and transmission system
a) Specified torque volume
b) Small but vital parts
c) Non-directional accessory-engine part
d) Engine removal and installation
e) ------ Cowling assembly
------Cylinder head assembly
-------Sub-cylinder shaft retainer assembly
----- Piston assembly
------Left crankcase cover assembly
---------Right crankcase cover assembly
--------Right crankcase
---Left crankcase parts assembly
----Crankcase assembly
----Transmission case
----Driven wheel disc clutch assembly
---- Kick starter shaft subassembly, transition gear shaft subassembly installation
---Driver wheel disc part assembly
---Exceeding clutch assembly
f) ---Power transfer chart
g) Lubricating system
h) Engine valve clearance setting
i) Cyliner pressure testing
j) Important standard dimension----engine
4. Oil----fuel system
--- Carburetor
----Carburetor removal/installation/
adjustment
5. Scooter body installation
6. Fixing torque---scooter body part
a) Front wheel assy.

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b) Rear wheel assy.
c) Muffler assy.
d) Front fork assy.
e) Front shock absorber assy.
f) Disc brake system
g) Points for motorcycle installation
h) Important dimension for scooter body
6．Electric work/electric
a) Magneto
b) Circuit diagram
c) Electronic ignition part test
d) Battery charge circuit and testing process for battery charge
e) Signal system circuit diagram
f) Various bulbs removal and installation
g) Inspection process for electronic accessories
h) Main electric accessories specification
i) Important electric parameters
C else
7. Inspection/inspection points before using
8. Periodical service
9. Permission and forbiddance
10. Safe driving
11. Fault inspection

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A
GENERAL
INFORMATION

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1．
．．
．B A S I C T E R M S O F E N G I N E
A. DEAD CENTER
DEAD CENTER IS THE TWO LIMITED
POINTS, WHERE PISTON MOVES UP
AND DOWN IN LINE.
TOP DEAD CENTER－WHICH IS FARTHEST
AWAY FROM THE ROTATION CENTER OF
CRANKSHAFT.
BOTTOM DEAD CENTER－WHICH IS NEAREST
AWAY FROM THE ROTATION CENTER OF
CRANKSHAFT.
B.
B.B.
B. CYLINDER DIAMETER
CYLINDER DIAMETER CYLINDER DIAMETER
CYLINDER DIAMETER
INNDRE DIAMETER OF CYLINDER IS CALLED CYLINDER DIAMETER.
C.
C.C.
C. JOURNEY
JOURNEY JOURNEY
JOURNEY
JOURNEY IS THE DISTANCE THAT PISTON
TRAVELS. WE USUALLY CALL ONE JOURNEY FROM
TOP DEAD CENTER TO BOTTOM DEAD CENTER.
D. WORKING CAPACITY OF THE CYLINDER
THE SPACE VOLUME OF PISTON WORKING
PATH, WHICH PISTON MOVES FROM TOP DEAD
CENTER TO BOTTOM DEAD CENTER IS CALLED
WORKING CAPACITY OF CYLINDER. USUALLY THE UNIT OF CYLINDER WORKING
VOLUME IS CC(CM³), SUCH AS 75CC, 125CC, WHICH IS DIFFERENT FOR WITH DIFFERENT
ENGINE MODEL.
E. TORQUE
TORQUE IS THE FORCE OF WHIRLING OR ROTATING.
WHEN WE LOOSEN OR SCREW NUTS/ SCREWS, WE HAVE
PUT TORQUE ON IT.
IN ORDER TO DRIVE THE WHEELS, THE ENGINE PUT TORQUE,
WHICH MAY STRENGTHEN LARGER FORCE ON WHEELS
WHEN CLIMBING SLOPE.
THE TORQUE IS EQUAL THAT THE FORCE MULTIPLIES THE

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ARM OF FORCE.
THE UNIT OF TORQUE IS KILOGRAM POWER-METER.
F. IGNITION TIMING
IN ORDER TO CONTROL THE BURNING OF
FIRE CHAMBER,, IGNITION IS TIMING.
THE IGNITION TIMING OF ENGINE QJ162FMJ
CHANGES AS FOLLOW:
WHEN ‘F’ IS 1400RMP, TOP DEAD CENTER
ADVANCES 15°..
WHEN “II” IS 4000RMP, THE TOP DEAD CENTER
ADVANCES 35°.
ENGINE CYCLE
ANY FOUR-STROKE GASOLINE ENGINE
HAS
FOUR STROKES, WHICH CONSIST OF ONE
WHOLE
OF CYCLE.
1.INLET: AIR AND MIXTURED AIR OF OIL
ARE ABSORBED INTO INLET CYLINDER.
2.COMPRESSION: MIXTURED AIR IS
COMPRESSED IN
THE CYLINDER.
3.POWER: WHEN IGNITING ENGINE, GAS
BURNS
AND EXPANDS, AND PUSH THE PISTON
MOVING
DOWN, CONNECTING ROD DIRVES ALONG
CRANKSHAFT AND OUTPUT MECHANICAL
ENERGY.
4.EXHAUST: THE EXHAUST GAS IS
EXPELLED FROM
CYLINDER.

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2．
．．
．4-STROKE ENGINE CYCLE
A：
：：
：INLET STROKE
1、CRANKSHAFT TURNS ANTICLOCKWISE.
2、CRANKSHAFT BRINGS ALONG PISTON TO MOVE THROUGH CONNECTING ROD.
3、WHEN PISTON TRAVES FROM TOP DEAD CENTER TO BOTTOM DEAD CENTER, INLET
PORT OPENS, MIXED GAS GOES INTO CYLINDER.
B. COMPRESSION STROKE
1. CRANKSHAFT REVOLVES CONTINUALLY, BRING ALONG THE PISTON TO MOVE FROM
TOP DEAD CENTER TO BOTTOM DEAD CENTER THROUGH CONNECTING ROD.
2. MIXTURE AIR IS COMPRESSED INTO A NARROW SPACE BETWEEN CYLINDER HEAD
AND PISTON HEAD, WHICH IS CALLED BURNING CHAMBER.
C
CC
C：
：：
： POWER STROKE
POWER STROKE POWER STROKE
POWER STROKE
1. SPARK PLUG INNITES COMPRESSED MIXED GAS OF AIR AND FUEL.
2. Burning of mixed gas of air and fuel results in sudden change of temperature
and pressure in Burning chamber, and then burning gas expands, the power acted on piston
push piston to move down. The power acted on piston transfers to crankshaft through
connecting rod, which leads that crankshaft moves more fastly. Expansion of burning mixed
gas provides enough power.
D: EXHAUST STROKE
D: EXHAUST STROKE D: EXHAUST STROKE
D: EXHAUST STROKE
b) When burning gas pushes piston continually to bottom, exhaust port opens.
c) For inertia crankshaft push piston to Move toward cyliner head.
d) As piston moves toward cylinder head, burning gas is excelled from exhaust port. When piston
travels to top end, exhaust port is shut off.

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3．
．．
．S E R V I C E W O R K S H O P S A F E T Y
WARNING
Don’t use the tool, which is damaged or easy to be
emerged, that may hurt you.
WARNING
Gasoline is flammable, and may explode in
some condition. Please never get it near smoke
or spark.
WARNING
Please often keep ground tidy and clear. Never
leak fuel on ground to avoid skidding and
damage.
WARNING
Never totate engine in close or bad ventilated
room, for exhaust contains poison gas.
WARNING
Please never clean brake hub, brake shoe and so
on with dry brush or compressed air to avoid
inhaling asbestos fibre, which may results in
cancer or other breath system disease.
WARNING
There is vitriol in storage battery, please protect
your eyes, skin and clothes. If touching vitriol
inadvertently, please wash it with water and see
doctor.
WARNING
Keep close privity with your colleague to ensure
safety.
WARNING
Please never touch brake fluid with your eyes,
otherwise wash it with water and see doctor.
Never touch brake fluid with hands for some
long time.
Never splash brake fluid on the surfaces of oil
pait parts and rubber accessories.
Never use superfluous fluid, which is exposed
in air, remaining fluid has absorbed moisture
from air, which may damage its speciality.
S E R V I C E R U L E S
1. Please use QianJiang genuine parts, and use recommended lubricant in pointed place.
2. Use special or universal tools.
3. When reassembling, use new sealed washer, O-ring, oil seal, clip, cottern 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 bolts and nuts 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 smear some lubrication on the
surface so that it is rusted and with dust deposition.

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4 . E L E C T R I C S A F E T Y
a) The relaxation of calbe is hidden trouble;
so remember to clamp each calbe to
ensure safety.
b) Don’t bend cable nip toward welding
point.
c) Band cable on oppointed position.
d) Never lay cable in the bottom of frame
or in needle angle position.
e) Never lay calbe in the end of bolts or
nuts.
f) Keep calbe away from hot source part
or some position where calbe may be
clipped when moving.
g) Lay cable along handlebar, don’t pull it
too tight or too loose, and never terrer
with other parts when ratoating in any
position.
h) Lay calbe smooth, never distort or tie it.
i) Before connecting joint, inspect if joint
is damaged and joint is stretched.
j) If calbe is layed in needle angle or
turning position, protect calbe with
adhesive tape or tube.
k) After repairing, band up it with adhesive
tape.
l) Never keep contolling calbe bended or
distorted. If controlling calbe is
damaged, you may lose stable.

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B
PRODUCT

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1 . S P E C I A L T O O L S L I S T
NECESSARY TOOLS TO DISASSEMBLE AND INSTALL MOTORCYCLE ENGINE AS FOLLOWS：
CODE
TOOLS CODE PURPOSE
1
2
3
4
5
6
7
8
9
10
11
12
T01
T02
T03
T04
T05
T06
T07
T08
T09
T10
T11
T12
“T”SHAPE GUIE CYLINDER
GUIDE CYLINDER TOOLS（8,10,12,13）
SCREWED ROD FOR FLY WHEEL DISASSEMBLAGE
TOOLS TO DISASSEMBLE VALVE SPRING
DISASSEMBLING TOOLS FOR OIL DRAINAGE
CYLINDER PRESSURE GAUGE
DISASSEMBLING TOOL FOR PISTON PIN
SOCKET FOR DISMOUNTING SPARK PLUGS
ELECTRIC TOOL FOR DISASSEMBLING LOCKING BOLT OF
FLY WHEEL
CULTCH CLAMP
DISASSEMBLING SCREW TOOL
GUIDE CYLINDER (17,18)

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○ 1
○
2
○ 3
○
4
○
5
○
6

14
○
7
○
8
○
9
○
10
○
11
○
12

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3．
．．
．E N G I N E A N D T R A N S I M I S S I O N S Y S T E M ( A ．
．．
．S P E C I A L T O R Q U E )
The following table liss torques of some locking accessories/fixers, which you can refer to in assembly.
NO.
NA ME QTY TORQUE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Tapping screw for fan snail cover assy.
Lucknut for fan snail cover assy.
Tapping screw for up and down guide air cover
Lucknut for up and down guide air cover
Tapping screw and nut for ventilating air chamber of cylinder head
covr
Locknut for cylinder head cover
Locknut for double head blot on cam fixing
holder
Locknut for atmolysis chain pulling rod
Lucknut for atmolysis chain adjustor
Lucknut for cylinder head
Locknut for cylinder observing oil read
Spark plug
Double head bolt for cylinder head inlet port
Double head bolt ofr cylinder head exhaust port
Lucknut for carburetor joint
Lucknut for cooling impeller of fan
Locknut for flywheel
Locknut for magnet stator coil
Locknut for magnet motor trigger
Locknut for right crankcase cover
Oil filter cover cap
Locknut for oil pump seperating board
Locknut for oil pump sprocket
Locknut for oil pump
Locknut for oil pump cover
Locknut for super-clutch
Locknut for super clutch outside
Locknut for right crankcase
Double head bolt for left and right crankcase
Fixing bolt for motro
Locknut for left crankcase cover and line coil
Tapping screw for ventilating guide board of left
crankcase cover
Locknut for driver disc
Locknut for driven disc
Locknut for driven disc clutch
Locknut for press-board of kick starter
Locknut for transmission case cover
Locknut for flowing oil hole of transmission case
Locknut for flowing oil hole of left crank.
Locknut for position shaft of left crank
2
2
3
1
3
4
4
1
2
2
1
1
2
2
2
4
1
2
2
9
1
2
1
2
1
1
3
2
4
2
11
4
1
1
1
1
5
2
1
1
1-3N••M
10-12N•M
1-3N••M
10-12N•M
1-3N••M
10-12N•M
22-25N•M
10-12N•M
10-12N•M
10-12N•M
10-12N•M
10-15 N•M
10-12N•M
10-12N•
M
10-12N•M
10-12N•M
45-55N•M
6-8N•M
10-12N•M
10-12N•M
55-60N•M
10-12N•M
8-10N•M
10-12N•M
1-3N••M
35-40N•M
10-12N•M
10-12N•M
22-25N•M
10-12N•M
10-12N•M
3-6N•M
45-55N•M
45-55N•M
55-60N•M
10-12N•M
10-12N•M
22-25N•M
40-45N•M
22-25N•M

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b . I M P O R TA N T PA R T S
The following is detail information of vital position pin, O-ring, bearing, pin shaft and gasket of
ENGINE/UNDERPAN:
POSITION PIN-14NOS.
S.NO.
Size (mm) Qty. Description Location
1 10Фx16 2 Camshaft fixing seat and
cylinder head Engine
2 10Фx16 2 Cylinder head and cylinder head Engine
3 10Фx16 2 Crankcase and cylinder body Engine
4 10Фx16 2 Left and right crankcase Engine
5 8Фx14 2 Left crankcase and gearbox Engine
6 10Фx16 2 Left crankcase and left cover Engine
7 8Фx14 2 Rignt crankcase and right
cover Engine
O-ring-7NOS.
S.NO.
Size (mm) Qty. Description Location
1 9Фx1.6 2 Inlet and exhast valve pipe Engine
2 13.7Фx1.5 1 Atmolysis chain pulling lever Engine
3 9.5Фx1.5 1 Atmolysis chain adjustor Engine
4 18Фx3 1 Oil gauge Engine
5 30Фx3 1 Filter spring cap Engine
6 26502470 1 Starting moto Engine
Oil seal- 4NOS.
S.NO.
Size (mm) Qty. Description Location
1 27x42x7 1 Output shaft---gearbox cover
Engine
2 20x32x6 1 Output shaft—left crankcase
Engine
3 19.8x30x7 1 Crank—left crankcase Engine
4 19.8x30x7 1 Crank—right cover Engine

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BEARING- 13NOS
S.NO.
Code Qty. Description Location
1 6004 1 Output shaft—gearbox cover Engine
2 6201 1 Middle shaft—gearbox cover Engine
3 6301 1 Output shaft—gearbox cover Engine
4 6203 1 Output shaft—left case Engine
5 6202 1 Middle shaft—left case Engine
6 6204 1 Output shaft—left case Engine
7 TM-SCO7A87 1 Left crank—left case Engine
8 TM-SCD5ASSCS12 1 Right crank—right case Engine
8 K28x33x14 1 Crank pin—crank connecting big rod Engine
9 K28x32x17 1 Clutch hub—cluch gear Engine
10 6902NSE28 x15x7 1 Driven disc—output shaft Engine
11 HK20 x29x18RS 1 Driven disc—output shaft Engine
12 6002 2 Camshaft—atmolysis shaft fixing holer Engine
PINSHAFT- 2NOS
S.NO.
Size (mm) Qty. Description Location
1 5Фx6 1 Super clutch Engine
2 4Фx6.5 1 Oil pump Engine
GASKET- 7NOS
S.NO.
Gasket Type Qty. Location
1 Cyliner head cover Rubber endurable against oil 1 Engine
2 Cylinder head Steel 1 Engine
3 Cylindr body Asbestos rubber endurable
against oil 1 Engine
4 Crankcase Endurable oil asbestos rubber 1 Engine
5 Right crankcase cover Endurable oil asbestos rubber 1 Engine
6 Left crankcase cover Endurable oil asbestos rubber 1 Engine
7 Atmolysis chain adjuster
Endurable oil asbestos rubber 1 Engine

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Shifting gears inforamtion
Gear down
ratio Gear Gear qty. Gear QTY.
2.8 A1 15 A2 42
3.077 B1 13 B2 40
GEAR INFORMATION
NO. GEAR QTY. POSITION
1Kick starter gear 38 ENGINE
2
Kick starter transition
small gear 13 ENGINE
3
Kixk starter transition big
gear 49 ENGINE
4
Crank kick starter driven
gear 20 ENGINE
5 Starting motor drvie gear 9 ENGINE
6
Electricity starter
transition gear 54/13 ENGINE
7 Clutch gear 52 ENGINE
SPROCKET INFORMATION
No.
No.No.
No. Sprocket wheel
Sprocket wheelSprocket wheel
Sprocket wheel QTY. POSITION
1 Right crank oil pump driver
sprocket wheel 17 ENGINE
2 Oil pump sprocket wheel 19 ENGINE
3 Left crank atmolysis shaft
driver sprocket 17
ENGINE
4 Atmolysis shaft sprocket 34 ENGINE
CHAIN INFORMATION
NO. CHAIN NODE POSITION
1 ATMOLYSIS SHAFT CHAIN 90 ENGINE
2 OIL PUMP CHAIN 42 ENGINE

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c . S PA R E PA R T S O F E N G I N E
Please read the following instruction carefully, and ensure spare parts in right position. Otherwise engine
cannot perform.
1. All marks of the following parts should be towards combined surface of left crankcase and
transmission case:Output shaft of left crankcase, middle shaft, output shaft bering
6203,6202,6204, and output shaft of transmission case, middle shaft, output shaft bearing
6004,6002,6301.
2. The side of driven wheel disc rolling needle bearing with mark needs to be toward seeable direction,
and the side of ball bearing with mark needs to be towards clip.
3. The convex prick side of the gasket between driver wheel disc and driven wheel disc is towards
locknut.
4. The side of kick-starter gear and transition gear with mark is towards left cover.
5. Chain guiding groove is towards chain, and column rod of chain guiding part is not higher than
the surface of cylinder.
6. White piston circle is the first one, black piston circle is the second one; hatches
of circle 1 and circle 3 are towards exhaust port, hatches of circle 2 and circle
4 are towards inlet port; the side with English letter is towards the top of piston.
7. “IN” mark on piston is towards carburetor side.
8. Valve spring (dense end) is towards valve pipe.
9. The side of camshaft bearing 6002 with mark is towards cam.
10. The side of oil pump with letters is towards outside.
The side of left and right crankcase bush with “W” mark is towards the reverse of combined surface
of left and right crankcase

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d . E N G I E N R E M O VA L A N D I N S TA L L AT I O N
REMOVAL INSTALLATION
Guiding-wind cover/fan cover/carburetor left crankcase assy./gearbox assy.
Left crankcase cover/gasket/piston pin gearbox
Outside part of left crankcase crankshaft/left and right crank motor
Chain adjustor /cylinder head cover oil pump/super-clutch/electric start transition gear
Camshaft holder/cam right crankcase cover/oil filter/oil gauge
Cylinder cover/gasket/pin coil/flywheel/fan impeller
Cylinder/gasket/pin piston/piston pin/spring clip
Spring clip/piston pin/piston cylinder/gasket/pin
fan impeller/flywheel/coil cylinder cover/gasket/pin
Right crankcase cover/oil filter/oil gauge cam/camshaft supporter
Right crankcase outside chain adjustor/cylinder head cover
Start motor/left and right crankcase/crank left crankcase outside assy.
Gearbox left crankcase cover/gasket/pin
Left crankcase/gearbox cover guiding-wind cover/fan cover/carburetor
NOTICE:
a) Before installation, wash engine parts, and then lubricate engine, refer to recommended torque volume to lock
screw.
b) Pay special attention to single direction fixing accessories.
Start and inspect oil road lubricating system after having reinstalled engine.