Genuine Scooter Company Buddy 170 Service Manual Download Page 136 | Manualshive

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(6)Handle bar switch

The colors for each switch cables:

Head Light Switch

                                                                                                                      Starting Button

                        HI/LO bean                                                                                Horn Switch

              Signal Light Switch                                                                                Main Switch

Operation Dark green Yellow Yellow/black Blue

/Color

OFF

●

●

ON

●

●

●

Operation Green/White Black
/Color
FREE

PUSH

●

●

Operation Blue Brown/White Purple/White
/Color
HI

●

●

LOW

●

●

Operation Yellow/green Black
/Color
PUSH

●

●

FREE

Operation/Color Pink Blue/White Brown

L

●

●

To L

●

●

N PUSH

To R

●

●

R

●

●

Lock Off On

●

Red/white

●

●

Blue/black

●

Orange

●

●

Black

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Summary of Contents for Buddy 170

Page 1: ......

Page 2: ...e whom may concern how to maintain repair change parts troubleshoot and reassemble etc At every important section we illustrate by assembly explosiondiagrams and photographs if necessary please check...

Page 3: ...35 11 Rear brake adjustment 36 12 Tire 36 13 Throttle cables adjustment 37 4 Dismantling maintaining repairing and assembling operation 38 1 Lubrication system 39 2 Plastic parts of chassis 43 3 Engi...

Page 4: ...2 Battery 124 3 Recharge system 126 4 Starting system 128 5 Starting clutch 130 6 Handle bar switch 132...

Page 5: ...al weight 257kg front 1 50 kg cm2 Front 81kg rear 1 75 kg cm2 Rear 176kg yBrake yPerformance front 190mm hydraulic Fuel consumption 40km L disk brake rear drum brake yGradient ability 26 ySpeedometer...

Page 6: ...p failing during start up 3 Trouble of hot start 4 Trouble of cold start 5 Trouble of start up anytime despite RPM normal 6 Start up normal but idle speed unstable anytime 7 Start up normal but idle s...

Page 7: ...ling please wash all parts necessary for checking and grease all contact surface when reassembling 5 Use grease recommended by P G O 6 When removing battery please dismantle the negative pole first wh...

Page 8: ...2 5 0 6 0 11 Spark plug 1 10 1 2 1 3 12 Nut drive clutch 1 22 9 0 10 0 Left thread 13 Screw inner chain adjuster 1 6 0 4 0 6 b Chassis NO Locking location Q TY Thread dia mm Locking torque kg m Remark...

Page 9: ...0 45 0 6 2 6mm bolt and nut 0 8 1 2 3 8mm bolt and nut 1 8 2 5 4 10mm bolt and nut 3 4 4 0 5 12mm bolt and nut 5 0 6 0 6 5mm screw 0 35 0 5 7 6mm screw 0 7 1 1 8 6mm flange bolt and screw 1 0 1 4 9 7...

Page 10: ...liding part premium 4 stroke Auto separated Lubrication 2 cylinder rotating part sliding part motorcycle oil or SAE15W40 Total 1000 c c Replacement 800c c 3 drive gear box SAE85 140 Total 110 c c Repl...

Page 11: ...B Chassis Steel ball steering item Front brake fluid Front brake cam 7...

Page 12: ...C Wheel bearing Final transmission mechanism gear oil Motor oil Speedometer gear clean grease Front wheel bearing clean grease 8...

Page 13: ...ss Adjust it if required I I I Rear absorber 4T Leaking and function check A A A Main Side Stand 4T Function check or replace it if required I I I I Nuts bolts fasteners 4T Tighten it if required I L...

Page 14: ...r disassembling of brake main cylinder or caliper do change the new fluid 2 Check the fluid level often Refill if necessary 3 Change the oil seal of main cylinder and caliper every two years 4 Change...

Page 15: ...5 Wiring diagram 11...

Page 16: ...subsequent diagnoses or reparation Diagnosis assist 1 Make sure of no engine related trouble records 2 Make sure of any offered troubles 3 Follow the said procedure to complete inspections and find no...

Page 17: ...or not running or slowly running No Repeat the said step 2 Engine running but start up failing during start up General trouble location 1 Oil tank empty 2 Fuel pump 3 RPM sensor 4 Ignition coils 5 Eng...

Page 18: ...high voltage flash blue white No Repair the ignition system Yes Correct circuits or replace the sensor No Next step 3 Press the engine temperature sensor connector and start the engine check if the e...

Page 19: ...he engine successfully started Or install a series connected resistor 2500 in lieu of the engine temperature sensor at the engine temperature sensor connector Observe if the engine is successfully sta...

Page 20: ...mable to specifications No Adjust or change the spark plug Yes Correct circuits or replace the sensor 5 Press the engine temperature sensor connector and start the engine check if the engine is succes...

Page 21: ...change Yes Cleaning 4 Check the air throttle and the idle air bypass for any carbon deposition No Next step Yes Replace the defective nozzle 5 Disassemble the nozzle and check any leakage or jam in t...

Page 22: ...r bypass for any carbon deposition No Next step Yes Correct circuits or replace any sensor 4 Press the engine temperature sensor connector and start the engine to check any instability of the idle spe...

Page 23: ...s for any carbon deposition No Next step Yes Correct circuits or replace any sensor 4 Press the engine temperature sensor connector and start the engine to check any instability of the idle speed duri...

Page 24: ...tep 2 Check if the engine s output power is increased with the load applied use the EMS diagnosis tester to check any change in the ignition advance angle duration of fuel injection and air input No R...

Page 25: ...eakage No Next step Yes Clean relevant parts 3 Remove the ISC and check the air throttle the ISCand the idle air bypass for any carbon deposition No Next step Yes Correct circuits or replace any senso...

Page 26: ...r replacement Yes Clean relevant parts 4 Remove the ISC and check the air throttle the ISCand the idle air bypass for any carbon deposition No Next step Yes Next step 5 Check the inlet pressure sensor...

Page 27: ...ement Yes Clean relevant parts 4 Remove the ISC and check the air throttle the ISCand the idle air bypass for any carbon deposition No Next step Yes Next step 5 Check the inlet pressure sensor the air...

Page 28: ...No Repair the ignition system Yes Next step 5 Check the spark plug in the cylinder and its model and gap conformable to specifications No Adjustment or replacement Yes Clean relevant parts 6 Remove th...

Page 29: ...g table 2 Battery 3 Clean air cleaner 4 Oil screen 5 The final reduction mechanism oil 6 Spark plug 7 Cylinder pressure 8 Valve clearance 9 Ignition timing 10 Front brake adjustment 11 Rear brake adju...

Page 30: ...column Brake lever b movement ofbrake Loose or damage brake Brake cables change per 2 years Brake cam Worn out a drum and plate clearance between b brake shoe and br ake plate worn out Brake drum And...

Page 31: ...ge Connecting part Loose Bracket loose or Damage Suspen sion Connecting Part loose Oil leakage Cracked Damper damper assy s part Loose Clutch and Change Speed mechanism Power Transmi ssion Supply grea...

Page 32: ...ng 1700 100rpm Exhaustion Check the clolr Or usting exha air Air cleaner Cylinder cyl inder head inlet Pipe locking Condition Locking torque Cylinder head cold 1 0 1 2kg m inlet pipe c d p 1 0 1 2kg m...

Page 33: ...Performance Lamp system Dirty cracked Horn turn Signal Reflector Performance Horn Turn signal lock Performance Rear view mirror Check the illumination Blinker linc Nese plate nu Mber mark Dirty cracke...

Page 34: ...egative cable and then the positive cable take out the battery to recharge 4 Re assembling the battery as the opposite procedure of disassembling after recharging Note A Do not take out the sealed bol...

Page 35: ...engine For 2 3 min then check the oil volume 1 Take out the oil meter to check the oil Volume 2 Refill oil to upper limit when oil volume Is below the lower limit Exchange Oil 1 Turn off the engine an...

Page 36: ...Oil draining bolt Locking torgue 1 5kg m O ring Oil Draining Bolt 2 Second oil filter z Replace it per 5 000km z Torque 8 0 2 N M Oil filter Oil Screen spring 5 The final reducing mechanism oil 1 Cha...

Page 37: ...2 Remove the cover at the right hand of the step floor 3 Remove the spark plug then place cylinder pressure gauge Then fully open the throttle and act on the starter motor to measure the compression...

Page 38: ...herwise valve can not be adjusted zValve clearance IN 0 08mm Ex 0 08mm zLoosen locking nut then rotate adjusting nut to adjust the valve clearance Note Re check valve clearance after lock the nut 9 Ig...

Page 39: ...uce or damage the brake efficiency or even its function 3 Check the oil level a Refill the brake oil when the level is under the LOWER line b Oil specification DOT3 Note a To prevent the oil splitting...

Page 40: ...cm2 3 Tire specification Front tire 100 90 10 Rear tire 100 90 10 Note 1 Check and adjust the tire pressure when it is too low The pressure is according to the carrier driver passenger accessories and...

Page 41: ...e zDepth front and rear According to the mark of tire indicating the necessity to change a new tire 13 Throttle cables Adjustment 1 Check the clearance of throttle 2 Normal clearance 1 5 3 5mm Adjust...

Page 42: ...is 3 Engine dismantling 4 Drive pulley starter clutch driven pulley 5 Cylinder head and valve 6 Cylinder and piston 7 AC generator 8 Final transmission mechanism 9 Crankcase crank shaft 10 Carburetor...

Page 43: ...1 Lubrication System Lubrication System Diagram PA150 39...

Page 44: ...r 2 Remove the AC flywheel magneto 3 Remove the AC generator coil 4 Tale off the locking bolts of the right crankcase cover 5 Remove the crankcase cover 6 Remove the washer lock pin 7 Remove starter r...

Page 45: ...nstall the lock pin 4 Match the lock pin hole to the pump cover and install the oil pump cover 5 Put on the screws and tighten them 6 After installing turn the shaft lightly to assure installation 7 P...

Page 46: ...045 0 10 0 12 Oil pump Clearance between gear end and Oil pump body 0 045 0 10 0 12 Troubleshooting Reduction in fuel oil volume Engine burning out a Natural consumption a Zero or too low oil pressure...

Page 47: ...1 Removal of luggage compartment z Open the seat take off the screws of the luggage compartment 2 Removal of fuel tank z Open the lock cover of the fuel tank zTake off the fuel tank cover zTake off bo...

Page 48: ...and right hand Side covers zTake off the screws of left and right side covers zRemove the left and right hand side cover 4 Removal of front mudguard zRemove the screws of front fender zTake off the f...

Page 49: ...mantling the Fender 1 Take off the screws of front inner cover And fender 2 Take off the screws between the front Fender and chassis 3 Separate the head light and signal lamp Cable 4 Take off the fend...

Page 50: ...ng the upper handle cover 1 Remove the left and right Back mirror 2 Remove the screws of upper And lower handle cover 3 Unplug the speedometer cable 4 Unplug each switch cables 5 Remove the upper hand...

Page 51: ...ont inner cover 1 screwing out the screws of battery cover 2 Disconnect the negative then positive cable 3 Screwing out the screws between the step floor and front inner cover Take off the front inner...

Page 52: ...3 Engine dismantling A Dismantling engine B lnstalling engine 48...

Page 53: ...arburetor pipe engine suspension nut starter motor cable flywheel plate and rear damper bolt 5 Remove the engine B Installing Engine 1 To install engine please reverse the Above procedures 2 Locking t...

Page 54: ...4 Drive pulley starter clutch driven pulley A troubleshooting B Measurement data C Driving pulley D Starter E Clutch driven pulley 50...

Page 55: ...e No grease and oil should be distributed over driving belt and driving plate B2 Measurement data for buddy170 Item Standard value mm Limit of use mm The inner dia Of slide driving plate 24 011 24 052...

Page 56: ...Take off the screws of Left cover Remove the left cover 2 Remove the lock nuts of driving Plate and the nuts of Starter gear And clutch 3 Take off the ramp plate Belt and clutch 4 Take off the boss a...

Page 57: ...se the engine s speed slowly and notice the RPM at which the motorcycle begins to move forward Specified Engagement RPM 3800 300 rpm 5 Clutch LOCK UP inspection Apply the rear brake as firm as possibl...

Page 58: ...ot rubber and fiber is loosened or not also check if they are extraordinary worn out 2 driving belt width change it below using limit 7 Disassemble slide driving plate set 1 Remove bush of slide drivi...

Page 59: ...ition 4 Check the outer diameter of the contact surface of the movable driving plate limit of use change it below 23 94mm 9 Assemble the slide driving plate 1 Clean up the inside surface of slide driv...

Page 60: ...the wearing condition of the outer diameter of spindle comp and the inner diameter of bush and gear b Check the wearing condition of shaft of driven gear comp Gear sets and ratchet 9 Assembling the s...

Page 61: ...e clutch follows the opposite procedure of dismantling Locking torque M10 4 0 5 5kg m 3 Checking clutch dismantling tool a Check clutch driving face Check clutch cover about its wearing condition And...

Page 62: ...riving plate sets And measure outer diameter zlimit of use change it above 33 95mm e Check wearing condition of slide driven plate And measure its Inner diameter zlimit of use change it above 34 00mm...

Page 63: ...5 Cylinder head and valve A Trouble shooting B The operation data information C Dismantling and installing 59...

Page 64: ...igh There is too much carbon accumulated in the combustion chamber 4 There is white fume coming out from the exhaust pipe The valve stem or valve guide pipe is worn out Valve stem s oil seal is damage...

Page 65: ...er and take off the cylinder head cover 4 Turn the flywheel counterclockwise and let the T mark on the flywheel point to the crankcase mark and make the round hole on the cam chain gear point upwards...

Page 66: ...The mark EX on the cam shaft holder is the exhaust rocker arm one way stopper Install the exhaust rocker arm the inlet rocker arm and the rocket arm shaft 2 Turn the flywheel to make the T mark pin c...

Page 67: ...gasket 8 Remove cam chain guide Notice Not to injure the contact Surface of the cylinder Avoid any object dropping info the engine Further dismantling Use the valve contracting tool to remove valve pi...

Page 68: ...n ring 2nd ring 0 01 0 05 0 10 lst ring 0 15 0 35 0 50 2nd ring 0 15 0 35 0 50 Clearance of cutting section side ring 0 2 0 7 0 9 Piston outer diameter 60 980 60 960 60 90 Measuring location of piston...

Page 69: ...rmal piston noise 1 Cylinder and piston worn out 2 Piston pin hole or Piston pin worn out 3 Connecting rod small end or bearing worn out d Abnormal piston or cylinder noise 1 Piston ring worn out or c...

Page 70: ...the carbon in the groove of the Don t make piston ring worn out or damaged piston ring c PISTON OUTER DIA MEASUREMENT 1 Measuring location Perpendicular to the piston pin hole down to 5mm BUDDY170 for...

Page 71: ...sition of the inner dia in X or Y direction d Checking the flatness of cylinder contact Limit of use Roundness change it when above 0 05mm Cylindrility change it when above 0 05mm surface Limit of use...

Page 72: ...n piston pin and piston pin NOTICE Do not drop other objects into the crankcase clip NOTICE a The mark IN on the piston tip should face to the INLET side b Do not drop the piston pin clip into the cra...

Page 73: ...7 A C Generator A Dismantling AC generator B Installing AC generator 69...

Page 74: ...C generator 1 Rimove fan cowl 2 Remove the M6 screws 3 Remove screws of flywheel magneto 4 Remove the AC flywheel magneto by special tool 5 Remove the flywheel 6 Remove the electric plug of AC flywhee...

Page 75: ...B Installing AC generator To install please reverse the dismantling procedure Locking torque M6 1 0 1 2kg m M10 3 2 4 0kg m 71...

Page 76: ...ion mechanism D Assemble the final transmission mechanism A Troubleshooting zEngine can be started but the vehicle doesn t move 1 Gear worn out or cracked 2 Gear burnt out zNoise occur when running 1...

Page 77: ...3 B Disassemble the final transmission mechanism 1 Remove the rear wheel 2 Drain the oil in the gear box 3 Remove the bolt in the gear box cover Take off the gear box 73...

Page 78: ...Remove the final reduction gear And idle gear 5 Clean up the gear box C Check the final transmission mechanism 1 Check the wearing condition of driving shaft and gears Gear teeth number 16 T buddy170...

Page 79: ...tion of the final reduction gear 43T 4 Check the wearing condition of the oil seal and bearing D Assemble the final transmission mechanism please follow the opposite procedure Of disassembling After l...

Page 80: ...9 Crankcase Crankshaft A Disassembling diagram B Troubleshooting C Data D Remove crankcase and crankshaft E Check crankshaft F Assemble the crankcase 76...

Page 81: ...A Disassembling diagram Torque 1 0 1 2kg m B Troubleshooting Engine noise 1 The bearing of final transmission mechanism is loosen 2 Crank pin of bearing is slack 3 The bearing of gear box is loosen 77...

Page 82: ...l direction 0 006 0 014 0 05 Swingness of the crank shaft journal 0 0 015 0 05 D Remove the crankcase and crankshaft by the following procedures 1 Remove the engine 2 Remove the muffler 3 The carburet...

Page 83: ...the crankshaft journal Limit of use A B Change it when above 0 05mm Change it when above 0 05mm B A 3 Check the looseness of crankshaft bearing If it is loosen replace to a new one F Assemble crankcas...

Page 84: ...carburetor air cleaner blocked oil pipe blocked bad adjustment of the fuel level float valve is jell zMixed air too dilute 1 Main jet blocked 2 Float valve blocked 3 Fuel level too low 4 Fuel system b...

Page 85: ...ystem blocked 2 Ignition system malfunction 3 Air mixture is too dilute or too thick 4 Fuel deterioration 5 Second air sucked into intake system 6 Bad idle adjustment 7 Bad fuel volume adjustment 8 Id...

Page 86: ...10 Steering stem front wheel frt brake comp and front fork A Troubleshooting B Data C Steering handlebar E Front wheel F Front brake G Front fork 82...

Page 87: ...per is not even b Front fork is crooked c The axle of front fork is crooked wheel is aslant 3 front wheel swings a wheel rim is distorted b bearing of front axle too free c wheel rib is distorted a Wh...

Page 88: ...speedometer cable 3 Remove the front handle cover 4 Remove the fixed screws of speedometer cable on the right of front wheel 5 Draw out the damage speedometer cable 6 Assemble the new cable follows th...

Page 89: ...on front fork and handlebar 4 Take off the fixing bolt 5 Remove the nut and bolt of the front fork fixed on The handlebar 6 Take off the handle bar 7 When assembling please follow the opposite procedu...

Page 90: ...wheel follows the opposite procedure of dismantling Locking Torque M10 3 0 4 0kg m Note 1 Put the lock block of speedometer gear assy upon the extrusion of the front fork 2 Put the grease onto the gr...

Page 91: ...g is Loosen or any occurrence for noise Please change a new one 7 Front wheel rim checking 1 Check the swing of the front wheel rim 2 Limit of use zHorizontal direction Change a new one when above 2 0...

Page 92: ...container b Do not let the brake oil overflow from the master cylinder or container when assemble the master cylinder cover c Put the spanner upon the drain screw a Lock and unlock the screw several...

Page 93: ...nt shock absorber checking Check is there any unusual damage or worn out condition and whether the guide rod of the Front fork is crooked or not Front fork oil type SAE 10W20 Capacity each side 80 CC...

Page 94: ...mble the disk follows the disassembling procedure Locking torque M8 2 0 3 0kgm 6 Checking the front brake disk Standard thickness of disk 3 6mm Limit of usage change it when below 3 1mm 7 Checking the...

Page 95: ...11 Rear wheel rear brake rear damper A Troubleshooting B Data C Dismantling the rear wheel D Checking the rear wheel E Rear brake F Rear damper 91...

Page 96: ...adjustment of brake is not good b the brake lining is dirty c the brake lining is worn out d the cam of brake lining is worn out e the brake cam lever is worn out f the brake hub is worn out g the as...

Page 97: ...r wheel drum 3 Remove the bolts 4 Remove the rear wheel 5 To assemble the rear wheel please reverse the dismantling procedures Locking torque M6 0 7 1 1kg m M14 8 0 10 0kg m D Checking the rear wheel...

Page 98: ...ing rear brake hub a measure the inner diameter of rear brake hub b limit of use change it as the diameter is above 131 0mm 2 Checking brake lining a measure the thickness of rear brake lining b Limit...

Page 99: ...F Rear damper 1 Rear damper disassembling diagram 95...

Page 100: ...5 Engine Management System PGO 2nd stage EMS 1 PGO 2nd stage EMS structure 2 EMS units 3 EMS diagnostic 96...

Page 101: ...tor EMS structure B coil Fuel supply ignition Engine temperature sensor Throttle position sensor Intake pressure sensor Crank speed sensor 4 sensors ISC Idle speed control ECU Engine temperature senso...

Page 102: ...thin the left body cover 2 Important PIN no of ECU ECU PIN 1 PIN 18 PIN 19 PIN 36 PIN PIN NO function 11 Control pole of fuel pump 12 Control pole of headlamp relay 13 supply 5V voltage to sensors 16...

Page 103: ...sensor at the right of engine dismantle 1 cover of fan 2 fan Function of Crank speed sensor function induct the engine speed tell ECU to control inject fuel ignition theory calculate the interval time...

Page 104: ...head cover dismantle 1 engine LH cover 2 middle cover function induct engine oil temperature then ECU knows engine is cold or hot theory different temperature vary resistence T resistance K 20 18 800...

Page 105: ...on induct throttle angle provides the road load condition to ECU theory angle changes resistance changes Lb output Pu power 5V Gr ground Lb Gr throttle output V close 0 6 0 02V WOT 3 8 0 10V above the...

Page 106: ...sure sensor above the engine dismantle 1 luggage comp function induct intake air pressure ECU judge intake or compress stroke to decide injection ignition theory different pressure outputs diferent re...

Page 107: ...Pu output 5V G B output Gr ground G B Gr press KPa output V 13 3KPa 0 5V 120 KPa 3 4V average resistance in ambient wire R K Pu Gr 2 4K G B Gr 2 4K average resistance in ambient wire R K Pu Gr 2 4K G...

Page 108: ...7 Injector above the intake manifold dismantle 1 luggage comp function inject the gas mixed with air theory control the opening time interval to decide the gas amount 104...

Page 109: ...time msec Gas amou nt time msec Gas amou nt feeding injecting R B output 12V Br W output 12V each terminal virus ground is 12V 105...

Page 110: ...8 Transistor ignition at the right inside the side cover dismantle 1 middle cover 9 FUEL PUMP below the rear rack dismantle 1luggage comp 2 rear rack 3 body cover 4 bracket of tank 106...

Page 111: ...ction pumping the gas to injector and keep the constant pressure as 3kgf cm2 theory the regulator keeps constant pressure regulator filter pump R B output 12V B ground R B B voltage 12V resistance 1K...

Page 112: ...wer and cease the engine theory there is ball mechanism inside the sensor act by gravity and conduct the wiring power degree output ground OFF any OFF ON 65 ON ON 65 OFF to recover the sensor function...

Page 113: ...er the sensors and decide how much air is required then tell the ISC to act forward or backward sample when cold engine ECU tell ISC enrich the by pass air to increase the engine speed After warm up E...

Page 114: ...ontrol zero point Procedure of ISC initialization 1 don t plug quick diagnostic 2 wide open throttle turn on the key the ISC sounds da da 3 release the throttle after the ISC stop acting 4 turn off th...

Page 115: ...13 Draining cap of injector bleed the air Used when replace the fuel pump pipe etc drain the gas The gas inside the pipe may become poor quality after 111...

Page 116: ...840G01 name quick diagnostic How to use quick diagnostic 1 Prepare quick diagnostic 2 Open the rubber cover inside the luggage comp 3 Plug in the quick diagnostic 4 turn on the key 5 wait for about 8...

Page 117: ...HIN adapter connect cable PGO vehicle RS232 or USB PC diagnostic assy S320891G01 S320838G01 software adapter connect cable part number S320891G01 name software adapter software adapter part number S32...

Page 118: ...at 2 wide open the throttle turn on the key 3 after the EMS led off release the throttle 4 don t turn off the key until EMS led on again 5 turn on the key to confirm again wot EMS led on Key ON EMS le...

Page 119: ...15 EMS system Repairing tool a pocket tester wiring pocket tester wiring part no S905310005 b Ignition gauge connect minimum distance 6mm Plug cap ground 115...

Page 120: ...l pressure gauge part no S905330008 Connect to the vehicle measure the fuel pressure standard 3kgf cm2 usage 1 dismantle the hose to injector 2 connect the gauge assembly to the pipe 3 turn on the key...

Page 121: ...m 10A Orange Deep Green ignition coil 7 5A Orange Green Black FUSE 1A 5A 7 5A 10A 15A protect the units when extra current occurs 1A protect the ECU 5A protect fuel pump injector 7 5A protect ignition...

Page 122: ...e EMS relays inside the RH body cover dismantle 1 luggage comp 2 Rear rack 3 body cover A EMS system Dg O Gr B Bl W B fuel pump injector R W R W R B Db C headlamp O O Y W Y A B C A B C 118...

Page 123: ...rent to control big current Usage fuel pump injector EMS whole system headlamp Measure the relays use the pocket tester 1 find the control coil 2 fit 12V to the control coil 3 the relay sounds ka 4 me...

Page 124: ...f General Electric units Horn Flasher relay inside the windshield dismantle 1 windshield inside the windshield dismantle 1 windshield 120...

Page 125: ...Fuel gauge below the rear rack make sure the arrow direction dismantle 1 luggage comp 2 rear rack 3 body cover Measure the fuel gauge gray output black ground gray black F 4 10 E 80 90 121...

Page 126: ...charge 3 Recharge system 1 the wiring diagram of recharge system 2 check A C flywheel magneto 3 check regulator rectifier 4 Starting system 1 the wiring of starting 2 checking the starter 3 dismantlin...

Page 127: ...y wiring 1 Spark plug is abnormal cIgnition coil is abnormal 2 Wire connects improperly broken or short dSpark plug is abnormal Circuit eH T coil is abnormal cbetween A C flywheel magneto and fSpark p...

Page 128: ...f the recharger to the negative cable of the battery Recharging currency Please recharge 12V according to the following currency and time Standard 0 7A 5 10HR OR Rapid 3A 1Hr NOTICE 1 It is not necess...

Page 129: ...e box to remove the white cable d Connect currency meter between red white cable fuse While testing the red wire cable must not touch the frame d Set the headlamp switch at OFF engine rotation is at 2...

Page 130: ...which helps to adjust the charging voltage and current c Measurement 1 Before engine starts the voltage need to be 13 V or above after engine starts the voltage need to be 14V or above If the voltage...

Page 131: ...he LH side strip and LH body cover b Measure the resistance value of terminals 3 Check regulator measure the resistance value between each terminal it should be in specified range otherwise change a n...

Page 132: ...4 Starting system 1 Starting wiring 128...

Page 133: ...le ends If there is anything abnormal change a new one zThe non conductivity check of the brush bracket If it is conductive change a new one 3 Start Relay Starting check zRemove the body cover zWhen t...

Page 134: ...5 Starting clutch Explosive diagram 130...

Page 135: ...emove the left crankcase cover 4 Use screwing tool to fix the driving plate 5 Remove the lock nut of the starting clutch NOTE Lock nut is left thread 6 Remove the starting clutch 7 When assembling ple...

Page 136: ...itch Main Switch Operation Dark green Yellow Yellow black Blue Color OFF ON Operation Green White Black Color FREE PUSH Operation Blue Brown White Purple White Color HI LOW Operation Yellow green Blac...

Page 137: ...133...

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