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Aeon 350cc, Service Manual

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Aeon 350cc Service Manual Download Page 75

ENGINE

 

 

4-75

FLYWHEEL REMOVAL / INSPECTION 
 

 

The crankshaft end contains an oil passage plunge 

joint (A) as shown below. The plunger must be able 

to move in and out freely. Avoid damage to the 

crankshaft end or plunge joint and spring, which 

can cause loss of oil pressure, resulting in severe 

engine damage.

 

1. Remove the oil passage plunge joint, flywheel nut and 

washer. 

 

2. Install Flywheel Puller. 

3. Remove flywheel. 

 

 

CAUTION 

Do not hammer or strike the tool while attached to 

the crankshaft end, which may become damaged. 

4.  Remove  stator  coil  and  pick  up  from  right  hand  crank 

cover.

 

 

5. Inspect stator coils and pick up. Replace complete stator if any one coil or 

pick up burnt. 

 

ONE-WAY CLUTCH REMOVAL / 

INSPECTION 

1. Remove the hex bolts that attach the one—way drive 

clutch to the flywheel. 

 

2. Inspect the one-way clutch gear contact surfaces and drive 

teeth for signs of wear or gouging. Replace the one-way 

clutch as an assembly if it is not working properly. 

 

 

 

 

Summary of Contents for 350cc

Page 1: ...and right side of the vehicle are from the operator s perspective when seated in a normal riding position Some procedures outlined in this manual require a sound knowledge of mechanical theory tool u...

Page 2: ...death to the operator bystander or person s inspecting or servicing the vehicle SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAU...

Page 3: ...GENERAL INFORMATION 1 3 1 GENERAL INFORMATION 1 MAINTENANCE 2 CVT 3 ENGINE TRANSMISSION 4 ELECTRONIC FUEL INJECTION 5 BODY FRAME 6 ELECTRICAL 7 2 3 4...

Page 4: ...ODEL INFORMATION 1 2 VIN IDENTIFICATION 1 2 ENGINE SERIAL NUMBER LOCATION 1 2 VEHICLE IDENTIFICATION NUMBER LOCATION 1 2 GENERAL SPECIFICATIONS 1 3 URBAN 350I 1 3 SPECIFICATION UEBAN 350I 1 4 CONVERSI...

Page 5: ...ht side of frame The vehicle identification number VIN and engine serial number are important for identification purposes See the illustrations VEHICLE IDENTIFICATION NUMBER LOCATION ENGINE SERIAL NUM...

Page 6: ...GENERAL INFORMATION 1 6 GENERAL SPECIFICATION URBAN 350 I Model AS31 62E Model number RF3SA3110AT Engine Model T62N...

Page 7: ...c start DC CDI Front brake Duel disc with single bore caliper Max Power 16 5kw 7500rpm Rear brake Single Disc with single bore caliper Max Torque 25Nm 4000rpm Front tire 120 70 16 29psi FUEL SYSTEM Re...

Page 8: ...s cc Cubic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quart...

Page 9: ...nsmission Drive Clutch System DCV Direct current voltage Dial Bore Gauge A cylinder measuring instrument which uses a dial indicator Good for showing taper and out of round in the cylinder bore Electr...

Page 10: ...mechanical sense friction or load In the electrical sense ohms resulting in energy conversion to heat RPM Revolutions per minute Seized Piston Galling of the sides of a piston Usually there is a tran...

Page 11: ...GENERAL INFORMATION 1 11...

Page 12: ...2 6 GASKETS OIL SEALS AND O RING 2 6 FUEL AND INTAKE SYSTEM 2 6 FUEL SYSTEM 2 6 FUEL LINES 2 6 FUEL PUMP FUEL FILTERS PUMP REGULATOR 2 7 VENT LINE 2 7 THROTTLE INSPECTION 2 7 THROTTLE FREEPLAY ADJUST...

Page 13: ...REMOVAL 2 15 BATTERY INSTALLATION 2 15 BATTERY OFF SEASON STORAGE 2 15 SPARK PLUG SERVICE 2 16 STEERING AND SUSPENSION 2 16 STEERING AND SUSPENSION 2 16 HANDLEBAR INSPECTION 2 16 STEERING HEAD INSPEC...

Page 14: ...severe use must be inspected and serviced more frequently SEVERE USE DEFINITION Frequency immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Exte...

Page 15: ...ce brake pads if necessary Brake hoses Check for cracks or damage Replace brake hose if necessary Wheels Check runout and for damage Replace if necessary Tires Check tread depth and for damage Replace...

Page 16: ...18 ft lbs 18 25 Nm 10 mm bolts and nuts 22 29 ft lbs 30 40 Nm 12 mm bolts and nuts 36 43 ft lbs 50 60 Nm 4 mm screws 22 30 in lbs 2 5 3 4 Nm 5 mm screws 30 43 in lbs 3 5 5 Nm 6 mm Hex bolts 87 121 in...

Page 17: ...d O rings must be cleaned 2 Properly oil all mating parts and bearings during reassembly Apply grease to the oil seal lips FUEL SYSTEM Gasoline is extremely flammable and explosive under certain condi...

Page 18: ...trol and the idle speed may be erratic Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary THROTTLE FREE PLAY ADJUSTMENT Inspe...

Page 19: ...ine is a wet sump engine meaning the oil is contained in the bottom of the crankcase To check the oil level follows the procedure listed below 1 Position vehicle on a level surface 2 Be sure the machi...

Page 20: ...ing surface on the drain plug should be clean and free of burrs nicks or scratches 6 Reinstall drain plug and torque to 20 Nm 15 ft lbs 7 Place shop towels beneath oil filter Using Oil Filter Wrench t...

Page 21: ...e with the maintenance schedule 1 Be sure vehicle is positioned on a level surface when checking or changing fluid 2 Check vent hose to be sure it is routed properly and unobstructed TRANSMISSION LUBR...

Page 22: ...OOLANT LEVEL INSPECTION The pressure cap and recovery tank are located under the left floor of the vehicle The coolant level must be maintained between the minimum and maximum levels indicated on the...

Page 23: ...ks deterioration abrasion or leaks Replace if necessary 2 Check tightness of all hose clamps Do not over tighten hose clamps at radiator or radiator fitting may distort causing a restriction to coolan...

Page 24: ...pressure 210kap 30psi Max tire pressure 280kpa 33psi Rear tire Max Load 325kg 716lb Tire pressure 252kpa 36psi Max tire pressure 280kpa 40psi WEAR INDICATOR It is dangerous to ride with a worn out tir...

Page 25: ...p water into the battery Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink l...

Page 26: ...store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Battery charge can be maintained by using a battery ch...

Page 27: ...f necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark plug is used 9 Apply anti seize compound to the spark plug threads 10 Install spark plug a...

Page 28: ...ront brake Push down hard on the handlebar several times and check if the front fork rebounds smoothly 4 If front fork rough movement repair or replace it REAR SHOCK PRELOAD ADJUSTMENT The rear shock...

Page 29: ...level line add brake fluid until it reaches the MAX level line 5 Install the reservoir cap and apply the brake lever forcefully for a few seconds and check for fluid leakage around the master cylinde...

Page 30: ...ODED VIEW 3 3 DRIVEN CLUTCH EXPLODED VIEW 3 3 CVT OVERHEATING DIAGNOSIS 3 4 DRIVE CLUTCH REMOVAL 3 5 DRIVEN CLUTCH EXPLORED VIEW 3 6 DRIVEN CLUTCH REMOVAL 3 6 DRIVEN CLUTCH SERVICE 3 7 DRIVEN CLUTCH D...

Page 31: ...s to push against the cam plate and force the moveable sheave toward the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the dr...

Page 32: ...CVT SYSTEM 3 32...

Page 33: ...ately 5 12 km Drive at higher speed for cooler CVT operating temperatures and longer component life Insufficient warm up of exposed to low ambient temperatures Warm engine at least 5 min then with tra...

Page 34: ...er clutch cover 3 Remove the inlet dust screw and inlet duct 4 Remove outer clutches cover screws and the clutch cover 5 Remove outer sheave from crankshaft 7 Remove belt 6 Use two hands to hold the c...

Page 35: ...omponents become free and could fall apart Mark or note parts during disassembly 1 Hold the driven clutch housing then releasing the nut from the shaft 2 Remove the nut by pincer and air wrench 3 Pull...

Page 36: ...drum Measure the inside diameter of the cover at 90 degree intervals using a caliper Inspect the condition and diameter of the drum lining If either the measurements or the lining indicates excessive...

Page 37: ...for final assembly Install the compression spring Place the friction pad assembly over the spring and compress the driven assembly together with both hands With the assembly compressed and the threads...

Page 38: ...with the locknut wrench 8 Hold the clutch housing with the holding tooling tighten the clutch housing nut to 50Nm Driven Assembly Nut Torque 50 Nm 37 ft lbs DRIVE CLUTCH DISASSEMBLT AND INSPECTION 1 R...

Page 39: ...clutch assembly when the pulley is at its widest position 2 Install the drive clutch outer sheave when the pulley is at its narrowest position 3 Ensure the V belt is tight 4 Holding the primary fixed...

Page 40: ...4 14 PISTON IDENTIFICATION 4 14 ASSESSIBLE COMPONNTS 4 14 ENGINE REMOVAL 4 14 RIGHT HAND ENGINE MOUNT 4 15 LEFT HAND ENGINE MOUNT 4 15 ENGINE INSTALLATION NOTE 4 16 ENGINE LUBRICATION 4 16 OIL FLOW T...

Page 41: ...T CAM OIL CHAIN SPROKET INSPECTION 4 37 CRANKCASE INSPECTION 4 38 CRANCASE OIL STRAINER INSPECTION 4 38 BEARING SEAL INSTALLATION 4 38 ENGINE RESASSEMBLY 4 39 CANKSHAFT AND CAM OIL CHAIN INSTALLATION...

Page 42: ...W POWER 4 50 PISTON FAILURE SCORING 4 50 EXCESSIVE SMOKE AND CARBON BUILDUP 4 50 LOW COMPRESSION 4 50 BACKFIRING 4 50 TRANSMISSION 4 51 TANSMISSION EXPLODED VIEW 4 51 TANSMISSION DISASSEMBLY 4 52 TANS...

Page 43: ...ENGINE 4 43 ENGINE SERVICE ENGINE EXPLODED VIEW 1...

Page 44: ...ENGINE 4 44 ENGINE EXPLODED VIEW 2...

Page 45: ...ENGINE 4 45...

Page 46: ...ENGINE 4 46 ENGINE COOLING SYSTEM COOLING SYSTEM EXPLODED VIEW...

Page 47: ...mended Coolant Use only high quality antifreeze coolant mixed with distilled water in a 50 50 or 60 40 ratio depending on freeze protection required in your area COOLING SYSTEM PRESSURE TEST 1 Remove...

Page 48: ...to confirm voltage reduced comply with temperature ride N Replace thermo unit Y Keep engine 3000 4000 rpm and inspect cooling fan was turn on after temperature gauge over 3rd scale N Measure fan ther...

Page 49: ...burns NOTE If the coolant level is LOW in the radiator or if there are leaks in the system the coolant system will not draw coolant from the reservoir tank NOTE Use this procedure when a unit overheat...

Page 50: ...filler neck the system should be purged of air 10 Stop the engine and let cool top off the radiator filler neck with coolant If you hear or see a glug at the filler neck or there is a dropping of the...

Page 51: ...g system pressure by using a commercially available pressure tester 3 The system must keep the 0 7 Bar 10 psi for five minutes or longer If pressure loss is evident within five minutes check the radia...

Page 52: ...peller shaft mechanical seal cracks damage or wear Replace it if these parts damaged 2 Check bearing rough movement Replace it if bearing worn 3 Check water pump inlet hose outlet hose and thermostat...

Page 53: ...ENGINE 4 53 TOP END DISASSEMBLY...

Page 54: ...gine removal for service 1 Cam Chain and Sprockets 2 Cylinder Head 3 Cylinder 4 Piston Rings 5 Camshaft 6 Crankshaft 7 Crankshaft Main Bearings 8 Crankcase 9 Transmission 10 Valves NOTE Cam chain serv...

Page 55: ...d air cleaner intake boot Insert a clean shop towel into the carburetor flange to prevent dirt from entering the intake port 16 Remove transmission inspection cover and air box 17 Remove Starter motor...

Page 56: ...ined as the first 10 hours of engine operation or a full tank of fuel Use only All Season Synthetic Oil or API certified SH oil Use fuel with a minimum octane of 87 R M 2 method Change break in oil an...

Page 57: ...ointing down and the valves should have clearance at this point 5 Remove the two cam chain tensioner flange bolts CAUTION The plunger is under spring tension Maintain inward pressure while removing 6...

Page 58: ...tation of the rocker shafts is important for reassembly Place only the exhaust rocker shaft into the exhaust side of the cam support 6 Measure O D of rocker shafts for out of round Inspect them for we...

Page 59: ...ened and cannot be ground or re faced CAMSHAFT REMOVAL AND INSPECTION NOTE Cam chain tensioner must be removed before performing this procedure 1 Remove the 4 cylinder head bolts evenly by loosening e...

Page 60: ...ENGINE 4 60...

Page 61: ...sively 4 Measure camshaft run out Replace camshaft if camshaft run out of specification CYLINDER HEAD REMOVAL NOTE Cam chain and tensioner must be removed If no crankshaft service is being performed s...

Page 62: ...ER HEAD INSPECTION 1 Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon Use care not to damage sealing surface If there is damage found on the cylinder head comb...

Page 63: ...y wound coils against the cylinder head on progressively wound springs 3 Push valve out keeping it in order for reassembly in the same guide 4 Measure free length of the inner and outer springs with a...

Page 64: ...e in two directions front to back and side to side 8 Subtract valve stem measurement to obtain stem to guide clearance Stem to guide clearance Limit 0 10mm NOTE Be sure to measure each guide and valve...

Page 65: ...ake a light cut 4 Inspect the cut area of the seat If the contact area is less than 75 of the circumference of the seat rotate the pilot 180 and make another light cut If the cutter now contacts the u...

Page 66: ...dry with compressed air 9 Lubricate the valve guides with clean engine oil and apply oil or water based lapping compound to the face of the valve Lapping is not required with an interference angle 10...

Page 67: ...split keeper installation to prevent loss of spring tension Install split keepers with the gap even on both sides 7 Repeat procedure for remaining another valve 8 When all valves are installed tap li...

Page 68: ...am chain guide at front of cylinder 2 Remove the two 6 mm cylinder base bolts 3 Remove coolant tube from cylinder 4 Tap cylinder lightly with a plastic hammer in reinforced areas only until loose 5 Ro...

Page 69: ...on 4 When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown Do not expand the ring more than the amount necessary to remove it from th...

Page 70: ...ning machine Cylinders may be wet or dry honed depending upon the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore HONING TO D...

Page 71: ...wears or damage is excessive it will be necessary to replace the cylinder Hone only enough to deglaze the outer layer of the cylinder bore PISTON INSPECTION 1 Measure piston outside diameter at a poin...

Page 72: ...ap with a feeler gauge at both the top and bottom of the cylinder NOTE Measure at two points in the cylinder A difference in end gap indicates cylinder taper The cylinder should be measured for excess...

Page 73: ...emoves housing 5 Remove the start drive gear and shaft by pulling the shaft and tilting the gear slightly Flywheel removal generally is not required 6 Measure the OD of the starter drive shaft on both...

Page 74: ...ENGINE 4 74...

Page 75: ...Flywheel Puller 3 Remove flywheel CAUTION Do not hammer or strike the tool while attached to the crankshaft end which may become damaged 4 Remove stator coil and pick up from right hand crank cover 5...

Page 76: ...ement 7 If the one way clutch and one way gear do not engagement replace the starter clutch 8 Turn the one way gear clockwise to check the one way gear for smooth operation 9 If operation is not smoot...

Page 77: ...6 Inspect the chain for worn damage or missing rollers Replace chain anytime the oil pump is replaced or if excessively worn OIL PUMP REMOVAL 1 Remove the oil pump retaining screws 2 When install oil...

Page 78: ...rocess to avoid damage to the cam chain NOTE Valve train and cylinder removal must be performed prior to this procedure NOTE Always replace the pto crankshaft seal after performing this procedure 1 Re...

Page 79: ...emely close tolerances and minimal wear the bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the outer race of each bearing The bearings should t...

Page 80: ...if it is out of specification CRANKCASE OIL STRAINER INSPECTION 1 Remove drain plug 2 Remove oil strainer and visually inspect for any rips tears or obstructions in screen 3 Replace oil strainer if it...

Page 81: ...the crankshaft end The balance flat must square with crankshaft PTO end 3 Install a new gasket onto the right hand crankcase half Applying a thin amount of crankcase sealer to the gasket will help ho...

Page 82: ...pump shaft 5 Install oil pump shield NOTE Do not use gasket sealer on the pump mating surfaces PISTON RING INSTALLATION NOTE Apply clean engine oil to all ring surfaces and ring lands Always check pi...

Page 83: ...ring lands piston pin bore piston pin and piston skirt Lubricate the connecting rod both ends and crankshaft main bearing area 3 IMPORTANT Install the piston on the connecting rod with the IN casting...

Page 84: ...new base gasket 1 Install the dowel pin s Install an new base gasket onto the mating surface and install the piston into cylinder NOTE Route cam chain through the cylinder chain room and secure it ho...

Page 85: ...aft to the crankshaft the piston must be precisely located at Top Dead Center TDC This can be accomplished using one of two methods Install the cam chain over the crankshaft When the stator housing is...

Page 86: ...and re check marks timing CAMSHAFT INSATALLATION TIMING METHOD 2 Refer to page 49 Stator housing is installed NOTE Use this method only when the stator is installed and camshaft drive sprocket is in v...

Page 87: ...hten to specification 3 Apply engine assembly lube to the cam lobes and cam follower surfaces 4 Verify the cam lobes are pointing downward before installing rocker assembly 5 Apply clean engine oil li...

Page 88: ...ENGINE 4 88 CAMSHAFT TIMING METHOD 1 Method 1 Camshaft Timing with Stator Housing Removed Sprocket marks aligned with gasket surface at TDC on compression stroke cam lobes facing downward...

Page 89: ...ETHOD 2 Method 2 Camshaft Timing Using Flywheel TDC Mark Sprocket marks aligned with gasket surface at TDC on compression stroke cam lobes facing downward Cam Timing View through timing inspection hol...

Page 90: ...locknut and turn adjuster screw until there is a slight drag on feeler gauge 4 When clearance is correct hold adjuster screw and tighten locknut securely 5 Re check the valve clearance 6 Repeat adjust...

Page 91: ...operly adjusted Excessive carburetor vibration loose or missing needle jet locating pins Loose jets in carburetor or calibration incorrect for altitude temperature Incorrect float level setting CVT sy...

Page 92: ...as Low Power Spark plug fouled Restricted exhaust muffler Dirty carburetor Cam lobe worn Too much engine oil in crankcase CVT not operating properly Cylinder piston ring or valve wear or damage check...

Page 93: ...SMISSION TRANSMISSION DISASSEMBLY NOTE Engine removal is not required to service 1 Remove the rear wheel 2 Drain out gear oil from gearbox 3 Remove cir clip of gearbox cover 4 Loosen 7 bolts and remov...

Page 94: ...without excessive movement or noise Replace any bearing that is removed as the removal process destroys the bearing 2 Bearings can be removed using a standard blind bearing remover Apply lithium grea...

Page 95: ...ly and also check if bearing outer ring is mounted on gear tightly If bearing rotation is uneven noising or loose bearing mounted then replace it Check oil seal for wear or damage and replace it if ne...

Page 96: ...URE SENSOR ECT 5 7 IGNITION COIL 5 7 IDLE AIR CONTROL VALVE 5 7 ROLLOVER SENSOR 5 7 O2 SENSOR 5 7 FUEL TANK 5 8 FUEL TANK EXPLODED VIEW 5 8 FUEL FLOW CHART 5 8 EFI INFORMATION 5 9 EFI OPERATION OVERVI...

Page 97: ...MENT 5 18 GENERAL TROUBLE SHOOTING 5 18 DIAGNOSTIC BLINK CODE 5 18 DIAGNOSTIC BLINK CODE CHART 5 19 BLINK CODE BREAKOUT DIAGRAMS 5 20 BLINK CODE RECONGNITION 5 20 PRIME CODE 5 20 MORE THAN 1 FAILS BLI...

Page 98: ...5 29 IDLE MODE VOLUMETRIC EFFCIENCY COEFFICIANT 5 29 RUN MODE VOLUMETRIC EFFCIENCY COEFFICIANT 5 29 INITIAL LEANING VALUE OF THROTTLE POSITION 5 29 ANALOG TO DIGITAL OF THROTTLE POSITION SENSOR 5 29 I...

Page 99: ...80 problems of all EFI problems caused by wiring harness connections Never attempt to service any fuel system component while engine is running or ignition switch is on Cleanliness is essential and mu...

Page 100: ...TEM EXPLODED VIEW 1 Electronic Control Unit ECU 2 Intake Air Temperature IAT 3 Crankshaft Position Sensor CPS 4 Fuel Injectors 5 Fuel Pump 6 Fuel Pump Regulator 6 Engine Coolant Sensor ECT 7 Throttle...

Page 101: ...etween the air box and throttle body 3 Crankshaft Position Sensor CPS Located in the magneto cover between the engine and transmission 4 Fuel Injectors Fuel Rail Attached to the fuel rail located in t...

Page 102: ...ody 9 Engine Coolant Temperature Sensor ECT Located in the cylinder head next to the thermostat housing 10 Ignition Coil Located under the storage box and fastened at left of frame 11 Idle Air Control...

Page 103: ...ELECTRONIC FUEL INJECTION 5 103 FUELTANK...

Page 104: ...ELECTRONIC FUEL INJECTION 5 104 FUEL TANK EXPLODED VIEW FUEL FLOW CHART Vent Overflow EFI INFORMATION Fuel Tank Fuel Filter Fuel Pump Relief Valve Fuel Injector...

Page 105: ...e ECU computer chip and the ECU adjusts the fuel delivery and ignition timing to match the values During operation the ECU has the ability to re adjust temporarily providing compensation for changes i...

Page 106: ...y or the mounting position of the TPS to the throttle body is altered the TPS must be re initialized see TPS Initialization for procedure if required For the purpose of troubleshooting a known good EC...

Page 107: ...pulses The two tooth gap creates an interrupt input signal corresponding to specific crankshaft position for PTO cylinder This signal serves as a reference for the control of ignition timing by the EC...

Page 108: ...e before beginning this service procedure 2 Remove seat 3 Remove storage box 4 Remove right side service panel 5 Remove right side footwall panel 6 Remove exhaust pipe and silencer 7 Drain all engine...

Page 109: ...oltage directly to the fuel injector s Excessive voltage will burn out the injector s Do not ground the injector s with the ignition on Injector wills open turn on if relay is energized If an injector...

Page 110: ...witch is turned to ON the ECU activates the fuel pump which pressurizes the system for start up The ECU switches off the pump preventing the continued delivery of fuel in these instances If the key sw...

Page 111: ...against the valve seat The combination of atmospheric pressure and regulating spring tension equals the desired operating pressure Any time the fuel pressure against the bottom of the diaphragm exceed...

Page 112: ...decrease smoothly with no jumps when the throttle is applied 7 The volt value should be 0 15V 1 15V at idle throttle position 8 The volt value should be 3 9V 4 9V at full throttle position 9 If the s...

Page 113: ...to level below sensor 2 Disconnect sensor from engine harness 3 Using a wrench remove and replace the sensor applying a light coating of thread sealant to aid installation 4 Torque the sensor to 20 Nm...

Page 114: ...NT 1 Remove the seat 2 Remove the storage box 3 Disconnect ignition coil from engine spark plug and main harness 4 Remove the fastener bolt and ignition coil 5 Install the new ignition coil Ignition C...

Page 115: ...O2 Sensor Open or Short to Battery NO P0134 16 O2 Sensor Open Load NO P0231 17 Fuel Pump Short Circuit to Ground NO P0232 18 Fuel Pump Open or Short to Battery NO P0601 19 RAM Error Defective ECU YES...

Page 116: ...times then light off for 1 5 seconds and twinkling 5 times PRIME CODE Every diagnostic by blink code there is a prime code showing before fail blink code The prime code is always 55 which set in fact...

Page 117: ...onomy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug TPS setting...

Page 118: ...r computer by K Line There are 7 majors mode to monitor engine system failure 1 Engine data 2 ECU version 3 Malfunction code 4 Malfunction history 5 Malfunction record 6 Freeze frame DIAGNOSTIC HARNES...

Page 119: ...in the communication cable to the diagnostic connector turn on the key switch execute the diagnostic software select User name as Manufacturer and key in Password to login 1 Connection and Convert Lo...

Page 120: ...TRONIC FUEL INJECTION 5 120 2 Eight options including Engine Data ECU Version Idle RPM Adjust PreBLM Learn Malf Code Malf History Malf Record and Freeze Frame will be shown after pressing Start Connec...

Page 121: ...acturer category Besides engine status will be shown on the bottom of screen including Stall Crank Idle Run PEEn Sequential Cut and CLCEn ENGINE PARAMETER DEFINITION RPM Engine Running Speed Every com...

Page 122: ...hrottle opening It is 0 when throttle plate full closed and is 100 when throttle plate open up to 80 and above Toil_physical ENGINE TEMPERATURE This refers to the metal or coolant temperature of cylin...

Page 123: ...take airflow IACCommDuty IDLE AIR CONTROL VLAVE OPENING This refers to the percentage of the idle valve opening It ranges from 0 to 99 6 Cyl1CmndPW BASE PULSE WIDTH BPW The unit of BPW is mini second...

Page 124: ...oop corrected according to the changes of engine efficiency Fuel BLMEn BLOCK LEAN MEMORY MODE ENABLE This mode will be activated under engine fully warm up condition TPS_idx THROTTLE POSITION OPENING...

Page 125: ...will happen should the gap be larger or smaller than tolerance This will also happen if there are burrs or metal filings on the teeth of target wheel EngRunTimer ACCUMULATED VEHICLE OPERATION TIME Th...

Page 126: ...will be 255 if the sensor or its circuitry is short to power and will be 0 when open or short to ground AFRChokeIdle IDLE MODE AFR CHOKE This is a simulation to the idle choke function similar to carb...

Page 127: ...emory address of engine under various rpm and throttle position RECORDING OF ENGINE OPERATION PARAMETERS The procedure of the engine operation parameters are 1 press Log Config 2 Choose Sampling Rate...

Page 128: ...NIC FUEL INJECTION 5 128 ECU Version This is to show the software hardware and calibration versions and ECU ID vehicle code of the ECU Malf Code This is to show the mal function codes occurred to the...

Page 129: ...This is to show the latest mal function occurred and its corresponding engine status Malf Record This is to record all mal functions have ever occurred to the vehicle Press Erase to eliminate mal fun...

Page 130: ...idle adjust screw will be done as first priority SA adjustment will then be used if the idle adjust screw has been rotated for more than 2 turns The following conditions need to be met in idle adjust...

Page 131: ...L INJECTION 5 131 PreBLM Learn This function can be used when it exceeds 10 of close loop control under engine fully warm up Convert Log File 1 Press Convert Log File under Not connected condition 2 P...

Page 132: ...ELECTRONIC FUEL INJECTION 5 132 3 Select file smd format 4 Press Convert 5 Press Confirm after transformation completed...

Page 133: ...LECTRONIC FUEL INJECTION 5 133 6 2 new files _smdDE txt and _smdDEEP txt will be added to the recorded archive Open _smdDE txt to check all records 7 Use Excel to open the records will see all the dat...

Page 134: ...S232 USB Conversion cable with computer and diagnostic cable 3 Connect diagnostic cable with computer and diagnostic harness on scooter 4 Turn on key switch and let the speedometer working but DO NOT...

Page 135: ...ELECTRONIC FUEL INJECTION 5 135 6 Click configuration button to select correct COM port 7 Click Download button The Stage bar will go up until end...

Page 136: ...rogram the Elapsed time stop at 4 5 sec Means wrong COM port choose Please repeat step 6 7 Ensure your battery has enough power capacity while update your ECU program Do not crank or ignition scooter...

Page 137: ...T WHEEL INSTALLATION 6 7 REAR WHEEL AND BRAKE 6 8 REAR WHEEL AND BRAKE EXPLODED VIEW 6 8 REMOVE THE REAR WHEEL 6 8 REAR WHEEL INSPECTION 6 9 REAR WHEEL INSTALLATION 6 9 BRAKE SYSTEM 6 10 BRAKE EXPLODE...

Page 138: ...VIBRATION 6 17 CALIPER OVERHEAT 6 17 BRKE LOCK 6 17 STEERING SHAFT 6 18 STEERING SHAFT EXPLODED VIEW 6 18 STEERING SHAFT REMOVAL 6 18 STEERING SHAFT INSPECTION 6 19 STEERING SHAFT INSTALLATION 6 19 S...

Page 139: ...screw or nut Never compacting or hammer force on the all plastic covers during assembly BODY COVER DISASSEMBLY PROCEDURE 1 Handlebar upper bottom covers 2 Windshield 3 Front fender 4 Headlight cover...

Page 140: ...ake calipers Do not apply the brake lever when removing the brake calipers 3 Remove front wheel axle nut speed sensor and spacer from front fork 4 Remove front wheel with disc assembly from front fork...

Page 141: ...eel axle 2 Inspect front tire and wheel radial or lateral run out by dial gauge Replace if out of specification Front Wheel Lateral Limit 2 00mm Front Wheel Radial Limit 3 00mm FRONT BRAKE DISC INSPEC...

Page 142: ...pplied to the outer race FRONT WHEEL ADJUSTING AND WHEEL STATIC BALANCE 1 After replacing the tire wheel or both the front wheel static balance should be adjusted 2 Adjust the front wheel static balan...

Page 143: ...ue to 30 Nm Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal 3 Lubricate oil seal lips speed sensor spacer and wheel axle by Lithium...

Page 144: ...lace the vehicle on a level surface and Stand the center stand that the rear wheel is elevated Severe injury could occur if machine tips or falls 2 Remove exhaust muffler from rear fork and cylinder h...

Page 145: ...points around the pad contact surface Replace disc if worn beyond service limit Rear Brake Disc Thickness New 5 00 mm Service Limit 4 40 mm Note After replacing the tire wheel or both the rear wheel s...

Page 146: ...the brake pedal returns freely and completely 4 Adjust stop pin on front caliper after pad service 5 Check and adjust master cylinder reservoir fluid level after pad service 6 Make sure atmospheric ve...

Page 147: ...Due to the high temperatures created within the system during heavy braking it is very important that the master cylinder reservoir have adequate space to allow for fluid expansion Never overfill the...

Page 148: ...the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID GETTING INTO THE EYES Flush with water for 15 minutes and get immediate medical attention 1 Visual inspects the junction and line lock...

Page 149: ...lds and holds 6 Hold brake lever on to maintain fluid pressure and open bleeder screw Close bleeder screw and release brake lever NOTE Do not release brake lever before bleeder screw is tight or air m...

Page 150: ...will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces NOTE Make note of front and rear brake line locations to master cylinder 5 Loosen the brake line banjo...

Page 151: ...nding brake line 4 Push mounting bracket inward and slip outer brake pad past edge Then remove inner pad NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir...

Page 152: ...nt air from entering the brake system BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise St...

Page 153: ...y pump the brake lever until pressure has been built up Maintain enough of brake fluid in the reservoir to prevent air from entering the brake system 7 Verify fluid level in reservoir is up to the MAX...

Page 154: ...s woodruff and handlebar 5 Remove handlebar lower clamp jammed nut then use a soft face hammer to remove handlebar lower clamp from steering shaft 6 Remove steering shaft bearing jammed nut 7 Remove l...

Page 155: ...ECTION 1 Inspect bearing race surface and steel ball pitting or damaged STEERING SHAFT INSTALLATION 1 Lubricate bearing race upper bearing and lower bearing with a light film of all season grease and...

Page 156: ...tall the handlebar pod and screws NOTE There will be a slight gap on the backside of the blocks after the procedure is performed Front fork removal 1 Elevate the vehicle off the ground to relieve the...

Page 157: ...ner tube into the outer tube during the above procedure as the oil flow stopper will be damaged Front Fork Inspection 1 Inspect inner tube chrome surface Replace it if has been scratched 2 Verify inne...

Page 158: ...into inner tube Make sure the oil levels in both front forks are equal Uneven oil levels can result in poor handling and a loss of stability Front Fork Oil Capacity 130cc 5cc 9 Install dust seal onto...

Page 159: ...ay occur if machine tips or falls 2 Remove both weights which locate on end of handlebar 3 Remove both grips by low pressure air 4 Blow compressed air between the handlebar and the handlebar grip and...

Page 160: ...d bracket loosely into the blocks 5 Install the handlebar pod and screws NOTE There will be a slight gap on the backside of the blocks after the procedure is performed 6 Install both switch housings a...

Page 161: ...he inline cable adjuster 2 Loosen the adjuster lock nut 3 Rotate the boot to turn the adjuster until 3 5 mm of freeplay is achieved at the throttle pedal NOTE While adjusting lightly pull the throttle...

Page 162: ...OMETER CIRCUIT 7 7 BRAKE LIGHT SWITCH 7 8 BULB 7 8 TYPE OF BULBS 7 9 BULB INSPECTION 7 9 BULB SOCKETS INSPECTION 7 9 IGNITION SYSTEM 7 10 ECU CIRCUIT EXPLORED VIEW 7 10 IGNITION CIRCUITS EXPLORED VIEW...

Page 163: ...CIRCUIT VOLTAGE TEST 7 21 SEALED LOW MAINTENANCE BATTERY LOAD TEST 7 21 SEALED LOW MAINTENANCE BATTERY OFF SEASON STORAGE 7 21 SEALED LOW MAINTENANCE BATTERY CHARGING PROCEDURE 7 22 CONVENTIONAL BATT...

Page 164: ...able for use when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multi meter reading K M etc and the position of the decimal point For...

Page 165: ...o check connector terminals 6 Check wires continuity by multi meter If there is no continuity clean the terminals 7 Perform steps 1 to 3 when checking the wire harness continuity 8 As a quick remedy u...

Page 166: ...ity between the red R1 and brown Br wires 4 When the key is turned to the position there should no continuity between any of the wires HEADLIGHT SWITCH Headlight switch include light and beam switch w...

Page 167: ...W DG wires 2 When the switch is pushed to the position there should be continuity between the Br W DB wires NOTE The turn signal button will not automatically return to the off position after a turn...

Page 168: ...ELECTRICAL 7 168...

Page 169: ...s A and B are used for headlights and usually use a bulb holder which must be detached before removing the bulb The majority of these bulbs can be removed from their respective socket by turning them...

Page 170: ...positive probe to terminal and the tester negative probe to terminal and check the continuity 4 Connect the tester positive probe to terminal and the tester negative probe to terminal and check the co...

Page 171: ...ELECTRICAL 7 171...

Page 172: ...OPERATE NO SPARK OR INTERMITTENT SPARK FOLLOWING PROCEDURE TO CHECKING Rollover Switch Check the rollover switch output voltage The normal voltage should be 0 4 1 4V If rollover condition voltage sho...

Page 173: ...ground the reading should be infinite open NOTE If there are any significant variations in ohm s readings between the three legs it is an indication that one of the three stator legs maybe weak or fai...

Page 174: ...per connection Use the illustration above and procedure below when troubleshooting a No Start condition STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor star...

Page 175: ...de noise repair or replace the start motor STARTER MOTOR SERVICE The starter motor is a complete service part If it is determined that the starter motor is the failed part replace as needed See the pa...

Page 176: ...housing and the tab on the brush plate engages the notch in the brush plate housing ARMATURE TEST 1 Inspect surface of communicator Replace if excessively worn or damaged 2 Using a digital multi teste...

Page 177: ...is present at the R B wire from the battery Once the switching side of the relay receives power from the brake switch G Y and a ground path from the starter button G R battery power is sent to the sta...

Page 178: ...ystem 3 Refer to KEY MAIN SWITCH at above and ensure fuse continuity If broken replace the fuse CURRENT DRAW KEY OFF Do not connect or disconnect the battery cable or ammeter with the engine running D...

Page 179: ...and tachometer With lights on charging should occur at or below 2000 RPM ALTERNATOR OUTPUT TEST AC AMP This test measures AC amperage from the alternator This test simulates a full load on the altern...

Page 180: ...must be fully charged before use or battery life can be reduced by 10 30 of full potential Charge battery for 3 5 hours using a variable rate charger Do not use the alternator to charge a new battery...

Page 181: ...h Allow it to cool before resuming charging BATTERY CHARGING REFERENCE TABLE State of Charge VOLTAGE ACTION CHARGE TIME 100 12 8 13 0V None FULL None Required 75 12 5 12 8V Slight Charge 3 6 Hours 0 5...

Page 182: ...may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encou...

Page 183: ...tery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or...

Page 184: ...distilled water Tap water contains minerals that are harmful to a battery Do not allow cleaning solution or tap water inside the battery Battery life may be reduced 5 Reinstall the battery caps CONVEN...

Page 185: ...50 Charged 25 Charged 0 Charged 12 60V 12 40V 12 10V 11 8V Less than 12 70V 12 50V 12 20V 12 0V Less than 11 9V SPECIFIC GRAVITY State of charge Conventional lead acid Low Maintenance Type 100 75 Char...

Page 186: ...ing Charge as needed to raise the specific gravity to 1 270 or greater 3 Install battery in vehicle with positive terminal toward the front Coat threads of battery bolt with a corrosion resistant diel...

Page 187: ...m switch on Connect probe into L terminal and probe into B terminal Both position and low beam bulb should come on 3 Check the voltage 12 V of the W L and B terminals on the bulb socket connector 4 Tu...

Page 188: ...on The open circuit voltage should be 12 8 V or more at 20 C 68 F Main Switch Refer to KEY MAIN SWITCH at above If main switch isn t continuity replace the main switch RADIATOR FAN MOTOR 1 Disconnect...

Page 189: ...t Trouble Shooting No voltage Battery discharged The cable disconnected The fuse is blown Improper operation of the main switch Low voltage The battery is not fully charged Poor contact Poor charging...

Page 190: ...crank smoothly Primary winding circuit Poor ignition coil Poor connection of cable and connectors Poor main switch Secondary winding circuit Poor ignition coil Poor spark plug Poor ignition coil cable...

Page 191: ...ELECTRICAL 7 191...

Page 192: ...ELECTRICAL 7 192...

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