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SERVICE MANUAL

1. 7 6 ciu eter ee 7 6 SIGN eis hohe a ee Ries ete decade sa eie apa ow oct ee eed ee 7 6 s atas S hoe A EROR ase Shon tee eee E EC Ee eens 7 6 SPEEDOMETER SENSOR AND MAGNE 5 2 4 xr xp bun ee ek s 7 6 SPEEDOMETER SIGNAL DESCRIPTION 4 2 bros SEGUE See eee 7 7 SPEEDOMETER GIBROULT qeu cee a ardet eee Lene ioo dede 7 7 BRAKE LIGHT SV CH S oui om ge od Gores xut indexes Su ye d des 7 8 29 ee 7 8 EB etd aren tangs Recher Editt ed ediad ii a but ro ec pe dE 1 9 BULBINSPE CHON cice oe en IO de dnd oh eae Soaks iia ee a Pot scala o s See ee we e dr 1 9 BULB SOGKETSINSPEGEION 25 1 HER rb RR toties Rep da ERR RERBA De LAE V ELS 1 9 IGNITION SY SIEM ids am nau Ep E o RR I SU GRO E heehee 7 10 ECU CIRCUIT EXPLORED WIE 5 5 eerte Bar bert do os eo tertie
2. capes Gade 5 17 IGNITION COIL OPERATION OVERVIEW ce 2 0 hm rrr 5 17 cc scc EL 5 18 ISNIION C OIL REPLACEMENT 351 0 53 3 tro Sx are SR IE OR db Ih EOS rarae vidco E Vna Sh ded ens 5 18 GENERAL TROUBEE SHOOTING 3 433 o9 93 oo ult He i ees 5 18 DIAGNOSING BENKE CODE rati rauca Ned tal aha he 5 18 DIAGNOSTIC BLINK CODE CHART tmr Gehan betel teal ee Sees So teu bee ee 5 19 BLINK CODE BREAKOUT DIAGRAMS 2228 nite etek ebe sl Ed 544444640445 et P BUS dd 5 20 BEINK CODE RECONGNITION 1 22 28 pde eh oo Seat troc ae Se eee oh a ade 5 20 PRIVE CODE ste cet oe ao hehe vd qub coer dL TU aed 5 20 MORE THAN TEAIES BLINK CODE 62424 deve Eee S bootie Pepe dot e bh neh INI P PUO 5 20 PROUBBE SHOOTING dade e ef 5 21 KWP DIAGNOSTIC TOOL tose ton 5 22 DIAGNOSTIC HARNESS dta s baee iet eR Re beeen tr ey aba bine E p de Pg utes db d 5 22 DIAGNOSTIC LOOK mM ft oem eh n 5 22 So ENO GIN PLE 5 23 ENGINE DAJTB iad anid stocky dh ane Mactan pa 5 24 ENGINE PARAMETER DEFINITION os atts ege onm Stale dart oodd Dre Bee
3. oe er 7 14 STARTER MOTOR SERVIC E e Sra ER tutela te Ex a the edd 7 14 SORTER MOTOR DISASSEMBLY 203300030 ect Mos 7 14 STARTER BRUSH INSPECTION REPLACEMENT 0 0000 tenes 7 15 ARMA TORE EST aa ee Sa ean ot Ped aces wee ia Sum iratus IR I 7 15 ELECTRICAL STARTER aoe shee ae au adc Rua 7 16 STARTER RELAY PORTER ate 7 16 MAIN SWITCH t Ried hee Soe Saad ee ewes 7 16 ROLEOVER SEGA eae eae ome eat bara gee 7 16 EO A 3o tte rod s vod be e a dee er dd ah ye ad eT uo at 7 16 STARTING WIRE CONNECTION 0 24 s44etecaneastede E t fub eo td ied oed e e 7 16 CHARGING SYSTEM Mir MEE 7 17 CHARGING CURCUIT EXPLORED VIEW 2 00 aen vated ees tertiae e IURE Pedo Een 7 17 DUINEN ps phe ostia Ged Be Se De ha mee 7 17 CURRENT DRAW REY OFF aco noc Rete er cse re dry Ec bb oe tee as eta ee
4. 2 12 COOLANT SYTEM ROSE s 26 wit at ird doo eai etas 2 12 RADIATOR edd sr eec d dades d qu in Rosi ded s dud Bot ducis d uas bam ax psi dtc E AD E DLE 2 12 COOLANT DRAIN ade edes O P UD Et shane ea heya eae ees wien s theta dana des 2 12 2 12 MAINTENANCE WHEELS AND TIRES X8 HORA RUE dedo ice eee eee eee eet 2 13 TRE PRESSURE MEASUREMENT 25 ath her cadens Oe ml est tu d te ek oe mea esa eee 2 13 WEARINDICATOR vie OT each Oen eee dedu 2 13 CHECKE WHEELS eth rarae de o ota a roro ae elegance ne duo Sut 2 14 ELECTRICAL AND IGNITION SYSTEM dpa RR SUR teed ca 2 14 BATTERY MAINTENANCE cx Reit o IE ed es eedues 2 14 BATTERY REMOVAL scutes ae take eee Vn Oi aen t vx Ud edu oie bod ee eios 2 15 BATTERY INSTALLATION s 22542352 cop deg Pede neq do cp She Dae Dota dob dedero oe i r padri p 2 15 BATTERY OFFSERSON SIORAGE 2 15 SPARK EUG SERVICE 14 i usta ues aie ion panied te eui idee t sube P M IPS DPI MEI I EE 2 16 STEERING AND SUSPENSION ra RR OX UG RR CR NUR RUN Roe ura qe co me num acc 2 16 STEERING AND SUSPENSION Ebr pu SUME eee d Es RE 2 16 INSPECTION ois Monee iota T ene gies E
5. 21 ECU CIRCUIT Elite Urban 350i ELECTRICAL Ignition Circuit Main switch Side stand R Power relay EK Y Fuse 15 Roll over sensor po Ignition coil GIR AC G GPS ECU Terminal P31 CPS L Y P2T Ing Coil W LZ P32 CPS G P11 Rollor Over Sesor L B P9 MPR R W2 RPM LIMITER SPECIFICATIONS Check the rollover switch output voltage The normal voltage should be NOTE The Scooter is limited through the ECU box 0 4 1 4V If rollover condition voltage should be reaching 3 7 4 4V located on the right frame under the seat In forward the ECU reads the RPM s from the stator The ECU acts as a limiter when the peak RPM is FUSE met Ensure fuse continuity If broken replace the fuse IF THE IGNITION SYSTEM FAILS TO OPERATE NO SPARK OR INTERMITTENT SPARK FOLLOWING PROCEDURE TO CHECKING Rollover Switch BATTERY Check the battery condition The open circuit voltage should be Vertical 0 4 1 4V 12 8 V or more at 20 C 68 F Rollover 3 7 4 4V If battery less than 11 8V inspect regulator and stator recharge or replace the battery 7 172 ELECTRICAL Ignition Coil Resistance 4 If stator pick up coil resistance reading overdue specified 5 Check that the secondary coil has the specified resistance replace completely stator Pickup coil CPS resistance A 12V Power C Ground Seconda
6. MPR Power 1247 30A GND GND GND BATTERY LAT t S_GHD CLT 7 9 lt Target i 5 REF HI 23X s REF LO MPR 4 Signal Sensor lt 5 GND Q2 HEATER THROTTLE SVREF OUT POSITION Los SENSOR 5 GND Rollover Switch MFR Normally Open lt 25W Swich to Ground ae 1 i F3 P1 P30 P26 P20 P22 P31 P32 P23 P10 P21 P11 P6 b OUT SVREF RETURN n 5 PIN 25 ANG XX XX X X X X X 1 Cod Fuse tai SA ECU connector viewed from harness side EST Spark Spark Plug Injector MPR MPR gt gi IDLE AIR CONTROL VALWE M FLIEL Pump MPR Hi Diagnostic Connector K Liria Diagnostic Check Engine Lig BAIL Coolant Gauge Light Fan Contorl PIN NAME n3 PUMP Diagnostic SVREF OUT SVREF RETURN 5 IGN KEY JV Power O2 HEATER Rollover Switch Coolant Gauge Light Fan Contorl Relay eter z gt coy Switch TPS O2 Signal IDLE_AIR_VALVE e IGN _GND m un j eo n i E REF Hi 5 REF Lo 23 T rol 5
7. NOTE Brake fluid will forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 4 Push caliper mounting bracket inward and slip outer brake pad past the edge to remove 5 Remove the inner brake pad PAD INSPECTION 1 Clean the caliper with brake cleaner or alcohol 2 Measure the thickness of the pad material Replace pads if worn beyond the service limit Rear Brake Pad Thickness New 10 mm Service Limit 6 5 mm 1 Lubricate mounting bracket pins with a light film of all season grease and install rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other A WARNING If brake pads are contaminated with grease oil or liquid soaked do not use the pads Use only new clean pads 3 Install brake line and tighten securely with a line wrench Torque the banjo bolt brake hose to the proper torque specification 4 Install caliper and torque mounting bolts to specification 5 Perform brake bleeding procedure as outlined earlier in this chapter Front caliper Bolt Torque 30 Nm 21 7 ft Ibs 6 Slowly 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 TROUBLESHOOTING 7 Verify fluid level in reservoi
8. 1 10 IGNEHON GIRCUITS EXPLORED VIEW sobrie e ect ere d dre c FOR andere 1 11 RPM EIMTER SPECIFICATION lt 65552 0 05 050 he are ini Duo e epe nr dee dr bet eae E 7 11 ROLVOVER SENSOR mc tn a 7 11 IU tated 7 11 BATDIBER Y ia ie DERE Be E det 7 11 IGNITION COILIRESIS TAN GE eco Sack d ace eee 7 12 icd eet Is 7 12 FAO BERE OMS ets aes disces at be es ah ae aud ee Pa eee ene 7 12 STATOR A Lm 7 12 STARTING SYSTEM DRE e LAU RE I Dee erint 7 13 STARTING CIRCUIT EXPLORED VIEW XR e EO Re RR o e m ol I x o a et aet 7 13 VOLIAGE DROP LEO d idee dope b doi ores d nde todos ye S aed b a ee ee 7 13 STARTING CIRCUIT OPERS TION o s ty 24 192 otis CR qud 406 i retira oet Perd OE des 1 13 POS Rise C ate eae eee eae ee 7 13 BATER D cece Sane ak Ags he att nla Ade ee aces oa m 7 13 APER MOTOR annee
9. 2 Rollover sensor Located in front of middle handlebar Rollover Switch 13 O2 Sensor Located in front exhaust pipe elbow 4 02 Sensor 5 102 ELECTRONIC FUEL INJECTION FUELTANK 5 103 ELECTRONIC FUEL INJECTION FUEL TANK EXPLODED VIEW Cap Gasket Gauge c Fuel Tank Hose Overflow Fuel Pressure Regulator i wae od Hose Injector E gt e d Hose Fuel Filter Discharge FUEL FLOW CHART Fuel Tank m Overflow Fuel Filter Fuel Pump Relief Valve Fuel Injector EFI INFORMATION 5 104 ELECTRONIC FUEL INJECTION EFI OPERATION OVERVIEW The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are electronically controlled monitored and continually corrected during operation to maintain peak performance The central component of the system is the Engine Control Unit ECU which manages system operation determining the best combination of fuel mixture and ignition timing for the current operating conditions An electric fuel pump is used to move fuel from the tank through the fuel line and in line fuel filter At the engine fuel is fed through the fuel rail and into the injectors which inject into the intake ports The ECU controls the amount of fuel by
10. we bee othe gt ele teed tase hl elses 4 49 SPARK PLUG FOULING za oth td Rake ewe eh eee titu ee pa e ee Pete ie eat o ed S Ss 4 49 ENGINE TROUBLESHOOTING 35 35 22 95 098 x En EROR peeve ee be base eee oO NE ER RR Rae Ro xod 0n 4 50 ENGINE TURN OVER BUT FAIESTART aaeeds 4 50 ENGINE DOESNOT TURNOVER Rees des Ew ao ob ace est wise bier E else e E pb dea 4 50 ENGINE RUNS BUT WILE NOV IDEE 32 243 rA o ee R acies eeu ea gau ae DEVE ERE 4 50 ENGINE IDEE BUT WIELNO T REV UP VERUS EIAS ORI EARS EAR HIER E ETHER SR 4 50 ENGINE PAS LOW POWER dcs aria arde t e tete us dex bc SC one Es oe p adiret a tb oe 4 50 PISTON FAILURE 9CORING o vt ol dd Wet TRI POIDS Doa eI 4 50 EXCESSIVE SMOKE AND CARBON 22 hrs 4 50 EOW COMPRESSION ut den Pesca cce dB 4 50 232606 gode S NE IIT eL vt EIN s Vedi vincet a 4 50 TRANSMISSIONS eee NUR SONT wes ee RC a 4 51 TANSMISSION EXPLODED VIEW voi eor e PP be PEL Ed I Ri ew ERE 4 51 TANSMISSION DISASSEMBLY VERE RE E PALDINE PO RA Gd EE br od decet 4 52 TANSMISSION INSPEC TION Jc cnet inate teste dr ad
11. LAE 5 31 FREEZE FRAME ete S dead eddie mo edere f es dob qu qud bie as 5 32 MAER RECORD s ua utar SUA arduo ume Salcedo ttal 5 32 JEN ESI e dE CLP 5 33 IDLE RPMADIUS e eicit gite dopo end 5 33 ERREUR TI TENTI EET 5 34 CONVER TEOG FEE i odo ito uda t varo ond rere ere ee ade Xon sert dun et tcu qund viue Ut DC 5 34 APPENDIX 263 24 eeGe ese eee te ee eee 5 37 UPDATE ECU PROGRAM A GS Cee eed 5 37 5 98 ELECTRONIC FUEL INJECTION SERVICE INFORMATION There had 80 problems of all EFI problems caused by wiring harness connections 4 WARNING Never attempt to service any fuel system component while Gasoline is extremely flammable and explosive under engine is running or ignition switch is certain conditions Cleanliness is essential and must be maintained at all times EFI components are under high pressure Verify when servicing or working on the EFI system Dirt even in system pressure has been relieved before disassembly small quantities can cause significant problems Never drain the fuel system when the engine is hot Do not use compressed air if the system is open Cover any Severe burns may res
12. P edi inedia sire tita de dde a auae d 6 3 FRONT WEHEEL AND Ra teks data Rh n ul Pac acc RE Ren 6 4 FRONT WHEEL AND BRAKE EXPLODED eee eee 6 4 REMOVE THE FRONT WHEE s xw Geese eis teeta TRE m D aes ea Shea EM IP re eee ene ated 6 4 FRONT WHEEL DISASSEMBLY 2224226 I RH te eed den Egi d an eg 6 4 FRONT cordance eae biu S db dtt tee ee Para ee EE ues 6 5 FRONT BRAKE DISCINSPECHON int hr tous tan aa Pew Bee 6 5 FRONT WHEEL TUB ASSEMBLY etii edt tented oet be vq dde ad ies 6 6 FRONT WHEEL ADJUSTING AND WHEEL STATIC BALANCE 00 2 020002 ce ee 6 6 FRONT WHEEL INSTALLATION sc 22662 cds ee odit ca OP hee eat eb dua iab dro A dica Baca ae ador POL dl 6 7 REAR WHEEL AND BRAKE eia OR AERE e HOME INR E eee pes 6 8 REAR WHEEL AND BRAKE EXPLODED VIEW iiber dE eed EPI CT CHOR 6 8 REMOVE REAR WHEEL s a eres utputa oe out dut Adeste adver dut 6 8 REAR WHEEL INSTALLATION eb aree Een eC HE IR ced 6 9 BRAKE SYSTEM cesses acia i REESE Pob RR RU RN RR 6 10 BRAKE EXPLODED VIEW aspetta tno p ebat OR ERE RET qu vem ted e ad
13. 176 5 4 F The fuse is blown Improper operation of the main switch Step Cooling Water temperature Continuity More than 70 C Yes 154 4 F Low voltage The battery is not fully charged Poor contact Poor charging system Less than 67 C 153 F Poor voltage regulator No spark produced by spark plug A WARNING The spark plug is out of work The cable is poorly connected open or Handle the thermo switch with special care Hot NEN short circuited Between AC Generator ECU Poor connection between ECU and ignition coil water could severe injury skin and eyes Always wearing protection gears Poor connection between ECU and the main o CAUTION o Bad main switch Never subject it to a strong shock or allow it to be ECU malfunctions dropped Should it be dropped it must be replaced 5 If the thermo switch does not continuity replace it MP Starter motor does not work Wiring connection e The fuse is blown Refer to CIRCUIT DIAGRAM Check the connections of the entire The battery is not fully charged cooling system If poor connecting repair or replace it Bad main switch Bad starter switch The front or rear brake switches does not function correctly otarter relay is out of work The ignition coil is poorly connected open or short circuited e The starter motor malfunctions 7 18
14. 9h hae Eee ee ee eee 4 14 PISTON IDENTIFICATION oia a atk a Sa ene eS nu Baye 4 14 ASOESSIBBECOMPONDBUDS 5 5 321 ees donee ae GU pA sone ee aos 4 14 ENGINE REMOVAL c Wey wae 2 ot sine Saec ae WE ee oe Bep ee ne Ae ean dao 4 14 RIGHPRHAND ENGINE MOUNT dla E a ru anes d br ees he at d 4 15 FANS ENGINE MOUNT ores a atk tala este hha the 4 15 ENGINE INSTALLATION NOT Beis iih ca rt Eno adis Re n i tin Nhe e d 4 16 ENGINE PUBIC AO Ns se cn hey eee Mop dp adu e cuta PEN Sed ee du Ea uA 4 16 GNI CS NUIT ae ee ina aba do Marae aaron ace 4 16 CAM CHAIN TENSIONER REMOVAL discurs eee he ER m eee oe wh 4 17 CAM GEDAIN TENSIONER INSPECTION 2 eaters Poe Os aegri Ser PS SLAG Shs Pu hd eee es 4 17 ROCKER ARM SHAFT DISASSEMBLY 1 5 2 eee 4 17 CAMSHAFT REMOVAL AND INSPECTION caan because kr d ph Sead Pee wed eS X a Reed RD Mawes 4 19 CANSHAPLINSPECTION lt 2 sod us td ant eaten ai d ON E Steal aca ead fopra ira ee EE eee o obs 4 20 CYLINDER HEAD REMOVAL DUO DRE
15. Master Cylinder Fluid Level Between the MIN and MAX line shown on the reservoir 11 Install master cylinder reservoir cover 12 Field test machine at low speed before putting into service Check for proper braking action and brake lever reserve 13 Check brake system for fluid leaks 6 149 BRAKE MASTER CYLINDER MASTER CYLINDER REMOVAL 1 Remove the handlebar covers CAUTION 2 Disconnect both wires of brake light switch Brake fluid will damage finished surfaces 3 Place a container to catch brake fluid under the master Do not allow brake fluid to come in contact with cylinder brake line banjo bolts Drain out the brake fluid finished surfaces Brake hose NOTE Make note of front and rear brake line locations to master cylinder 5 Loosen the brake line banjo bolts and allow fluid to drain NOTE Dispose of fluid properly Do not re use 1 Reverse Steps 1 5 for master cylinder installation Brake switch Right Hand re Refer to torque specifications in the illustration 4 Remove the two mounting fastener bolts that secure the 2 Connect brake hoses with 2 new copper washers master cylinder to the frame 3 After installing the brake lever check lever free play Brake Lever free play should be around 090 2 286 mm Right Hand Hand 6 150 PAD REMOVAL 1 Elevate and support front of scooter CAUTION Use
16. Using a wire brush or knife remove any corrosion from the cables and terminals Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the voltage reaches 13 0VDC or greater Store the battery either in the machine with the cables disconnected or store in a cool place NOTE Stored batteries lose their charge at the rate of up to 1 per day Recharge to full capacity every 30 to 60 days during a non use period If the battery is stored during the winter months electrolyte will freeze at higher temperatures as the battery discharges The chart below indicates freezing points by specific gravity 7 182 ELECTRICAL SEALED LOW MAINTENANCE BATTERY CHARGING PROCEDURE 1 Remove the battery from the ATV to prevent damage from leaking or spilled acid during charging 2 Charge the battery with a variable rate charging output Charge as needed to raise the voltage to 12 8VDC or greater 3 Install battery in vehicle with positive terminal toward the front Coat threads of battery bolt with a corrosion resistant Grease 4 Route cables so they are tucked away in front and behind battery 5 Connect battery cables To avoid the possibility of sparks and explosion connect positive red cable first and negative black cable last 6 After connecting the battery cables install the cover on the battery and attach the hold down strap CONVENTIONAL BATTERY ACTIVATION SVC To ensure m
17. exhaust Mam gnition Exhaust MANIFOLD PRESSURE The manifold pressure measured during intake process TPS percent THROTTLE OPENING PERCENT This refers to the percentage of the throttle opening It is 0 when throttle plate full closed and is 10096 when throttle plate open up to 80 and above Toil physical ENGINE TEMPERATURE This refers to the metal or coolant temperature of cylinder head It is used as the reference of engine operation condition idx INTAKE AIR TEMPERATURE This refers to the air temperature measured on air cleaner or intake pipe SA SPARK ANGLE 5 122 ELECTRONIC FUEL INJECTION TDC is set as the 9th tooth of target wheel aiming the center of crank sensor Spark angle refers to the ignition angle before the 9th tooth Cyl1AFLCMult FLOW ADJUSTMENT COEFFICIENT This refers to the adjustment factor according to the change of intake airflow IACCommDuty IDLE AIR CONTROL 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 ECU will calculate and determine the BPW according to related parameters such as engine rpm intake and engine temperatures and throttle opening etc 2 Volt OXYGEN SENSOR VOLTAGE The voltage of Oxygen sensor will range from 100 to 800mV and will oscillate during normal operation 5 123 ELECTRONIC FUEL INJECTION VB
18. tee dun ados icd Suse ea ee Pul a rie sicud 6 21 HANDLEBAR enenatis dumm hes eei vea pq omnes m E nba dea a dv eq 6 23 HANDLEBAR REMOVAL rnb eS ek bare d Rp Hs bedeutend dst sd sd ptu 6 23 HANDEEBAR ANSALEATFIODU ob Beet ution oe oa Gore cien ORs blade on Que we as 6 24 THROTTLE EREEPLAY ADJUSTMENT i ic bine ong abe Rb EIS meter eed wad cies Jae eee 6 26 INSPECTION ak bao eee yee eee 6 26 ADJUSTMENT uei pe os Baie Piece Oe Lede ee dub Esau dede ee dept 6 26 6 138 Body Cover Exploded View ES Handlebar Cover A Windshield wd Front Fender uidi Z 4 E 3 j Headlight Cover A3 Note 6 Be careful do not damage plastic covers while assembly or 7 disassembly operation 8 9 Never broken tongue or tab while assembly or disassembly operation 10 Align all tongues and grooves of plastic cover first then 11 fasten screw or nut 12 Never compacting or hammer force on the all plastic 13 covers during assembly 14 15 16 1 Handlebar upper bottom covers 17 Windshield 18 Front fender Headlight cover DE Ee Speedometer cover 6 139 BODY COVER Seal Luggage Box Yes ggag Rear Feder gt pts License Plate Mount i2 RN S
19. 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 lever 4 Tighten the lock nut 5 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position WARNING After adjusting the throttle cable free play start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change 2 18 MAINTENANCE AIR CLEANER SERVICE 1 The air cleaner is located just above the rear wheel in the left of vehicle BANG h LE LE l1 nl z A A MM mu T i NOTE It is recommended that the air filter be inspected as part of pre ride inspection When riding in extremely dusty conditions air filter replacement Will be required more often 2 Remove all screw and remove the air box cover Inspect the seal It should adhere tightly to the cover and seal all the way around 3 Remove air filter assembly Blow by compressed air to filter outer surface 4 Inspect the air filter element and replace if necessary ENGINE ENGINE OIL LEVEL The horizontal cylinder engine 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 machine has
20. IMPORTANT provides key reminders during disassembly assembly and inspection of components 1 2 GENERAL INFORMATION GENERAL INFORMATION MAINTENANCE CVT ENGINE TRANSMISSION ELECTRONIC FUEL INJECTION BODY FRAME ELECTRICAL GENERAL INFORMATION CHAPTER 1 TION eo DER dU 1 cian UE RUE EU EROR de bates 1 2 VIN IDENTIFICATION 62 sees tees eau SOME abo es ele D 1 2 ENGINE SERIAL NUMBER EOCATION aes hese wees Ober ante Ph be Reeve se 1 2 VEHICLE IDENTIFICATION NUMBER LOCATION 0 0 000 eee eee 1 2 GENERAL SPECIFICATIONS xx xar FAR ER T Ce ea o FR Ea 1 3 URBAN i i past T itt e ie Rss eee ded esas duod Oda ee dip d aras 1 3 SPECIEICAIONUEBAN GOON sae ee urbe d bc atat i seth aed Soon fare 1 4 CONVERSION JTABIIE E de Mews in ede eU aed dd 1 5 GLOSSARY OB TERMS fe NOSE edu uu cute ed fepe oem 1 6 1 4 GENERAL INFORMATION MODEL INFORMATION VIN IDENTIFICATION ENGINE SERIAL NUMBER LOCATION The frame can be found under foot pedal stamped on the right Engine serial number local under rear seat stamped on side of frame front of crankcase beneath passenger foot pedal The vehicle identification number VIN and engine serial number ar
21. Inspect the final shaft and gear visually without excessive wear or crack Replace any damaged components BEARING AND OIL SEAL INSPECTION Check bearings on gearbox cover Rotate each bearing s inner ring with fingers Check if bearings can be rotated smoothly and silently 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 necessary Check gearbox bearing as the same way above and replace it if necessary 4 05 ELECTRONIC FUEL INJECTION CHAPTER 5 SERVICE INFORMATION RT eee a eda AE 5 4 vids SR mE C ee ee eee ee LETT 5 4 SERVICE NOTE wen ead ames acts Bea ee ee uaa une pias eee bok saree 5 4 ELECTRONIC FUEL INJECTION SYSTEM 4 545 ERAI A Rex TRO RR ROCK OR CY DR UI Pewee 5 5 EL SYSTEMEXPEODEB WVIEV S atte ii aia t euis Sha c ero Salud oed E mete 5 5 EFI SYSTEM COMPOMENTS LOCATION RR pale E Se aa ac bead 5 6 ELECTRONIC CONTROL UNIT ECU 5 Sue Robots a dd Lee db qus eor oa ede aed qe Aor dou 5 6 INTAKE AIR TEMPERATURE TA 4 Esc Seo petri detiene d ioter meee MES ound ent ae fotos 5 6 CRANKSHAFT POSITION SENSOR GPS auae RER
22. 6 157 4 Place inner tube slowly into outer tube 10 Install Spring into inner tube Install oil seal retainer 6 Slowly adjust oil seal retainer until fit into outer tube groove 7 Install dust seal onto inner tube 8 Fill recommended fork oil into inner tube Triple Tree Clamp Torque 30 Nm 21 7 ft Ibs 12 Torque the cap bolt to specification A WARNING Make sure the oil levels in both front forks are equal Uneven oil levels can result in poor handling and a loss of stability 130cc 5 9 Install dust seal onto inner tube Front Fork Cap Torque 70 Nm 50 ft Ibs 6 158 Handlebar Exploded View 4 Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar 5 Remove handlebar from steering shaft Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 Remove both weights which locate on end of handlebar 3 Remove both grips by low pressure air 1 Inspect handlebar replace it if has bent cracked damaged 6 159 6 Install both switch housings and master cylinders 4 WARNING 7 Lubricate the inside of the throttle grip with a thin coat Do not attempt to straighten a bent handlebar as 9 grease and install it onto the handlebar th
23. CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 Remove handlebar cover 3 Disconnect the speedometer brake switch both switch housing harnesses and throttle cables 4 Remove handlebar upper clamps woodruff and handlebar 5 Remove handlebar lower clamp jammed nut then use a soft face hammer to remove handlebar lower clamp from steering shaft 6 154 STEERING SHAFT amp Jammed Nut 7 __ Lower Handlebar Clamp Jammed Nut Washer Ring Nut Sb Race Upper Bearing gt Race Main Frame 6 Remove steering shaft bearing jammed nut 7 Remove lock washer from ring nut groove WARNING The locking agent on the existing bolts was destroyed during removal DO NOT reuse old hardware Serious injury or death could result if fasteners come loose during operation 8 Remove ring nut races bearings and steering shaft from mainframe 9 Remove both bearing races from steering head pipe with long rod and hammer 1 Lubricate bearing race upper bearing and lower bearing with a light film of all season grease and install them into steering shaft 2 Install lower steering ring nut and torque it to 103 10 Remove the bearing race from the lower bracket with a floor chisel and hammer 11 Install a new rubber seal and new bearing races CAUTION The steering
24. Pinch Bolt Torque 20 Nm 14 5 ft Ibs 7 Install front brake calipers ensure the brake cable is routed properly CAUTION Front caliper Bolt Torque 30 Nm 21 7 ft Ibs 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 base grease 4 Install wheel onto front fork 6 143 REAR WHEEL AND BRAKE REAR WHEEL AND BRAKE EXPLODED VIEW e 2 7 Rear Shock Nut NIA Spacer Oil Seal Rear Brake Disc Rear Rim Rear Tire Pd Rear Fork Oil Se l REMOVE THE REAR WHEEL Place the vehicle on a level surface and Stand the center stand that the rear wheel is elevated 6 144 4 Remove rear fork jammed bolts and rear axle nut then 1 Refer page 6 4 to measure rear wheel radial wheel run out and lateral wheel run out Rear Wheel Lateral Limit 2 00mm Rear Wheel Radial Limit 3 00mm 2 Inspect rear wheel drive hub Replace it if crack or damaged 3 Visually inspect disc for scoring scratches or gouges Replace the disc if any deep scratches are evident Rear Brake disc deflection limit 0 30 mm 4 Use a 0 1 micrometer and measure the disc thickness at eight different points around the pad contact surface Replace disc if worn beyond service limit Rear Brake Disc
25. Springs are under tension Wear safety glasses and use caution when removing springs Severe injury can result 3 Remove the spring from front shock 4 Stroke the outer tube several times while draining the fork oil 5 Use a bowl to get draining oil 6 156 6 Remove dust seal and oil seal retainer Front Fork Inspection 1 Inspect inner tube chrome surface Replace it if has been scratched 2 Verify inner and outer tube body Replace them if has bent and damaged Inner Tube Outer Tube Do not scratch the inner tube surface 7 Hold the front fork leg horizontally 3 Inspect spring free length Replace it if out of 8 Securely clamp the brake caliper bracket in a vise specification with soft jaws 9 Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully Front Fork Spring Free Length 270mm Front Fork Spring Service Limit 250mm CAUTION Excessive force will damage the oil seal and Note Before assembling the front fork leg ensure all of the bushing A damaged oil seal or bushing must components are clean be replaced _ 1 Apply grease onto oil seal lips Avoid bottoming the inner tube into the outer 2 Lubricate surface of inner tube with fork oil tube during the above procedure as the oil 3 Install oil seal onto inner tube flow stopper will be damaged
26. fan stop or longer 4 Replace thermo switch if it doesn t meet with specification If pressure loss is evident within five minutes check the radiator hoses or clamps and water pump seals for leakage 4 51 ENGINE WATER PUMP Check water pump seal coolant leaking inspection Retainer 1 Check water pump cover impeller 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 inlet hose Replace it if these crack CAUTION The mechanical seal and inside seal must be replaced as a unit 4 52 ENGINE TOP END DISASSEMBLY 4 53 ENGINE PISTON IDENTIFICATION The piston has an identification mark for piston placement 5 Camshaft 6 Crankshaft Note the directional and identification marks when viewing the 7 Crankshaft Main Bearings pistons from top The letters must always be toward the intake side of the engine The other numbers are used for identification as to diameter length and design Four stroke engine rings are rectangular profile The numbers or letters on all rings except oil control rings must be positioned upward See text for oil control ring upper rail installation Use the information below to identify pistons and rings ACCESSIBLE COMPONENTS The following components ca
27. heavy more acidic state at full charge to a light more water state when discharged The hydrometer can measure state of To prevent shock or component damage remove charge and differences between cells in a multi cell battery Spark plug high tension leads and connect securely to engine ground before proceeding NOTE This test can only be performed on machines With electric starters This test cannot be performed Differences of more than 025 between the lowest and highest with an engine or starting system that is not working cell readings indicate a need to replace the battery properly A battery may indicate a full charge condition in the OCV test and the specific gravity test but still 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 encountered To perform this test hook multi tester to the battery in the same manner Detail A as was done in test The reading should 12 6 volts or greater Engage the starter and observe the battery voltage while cranking the engine Continue the test for 15 seconds During cranking the observed voltage should not drop below 9 5 volts If the beginning voltage is 12 6 volts or higher and the cranking voltage drops below 9 5 volts during the test replace the battery Readings of 1 270 or greater should be observed in a ful
28. remove the battery from the vehicle ensure that it s fully charged and 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 charger or by charging about once a month to make up for normal self discharge Battery tenders can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multi meter to measure the DC voltage at the battery terminals 1 Check the battery voltage with a voltmeter or multi meter The battery voltage should read 12 8 VDC or higher 2 If the voltage is less than 12 8 volts charge the battery at 1 2 amps or less until battery voltage is 12 8 VDC or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for battery charging directions When using a constant current charger follow the guidelines in the following table Note Fully charged over 12 8 V Failure charged under 12 5 V Relationship between the open circuit voltage and ihe charging time al 20 voltage V 5 5 10 lime hours T
29. the ECU activates the 1 Be sure the engine has cooled enough to work on fuel pump which pressurizes the system for start up 2 Remove the seat and the storage box The ECU switches off the pump preventing the continued 3 Thoroughly clean the area around the fuel injectors delivery of fuel in these instances including the throttle body manifold e If the key switch is not promptly turned to the start 4 Using a 6mm hex wrench loosen the fuel rail mounting position screw from the cylinder head Carefully pull the rail away If the engine fails to start the injectors and remove the injector from the cylinder head If the engine is stopped with the key switch on as in the along with the harness case of an accident In these situations the check engine light will go on but will Fuel turn off after 4 cranking revolutions if system function is OK Injector TP Once engine is running the fuel pump remains Harness FUEL PUMP TEST The fuel pump is non serviceable If fault code diagnosis indicates a problem within this It may be possible that the fuel pump must be replaced Disconnect Here A 12V Power Input H B Ground 5 Reverse the previous procedures to install the new injector and reassemble 6 Lubricate O rings lightly with oil to aid installation Torque the fuel rail mounting screw to specification Check the fuel test for any possible fuel seepage after performing any tests or procedures
30. to activate the brake light 1 Locate the brake switches under the brake levers 2 Disconnect wire harness from brake switch and connect an ohmmeter across the two switch wires The reading should be infinite 3 To act the brake lever and check for continuity between 2 Bulb C is used for turn signal and brake tail lights and can be switch contacts Replace switch if there is no continuity or if the removed from the socket by pushing and turning the bulb resistance is greater than 5 ohms when the brake is applied with counterclockwise slight pressure YR 20 2VISW LICENSE BULB 3 Bulbs D and E are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out Brake Light Sensor 2W 4 TAN TIGHT BULB INSPECTION The following procedure applies to all of the bulbs 1 Remove bulb BULBS Check each bulb and bulb socket for damage or wear proper CAUTION connections and also for continuity between the terminals Be sure to hold the socket firmly when removing Repair or replace the bulb bulb socket or both If they are the bulb Never pull the lead otherwise it may be Damaged or worn pulled out of the terminal in the coupler Avoid touching the glass part of the headlight bulb TYPES OF BULBS to keep it free from oil otherwise the transparency The bulbs used on this scooter are shown in the illustration on of the glass
31. to check all records ARSE deno Pee RA Q1 O xx E C Program File WP TOOLS DisgTooliLog RAR 9Box A E 2009070 EngineDetsLo z 0001 zmd DEEP tet ACD Systems _ lE 20 ator ant DE tet Acrons 2 2 Adobe or OL kk Annlog Devres C ATI Technologies amp unCAD 2018 Autodesk L Compare 7 H Broodcom D CCleaner 5 Common Fiks 73 Compl Applications 2 DIFK 9 2 3 P3 KCNS Coogle L Rewlet Peckand HP HPQ L DH Computer Soluhons amp 3 Installation Infomation Inl nemet Explorer 7 Use Excel to open the B Microsoft Excel 20000730 EngmneDataLo p 0001 emdDE txt D Time SWE STALE decem t SS ELANA uter seconds pm kPa percent degC degc percent factor percent mes mV 1 48 171 92 47 20 4 10 16 8 0 1 51 4 D 352451 12 5 1 57 171 9247 204 10 16 al 9 914 D 3524 51 2 5 1 72 171 92 47 20 4 10 16 8 9 91 4 0 352451 12 5 1 79 11 9 204 10 16 8 9 L BLA Q 3524 51 12 5 19 17 9247 204 10 16 8 4 914 D 352451 125 2 01 171 92 47 20 4 10 46 8 0 91 4 D 3524 51 12 5 2 12 171 9247 2 4 10 L d 0 L 914 0 352451 12 5 2 37 171 9247 214 10 l 8 9 L 914 352451 125 2 45 171 92 47 20 4 10 16 8 0 L 81 4 0 3524 5 25 2 56 171 92 47 20 4 10 16 8 9 1 91 4 0 3
32. varying the length of time that the injectors are on This can range from 1 5 8 0 milliseconds depending on fuel requirements The controlled injection of the fuel occurs each crankshaft revolution or twice for each 4 stroke cycle One half the total amount of fuel needed for one firing of a cylinder is injected during each injection When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned The ECU controls the amount of fuel being injected and the The ECU is the brain or central processing computer of the entire EFI fuel ignition management system During operation sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU Signals to the ECU include ignition on off crankshaft position and speed RPM throttle position engine coolant temperature air temperature and intake manifold air pressure and battery voltage The ECU compares the input signals to the programmed maps in its memory and determines the appropriate fuel and spark requirements for the immediate operating conditions The ECU then sends output signals to set the injector duration and ignition timing ignition timing by monitoring the primary sensor signals for air During operation the ECU continually performs a diagnostic temperature barometric air pressure engine temperature speed RPM and throttle position load These primary signals are compared
33. 4 Remove the filler caps and add distilled water only as needed to bring each cell to the proper level Do not overfill the battery CAUTION Refill using only distilled water Tap water contains minerals that are harmful to a battery CAUTION Do not allow cleaning solution or tap water inside the battery Battery life may be reduced 5 Reinstall the battery caps CONVENTIONAL BATTERY INSTALLATION 1 Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse well with clean water and dry thoroughly 2 Route the cables correctly 3 Reinstall battery attaching positive red cable first and then the negative black cable Coat terminals and bolt threads with Grease 4 Install clear battery vent tube from vehicle to battery vent WARNING Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion The vent tube should be routed away from frame and body to prevent contact with electrolyte Avoid skin contact with electrolyte as severe burns could result If electrolyte contacts the vehicle frame corrosion will occur 5 Reinstall the holder strap CONVENTIONAL BATTERY TESTING Whenever a service complaint is related to either the starting or charging systems the battery should be checked first Following are
34. 9 Lubricate O ring on new filter can with a film of fresh engine oil Check to make sure the O ring is in good condition 2 20 MAINTENANCE TRANSMISSION CASES ENGINE MOUNT LOCATIONS TRANSMISSION LUBRICANT CHANGE Periodically inspect engine and transmission mounts for cracks Remove the fill plug D We or damage 2 Place a drain pan under the main drain plug 3 Remove the drain plug and allow draining completely 4 Clean the drain plug TRANSMISSION LUBRICATION 5 Reinstall the drain plug with a new o ring and torque to NOTE is important to follow the transmission and 60 Nm 44 ft Ibs gear case maintenance intervals described in the 6 Add the recommended fluid through the fill plughole Periodic Maintenance Chart Regular fluid level Maintain the fluid level at the bottom of the fill plughole when inspections on these components should be filling the gear oil Do not overfill performed as well 7 Reinstall the fill plug and torque to 5 Nm 45 in Ibs 8 Check for leaks Discard the used lubricant properly Transmission Specifications 9 Reinstall the filler Specified Lubricant 10 Start the engine Allow it to idle for one to two minutes Gear case Lubricant SAE 80W 90 11 Stop the engine and inspect for leaks Approximate Capacity at Change 200ml Drain Plug Torque 60 Nm 44 ft Ibs Fill Plug Torque 5 Nm 45 in Ibs The transmission lubricant levels should be checked and chan
35. Be le 5 14 FOE OPERATION OVERVIEW E Er Ent eae Pe ea diia ea 5 14 miUe E IBI PE eis a eat ee al Grae ee Serna et Rd eee 5 14 ELECTRONIC FUEL INJECTION FUEL PRESSURE REGULATOR 55e Ennii ERR CR SI 5 15 FUEL PRESSURE REGULATOR OPERATION OVERVIEW 2 eee ee 5 15 FUEL PRESSURE REGULATOR TES Ua us Reto e jelous ede dibs aa bk dn edo bali a 5 15 FUEL PRESSURE REGULATOR REPEAGCEMEBENT 2 VT e deeb ee laste ie ri eap i 5 15 FZHROTIEEPOSITION SENSOR ux eU re de oU 5 15 TESSIPERATIONOVERVIEV ial tae a apte at cia ita tate 5 15 Tipo TES PROCEDURE ieee a uideo qb er ai E careers d du datur dades 5 15 TPS REPLACEMENT eas on bared doers ES 5 16 ENGINE COOLANT TEMPERATURE 5 5 5 16 ECT OPERATION OVERVIEW haw ee ve ee pode ee tre edo evi ee eae ied dea eee 5 16 ECT SENSOR TEST PEDES EDITOS eked chutes seat bh Bc SEE AS 5 17 SENSOR REPLACEMENT eee Sox ooh ne hee Re e ded tks ide tete a 5 17 IGNITION COIE
36. ELECTRONIC FUEL INJECTION Freeze Frame This is to show the latest mal function occurred and its corresponding engine status Tal B ONES His tory mu d guru Freeze Frame P0112 IAT Short GND RPM Freeze Freeze Freeze CLT Freeze BLM Freeze CLC Freeze SA Freeze EngineRunTime Freeze AccumEngRun Min Freeze AccumEnaRun Hour Free Malf Record This is to record all mal functions have ever occurred to the vehicle Press Erase to eliminate mal function codes after mal function being solved ERF urnas Tool k Enge Dara coda Mat H gory Discription Short GND Inj Open GND gn shart GND Cyl Ign Short V 5 129 ELECTRONIC FUEL INJECTION Malf History This is to show the mal function codes have ever occurred after the ECU key on The codes will be cleared after ECU key off BREW Tool en 29 CORPORATION idiot Ma Malf History LJ MOLON IAT Short GND inj Open GND Ign Short GND Cyli Ign Short V Idle RPM Adjust This is to carry out idle adjustment after vehicle off the line The adjustment of 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 adjustment 1 No
37. Pounds per square inch PTO Power take off qt Quart quarts Regulator Voltage regulator Regulates battery charging system output at approx 14 5 DCV as engine RPM increases Reservoir Tank The fill tank in the liquid cooling system Resistance In the 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 transfer of aluminum from the piston onto the cylinder wall Possible causes 1 improper lubrication 2 excessive temperatures 3 insufficient piston clearance 4 stuck piston rings Stator Plate The plate mounted under the flywheel supporting the battery charging coils TDC Top dead center Piston s most outward travel from crankshaft Volt The unit of measure for electrical pressure of electromotive force Measured by a voltmeter in parallel with the circuit Watt Unit of electrical power Watts amperes x volts WOT Wide open throttle GENERAL INFORMATION 1 11 MAINTENANCE CHAPTER 2 PERIODIC MAINTENANCE CHART 4 rea EU m eser din ei m eR RR nn RR cen 2 3 PERIODIC MAINTENANGE OVERVIEW 2 12 Da reto bx re CTS been te RE Rd dura 2 3 SEVERE USE DEFINITION s ipao aea ne eet CORN arri qus oro REP S ted da 2 3 MANTENANGE CHART KEY Ur t ur E I PETRO rds Tu Gottes addi der dea 2 3 MAINTENANCE INT
38. TAILLIGHT AND LICENSE LAMP HEADLIGHT 1 Connect the multi meter DC 20 V probe into headlight 1 Connect the multi meter DC 20 V probe into the headlight connector connector 2 Turn the main switch on and connect probe into 2 Turn the main switch and beam switch terminal and probe into terminal Connect probe into 17 terminal and probe into terminal Both position and low beam bulb should come on VSW 3 Check the voltage 12 V of the W L and B terminals on LICENSE BULE the bulb socket connector 99 4 Turn main switch and beam switch Connect probe into L W terminal and probe into terminal Both position and high beam bulb should come on P 12VH 8W10 2W 5 Check the voltage 12 V of the L and terminals on TAIL LIGHT the bulb socket connector 6 Turn the main switch on anyone beam switch Connect 3 Check the voltage 12 V of the Y and terminals on probe into Y W terminal and probe into terminal the taillight and license bulb socket connector Both position and anyone beam bulb should come on 7 187 ELECTRICAL 4 Turn the main switch on and apply brake lever Connect probe into Y W and probe into R 12VI5W LICENSE BULB Brake Light Sensor 12V 80 2W T
39. a a dore x f 3 3 DRIVEN CLUTGHIEXPLODED VIEW S ertt Ie E atcur quo xv pe dede made ee aes 3 3 OVI OVERFHEATING7 DIAGNOSIS E S id oiu ER Ri 3 4 DRIVE GE BOERSSENGGNAI d o ditare uut im VEHI Minas plua ideas ut iratus ta eee 3 5 DRIVEN CEUTCHEXPLORED VIEW Sadat wet Rees EA DE ENIRO RR E NEIN AME REX 3 6 DRIVEN CEUTCRIREMOV Als PERPE NIB PIPER ee NR Abd ond Soh on See hee ani E 3 6 DRIVEN CLUTCH SERVICE OPERI ek BGR I E 3 7 DRIVEN CLUTCH DISASSEMBLY 1 5 et ee dep RI RR 3 7 DISIVEN CEUTCELUASSEMBLY 1429 15 usd a RR eae head b DR 3 8 DRIVE CLUTCH SERVICE ie 22234929 e0es bucks ne uei ERE Re RP Ros areis 3 9 DRIVE CLUTCH DISASSEMBLY AND 1 5 n 3 9 DISIVEGLUTCIHASSEMBISY ra it t ott ates he ate teat spins eod 07 3 10 3 30 CVT SYSTEM WARNING Only a certified Aeon Service Dealer technician who has received the proper training and understands the procedures outlined in this manual should perform all CVT maintenance or repairs Because of the critical nature and precision balance incorporated into the CVT components it is absolutely essential that no disassembly or repair be made without factory authorized special tools and service procedur
40. are removed and a new valve must contact the valve seat over the entire seat surface is evident circumference of the seat and the seat must be the NOTE Remove only the amount of material proper width all the way around If the seat is uneven necessary to repair the seat surface compression leakage will result If the seat is too wide seat pressure is reduced causing carbon 5 To check the contact area of the seat on the valve face apply accumulation and possible compression loss If the thin coating of Prussian Blue paste to the valve seat If using seat is too narrow heat transfer from valve to seat is interference angle 46 apply black marker to the entire reduced and the valve may overheat and warp valve face A resulting in burnt valves 1 Install pilot into valve guide 6 Insert valve into guide and tap valve lightly into place a few times 2 Apply cutting oil to valve seat and cutter 7 Remove valve and check where the Prussian Built or black 3 Place 46 cutter on the pilot and make a light cut marker indicates seat contact on the valve face The valve seat should contact the middle of the valve face or slightly above and must be the proper width A 4 65 ENGINE 8 Clean all filings from the area with hot soapy water rinse and 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 La
41. be disassembled drained cleaned properly filled and Brake caliper Brake disk bled after reassembly Never use solvents on internal brake components Use only clean or new brake fluid for cleaning Brake pad wear limit brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury 6 Keep fluid level in the master cylinder reservoir to the e FIRST AID FOR BRAKE FLUID GETTING indicated level inside reservoir INTO THE EYES Use DOT 3 or DOTA Brake Fluid Flush with water for 15 minutes and get immediate medical attention 1 Visual inspects the junction and line locked fluid leaking NOTE When bleeding the brakes or replacing the 2 Turn handle bar full right and full left to inspect brake hose fluid always start with the furthest caliper from the whether contact movement parts master cylinder 3 Press the front fork by handlebar to inspect brake hose A CAUTION whether interferes other parts 4 Remove front brake calipers Do not apply the brake lever Always wear safety glasses when removing the brake calipers 6 148 CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces This procedure should be used to change fluid or bleed brak
42. care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 Loosen pad both support screw 2 3 turns 3 Push caliper piston into caliper bore slowly Remove the upper and lower caliper mounting bolts and remove the caliper from the front wheel NOTE When removing caliper use care not to damage brake line Support caliper so to avoid kinking or bending brake line 4 Push mounting bracket inward and slip outer brake pad past edge Then remove inner pad FRONT BRAKE CALIPER NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required PAD INSPECTION 1 Measure the thickness of the pad material Replace pads if worn beyond the service limit Brake pad wear limit Front Brake Pad Thickness New 9 mm Service Limit 5mm PAD ASSEMBLY INSTALLATION 1 Lubricate mounting bracket pins with a light film of grease and install rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other 6 151 Front Wheel Nut Torque 55 Nm 40 ft Ibs 5 Slowly pump the brake pedal until pressure has been built up Maintain enough of brake fluid in the reservoir to prevent air from entering
43. 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 Rock cylinder forward and backward and lift it from the crankcase supporting piston and connecting rod Support piston with Piston Support Block 4 68 ENGINE CAM CHAIN FOLLOWER TENSIONER BLADES 1 Remove bolt securing tensioner blade to crankcase A CAUTION Do not expand the ring more than the amount necessary to remove it from the piston or the ring may break 2 Remove blades and inspect for cracks wear or damage By hand Placing both thumbs as shown spread the ring PISTON REMOVAL open and pushes up on the opposite side Use care to not 1 Remove cir clip Note that opening for cir clip access is on scratch the ring lands the exhaust side 5 Repeat procedure for second ring 2 Remove piston cir clip and push piston pin out of piston If 6 The oil control ring is a three piece design consisting of a necessary heat the crown of the piston s ightly with a propane and bottom steel rail and a center expander section torch Remove the top rail first followed by the bottom rail and expander CAUTION Do not apply heat to piston rings The ring may CYLINDER INSPECTION lose radial tension 1 Remove all gasket material from the cylinder sealing surfaces 2 Inspect the top of the cylinder for warp gage using a
44. default values will be used in case of pressure sensor mal function Cyl1AFLCFilteredMAP MANIFOLD PRESSURE READINGS This refers to the actual measuring values from the pressure sensor ColdCyl1VEFactorldle IDLE MODE VOLUMETRIC EFFICIENCY COEFFICIENT This refers to the BPW correction value according to different temperature in idle condition ColdCyl1VEFactorRun RUN MODE VOLUMETRIC EFFICIENCY COEFFICIENT This refers to the BPW correction value according to different temperature in operation TPSLean INITIAL LEANING VALUE OF THROTTLE POSITION This refers to the learning value at zero closed throttle position TPS_AD ANALOG TO DIGITAL OF THROTTLE POSITION SENSOR This refers to the digitized value according changes of throttle position The value will be 255 if the sensor or its circuitry is short to power and will be 0 when open or short to ground AFRChokeldle IDLE MODE AFR CHOKE This is a simulation to the idle choke function similar to carburetor system AFRChokeRun RUN MODE AFR CHOKE This is a simulation to the operation choke function similar to carburetor system AFRChokeDecayCounter AFR CHOKE COUNTER This refers to the time after the engine start It s a calibration value according to different engine temperature PreBLM PRE BLOCK LEAN MEMORY It refers to the automotive correction with the learning function at vehicle off line if the engine variance over certain level SAldleDyn IDLE SPARK A
45. ee Ae Cea dte e oe Ra ba 5 25 MANIFOLD PRESSURE Qt vores icri Ee 5 25 THROTTLE OPENING PERCENT 4252222225 SS RE TES EI HE at eee kee eee 5 25 ENGINE TEMPERATURE out eet ratem aen de tn d Rete abe eto REE ca ce ao nes eh 5 25 INTAKE AIR DE WIPER IRE 13 3352599 50 b re pud a odi ri dive tone di eod pe use 5 26 SEARIK ANGEE eat pees boone eet quide dos desu eats 5 26 FEOW ADJUSTMENT COEFFICIENT Fade gc e d eye dak telo Doe ro eis das 5 26 IDDE AIR CONTROL VALVE OPENING o OO lek peated va tay orb ws eat ES 5 26 BASE PIESE WIDTH ia oem ded 1203 both at iot adr delice tats P dodi Pei en dat od mh FORE dope 5 26 OZ SENSOR VOLTAGE i a S Bor soe do bartender facite 5 27 BATTERY VOLTAGE dita addin oe be as te ouo amos wane ude Uae a de tors 5 27 BAROMETRIC PRESSURE nip m T dedu a betaine deseo enna ween eee 5 27 CEO SE OOF CONTR OL ate shear esa Ant eo ol eae ee kanes alae od deeb 5 27 BLOCK LEAN MEMOR F batis Se adie elds 5 27 ELECTRONIC FUEL INJECTION BEOCK LEAN MEMORY 34 eds cd onse es esie e oer
46. eire Sem dont OI PIRE oe DEC RP E IH PELO 4 30 PISTON RING INSTALLED GAP o deat euch irs ubt gol ue ede n puo ee B tte ee apta diste dinde eee s 4 31 ALTERATOR STATOR OIL PUMP EXPLODED VIEW RR eee 4 32 STARTERDRIVE GEAR 1 5 eee eee 4 32 FEYWHEEL REMOVAL INSPECTION Oe a eR ou hod Meds to ee Bak du a dci d 4 34 ONE WAY CLUTCH REMOVAL INSPECTION Gis a Lee bur Red era xk 4 33 OIL PUMP DRIVE SPROCKET REMOVAL INSPECTION 0 00000 ee 4 34 SEI simu enh aie ti gach SR Bae tiie 4 35 GRANKCASE DISASSEMBLY ebur DDR eee 4 36 CRANKCASE SEPARATION AND CAM CHAIN REMOVAL 0000 00 cee 4 36 CRANKSHAFT REMOVAL t the te hea ale Sh estate woe B arae esie d 4 37 CRANKSHAFT amp OIL CHAIN SPROKET INSPECTION 0 02222 4 37 OIRSANKCASETZINSPEGTION re RRCERE PEU 0 IR 4 38 CRANCASE OIL STRAINER 1 5 hrs 4 38 BEARING SEALINSTALPEALTIODU4 v5 rb eet ar uet Sheen uxo ubt 4 38 ENGINE RESASSEMBLEY RT APR a ede erede Os Re Ewe eee Lewes 4 39 CANKSHAFT AND CAM OIL CHAIN I
47. engine is cold Roe Check engine idle speed Eo Le Replace if necessary ly Replace brake pads if necessary lyin Replace brake pads if necessary O Replace brake hose if necessary Replace if necessary nomme Replace if necessary Check air pressure Correct if necessary e mem Replace if necessary and apply with grease lt lt S SN S S ES S S S S S Sy S S gt S 5 5 Side stand pivots Change brake switches cable Lubricate the throttle grip and cable and switches Adjust headlight beam 2 15 o i dt MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE FRAME NUTS BOLTS AND FASTENER INSPECTION Periodically inspect the torque of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views in each manual section when available for torque values of fasteners before using standard torque STANDARD FASTENER TO
48. etc 7 Perform steps 1 to 3 when checking the wire harness continuity 1 Disconnect connector 8 As a quick remedy use a contact revitalizer available at 2 Check connector moisture Dry each terminal with an air most part stores blower 3 Check connector stains rust Connect and disconnect the CHECK THE SWITCH terminals several times Use a multi meter to check the terminals for continuity If the continuity is faulty at any point replace the switch 4 Check connector leads looseness Bend up the pin 1 and connect the terminals 5 Click two terminal together going to check connector terminals 1 Set the multi meter to 0 before starting the test 2 The pocket tester should be set to the 1 range when testing 6 Check wires continuity by multi meter If there is no the switch for continuity continuity clean the terminals 3 Turn the switch on and off a few times when checking it 7 165 ELECTRICAL CHECK A SWITCH SHOWN IN THE MANUAL HEADLIGHT SWITCH The terminal connections for switches main switch handlebar Headlight switch include light and beam switch which light switch engine stop switch light switch etc are shown in chart similar to the one on the right This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position indicates terminals with continuity The example chart shows that D There is
49. following parts as required Storage box Left and Right Side Covers Rear shocks 13 Remove exhaust pipe there are 3 bolt on swing arm and 2 bolts on cylinder 14 Lift up the rear tire before remove engine mount 15 Loosen the strap which between throttle body and air cleaner intake boot Insert a clean shop towel into the carburetor flange to prevent dirt from entering the intake port 17 Remove Starter motor ground cable Note ground cable location Mark positive cable mounting location 18 Remove engine to chassis ground cable 19 Remove all engine mount nuts and shafts 20 Remove engine with rear wheel as an assembly toward rear side of frame 4 55 ENGINE ENGINE INSTALLATION NOTE After the engine is installed in the frame review this checklist and perform all steps that apply WARNING Always wear safety glasses and proper shop clothing when performing the procedures in this manual Failing to do so may lead to possible injury or death General Items Install previously removed components using new gaskets seals and fasteners where applicable Perform regular checks on fluid levels controls and all important areas on the vehicle as outlined in the daily pre ride inspection checklist refer to Chapter 2 CVT System Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing Inspect clutch rol
50. freeplay is achieved at the throttle pedal NOTE While adjusting lightly pull the throttle lever 4 Tighten the lock nut 5 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position WARNING After adjusting the throttle cable free play start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change 6 161 ELECTRICAL CHAPTER 7 GENERAL INFORMATION eee o oy bee Sed ER dE ates ene 7 3 ELECTRICAL ST STEM SERVICE NO VES e the He CR d d e et LITE Eon let P tetro 1 3 WIRE COLOR LETTER EISE E ea abe PUR E e desee meet i eai be rds 1 3 SWITCH SERVICE QU DS RR UP CA ACTU D NOR AUS acu Up do E 7 4 CHECK ATE CONNECTION din et Gia bt etry cS vio opem e ES cett doit ou E ient iod d tesi eade 7 4 CHECK THE 1 2 2 treet eu Roe man decer e uen Ds eo M aab e 1x DC g cde E ob Lo 1 4 CHECK A SWITCH SHOWN IN THE MANUAL s esses 1 5 KEYLMAIN auam T tdeo eben dte Cue ihe ed etc dread e dame ind ee 1 5 HEADHRA TE aes ee 7 5 eS T ETE 7 5 BEAN OVO ha ob oe echa bade Ebbene beider ies dS eds este dd bet a 1 5 xav dara seit
51. ground and remove the left hand rear tire WARNING FUEL INJECTOR OPERATION OVERVIEW The fuel injector mount into the cylinder head and the fuel rail Be sure the vehicle is secure before beginning this attaches to them at the top end Replaceable O rings on both Serious injury may result if machine tips or falls service procedure ends of injector prevent external fuel leaks and also 2 Remove seat insulate it from heat and vibration 3 Remove storage box 4 Remove right side service panel Fuel Injector 5 Remove right side footwall panel 6 Remove exhaust pipe and silencer dump 7 Drain all engine oil When the key switch is on the fuel rail is pressurized and 8 Remove 10 bolts retain on right crankcase voltage is present at the injector At the proper instant the 9 Remove right crank cover which with stator and CPS ECU completes the ground circuit energizing the injector 5 108 ELECTRONIC FUEL INJECTION If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows Injector leakage is very unlikely but in rare instances it can be internal past the tip of the valve needle or external weeping around the injector body The loss of system pressure from the leakage can cause hot restart problems and longer cranking times Injector problems due to dirt or clogging are unlike
52. mm 4 90 ENGINE STATOR HOUSING INSTALLATION NOTE The stator flywheel starter drive and stator can be serviced with the engine in the frame 1 Apply a light amount of Crankcase Sealant to the mounting surface and install a new gasket Install the dowel pins 2 Seal stator wire grommet with Crankcase Sealant 3 Install the housing Torque bolts in sequence to specification Stator Cover Bolt Torque 8 Nm 6 ft Ibs SPARK PLUG FOULING TROUBLESHOOTING Spark plug cap loose or faulty Choke cable adjustment or plunger cable sticking Foreign material on choke plunger seat or plunger Incorrect spark plug heat range or gap Carburetor inlet needle and seat worn Jet needle and or needle jet worn or improperly 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 system calibrated incorrectly or components worn miss adjusted Fuel quality poor old or octane too high Low compression O Restricted exhaust Weak ignition loose coil ground faulty coil or stator Restricted air filter main or pre cleaner or breather system Improperly assembled air intake system Restricted engine breather system contaminated with fuel O Restricted crankcase vent 4 91 ENGINE TROUBLESHOOTING Engine Turn
53. roller bearings oil pressure readings hot or cold Will be very low Low oil pressure is not an indication of an oil delivery problem 1 Remove center plug from the stator housing on the crankcase 2 Insert an M6x8 1 00 oil pressure gauge adaptor into the crankcase and attach a low pressure gauge 0 10 0 70 3 Start engine and allow it to reach operating temperature while monitoring gauge indicator Any pressure above zero is an indication of good oil flow 4 56 ENGINE CAM CHAIN TENSIONER REMOVAL 1 Remove oil fill cap from the stator housing and valve cover To position crankshaft at Top Dead Center TDC on compression stroke 2 Rotate engine slowly in the direction of rotation watching intake valves open and start to close 3 Continue to rotate engine slowly while watching camshaft sprocket marks and the mark in the timing inspection hole Single TDC Mark Aligned TOC Mark 7 Replace entire tensioner assembly if any part is worn or damaged CAM CHAIN TENSIONER INSPECTION 4 Align single TDC mark on flywheel with in the inspection 1 Allow cam chain tensioner plunger to extend outward to the hole and the cam sprocket pin facing upward aligned with end of its travel Inspect tensioner the camshaft to crankshaft centerline A and B plunger for wear or damage NOTE The sprocket marks align with gasket surface the cam lobes should be pointing down and the valves should have cl
54. small hole gauge and a micrometer Measure in two directions front to back and side to side CYLINDER HEAD RECONDITIONING NOTE Servicing the valve guides and valve seats requires special tools and a thorough knowledge of reconditioning techniques Follow the instructions provided in the Valve Seat Reconditioning Kit 4 64 ENGINE 4 Inspect the cut area of the seat If the contact area is less CAUTION than 75 of the circumference of the seat rotate the pilot Wear eye protection when performing cylinder head 180 and make another light cut service Valve guide replacement will require heating If the cutter now contacts the uncut portion of the seat check of the cylinder head Wear gloves to prevent burns the pilot Look for burrs nicks or run out If the pilot is bent it must be replaced Follow the manufacturers instructions provided with the valve If the contact area of the cutter is in the same place the valve seat cutters in the Valve Seat Reconditioning Kit Abrasive guide is distorted from improper installation and must be stone seat reconditioning equipment can also be used Keep replaced Be sure the cylinder head is at the proper temperature valves in order with their respective seat and replace the guide NOTE Valve seat width and point of contact on the Ifthe contact area of the initial cut is greater than 75 valve face is very important for proper sealing The continue to cut the seat until all pits
55. straight edge and feeler gauge 3 Remove the compression rings starting with the top ring Using piston ring pliers Carefully expand ring and lift it off the piston 4 Cylinder Warp 0 05 mm MAX 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 4 69 ENGINE Cylinder Bore Gauge 3 Inspect cylinder for wear scratches or damage 4 Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge Measure in two different directions front to back and side to side on three different levels 10mm down from top in the middle and 0 from bottom 10mm Down From Top of Cylinder 10mm Up From Bottom 5 Record measurements If cylinder is tapered or out of round beyond specification the cylinder must be honed bored or replaced CYLINDER HONE SELECTION HONING PROCEDURE 4 CAUTION A hone which will straighten as well as remove material from the cylinder is very important Using a common spring loaded glaze breaker for honing is not advised Polaris recommends using a rigid hone or arbor honing 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 DEGLAZE A finished cylinder should have a crosshatch patt
56. the spring replace the clutch cover Driven Compression Spring Service Limit 130 mm 51 2 4 Remove the outer guide pin cover by turning and pulling up on the cover Replace the 2 o rings 1 Secure the assembly in a clamping device To access driven spring mark and remove the outer sheave retaining nut Remove the friction pad assembly and driven spring N p m Cam LUE Groove 2 Inspect the condition of the clutch drum Measure the inside diameter of the cover at 90 degree intervals using a caliper 5 Remove the rollers and pins using a needle nose pliers Inspect the condition and diameter of the drum lining If either and inspect all components Replace if any damage or excess the measurements or the lining indicates excessive wear wear is found Replace the o rings and seals anytime the replace the clutch cover driven is apart Cuter Sheave Assembly 3 36 CVT SYSTEM 6 To replace the friction shoes remove the e clips that retain the backing plate Use a suitable tool to remove and install the springs connecting the shoes using care not to over stretch the springs more than is necessary Apply loctite 272 aoMm DRIVEN CLUTCH ASSEMBLY 1 Insert new seals into the outer sheave assembly Fill the outer sheave cavity with fresh grease and slide onto the inner NOTE Outer sheave retaining nut replacement is sheave shaft Align and insert the roller pin assem
57. the tank The throttle position sensor TPS is a non serviceable item If Fuel Pressure Regulator it is faulty it must be replaced It can be tested using the following method LE Went NOTE Before proceeding with any of the following measurements or tests it s extremely important to Fuel Inlet from Fuel Pump m Q build up Remove intake boot and inspect verify the throttle body bore is clean of any carbon throttle body bore If required remove the throttle Discharge to Injecotr body and clean the bore using carburetor cleaner Overflow to Fuel Tank ENGINE COOLANT TEMPERATURE SENSOR 5 111 ELECTRONIC FUEL INJECTION 1 Disconnect the vehicle harness from the TPS 3 Connect the red voltmeter test probe in black white port A and black voltmeter test probe in the blue port C and set the meter to read VDC 4 The volt value reading should be around 5V 5 Connect the red voltmeter test probe in red green port and black voltmeter test probe in the blue port C and set the meter to read VDC 6 Move the throttle open and closed slowly while reading the display The voltage should increase and 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 sensor did not function correctly replace it TPS REPLACEMENT NO
58. vary in length from 1 5 8 milliseconds depending on the clogging has been a problem speed and load requirements of the engine FUEL INJECTOR TEST FUEL INJECTOR SERVICE The fuel injectors are non serviceable If fault code diagnosis Injector problems typically fall into three general categories Indicates a problem with injector test the resistance of fuel electrical dirty clogged or leakage An electrical problem injector s by measuring the harness pin terminals usually causes one or both of the injectors to stop functioning Ground Several methods used to check if injectors are power Input operating With the engine running at idle feel for operational vibration indicating that they are opening and closing When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration NOTE Do not apply voltage directly to the fuel injector s Excessive voltage will burn out the Fuel Injector Resistance Specification injector s Do not ground the injector s with the 13 8 15 20 25 C 77 ignition on Injector wills open turn on if relay is energized FUEL PUMP 5 109 ELECTRONIC FUEL INJECTION FUEL INJECTOR REPLACEMENT When the key switch is turned to ON
59. wire may burn 4 If start motor does not turn or has gride noise repair or replace the start motor STARTER MOTOR SERVICE NOTE Some starter motors may not be serviceable Replacement of entire assembly may be required Check the parts manual for replacement part information 1 Disconnect the negative battery cable and starter motor harness Remove the 2 bolts from the starter and pull it from the engine 2 Remove the 2 main screws The starter motor is a complete service part If it is determined 3 Remove magnet housing while holding the armature and that the starter motor is the failed part replace as needed See the parts manual for correct part numbers brush holder section together 7 175 ELECTRICAL STARTER BRUSH INSPECTION 2 Using a digital multi tester measure the resistance between REPLACEMENT each of the communicator segments The reading should be 1 Release the brush coil spring away 3 ohms or less 2 Push the armature out of case Recoil Spring Armature coil resistance Continuity 3 Using an Ohmmeter measure the resistance between the Less 3Qat 20 C 68 F cable terminal and the insulated brush The reading should be 3 ohms or less Measure the resistance between the cable 4 Measure the resistance between each communicator terminal and brush housing Make sure the brush is not segment and the armature shaft The reading should be infinite touching the cas
60. 4 If the pump did not activate disconnect the harness Mounted on the throttle body and operated directly off the end connector from fuel pump Connect a DC voltmeter across of the throttle shaft the TPS works like rheostat varying the terminals A and B in the plug on the vehicle harness side voltage signal to the ECU in direct correlation to the angle of Turn on the key switch and observe voltage to ensure a the throttle plate This signal 15 processed by the ECU and minimum of 10 volts is present compared to the internal pre programmed maps to determine NOTE If the voltage was below 10 VDC test the the required fuel and ignition settings for the amount of engine battery ignition switch relay s wiring harness and load ECU FUEL PRESSURE REGULATOR OPERATION OVERVIEW The fuel pressure regulator maintains the required operating system pressure of 3 0 bar A rubber fiber diaphragm divides the regulator into two separate sections the fuel chamber and the pressure regulating chamber The pressure regulating spring presses against the valve holder part of the diaphragm pressing the valve 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 exceeds the desired top pressure the valve opens relieving the excess pressure TPS TEST PROCEDURE returning the excess fuel back to
61. 52451 12 5 2600 9047 204 10 46 8 9 1 l4 D 3524511 125 2 78 171 _ 9247 20 4 10 16 8 0 l 914 0 3524 51 12 5 2 89 171 92 47 2 4 10 16 8 0 l 91 4 D 3524 5 12 5 3 04 171 9247 20 4 10 L6 8 0 1 51 4 0 3524 51 12 5 3 11 171 9247 204 10 16 8 4 L 91 4 3524 51 12 5 3 22 171 92 47 20 4 10 16 8 0 91 4 D 352451 12 5 3 22 171 92 20 4 10 16 8 0 1 914 0 352451 12 5 5 133 ELECTRONIC FUEL INJECTION APPENDIX UPDATE ECU PROGRAM 1 Ensure your computer has update program WT CU 7 POS Book small Enem m ie 152 SS f 10701 5129 1004260110 519 a zm 10701 2129 1004260110 819 aE AAR TF EMS Download Tool Bea LITEON Automotive Corp MSHA ee ies pc Sf T 2 Connect RS232 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 crank ignition engine turning 5 Select update program on computer screen Click twice then screen shoes as follow 2 eK FELT ie EMS Download Tool c ub E o dibus arming ool will update ECM to 10701 5129 1004260110 19 Please Check connection engine state stall and power carefully Elapsed time sec Please Click Download ECU count 5 134 ELECTRONIC FUEL INJECTION 6 Click configuration bu
62. 6 Nm 3 6 m kg 25 ft Ib 4 To adjust the suspension use the adjustment cam located Then LOOSEN the lower steering ring nut 1 4 turn near the bottom of the shock 8 Tighten the upper lock ring nut to 90Nm Adjustment 1 9 Ensure can lightly turn the handlebar left and right to end Gam Sb WARNING Do not over tighten the lower steering ring nut FRONT FORK Salting setting Highest ee Lowest Softest L x d 1 Stand scooter on a level surface 2 Inspect front fork inner tube damage crack or oil leakage at 5 Rotate the adjustment cam clockwise to increase spring oil seal If necessary replace it tension or counter clockwise to decrease spring tension 6 Each notch of the adjustment will add 6 8 more preload to the spring over the primary position 2 28 MAINTENANCE BRAKE FLUID INSPECTION BRAKE SYSTEM BRAKE PAD DISC INSPECTION Always check the brake lever travel and inspect the brake fluid 1 Check the brake pads for wear damage or looseness reservoir level before each operation If the fluid level is low add DOT 4 brake fluid only Brake fluid should be changed every two years The fluid should also be changed anytime the fluid becomes contaminated the fluid level is below the minimum level or if the type and brand of the fluid in the reservoir is unknown 1 Position the scooter a level surface 2 View the brake fluid level in the res
63. 9 ELECTRICAL Intermittent power supply Starter motor is working but engine does not The connector of the charging system becomes crank loose Poor starter motor pinion Poor connection of the battery cable The starter motor runs in reverse direction Poor connection or short circuit of the Poor battery discharging system Poor connection or short circuit of the power generation system Charging system does not operate properly Burnt fuse Poor contact open or short circuit Regulator Rectifier malfunctions e AC Generator malfunctions Engine does not 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 Current leakage in the spark plug Incorrect ignition timing AC Generator malfunctions Improper installation of CPS ECU malfunctions Weak starter motor Poor charging system The battery is not fully charged Poor connection in the windings The motor gear is jammed by foreign material 7 190 ELECTRICAL R LEVEL ASS Y SIGNAL WARNER PARKING LIGHT CONTROLLER RECT amp REGU PETROL GAUGE ASS Y SPARK PLUG 2 X cry IGNITION COIL FUSE BOX ASS Y VOLT ACCESSORY OUTLET Bril GY GIy R Y2 FUSH 10A 2v aW F R SIGNAL REFLECTOR ve 8 POSITION BULBILE
64. AIL LIGHT 5 Check the voltage 12 V of the G Y and B terminals on the taillight bulb socket and foot brake pedal sensor connector 6 If the wiring circuit from the main switch to the bulb socket connector is faulty repair it COOLING SYSTEM IF THE FAN MOTOR DOES NOT TURNING FOLLOWING PROCEDURE TO CHECKING Fuse Check the fuse main continuity If broken replace the fuse Battery Check the battery condition The open circuit voltage should be 12 8 V or more at 20 68 F Switch Refer to KEY MAIN SWITCH at above If main switch isn t continuity replace the main switch RADIATOR FAN MOTOR 1 Disconnect the radiator fan motor coupler 2 Connect the battery 12 V as shown 3 Check the operation of the radiator fan motor If the fan does not run replace it THERMO SWITCH 1 Remove the thermo switch 3 from the radiator 2 Connect the multi meter 1 to the thermo switch 3 Immerse the thermo switch into hot water 4 Check the thermo switch for continuity While heating the coolant use a thermometer to record the temperatures 158 F 176 5 4 Note A The thermo switch circuit is closed B The thermo switch circuit is open 7 188 ELECTRICAL Step Heating Trouble Shooting Water temperature Continuity Less than 80 3 C No voltage 176 5 4 F More than 80 3 C Battery discharged The cable disconnected
65. AL BATTERY CHECK 1 Check the date label on the side of the battery to calculate CONVENTIONAL BATTERY Removable Es when to check voltage The battery should be checked every 3 hiui E Top View E Ca A fully charged battery should be 12 8 or higher 3 If voltage is below 12 8 V battery will need to be months 2 Check the voltage with a voltmeter or multi meter Electrolyte Level recharged Indicator Side View TE TF STE P 1 Examine date to calculate when to SEALED LOW MAINTENANCE BATTERY Check voltage with Caps EE or multimeter Non removable HE Fully charged is 12 8 higher sealed top EU I STEP 3 HESSE geret ttc amm If voltage is below 12 8 volt a refresh charge may be required New Batteries Batteries must be fully charged before use or battery life can be reduced by 10 30 of full potential No Electrolyte o Charge battery for 3 5 hours using a variable rate charger Level Indicator i a Do not use alternator to charge new battery high rate battery charger can cause battery damage Low Maintenance batteries are permanently sealed at the time of manufacture The use of lead calcium and AGM Side View technology instead of lead antimony allows the battery acid to be fully absorbed For this reason a Low Maintenance batte
66. AY ADJUSIMENT 22320055 Rate Geen eee Ate eee ee ERR eee ee keen 2 AR CLUBANER SERVICE an esten ER d are Le S REG En SS wade da hang e 2 8 ENGINE aAA E RU ba qi epu Eu 2 8 ENGINE OIL EEVEBL S ir thu mdr DO dicito TUE Sd Ln PR I cb Eee t ird Dad eie e p do di ie e 2 8 ENGINE DIE AND FILTER SERVICE isa Pate ain Erase hoe eek REIS TEE ded ande ds 2 9 ENGINE BREATHER POSE INSPECTION RARE GR RACINE Up PUE Gee Abas ed qb dep de s 2 9 ENGINEMOUNTTEOGABDIODN s i utitur us eet ocior ete Pie i dud SS 24S Wr OUS 2 10 TRANSMISSION CASE RC at 2 10 TRANSMISSION LUBRICATION Ato IEEE IE qr Inepte aao nb SER oboe soe diens 2 10 TRANSMISSION LUBRICANT 2 22 ele hh hr nn 2 10 COOLING S YS TEM 3 533 bie x ux CSS tweaks oes CRUS a Rd ete dU XC RA Ra ee ees 2 11 COOLING SYSTEM OVERVIEW mde Eb actae dp dc e or dle RO ecd Hh dor debt etes 2 11 IU dps oe a eas dt antes eet ee ee e ee CB ee ae oe eee 2 11 COOLANT STRENGTH IXP Eos icc een eta dtc od eee aise
67. C FUEL INJECTION de EET Ts ue dus T Nas B Hal Histor Liteon Group IE L The Lite On Group is one of Taiwan s leading IT manufacturers Many of products have heen place Globally The Group has approximately 30 thousand employees and annual turnover of aver USS 5 2 ENGINE DATA Two 2 pages of Engine running parameters will be shown under Manufacturer category Besides engine status will be shown on the bottom of screen including Stall Crank Idle Run PEEn Sequential Cut CLCEn ze Oami COR B mlar Hia EH Reco Engine Data rpm Fuelz DEEn 90 00 kPa Fuel1 2 SFCOEn TPS Percent 3 5 percent MisSyneCnt Toil Physical 121 degt EngRun Timer degt percent CyITAFLCMult iAcCCommbDuty Cyli1CcmndP Vy O2Valt Baro BLM Fuel BLMEn TPS MIL Fuel AEEn 4936 27 13 1 102 0 00 T On Off factor percent ms mv V count flag flag Engine Status flags ie ee UO ea Click to next Page ENGINE PARAMETER DEFINITION RPM Engine Running Speed Every complete cycle of a 4 stroke engine requires 2 revolutions including 4 processes of intake compress ignition and 5 121 ELECTRONIC FUEL INJECTION
68. CAMSHAFT INSTALLATION TIMING METHOD 1 Refer to page 48 Stator housing is removed NOTE Use this method only when the stator is removed and camshaft drive sprocket is in view 1 Rotate the crankshaft until the keyway on the crankshaft is pointed keyway facing upward 2 Align the cam chain onto the teeth of the crankshaft sprocket Use a wire to pull the chain up through the cylinder and cylinder head and to hold it in place Secure the chain 3 Apply grease or engine assembly lubricant to the camshaft main journals and cam lobes Lubricate automatic compression release mechanism with clean engine oil 4 Orientate the camshaft with the lobes facing downward 5 Disconnect the wire securing the cam chain and loop the 1 Rotate the crankshaft until the single TDC timing mark Top Dead Center on the flywheel is view in the center of the timing inspection window Be sure to use the single TDC mark when installing the cam Do not use any advance marks if evident cam chain over the sprocket while verifying the cam is inserted 2 Align the cam chain onto the teeth of the cam chain drive with the alignment marks parallel to the gasket surface N 6 Check all cam timing marks to verify proper cam timing and install the rocker arm assembly Torque the cylinder stud nuts to specification NOTE Do not rotate engine until tensioner and rocker assembly is installed 7 Install the tensioner and rocker a
69. DVI2ZV 1W CT HI BULB HWI2N oo SS es LLL Ll EE Pel d E POSITION BULAILE HEAD LIGHT ASS Y 3 F L SIGNAL REFLECTOR J TERMINALS PIN PINT W PIN 2 PIN 10 0G 3 PIX IUW PIN 12 OS PIN YAN ow B SENSOR Bril GIY HORN L LEVEL ASS Y Switch Lamp Storage Box Br L L R R2 Switch Main Sensor Intake Air AT Relay EFI tet Lamp Storage Box ensor Uz Valve Idle Air Controller Switch Topple Ove H Sensor Engine Coolant ECT Fuel Pump STARTER RELAY Fuel Injector BATTERY 12V Electroni Control Unit ECU pooooooop 50000000001 TERMINALS PIN PIN 1 B L PIX 2 CR 4 WA PIA RA 5 5 vw RIO ARW 1 SUE 06 4 DG ILS R R SIGNAL REFLECTOR LICENSE BULB 12V 210 W SIGNAL REFLECTOR Wh Ilo DG P UR V RIBeWw IDEE VE L c EAA Bl YIR UW YIR Y B Bev UR DB El T BW DB DG Drawing Name 107 oIQI EO L SWITCH ASS Y 3210062U 001 00 AS31 34 62E R
70. ERNWALE so ROO d Gad c UE de ouem Scio ud de aua Ede duas Gut 2 4 GENERAL VEHICLE INSPECTION AND 2 5 FRAME NUTS BOLTS AND 5 5 5 hr 2 5 STANDARD TORQUE SPECIFICATION 2r rr tdm Rt ete Se REOR feb EL ole eO Rob 2 5 STANDARD EASTENER TORGUES rense EORUM ACRAS US RS d 9 race s ee tae EC e uS dea n be e os 2 5 VAIN TENANCE QUICISISEFBERENGE 3224 514 t ERAT CEPI DS dut Tode qve dd ee en edad entes tus 2 5 PREPARATION FOR REMOVAL PROCEDURES ete ee e depu x qa nCDER TR Ku ewes 2 6 REPLACEMENT PARTS e224 43 eee bosse Seg Sea Seer A a eda aute bea aped cds 2 6 GASKETS Vil SEALS AND O RING hack Rain vue Jas RACER ESI ELA SEES 2 6 FUEL AND INTAKE SYSTEM 3d x a fu nce eee a puta i eae 2 6 SYSTEM 2 an Se m Qa tobe esos ioe he one bea eee ks 2 6 FE INE S ono be oe dut mam EU erp Ipaa 2 6 FUEL PUMP FUEL FILTERS PUMP rrr 2 7 cs ty te eh eh ea utet 2 7 THROTTLEINSPECIION 2 oe bie he bau ae ed e Ee Se tel ids ge eA eee eae 2 7 THROT TEE FREEPL
71. F TY CONVENTIONAL BATTERY CHARGING 1 200 27C 17 10 Route cables so they are tucked away in front and behind battery PROCEDURE 11 Reinstall battery cover and holder strap 1 Remove the battery from the ATV to prevent damage from leaking or spilled acid during charging CAUTION 2 Charge the battery with a charging output no larger than Do not run the engine with the battery disconnected 1 10 of the battery s amp hr rating Charge as needed to raise Electrical components can become damaged 7 186 the specific gravity to 1 270 or greater ELECTRICAL LIGHT SYSTEM IF THE HEADLIGHT AND TAILLIGHT FAIL TO COME ON FOLLOWING PROCEDURE TO CHECKING Fuse p o Position Check the fuse main light system continuity If broken replace the fuse Battery Check the battery condition 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 LO isn t continuity replace the main switch Wire connection Refer to CIRCUIT DIAGRAM to check properly connect the light system If light wires are poor continuity repair the Wires Light Switch Refer to SWITCH SERVICE to check properly connect the 7 If the wiring circuit from main switch to the bulb socket light switch If light switch is poor continuity replace the connector is faulty repair or replace it switch
72. Fuel is extremely flammable and may cause severe burns injury or death from the fuel tank Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors FUEL PUMP OPERATION OVERVIEW An electric fuel pump is used to transfer fuel to the EFI system 1 Remove both inlet and discharge hoses from the fuel pump Fuel Pressure Gauge Kil The pump rate had a minimum 14 4 liters per hour at 3 0 bar 43 5 psi output iN _____FUEL PRESSURE REGULATOR THROTTLE POSITION SENSOR 5 110 ELECTRONIC FUEL INJECTION 2 Connect the pressure hose of the fuel pressure gauge to the FUEL PRESSURE REGULATOR TEST fuel pump discharge cock Refer to the Fuel Pump Test procedure Connect the clear hose into fuel pump inlet and another side to a portable gasoline container or the equipment fuel tank FUEL PRESSURE REGULATOR 3 Turn on the key switch to activate the pump and check the IREPLACEMENT system pressure on the gauge If system pressure of 3 bar 43 5 The pressure regulator is a sealed non serviceable assembly If psi is observed the ignition switch ECU fuel pump and it is faulty the fuel pressure regulator must be replaced pressure regulator are working properly Turn the key switch off and depress the valve button on the tester to relieve the TPS OPERATION OVERVIEW system pressure The throttle position sensor TPS is used to indicate throttle plate angle to the ECU
73. GENERAL INFORMATION SERVICE MANUAL FOREWORD This service manual is designed primarily for use by certified Aeon Master Service Dealer technicians in a properly equipped shop and should be kept available for reference All references to left 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 use and shop procedures in order to perform the work safely and correctly Technicians should read the text and be familiar with service procedures before starting the work Certain procedures require the use of special tools Use only the proper tools as specified MOTOR ww Son a 1 1 GENERAL INFORMATION UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual important information is brought to your attention by the following symbols WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator bystander or person s inspecting or servicing the vehicle CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage NOTE NOTE provides key information by clarifying instructions IMPORTANT
74. MEASUREMENT WEAR INDICATOR 1 Position the vehicle on a level surface Use the center stand 2 Measure tires pressure by gauge and corrected it A WARNING It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately 1 Inspect tire thread depth and side wall surface condition If reach worn limit replace it immediately 1 Thread THEBELE A f LOW CAUTION The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to the total weight including 2 When replacing a tire always use original equipment size cargo rider passenger and accessories and the and type anticipated riding speed Note Patching a punctured tire is not recommended If tire were patched replace it CAUTION WARNING New tires have a relatively low grip on the road surface until they have been slightly worn Operation of an overloaded scooter could cause Therefore approximately 100 km should be traveled tire damage an accident or an injury at normal speed before any high speed riding is NEVER OVERLOAD THE SCOOTER done There is a direction of rotation mark on tire surface Install the tire with the mark pointing in the direction of wheel rotation Rotation Mark d 325kg 71616 252kpa 36psi 280kpa 40ps
75. NAL BATTERY TESTING vaeseds oe epee cc RE o c Ree 7 23 CONVENTIONAL BATTERY OCV OPEN CIRCUIT VOLTAGE 5 1 23 CONVENTIONAL BATTERY SPECIFIC GRAVITY TEST airera nuire i hrs 1 24 CONVENTIONAL BATTERY LOAD TEST sh iode 8293 RES sur iex 1 24 CONVENTIONAL BATTERY OFF SEASON 1 25 CONVENTIONAL BATTERY CHARGING PROCEDURE 0 00 00 hn 1 25 LIGHT SYSTEM scii aem dies ROS ap wed db egere s xx o E ACRI ee eae peat tci IE 7 26 HEADPEIOLNT tos bbc xe tet ta Dd a sheet ete boe 7 26 TAILIGET AND LICENSE dakoh dedos 5 tot de ed Eo Rr ab s 7 26 COOLING SYSTEM 3 2 rx EORR A pues Behe ewe 7 27 REDATOR FAN MOTOR ec imde ty oh eat Mat eani lee Seed ace Bd de dad d 7 27 THERMO STGP 7 27 HEATING ete Md ek hele oe 7 27 OUOOPING STER IUE 7 28 tok Sater eerie 7 28 TROUBLESHOOTING 19 SS SS YR QU E PUEDE PPP GC Kp 7 28 CIRCUIT DIAGRAM pii aede ORE Ue eh Pro apad ee DS RUE ott esos des Bea ed 7 30 7 163 ELECTRICAL GENERAL INFORMATION ELECTRICAL SYSTEM SERVICE NOTE WIRES COLO
76. NGLE CORRECTION The correction 15 made according to the difference to target rpm in idle condition AFCorrectionState EnableCondMet AIR FLOW CORRECTION MODE This refers to the indication of opening of the mode IAT_AD ANALOG TO DIGITAL OF IAT SENSOR This refers to the digitized value according changes of intake air temperature The value will be 0 the sensor or its circuitry is short to ground and will be 255 if open or short to power Toil_ AD ANALOG TO DIGITAL OF CLT SENSOR 5 126 ELECTRONIC FUEL INJECTION This refers to the digitized value according changes of engine temperature The value will be 0 the sensor or its circuitry is short to ground and will be 255 if open or short to power BLMCellNum BLM CELL NUMBER This refers to the memory 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 setup Save to OK to complete Log Config ERP Dusansis Tool SHON im ri utri bon RPM Cyli Toll Physical idx SA CLC Cylt AFLCMult amp CCommbDuty CmndP Vy OP Valk VBall idx BLM Fuel BLMEn 5 idx Malf MIL Fuel AEEn Engine Status System will start logging engine parameters and display recording timer Press Stop Log recording EHON CH
77. NSTALLATION sssssssssesesee eR les 4 39 OIE PUMP AND CHAIN INSTALLATION 2135593 Get 4 40 PISTON BINGJINSTABEBTIODN tnu ok eco cnt ur eee Rer Ee ae deb eee ead om eee hee 4 40 PIS TFONINS TALLA RON 36 23 cared ee ino agr bates tee eee SO hae eh ase eb ar tator geo Se 4 41 TENSIONER BLADE INSTALLATION RADO RM RRPAISS 4 42 dB Br M T ob aac sah ethane vata ds 4 42 CYLINDER HEAD AND CAMSHAFT 1 5 tees 4 43 CAMSHAFT TIMING i22 dui ested PER lied Ghee eee sede ep 4 43 IMPORTANT CAMSHAFT TIMING NOTE 00 000 cee eee 4 43 CAMSHAFT INSTALLATION TIMING METHOD 1 0 000 teens 4 44 CAMSHAFT INSTALLATION TIMING METHOD 2 00 000 cc e rers 4 44 ROCKER SHAFT ARM 1 5 hh 4 45 CAM CHAIN TENSIONER INSTALLATION i 32v 1T39 38 verte terr ee Ee e 4 45 INTAKE VALVE CLEARANCE 5 2 2 tte tees 4 48 EXHAUST VALVE CLEARANCE ADJUSTMENT 0 00 00000 eee eee 4 48 FEY WrEELINSTALLATION pue Sat D End ol Bee eh d ede eee 4 48 SLATER DRIVE ASSEMBLY 4 262 214 reb deat tke wad bees eee Pave ge kip ees bs 4 48 SIATOR FIOCUSING INSTALETION
78. ON GLOSSARY OF TERMS ABDC After bottom dead center ACV Alternating current voltage Alternator Electrical generator producing voltage alternating current ATDC After top dead center BBDC Before bottom dead center BDC Bottom dead center BTDC Before top dead center CC Cubic centimeters Center Distance Distance between center of crankshaft and center of driven clutch shaft Chain Pitch Distance between chain link pins No 35 3 8 or 1 cm Polaris measures chain length in number of pitches CI Cubic inches Clutch Buttons Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch Clutch Offset Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face Clutch Weights Three levers in the drive clutch which relative to their weight profile and engine RPM cause the drive clutch to close and grip the drive belt Crankshaft Run Out Run out or bend of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase Measure at various points especially at PTO CVT Centrifugal Variable Transmission 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 Electrical Open Open circuit An electrical circuit which isn t complete Electric
79. R LETTER LIST Reference the following notes when diagnosing electrical problems B Bak LW Blue White B G Blue Yellow Refer to wiring diagram for stator and electrical Black L G Blue Green component resistance specifications BL Black Blue _ Orange When measuring resistance of a component that has a low resistance value under 10 Ohms remember to subtract B W Black White Pink meter lead resistance from the reading BY Black Yellow Pu Pupe Connect the leads together and record the resistance Br Brown R Rd o The resistance of the component is equal to tested value minus the lead resistance Become familiar with the operation of the meter Be sure leads are in the proper jack for the test being performed i e 10A jack for current readings Refer to the owner s manual included with the meter for more information Voltage amperage and resistance values included in this DB Deep Brown White Black manual are obtained with a Digital Multi meter This meter is acceptable for use when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multi meter reading M etc and the position of the decimal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness or power km ema _ 7 164 ELECTRICAL SWITCH SERVICE CHECK THE CONNECTION Check the connectors for stains rust moisture
80. RPCEATIA RPM Percent Physical AT idx CLC amp CCommbuby Cyl1CmndadPVv O2 Volt VBatt idx Baro Fuel BLMEn MIL Fuel Engine Status Fe Engine Data 0 rom 90 00 kFa 3 8 percent Fust1 OSFCOEn MisSyncent VIYYHMDO men bd Sep 15 ExgrasDadjsDog DOC bri 4 Don Pi vet Page cse E 13sconmnect Connect ki Histor ia Engine Data Fuel2 DEEn Fuel OSFCOEn MiscyncCnt EngRunTimer degc percent factor percant ms v kPa percent flag count flag flag ET est rage 5 127 Sampling Rate Period 3 and the default will be C Program Files KWP TOOLS DiagTool Log if no route being set 4 press after the completion of ELECTRONIC FUEL INJECTION ECU Version This is to show the software hardware and calibration versions and ECU ID vehicle code of the ECU erectus Fi E TE i CURPFORAT B 1 ECU Version Software Version 09091100 lardware Version 00001060 alibration Version 1003150111 ustomer ID 11502 Malf Code This 15 to show the mal function codes occurred to the vehicle ge ENT Direne EHON usi usi T Nuls Jiscripiion Inj Open GND Ign Short GND Cyl Ign Short V 5 128
81. RQUES Thread Size TORQUE ft Ibs in Ibs TORQUE Nm 6 mm bolt and nuts 69 104 in Ibs 8 12 Nm 8 mm bolts and nuts 13 18 ft 108 18 25 Nm 10 mm bolts and nuts 22 29 ft los 30 40 Nm esam _ BR MAINTENANCE QUICK REFERENCE litem Method Frequency lH EN sg change oil oil every 2000km reading on odometer Transmission SAE80W 90 Gear Lubricant Check level Inspect periodically and change lubrication every 4000km reading on odometer Brake fluid DOT 4 Brake Fluid Fill master cylinder As require Change fluid every 2 years reservoir to indicated lever inside reservoir Front and rear Premium All Season Inspect tighten Every 4000km reading on odometer or 6 Suspension fasteners grease months also after washing scooter driving in water More often in severe use 2 16 MAINTENANCE PREPARATION FOR REMOVAL PROCEDURES 1 Remove all dirt mud dust and foreign material before removal and disassembly 2 Use proper tools and cleaning equipment 3 When disassembling the vehicle always keep mated parts together This includes gears cylinder piston and other parts that have been mated through normal wear Mated parts must always be reused or replaced as an assembly 4 During vehicle disassembly clean all parts and place them in trays in the order of disassembly This will speed up assembly and allow for the correct installation of all parts 5 K
82. Re ES 4 20 CYLINDER HEAD INSPECTION ded dedu dicia a ee APRI e qc drame ip d d ade 4 21 CYLINDER HEAD VVABFEINSPEGTION fas UR eoa esc em wundern Noon hee eR Py pce 4 21 CYLINDER HEAD DISASSEMBLY 5 1422 prote PIE HEEL bm ob d her Ua a 4 22 VALVE INSPECTION RIO b Ege cr dad c Yow aaa das Gee Pos booa duda btt 4 22 VALVE SEAT RECONDITONING E S Capi de Oed aed a deste ia 4 23 CYLINDER HEAD RECONDITIONING iR ee UE ER Dee EROR 4 23 CYLINDER HEAD ASSEMBLY 225 0 beeches teva poa ra od pe Brace ero adopt d dcus Eden qo am era 4 25 VAENE SEAEING itti foes penu Seta teeta du Cette xa miU ae apt ce od matar dE iut bec Ed ue Ent 4 26 4 40 ENGINE BOTTOM END DISASSEMBLY 2205425008500 UR eR RR Rr wae oE cua teases 4 27 CYLINDER REMOVAL 152 pp PemIeSe PME I on Pee eee 4 27 CAM CHAIN FOLLOWER TENSIONER 5 2 2 eser rers 4 28 PISTONISEMO ciere nino tad ut bee qu e ac ou Let pado decre C d a dre 4 28 OYLINBEIS INSPEGTIGON 2422200852 S Eod EVER P Ud RP rd obe dum dox mid educated t ap habei iu died 4 28 CYLINDER HONE SELECTION HONING hes 4 29 HONING FODE GLAZE Lc XS RV ENERO toes bs A a are ee eee eae dran d 4 29 PITON INSPECTION 2 doni
83. SWITCH ASS Y GENERATOR 7 191 ELECTRICAL 7 192
84. TCH OPERATION Drive clutch primarily sense engine RPM The major components which controls shifting function are the shift centrifugal weights rollers inside the moveable sheave CVT SYSTEM OVERVIEW Whenever engine RPM 15 increased centrifugal force is created causing the rollers 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 driven clutch If belt speed 15 sufficient centrifugal friction shoes on the driven clutch overcome their return spring pressure and swing outward against the transmission drive hub and the vehicle if in gear begins to move At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves changing the ratio of the drive to driven clutch from low to high DRIVEN CLUTCH OPERATION CVT driven clutches primarily sense torque but also react to RPM applying and retracting the friction shoes according to the forces applied to it from the drive belt while at the same time reacting to the torque at the transmission input shaft If the torque resistance at the transmission input shaft is greater than the load from the drive belt the drive belt is kept at the outer diameter of the driven clutch sheaves low ratio As engine RPM and horsepower increase t
85. TE The correct position of the TPS is established and set at the factory 1 Disconnect TPS harness from throttle body 2 Remove screw from throttle body 4 Replace the TPS sensor ECT OPERATION OVERVIEW Mounted on the cylinder head the engine temperature sensor measures coolant temperature The engine temperature sensor is a Negative Temperature Coefficient NTC type sensor as the temperature increases the resistance decreases IGNITION COIL 5 112 ELECTRONIC FUEL INJECTION Coolant passes through the cylinder and by the sensor probe varying a resistance reading which is relayed to the ECU This signal is processed by the ECU and compared to its programming for determining the fuel and ignition requirements during operation The ECU also uses this signal to determine when to activate the fan during operation If for any reason the engine temperature sensor circuit is interrupted the fan will default to ECT SENSOR TEST A Ground Signal Output To quickly rule out other components and wiring related to the ETS disconnect the harness from the ETS The fan should turn on and should indicate on the instrument cluster This indicates all other components are working properly ECT Resistance Specification 1000044390 25 C 77 F ECT SENSOR REPLACEMENT 1 Drain coolant to level below sensor 2 Disconnect sensor from engine harness 3 Using a wrench remove and repl
86. Thickness New 5 00 mm Service Limit 4 40 mm Note After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed Refer to FRONT WHEEL ADJUSTING AND WHEEL STATIC BALANCE on page 6 5 to adjust rear wheel static balance REAR WHEEL INSTALLATION 1 Clean the wheel hub mating surface and install new disc wheel hub 2 Install new bolts and tighten disc bolts Dy crisscross pattern then torque to 30 Nm Apply Loctite CAUTION Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal 6 145 BRAKE SYSTEM Master Cylinder Master Cylinder Rear Brake LH Disc brake systems are lightweight low maintenance and perform well in the conditions this vehicle will routinely encounter There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life 1 Optional pads are available to suit conditions in your area Select a pad to fit riding style and environment 2 Do not over fill the master cylinder fluid reservoir 3 Make sure the brake pedal returns freely and completely 4 Adjust stop pin on front caliper after pad service 5 Check and adjust mast
87. UM ua iss 5 6 FUEL INJECTOR PUBL RAl O e Od e e aes Dira o qeu ara Cede dn a fs d 5 6 POE GROME aeaa See da a as oe Se Seca a aes 5 6 FUEL PROMP REGULA FOR ioi a iretur Ere Bi wan e ate nsec BES Be eh e oa aae 5 6 TAROT ILE BODY cise tues auth at ad tes Cee ah Peele hes oe ree doti gine 2 AEE 5 7 POSITION SENSOR iPS tances a udis o rice abes ur Tb drop Bane eee 5 7 ENGINE COOLANT TEMPERATURE SENSOR 5 7 IS NEON Rite wwe aaa eee ae 5 7 IDEE CONTROL VALVE abet desto Leeds oe hie ne Li rae aon aet 5 7 ROLLOVER SENSOR LE ETUDES dicus ad 5 7 OZ SEINS OR Kec MTM TETTE 5 7 EUEL TANK Cube bu a 5 8 FUEL TANK EXPLODED VIEW end ees oaths hese on Edible te isdem A dE CER 5 8 FUBLIPEOW CHAR oa Ge cea rne 5 8 EFLINFORMATIOI fii cs Ec See nae eae aioe e be sare ala hee oth 5 9 El OPERALION OVERVIEW 5 eet See Pathe eee do ER barat weet
88. Y COEFFICIANT 0 0 0002 eee 5 29 INITIAL LEANING VALUE OF THROTTLE 5 2 hr 5 29 ANALOG TO DIGITAL OF THROTTLE POSITION eee 5 29 IDEE MOBDEJAAER CHOKE i 2225255544453 son ANI Ie usu aspis adt e dri dieto 5 29 PIN MODE ARR CHOKE rapt BY a ede demas eat Sv nd 5 29 CHOKE COUNTER pick vA qe t ento rA cb ede tex Om MP VPE ee eee 0 29 PRE BLOCK LEAN MEMORY er pP itp de Bored utere edet du buses baa icio 5 29 IDLE SPARK ANGLE CORRECTION wher Battal deb En ded dex end vcn das Ben De i deb roca here ed toe ba 5 29 AIRFLOW CORRECTION 5 vie cre toU I pet qe oman ede le eee eee eee eid 5 29 ANALOG TO DIGITAL OFAJAT SENSOR dhe 5 29 ANALOG TO DIGITAL OF GET 5 5 222 delen acere m eis o e eae dl a ee 5 30 NUMBER loa dep PSU ES ere dae eee eee To oat eb awe UO be pd ui pst ee 5 30 RECORDING OF ENGINE OPERATION 5 cette ees 5 30 BN ONG t atat ticas tos gent EM deta acest ete ES 5 31 MALE CODE Od ADI PD Cm ata dt As Bee
89. a cool place corrosion will occur distilled water if necessary Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater Store the battery either in the machine with the cables NOTE Stored batteries lose their charge at the rate of 7 Route cables so they are tucked away in front and behind 1 per day Recharge to full capacity every 30 to 60 gt battery days during a non use period If the battery is stored 8 Reinstall battery attaching positive red cable first and then the negative black cable Coat terminals and bolt threads with Dielectric Grease 9 Conventional Lead Acid Batteries Only Install clear during the winter months electrolyte will freeze at higher temperatures as the battery discharges The chart below indicates freezing points by specific battery vent tube from vehicle to battery vent gravity WARNING Electrolyte Freezing Points Specific Gravity of Electrolyte Freezing Point 1 265 80 75 Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion Vent should be routed away from frame and body to prevent contact with electrolyte To avoid skin contact with battery electrolyte severe burns could result If electrolyte contacts the vehicle frame corrosion will occur 37 C 35 F i SC SF 110 CB
90. ace the sensor applying a light coating of thread sealant to aid installation 4 Torque the sensor to 20 Nm 15 ft Ibs ECT Retaining Bolt Torque 20 Nm 15 ft Ibs IGNITION OPERATION OVERVIEW The ignition coil is used to provide high voltage to fire the spark plugs When the ignition key is on DC voltage is present in primary side of the ignition coil windings During engine rotation an AC pulse is created within the crankshaft position sensor for each passing tooth on the flywheel 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 The ECU then calculates the time interval between the consecutive pulses and determines when to trigger the voltage spike that induces the voltage from the primary to the secondary coil windings to fire the spark plugs GENERAL TROUBLESHOOTING 5 113 ELECTRONIC FUEL INJECTION IGNITION COIL TEST Using an ohmmeter can test the ignition coil Use the following illustration and specification table to test the ignition coil C D ignition Current Output A 12V Input H Ground 1 Disconnect ignition coil from engine spark plug 2 Connect the red voltmeter test probe in B port and black voltmeter test probe in the D and set the meter to read VDC 3 Start the engine and the volt value should be around 2 5KV 4 Disconnect ignition coil fro
91. adial Limit 3 00mm 1 Place the wheel with disc on a suitable stage Or install back front fork and elevated front end 2 Hold the dial gauge at a right angle against the brake disc 1 Inspect the wheel axle Roll the wheel axle on a flat surface surface Replace if worn or rough movement Discard hardware 3 Mount a dial indicator and measure disc run out Slowly rotate the disc and read total run out on the dial indicator Replace the disc if run out exceeds specifications WARNING Do not attempt to straighten a bent wheel axle Front Brake disc deflection limit 0 30 mm 6 141 4 Visually inspect disc for scoring scratches gouges 4 Place the front wheel on a suitable balancing stand Spin the Replace the disc if any deep scratches are evident front wheel When front wheel stops put a mark 1st at the bottom of the wheel 5 Use a 0 1 micrometer and measure the disc thickness at eight different points around the pad contact surface Replace disc if worn beyond service limit 5 Turn the front wheel 90 shown as left Front Brake Disc Thickness New 4 40 mm Service Limit 4 00 mm FRONT WHEEL HUB ASSEMBLY 1 Install the new wheel bearings and oil seal in the reverse order of disassembly Note Do not apply pressure to the wheel bearing inner race 6 Release the front wheel When the wheel stops put 2nd or balls Pressure should only be applie
92. al Short Short circuit An electrical circuit that is completed before the current reaches the intended load 1 a bare wire touching the chassis End Seals Rubber seals at each end of the crankshaft Engagement RPM Engine RPM at which the drive clutch engages to make contact with the drive belt ft Foot feet Foot Pound Ft lb A force of one pound at the end of a lever one foot in length applied in a rotational direction Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In Ib 12 in Ibs 1 ft Ib kg cm2 Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a rotational direction Itr Liter Ibs in2 Pounds per square inch Left or Right Side Always referred to based on normal operating position of the driver m Meter meters Mag Magneto Magnetic Induction As a conductor coil is moved through a magnetic field a voltage will be generated in the windings Mechanical energy is converted to electrical energy in the stator mi Mile miles GENERAL INFORMATION mm Millimeter Unit of length in the metric system 1 mm approximately 040 Nm Newton meters OD Outside diameter Ohm The unit of electrical resistance opposing current flow 07 Ounce ounces Piston Clearance Total distance between piston and cylinder wall psi
93. ally charged condition or with low electrolyte levels hard crystal sulfa ion will form on the plates reducing the efficiency and service life of the battery NOTE Use a voltmeter or multi meter to test batter voltage OPEN CIRCUIT VOLTAGE State of charge Maintenance Free Low Maintenance 100 75 Charged 13 0V 12 80V 12 50V 12 20V Less than 12 0V At 28 C 50 Charged 25 Charged 0 Charged Less than 11 9V NOTE Subtract 01 from the specific gravity reading at OC SEALED LOW MAINTENANCE BATTERY LOAD TEST CAUTION Whenever removing or reinstalling the battery disconnect the negative black cable first and reinstall the negative cable last NOTE This test can only be performed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly Continue the test for 15 seconds During cranking the observed voltage should not drop below 9 5 volts If the beginning voltage is 12 6 volts or higher and the cranking voltage drops below 9 5 volts during the test replace the battery SEALED LOW MAINTENANCE BATTERY OFF SEASON STORAGE To prevent battery damage during extended periods of non use the following basic battery maintenance items must be performed Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with lots of fresh water after cleaning
94. am assembly and simultaneously lifting the chain 8 Remove each rocker arm shaft using the 10 mm hex bolt that secures the lock plate NOTE Placing the hex bolt in a vise and lightly tapping the rocker assembly with a non marring hammer may be required to pull stuck rocker arm shafts 3 If not removing the cylinder for other service secure the 9 Inspect rocker adjuster screws for wear pitting or damage cam chain with a wire to prevent it from falling into the to threads of the adjuster or locknut Replace all worn or crankcase damaged parts NOTE The end of the adjuster is hardened and cannot be ground or re faced CAMSHAFT REMOVAL AND INSPECTION NOTE Cam chain tensioner must be removed before performing this procedure 1 Remove 4 cylinder head bolts evenly by loosening each one 1 4 turn at a time until loose Tap the rocker assembly with a non marring hammer to loosen the assembly 4 Inspect cam sprocket teeth for wear or damage Replace if necessary Inspect for Areas of Tooth Wear or Damage 4 59 ENGINE 4 60 ENGINE CAMSHAFT INSPECTION 4 Measure camshaft run out 1 Visually inspect each cam lobe and bearing for wear Replace camshaft if camshaft run out of specification chafing or damage CYLINDER HEAD REMOVAL NOTE Cam chain and tensioner must be removed If no crankshaft service is being performed secure cam chain with mechanics wire to avoid chain drop into th
95. anufacturers Many of our products have been ranked in first place globally The Lite On Group has approximately 50 thousand employees and annual turnover of over USS 5 2 billion 2 Press Open File 5 131 ELECTRONIC FUEL INJECTION zi Engine Data Fale Convert 1 Engme Data Los File 2 Dak Log File 3 Select file smd format Sare t file 20 00416 EnzinsDatsLee and pee an 12010016 Engine DatLoz 0001 sd Le 4 Press Convert Read Engine Data File CuPrmgren FilesE WF 20 1003186 EngimeDetalog 0001 smd Convert 1 Engine Log File CProerem TOOLS 20100316 EngrmeLetelog 0001 smd tet 2 EEPROM Data Loz File CuPmgrem F esE WP TOOLS Diag ToolLog20100316 EngiveDataLog O001 smdDEEP txt 5 Press Confirm after transformation completed 5 132 ELECTRONIC FUEL INJECTION ener OR PARAL T Liteon Struma Deta tin NE Erud nde pm Dali DUCI sand The Lite Lin IT manufacti been ranked eis On Group employees z 5 2 billion 2 EEPROM Doi Lg IC PLAE MT TOOLS Da Tool 2200 COLL Er gres Det 6 2 new files smdDE txt and smdDEEP txt will be added to the recorded archive Open smdDE txt
96. ard Cam Timing View through timing inspection hole Position crankshaft at TDC 4 89 ENGINE INTAKE VALVE CLEARANCE ADJUSTMENT 1 Verify cam lobes are pointed down 1 Install flywheel key flywheel washer and nut 2 Insert a 0 1mm feeler gauge between end of intake valve Torque flywheel nut to specification stem and adjuster screw 2 Install oil passage plug onto crankshaft 3 When clearance is correct hold adjuster screw and tighten locknut securely 4 Re check the valve clearance 5 Repeat adjustment procedure if necessary until clearance is correct with locknut secured VALVE CLEARANCE 0 1 mm Flywheel Nut Torque STARTER DRIVE ASSEMBLY 1 Be sure the washer is positioned on the back of the drive gear EXHAUST VALVE CLEARANCE ADJUSTMENT 1 Verify cam lobes are pointed down 2 Insert a 0 12mm feeler gauge between end of exhaust valve stem and adjuster screw 3 Loosen 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 cleans 2 Apply Starter Drive Grease to the drive bushings in cases and all moving surfaces of starter drive gears and 6 Repeat adjustment procedure if necessary until clearance is 5 5 install correct with locknut secured VALVE CLEARANCE 3 Install stator housing and torque bolts to specification 0 12
97. arefully use fast aggressive throttle application to engage clutch Warning Excessive throttle may cause loss of control and scooter overturn Belt slippage from water or snow ingestion into the CVT engine keep in idle speed Using the throttle vary the engine rpm from idle to 3 4 WOT and test for belt slippage Repeat several times as required During this procedure the throttle should not be held at the full position CVT seals should be inspected for damage if repeated leaking occurs CVT SYSTEM DRIVE CLUTCH REMOVAL 7 Remove belt Some fasteners and procedures will vary Refer to the 6 Use two hands to hold the cam plate and the primary sliding appropriate parts manual for proper fasteners and fastener sheave together when removing the primary sliding sheave and placement the cam plate assembly 1 Position the scooter on a level surface Use the center stand This prevents the roller weights from falling out of the assembly WARNING Sliding Sheave Serious injury may result if machine tips or falls Be sure machine is secure before beginning this service procedure 2 Remove seat storage box and LH plastic panel to gain access to the outer clutch cover 3 Remove the inlet dust screw and inlet duct 8 Remove the roller weights from the primary sliding sheave Check the rollers for wear and scoring slide Sheave Outer Sheave Roller Weight Sleeve 4 Remove outer clutches cover scr
98. ately test each leg of the stator by connecting the meter leads to the wires leading from the alternator Yl to Y2 Y1 to Y2 to 8 Alternator Current Output Reading should be no less than 30 40V AC above 2000 RPM on each leg NOTE If one or more of the stator leg output AC voltage varies significantly from the specified value the stator may need to be replaced 7 173 ELECTRICAL Starting circuit Main switch Fuse 15 FA BriL e 2 Side stand switch VOLTAGE DROP TEST The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage drop shown on the meter when testing connections should not exceed 0 1 VDC per connection or component To perform the test place the meter on DC volts and place the meter leads across the connection to be tested Refer to the chart on next page to perform voltage drop tests on the starter system Voltage Drop should not exceed 0 1 DC volts per connection Use the illustration above and procedure below when troubleshooting a No Start condition Rear brake switch 24 brake switch Brake light e lt gt 3 CN Start switch STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter m
99. att_idx BATTERY VOLTAGE The voltage of battery that normally will be range from 13 to 14 5V after engine start Baro BAROMETRIC PRESSURE This refers to the current atmospheric pressure being measured As reference the atmospheric pressure is 101 3kPa at sea level and is 69kPa at altitude of 3250m CLC CLOSE LOOP CONTROL This refers to the air to fuel ratio AFR being controlled around stoichiometry point AFR 14 6 BLM BLOCK LEAN MEMORY The values will be close loop 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 idx THROTTLE POSITION OPENING Throttle position opening is a digitized unit transferred from throttle opening to be used by micro controller It will be zero 0 when ignition key turned on engine not started If the value is not zero then it can be a learning error of throttle position Turn off the ignition key for two 2 seconds and turn on again to get a correct value Malf8 MIL MAL FUNCTION INDICATION LIGHT The MIL will be turned on whenever the EMS component becomes mal functioned during engine operation MIL can also be 5 124 ELECTRONIC FUEL INJECTION used for mal function code reading Fuel2 AEEn ACCELERATION MODE ENABLE It refers to the operation conditions that additional fuel will be supplied to engine combustion so as to obtain better vehicle acceleration F
100. aw Key Off Maximum of 02 DCA 20 mA 1 The break even point of the charging system is the point at ALTERNATOR OUTPUT TEST AC AMP This test measures AC amperage from the alternator CAUTION which the alternator overcomes all system loads lights etc and begins to charge the battery Depending on battery condition and system load the break even point may vary slightly The battery should be fully This test simulates a full load on the alternator Do charged before performing this test 2 Clamp an inductive ammeter or connect an ammeter set to DC amps in series between the negative battery cable and terminal Current Drain Inspection Less Than 9 mA Do not use electric start 3 Connect a tachometer according to manufacturer s instructions 4 With engine off and the key and kill switch in the ON position the ammeter should read negative amps battery discharge Reverse meter leads if a positive reading is indicated 5 Shift transmission into neutral and start the engine If using an ammeter in series start engine with kick start only 6 Turn headlight on high beam and apply the brake light Increase engine RPM while observing ammeter and tachometer 7 Note RPM at which the battery starts to charge ammeter indication is positive 8 With lights and other electrical load off this should occur at approximately 1500 RPM or lower 10 Repeat test observing ammeter and tachome
101. aximum service life and performance from a battery perform the following steps NOTE This section contains information for both conventional Lead Acid batteries and Sealed Low Maintenance batteries Before service identify the battery type in the vehicle Use the section that applies to the battery WARNING 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 large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN The gases given off by a battery are explosive Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it Should there be contact with battery acid wash the affected area with large quantities of cool water and seek immediate medical attention NOTE New Battery must be fully charged before use or battery life will be significantly reduced 10 30 of the battery s full potential To activate a new battery 1 Remove vent plug from vent fitting Remove cell caps 2 Fi
102. battery life will be reduced for 10 30 of full potential After a tire or wheel has been changed or replaced always Charge battery for 3 5 hours at a current equivalent of balance the wheel 1 10 of the battery rated amp hour capacity Do not use the alternator to charge a new battery To reduce the chance of sparks Whenever removing the battery disconnect the black negative cable first When reinstalling the battery install the black negative cable last MAINTENANCE BATTERY REMOVAL 1 Remove the inspection panel to access the battery Inspection Cover 2 Disconnect the black negative battery cable 3 Disconnect the red positive battery cable 4 Remove the clamp bracket and slide the battery out of the scooter BATTERY INSTALLATION IMPORTANT Using a new battery that has not been fully charged can damage the battery and result shorter life It can also hinder vehicle performance Follow the battery charging procedure before installing the battery 1 Ensure the battery is fully charged 2 Place the battery in the battery holder and secure with clamp bracket 3 Coat the terminals with dielectric grease or petroleum jelly 4 Connect and tighten the red positive cable first 5 Connect and tighten the black negative cable last 6 Verify that cables are properly routed and reinstall BATTERY OFF SEASON STORAGE Whenever the vehicle is not used for a period of three months or more
103. bee od eS er tbe eames Ed ee 6 17 CALIPER INSTALLA HON 3336050 0600 PLE E Eia e dires eed Vei Rd Ra pex bes 6 17 BISAKE BUIRNISEINGTPROGEDURE peteret dead ere EE ete Past ios ata dee ag derat 6 17 BRAKE SQUEAL POOR BRAKE erre 6 17 PEBATSVIBRSATTION oS soit duode as oe eee Dope edere dot Ba Ure eer ree stro 6 17 CALIPEISOVEREEAT xxnameuanamP AER EURSRISeERESERe IIS Tess 6 17 BRKE LOCK 224 a ar dub dde desto teet e ot d Pee 6 17 STEERING SHAFT qu e aC RH or etia n RU Lu MARK IHR teow hee ae ews 6 18 STEERING SHAFT EXPEODED VIEW Sca UE CC iod ad act danse nena eesti an x bred tan 6 18 STEERING SHAFT IRSEMOVALD ctio Ide D PE EUR beta nem POLVO E 6 18 STEERING SHAFT INSPEGTIODN zm pep eo undue t etus seda dc ee dol ne iet gati AR E a ISSUE E OR ers 6 19 STEERING SHAFTINSFALLATON df eee acc po iSo riui qb Seed oH 6 19 STEERINGIPOSI ASSEMBLY 43 3 2 54 S pla eae la Mee eae make pg a ote weed outer 6 20 FRONT PORK REMOVAL c Insti eine ena adeb Sai ead ict CU ot he deor oe Cani good ac CIE Ss 6 20 FRONT FORK INSPECTION s o i t sert bred eb Pp d dE Ups EU ES EE DeL E EIER REUS 6 21 FRONT FORK ASSENBIDY utitur
104. blies strongly recommended Use Loctite 272 on the Install new o rings and the outer roller pin cover Place the threads during reassembly washer onto the threaded shaft and apply Loctite 272 to the Driven Assembly Nut Torque threads 90 Nm 67 ft Ibs CVT Belt Inspection 3 Inspect the surface of the drive belt for uneven wear or grease deposits Using a caliper measure the width of The service limit of the belt is 24 mm If the width of the belt is less than service limit or if belt is worn glazed or hour glassed replace 2 Have an assistant available 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 exposed have an assistant thread a new retaining nut onto the shaft Secure the assembly in a clamping device and torque the retaining nut to 90 Nm 3 37 CVT SYSTEM DRIVE CLUTCH SERVICE Service Limit 24mm 50 Nm 37 ft Ibs 4 Install the drive clutch assembly into Crankshaft 5 Install the drive belt on driven clutch sheave side and move DRIVE CLUTCH DISASSEMBLT AND belt as far into the sheaves as possible INSPECTION 6 Install the V belt with the printed arrow mark on the V belt 1 Remove outer drive clutch sheave and drive belt Note parts facing in the direction shown in the illustration assembly order 2 Slide
105. ce angle the seat contact point on the valve will be very narrow and is a normal condition Look for an even and continuous contact point on the black marker all the way around EN 2 Apply engine oil to valve guides and seats the valve face 3 Coat valve stem with molybdenum disulfide grease 4 66 ENGINE 7 Repeat procedure for remaining another valve Valve Stem 5 8 When all valves are installed tap lightly with soft faced Valve Stem orp hammer on the end of the valves to seat the split keepers 4 Install valve carefully with a rotating motion to avoid damaging valve seal 5 Dip valve spring and retainer in clean engine oil and install spring with closely spaced coils toward the cylinder head 6 Closely spaced coils toward cylinder head lt VALVE SEALING TEST 1 Clean and dry the combustion chamber area 2 Pour a small amount of cleaning solvent into each port and check for leakage around each valve The valve seats should hold fluid with no seepage 7 Use compressor to compress spring only enough to allow split keeper installation to prevent loss of spring tension Install split keepers with the gap even on both sides ENGINE BOTTOM END DISASSEMBLY 4 67 ENGINE CYLINDER REMOVAL Follow engine disassembly procedures to remove valve cover camshaft and rocker arms and cylinder head 1 Remove cam chain guide at front of
106. continuity between the Red Brown Blue and Brown leads when the switch 15 set to ON D R Br F HOT KEY MAIN SWITCH 1 When the key switch is turned to the ON position there should be continuity between the red R1 and brown Br wires 2 When the key is turned to the OFF position there should no continuity between any of the wires 3 When the key switch is turned to amp seat open position there should be continuity between the red R1 and brown Br wires 4 When key is turned to 81 position there should no continuity between any of the wires Main Switch switch local on handlebar by right side and beam switch local on handlebar by left side Light Switch 1 When the headlight switch is pushed to the position there should be continuity between the Y R amp Y W wires 2 When the headlight switch is pushed to the A position there should continuity between the Y R amp Y W amp Y B wires 3 When the headlight switch is pushed to the OFF position there should no continuity between any of the wires ighi Switch 1 LIGHT SWITCH BEAM SWITCH 1 When the beam switch is pushed to the gO position there should be continuity between the Y B amp L wires AM 2 When the beam switch is pushed to the D position th
107. d to the outer mark at the bottom of the wheel race 7 Repeat steps 4 amp 5 several times until all the marks come to rest at the same spot where 15 the front wheel s heavy spot 8 Install a balancing weight onto the rim exactly opposite the heavy spot p Weight 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 balance with the brake disc installed 3 Remove balancing weights on front rim 6 142 9 Turn front wheel 90 that heavy spot is positioned as Note shown Ensure the slot in the speed sensor fits over the blocker on the outer tube Blocker 10 Release the front wheel if the heavy spot does not stay in that position install a heavier weight 5 Before fully tightening the wheel axle push down hard on 11 Repeat steps 9 and 10 until the front wheel is balanced the handlebar several times and check if the front fork 12 Turn the front wheel and make sure it stays at each position rebounds smoothly without any one heavy point 6 Tighten front wheel axle and front wheel axle pinch bolt FRONT WHEEL INSTALLATION 1 Clean the wheel hub mating surface and install new disc on Front Wheel Nut Torque wheel hub 55 Nm 40 ft Ibs 2 Install new bolts and tighten disc bolts by crisscross pattern then torque to 30 Nm
108. ded material on pads or disc Spray disc and pads with CRC Brakeleen or same equivalent non flammable aerosol brake cleaner Remove pads and or disc hub to clean imbedded material from disc or pads Pad s dragging on disc noise or premature pad wear because of improper adjustment Adjust pad stop front calipers Master cylinder reservoir overfilled Set to proper level Master cylinder compensating port restricted Clean compensating port Master cylinder piston not returning completely Inspect Repair as necessary Caliper piston s not returning Clean piston s seal Operator error riding the brake Educate operator Loose wheel hub or bearings Check wheel and hub for abnormal movement Brake disc warped or excessively worn Replace disc Brake disc misaligned or loose Inspect and repair as necessary Noise is from other source axle hub disc or wheel If noise does not change when brake is applied check other sources Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pad Brake System Inspection 6 147 5 Inspect brake pads wear limit 4 WARNING Brake Pads wear limit groove Disc brake components rarely require disassembly Therefore always follow these preventive measures e Never disassemble brake components unless absolutely necessary If any connection on the hydraulic brake system is disconnected the entire brake system must
109. dedo dup Sock eave tated E ears ges iod eager 5 27 THROTTILE POSITION OPENING 522 gh eerie ete S meses eee 5 27 MALFUNCTION INDICATION LIGHT eee eee 5 28 AG CENLERATION MODE ENABLE ce IE PURUS ee ee os 5 28 DECELERATION MODE ENABLE 2222 1 92 2 8 p dcbet p 2n Q9 be eons tate 5 28 OVERSPEED FUEL CUTOFF MODE ENABLE 33s 144 zr eh See x t agate abt ete toe 5 28 MISSING COUNT DETECTION cs utet ibd beo Ta r ad d deca n 5 28 ACCUMULATED VEHICLE OPERATION TIME 0 RI RR rrr 5 28 TARGET Biceps hes be eal BE LS Se sees tiw aes pate ee 5 28 IDLE DESIGN REM TARGET sausage ve TIED du dd mda epe ewe ag S eae 5 28 DELTA OF IDLE DESIGN RPM dide bse ue sent 5 28 Fe E e t em t iet 5 28 FINALE VOLUMETRIC EFFICIENCY sitet qoe dado d redet pee Oa IET er tee v E ee ar PN dor eee 5 29 INDICATION VALUE OF MANIFOLD 5 0 0000 tees 5 29 MANIFOLD PRESSURE READING 1 33 eet Se ede e d need en 5 29 IDLE MODE VOLUMETRIC EFFCIENCY COEFFICIANT 0 0 0000 RR 3r 5 29 RUN MODE VOLUMETRIC EFFCIENC
110. ds with Grease 12 5 12 8V Slight 3 6 Hours 0 5 A 4 Reinstall the holder strap ERU SEALED LOW MAINTENANCE BATTERY 50 ILI25V Charge 5 11 Hous 0 5A TESTING 25 Whenever service complaint is related to either starting Check Charging Less than Charge 20 Hours 0 0 5 or charging systems battery should be checked first 11 5v Battery may be dead 7 181 ELECTRICAL Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test SEALED LOW MAINTENANCE BATTERY OCV OPEN CIRCUIT VOLTAGE TEST Battery voltage should be checked with a digital Multi tester Readings of 12 8 volts or less require further battery testing and charging See charts and Load Test A battery may indicate a full charge condition in the OCV test and the specific gravity test but still 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 encountered To perform this test hook a multi tester to the battery in the same manner as was done in the OCV test The reading should be 12 6 volts or greater Engage the starter and NOTE Lead acid batteries should be kept at or near a observe the battery voltage while cranking the engine full charge as possible If the battery is stored or used in a parti
111. e Engine coolant inlet P pipe Water pump 4 50 ENGINE RADIATOR CHECK THERMOSTAT CHECKING 1 Check radiator fins for obstruction any time clean NOTE A faulty thermostat could cause engine obstruction serious overheating or overcooling 2 Straighten any flattened fins with a thin flathead 1 Suspend the thermostat in a container filled with water screwdriver 2 Slowly heat the water 3 Place a thermometer into the water 4 While stirring the water observe the thermostat and thermometer s indicated temperature 3 Verify the connect radiator hoses for signs of wear deterioration damaged or leakage Replace if necessary 4 Check radiator fan motor for electric function Repair or replace if necessary The thermostat should start open at 65 C and full 5 Measure radiator cap opening pressure The pressure cap pen at 80 C relief pressure is 0 9 Bar 13 psi Make sure pressure maintain for ten seconds and there 15 no drop in pressure Replace cap if THERMO SWITCH it does not meet this specification Cooling System Pressure Test 1 Remove battery inspection cover 1 Connect the fan thermo switch harness with multi meter 2 Remove pressure cap and determine the cooling system 2 Place a thermo switch into the water pressure by using a commercially available pressure tester 3 Ensure switch connect at 80 C fan start and disconnect at 3 The system must keep the 0 7 Bar 10 psi for five minutes 70
112. e The reading should be infinite no reading No continuity 4 Remove the brush plate and brushes Measure the brush length and replace if worn past the service limit Brush Length Service Limit 10 mm 0 40 5 Inspect the surface of the communicator for wear or discoloration See Armature Test 4 Be sure that the terminal bolt insulation washer is properly seated in the housing and the tab on the brush plate engages the notch in the brush plate housing Insulation check Infinite at 20 C 68 F Brush Length 5 Check communicator bars for discoloration Bars discolored in pairs indicate shorted coils requiring replacement of the Starter motor 10 mm 0 4 Place armature in a growler Turn growler and position a hacksaw blade or feeler gauge lengthwise 3mm 1 8 above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to armature on any pole the armature is shorted ARMATURE TEST and must be replaced 1 Inspect surface of communicator Replace if excessively worn or damaged 7 176 ELECTRICAL 7 Inspect the permanent magnets in starter housing Make sure MAIN SWITCH they are not cracked or separated from housing Refer to KEY MAIN SWITCH at above If main switch CAUTION isn t continuity replace the main switch Use care when handling the starter housing Do not drop or strike the housing as magnet ROLLOVER SWITCH damage is possible If the ma
113. e 7 17 AETERATOR OUTPUT TEST 5 i Ich en e ppp rcr end ee 7 18 BATTERY IDENTIFICATION da ciu ttr RR Bees ae Babe ei it dr Doe Dots eco 7 18 SEALED LOW MAINTENANCE BATTERY 534 e ER C ERI eoe eee tia ee 7 19 BATTERY CHECK Aper 7 19 SEALED LOW MAINTENANCE BATTERY teens 7 20 BATTERY CHARGING REFERENCE TABLE 265 034 ada cate oe ioe ch a ade Po PRECOR Rete SEEK Oe wha 7 20 SEALED LOW MAINTENANCE BATTERY INSPECTION REMOVAL 2 2 2 ee 7 20 SEALED LOW MAINTENANCE BATTERY cee eee 7 20 SEALED LOW MAINTENANCE BATTERY TESTING 0 00002 m rs 7 20 SEALED LOW MAINTENANCE BATTERY OCV OPEN CIRCUIT VOLTAGE 1 21 SEALED LOW MAINTENANCE BATTERY LOAD 5 sehen 1 21 SEALED LOW MAINTENANCE BATTERY OFF SEASON 1 21 SEALED LOW MAINTENANCE BATTERY CHARGING PROCEDURE 1 22 CONVENTIONAL BATTERY ACTIVATION SVC 0 2 RR Rees 1 22 BATTERY TERMINAES TEIRSMINAEBOLTS zt atau ede PRG rh T eco cta 1 23 CONVENTIONAL BATTERY INSPECTION hrs 1 23 CONVENTIONAL BATTERY INSTALLATION uussessssseeeees Rr hh 7 23 CONVENTIO
114. e crankcase 1 Loosen each of the four cylinder head nuts evenly 1 4 turn each time in a cross pattern until loose Cam Lobe Dimension Cam Lobe Dimension Intake Height Exhaust Height Std 135 64 mm Limit 35 60 mm 2 Remove the cylinder bolts and taps the cam support tower Exhaust width Std 029 15 mm with a plastic hammer until loose Limit 29 11 mm 3 After removing the camshaft and securing the cam chain tap cylinder head lightly with a plastic hammer until loose 2 Thoroughly clean the cam shaft 3 Measure height of each cam lobe using a micrometer Tap only in reinforced areas or on thick parts of Replace cam if worn below minimum height cylinder head casting to avoid damaging casting Replace camshaft if damaged or if any part is worn excessively 4 61 ENGINE 4 Remove the thermostatic CYLINDER 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 combustion e chamber it is recommended the component be replaced CYLINDER HEAD WARP INSPECTION Lay a straight edge across the surface of the head at several different points and measure warp age by inserting a feeler gauge between the straight edge and the cylinder head surface Straigtedge 50222 Thickness Gauge 6 Remove cylinder head and head gasket 7 If not removing th
115. e cylinder for other service secure the cam chain with a wire to prevent it from falling into the crankcase 4 62 ENGINE CYLINDER HEAD DISASSEMBLY 4 Measure free length of the inner and outer springs with a caliper Wear eye protection or a face shield during cylinder head disassembly and reassembly NOTE Keep all parts in order with respect to their location in the cylinder head NOTE Valves have inner and outer springs 1 Using a valve spring compressor compress the valve Valve Spring Free Length springs and remove the split keeper Outer Spring Limit 41 5mm NOTE To prevent loss of tension do not compress Inner Spring Limit 31 3mm the valve spring more than necessary 5 Check spring for squareness as shown Replace spring if measurements are out of specification n Valve Spring Limit 2 Remove spring retainer and spring Both Spring Limit 2 5 1 5mm NOTE The valve springs should be positioned with NOTE Replace seals whenever the cylinder head is the tightly wound coils against the cylinder head on disassembled Hardened cracked or worn valve progressively wound springs seals will cause excessive oil consumption and 3 Push valve out keeping it in order for reassembly in the carbon buildup same guide VALVE INSPECTION spring Retainer 1 Remove all carbon from valve with a soft wire wheel Cott 2 Check valve face for run out pitting and burnt spots ste
116. e important for identification purposes See the illustrations VEHICLE IDENTIFICATION NUMBER LOCATION Engine serial Location Frame Location 1 5 GENERAL INFORMATION GENERAL SPECIFICATION URBAN 350 Engine Model T62N GENERAL INFORMATION SPECIFICATIONS MODEL URNAN 350i ENGINE DRIVE SYSTEM Type 40 12 38 13 9 74 Compression ratio tots Number ofvalve 2Roceramacived Imietvalve 3350mm CHASSIS Oil capacity Single Disc with single bore caliper FUEL SYSTEM _ Electrical Fuel Injection Fuel Delivery Electronic Fuel pump 3 Bar 43 5psi DIMENSIONS Throttle dimensions 30mm length 2175 mm Fuel Capacity 13 5 Liter Overall width Idle RPM 15002100 Overall height 1290 mm E 800mm 1545mm ENG ELECTRICAL Alternator and voltage regulator 120 km hr RPM limiter setting S500pm Charge 30A Main 15A Light Fuse type 10 Spare 15A 1 7 GENERAL INFORMATION CONVERSION TABLE 0095 Ounces 00 0 2206 liters x16 imperial pints Imp pt Imperial quarts Imp qt x1487 biter US quarts US qt x0833 gt Imperial quarts Imp qt USqurs USq O96 biter Pounds force per square inch Kilograms force per square 3 14 xR2x H height Cylinder Volume Cs 32 F to C 5 9 F 32 1 8 GENERAL INFORMATI
117. e 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 Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues rise discontinue use and determine the cause or see your dealer MAINTENANCE CHART KEY The following symbols denote potential items to be aware of during maintenance Dueto the nature of these adjustments it is recommended this service be performed by authorized AEON dealer SEVERE USE ITEM See information provided above WARNING Improperly performing the procedures marked with a B could result in component failure and lead to serious injury or death Have an authorized AEON dealer perform these services 2 14 MAINTENANCE MAINTENANCE INTERVAL Periodic Maintenance and Lubrication Chart CHARACTERISTIC MAINTENANCE INTERVAL e When the oil change indicator flashes Check oil level vehicle for oil leakage Change v Spark plug Check condition Z e Adjust gap and clean e Replace every 10000 km Valve clearance Check and adjust valve clearance when v
118. e of each bearing The bearings should turn smoothly and quietly The inner race of each bearing should fit tightly in the crankshaft The outer race should be firm with minimal side to side movement and no detectable up and down movement 2 Replace the crankshaft if the components fail visual inspection 3 Measure crankshaft run out Replace crankshaft and both bearings if out of specification 4 The connecting rod utilizes a roller bearing Clearance is minimal and cannot be measured Visually inspect bearing journal for scoring damage or excessive wear Replace crankshaft if it fails visual inspection 4 79 ENGINE 5 Inspect the clearance of connecting rod big end and flywheel by feeling gauge If clearance is excessive replace the crankshaft assembly Connecting rod clearance limit 0 5 mm 6 Inspect chain for worn or missing rollers or damage Replace if worn excessively or as part of any crankshaft repair Tw 3 N We N ON AUT Pat SCS fr a CRANKCASE STRAINER INSPECTION 1 Remove drain plug ZI Timing Chain 2 Remove oil strainer and visually inspect for any rips tears or obstructions in screen 3 Replace oil strainer 1f it fails visual inspection BEARING SEAL INSTALLATION NOTE To ease crankcase bearing installation warm the crankcase until hot to the touch Placing the CRANKCASE INSPECTION NOTE Removal and i
119. e the rear wheel 2 Drain out gear oil from gearbox 3 Remove cir clip of gearbox cover 4 93 ENGINE 5 Remove the gasket amp dowel pin 2 Bearings can be removed using a standard blind bearing 6 Remove counter gear first remover Apply lithium grease to outer race of new bearings and press into cover or case by the outer race Do not press on inner race or bearing will be damaged DRIVE SHAFT INSPECTION 7 Remove Final shaft and gear It is not necessary to remove the drive shaft Inspect the drive shaft and gear visually without excessive from the cover upper side wear or crack Replace any damaged components If remove the drive shaft from the gear box cover which its bearing has to be replaced COUNTER SHAFT GEAR INSPECTION Inspect the counter shaft and gear visually without excessive wear or crack Replace any damaged components TRANSMISSION INSPECTION 1 With transmission components removed inspect all shaft bearings visually and by feel Bearings should roll smoothly without excessive movement or noise Replace any bearing that is removed as the removal process destroys the bearing 4 94 ENGINE FINAL SHAFT GEAR INSPECTION TRANSMISSION TROUBLESHOOTING Noise e Incorrect transmission lubricant Lubricant level too low Lubricant level too high Bearings worn or damaged Gears worn or damaged CVT problem belt Final drive chain or sprockets worn or damaged
120. earance at this point ROCKER ARM SHAFT DISASSEMBLY AND INSPECTION NOTE Orientation of the components is important for 5 Remove the two cam chain tensioner flange bolts reassembly Mark all components before disassembly The plunger is under spring tension 1 Loosen each of the four cylinder head nuts evenly 1 4 turn Maintain inward pressure while removing each time in a cross pattern until loose 6 Using a screwdriver turn the tensioner clockwise to retract the plunger The plunger should move smoothly in and out of the tensioner body 4 57 ENGINE 2 Remove bolts and taps the cam support tower with a plastic hammer until loose 3 Remove the rocker shaft locking plate 4 Mark or tag rocker arms and shafts to keep them in order for assembly 6 Measure O D of rocker shafts for out of round Inspect them for wear or damage Replace if excessive wear is evident 5 Remove rocker shafts from seat by blade drive screw Rock Arm ID 10 10mm Rocker Arm OD 9 91mm 7 Inspect each rocker arm cam follower surface If there is any damage or uneven wear replace the rocker arm NOTE Always inspect camshaft lobe if rocker arms are worn or damaged NOTE Orientation of the rocker shafts is important for reassembly Place only the exhaust rocker shaft into the exhaust side of the cam support 4 58 ENGINE 2 Remove the cam chain from the sprocket by tilting the c
121. ed For the purpose of troubleshooting a known good ECU from another AEON ELITE 350i OR URBAN 350i EFI of the same model may be used without system or engine component damage ry ECU REPLACEMENT MER Hairdryer F 1 Remove 2 retaining screws holding ECU m 2 With the Ignition turned off disconnect the wire harness ED Mutimeter Thenmometer from the ECU 3 To install reverse the procedures and tighten screws to specification 2 Connect an ohmmeter between the pin terminals leading from the Red and White wires A resistance value of 2795 70 at room temperature 25 77 should be obtained ECU Retaining Screws Resistance Specification 2 5 Nm 22 in Ibs 5600 10 25 C 77 F CRANKSHAFT POSITION SENSOR 5 106 ELECTRONIC FUEL INJECTION IAT Replacement Synchronization of the CPS and crankshaft position takes 1 Disconnect sensor from engine harness place during the first two revolutions each time the engine 15 started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will quit running CPS TEST 1 Disconnect CPS 5 wire harness connector under storage box of the vehicle located front the cylinder 2 Remove the retaining ring and remove the sensor from the intake boot 3 Install new sensor CPS OPERATION OVERVIEW The crankshaft position sensor is es
122. ed PIU Wii Feeler Gauge Piston Ring 2 Measure the gap 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 excessive taper and out of round 4 72 ENGINE ALTERNATOR STATOR OIL PUMP EXPLODED VIEW Fill Cap stator 10Nm 87in Ibs 10Nm 87in lbs Oil Pump with Lotite 272 STARTER DRIVE GEAR REMOVAL 5 Remove the start drive gear and shaft by pulling the shaft INSPECTION and tilting the gear slightly Flywheel removal generally is not 1 Remove water pump tube required 2 Take off water pump bolts 6 Measure the OD of the starter drive shaft on both ends for 3 Tap water pump lightly with a plastic hammer in reinforced tone 7 the ID of bushing in stator housing A and areas only until loose the crankcase B in two directions 90 apart to determine if out of round Calculate clearance Replace components if clearance is excessive 4 Remove stator housing bolts and removes housing 4 73 ENGINE ENGINE FLYWHEEL REMOVAL INSPECTION CAUTION 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 ia Pick up CPS Crankshaft Position Sensor crankshaft end or plunge joi
123. eee eee 5 9 2p edu ded ee raya ed hee nt Pe rb cibos OR npe ed dob oso ees Sede tee oe eae ks 5 10 EGU REPLACEMENT itid did riens th be dese ee a ned see ee eee Eee es dos Eas 5 10 INTAKE AIR TEMPERATURE nass EE DERE alee eas eee e pase ERES 5 10 IAT OPERATION OVERVIEW 3d tdt oed d onere reped bp RR e dre ate eee dU dece arn 5 10 eee te ee 5 10 AT REPLACEMENT sy dae see ve becca gotta teamed 5 11 CRANKSSHAFT POSITION SENSOR 4 ex axe eunte RS p RR CR eee e 5 11 OPS OPEISATIONOVERVIEMV s yis aeter dr Fb redditas edo tois us seus re ete exer Sus act 5 11 5 11 CPS Seite wane hie oe A 5 12 5 12 FUEL INJECTOR OPERATION eee rn 5 12 PFUELINJECTOR SERVICE m cud tees uad fre ce Se oe ead ea 5 13 PUB ECU OR We Slee cate oes bakerc arp oe Bis a oe aa Ge Gale on 5 13 FUEL INJECTOR REPEACEMENT oso oa ar Ed seaweed deb E aded PR E eds 5 14 Be IM secre ts ee ee ice eee aie
124. eep all parts away from any source of fire REPLACEMENT PARTS Use only genuine AEON parts for all replacements Use oil and grease recommended by service manual for all lubrication jobs GASKETS OIL SEALS AND O RINGS 1 Replace all gaskets seals and O rings when overhauling the engine All gasket surfaces oil seal lips and O rings must be cleaned 2 Properly oil all mating parts and bearings during reassembly Apply grease to the oil seal lips FUEL AND INTAKE SYSTEM FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel outdoors or ina well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time Never drain the fuel when the engine is hot Severe burns may result FUEL LINE 1 Check the connect fuel line for signs of wear deterioration damage or leakage Replace if necessary Fuel Line 2 Be sure fuel line is routed prop
125. en AIR E 6 10 BRAKE SYSTEM SERVICE NOTES 22 253222 R hederae ey ee deb bo Roe ER Did dates 6 10 HYDRAULIC BRAKE SYSTEM OPERATION etae ma wes Sedet ed heath dan dee 6 11 BRAKE NOISE TROUBLESHOOTING sn ime ete ea eee TI DERE UP deii mca nuu n a oec de Puce 6 11 BRAKE BLEEDINGJ FLUID CHANGE 35 5848999 Gs amd ee RUP eo De tad oett and dub dieta eames dae 6 12 BRAKE MASTER CYLINDER ci0 2 lt 0t0cnaebancasnavetucs RE RUE 6 14 MASTER CYEINDER REMOVAL rm ede Sac edere e e t at Rotes 6 14 INS ALTON PTT TT EP 6 14 FRONT BRAKE CALIPER ees 6 15 PADO LETTERE 6 15 PROANSPECTION uisi uode p uuu 309 909 UO od eae dp aene Vo adt eee ats ee 6 15 PADIASSENMBEY INS TALEATION hh se eee ee eel eh Eo xa 6 15 CALIPERANSTALLATION eee aat dod eec UR eee en me d o Ee etd 6 16 BRAKE BURNISHING PROCEDURE 54322 E e RR e net kd Bola 6 16 6 137 REAR BRAKE CALIPER xia o sae eee seek eee eared 6 16 Spas Srl es aan 6 16 PADIN TIONG au eamm itn Eois eU aie Seles Heo aaa a ae LI 6 17 PAD ASSEMBEY T INSTAEBATION 2 irit tore VA
126. er 2 The pressure cap relief pressure is 0 9 Bar 13 psi Replace cap if it does not meet this specification 4 47 ENGINE COOLIING SYSTEM FAILURE ELIMINATION CHART Temperature indicator too high Stop engine and wait completely cooled down Remove pressure to check coolant lever in radiator Turn on main switch and check coolant temperature indicator back to N zero Remove radiator pressure cap and lightly throttle verify coolant has circulated Install radiator and measure thermo unit to confirm voltage reduced comply with temperature ride Keep engine 3000 4000 rpm and inspect cooling fan was turn on after temperature gauge over 3 scale Connect with multi meter and verify cooling fan turns on If circuit connects reverse cooling fan will forward correct wires and confirm again Refill coolant into radiator and check any leakage Measure thermostat and confirm voltage 6 V above Inspect the circuits of coolant temperature short cut or ground Coolant leakage problem Replace thermostat unit Short cut and ground handle test N ENT Meter problem Stop engine and remove water pump N cover Start engine to inspect pump rotation Measure fan thermo switch terminal to verify opening circuit or ground Keep engine 3000 4000 rpm and inspect coolant flow into reserve tank after temperature gauge over 3 scales Remove thermostat and heat it by hot water to check fu
127. er cylinder reservoir fluid level after pad service 6 Make sure atmospheric vent on reservoir is unobstructed 7 Test for brake drag after any brake system service and investigate cause if brake drag is evident 8 Make sure caliper moves freely on guide pins where applicable 9 Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely 10 Perform a brake burnishing procedure after installing new pads to maximize service life 11 DO NOT lubricate or clean the brake components with aerosol or petroleum products Use only approved brake cleaning products 6 146 Brake system consists of the following components or assemblies brake pedal master cylinder hydraulic brake lines brake calipers brake pads and brake discs which are secured to the drive line When the hand activated brake lever is applied it applies pressure on the piston within the master cylinder As the master cylinder piston moves inward it closes a small opening compensating port within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the pistons located in the brake calipers move outward and apply pressure to the moveable brake pads These pads contact the brake discs and move the calipers in their floating bracket pulling the stationary side pads into the brake discs The resulting friction reduces brake disc and
128. ere should be continuity between the L W amp Y B wires 3 When the beam switch is pressed to BOTH position there should be continuity between the Y R amp L W wires Both headlights have high and low beams Beam Switch 821 OTOL BEAM SWITCH 7 166 ELECTRICAL HAZARD SWITCH NOTE The turn signal button will not automatically 1 When the hazard switch is pushed to the 4A position return to the off position after a turn the operator there should be continuity between the Br W L R amp DB should manually move the button to the center wires position upon completing each turn 2 When the hazard switch is pushed to the o position there should no continuity between any of the wires HAZARD SWITCH SIGNAL REFLECTOR TURN SIGNAL HORN SPEEDOMETER ODOMETER 1 When the switch is pushed down there should be The speedometer is located on top of the vehicle dash and will read vehicle continuity between the B amp P wires speed from 0 to 999 9 km The gauge will also record the total distance 2 When the switch is loosened to the FREE position there traveled hould tinuity bet f the wires Within the speedometer is trip odometer that can set by depressing the set buttons This feature is especially useful in measuring the distance between each charge cycle Speedometer Sensor and Magnet PUSH CH roj The sens
129. erly IMPORTANT Make sure line is not kinked or pinched 3 Replace fuel line every two years 2 17 MAINTENANCE FUEL PUMP FUEL FILTERS PUMP REGULATOR The 350 EFI engine uses a non serviceable high volume high pressure fuel pump system that includes a filter and a pump regulator NOTE For all other information related to the EFI System refer to Chapter 6 VENT LINES 1 Check fuel tank front gear case rear gear case and transmission vent lines for signs of wear deterioration damage or leakage Replace every two years 2 Be sure vent lines are routed properly and secured with cable ties IMPORTANT Ensure lines are not kinked or pinched THROTTLE INSPECTION If the throttle has excessive play due to cable stretch or cable maladjustment it will cause a delay in throttle speed Also the throttle may not open fully If the throttle has no play the throttle may be hard to control 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 Inspection 1 Start the engine and warm it up thoroughly 2 Measure the distance the throttle pedal moves before the engine begins to pick up speed Free play should be 3 5 mm Adjustment 1 Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster 2 Loosen the adjuster lock nut
130. ern to ensure piston ring seating and to aid in the retention of the fuel oil mixture during initial break in Hone cylinder according to hone manufacturer s instructions or these guidelines Use a motor speed of approximately 300 500 RPM run the hone in and out of the cylinder rapidly until cutting tension decreases Remember to keep the hone drive shaft centered or cylinder centered on arbor and to bring the stones approximately 1 3 cm above and below the bore at the end of each stroke Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently deglazed and to check for correct cross hatch NOTE Do not allow cylinder to heat up during honing After honing has been completed inspect cylinder for thinning or peeling 4 70 ENGINE IMPORTANT Clean the Cylinder After Honing 3 Measure piston pin bore Replace piston if out of round It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylinder in a solvent then in hot soapy water Use electrical contact cleaner if necessary to clean these areas Rinse thoroughly dry with compressed air and oil the bore immediately with 4 Cycle Lubricant to prevent the formation of surface rust If cylinder 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 Pin Bore 4 Measure p
131. ervoir The level should be between the MAX and MIN level lines 4 If the fluid level is lower than the MIN 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 cylinder fittings and the brake caliper fittings 2 Inspect the brake pad wear surface for excessive wear 3 Pads should be changed when the friction material is worn to 1 mm m ey Measure Pad Materia Thickness Service Limit Imm 4 Check surface condition of the brake discs 5 Measure the thickness of the front and rear brake discs 6 The disc s should be replaced if thickness 15 less than 4mm rear disc and 3 5mm front disc BRAKE HOSE AND FITTING INSPECTION Check brake system hoses and fittings for cracks deterioration abrasion and leaks Tighten any loose fittings and replace any worn or damaged parts 2 29 CVT SYSTEM CHAPTER 3 OVERVIEW relia een thee aN ee eee eee cates 3 2 CVT MAINTENANCE JINSPEGHION 42 2 wah abe penile eee cate RR 3 2 DRIVE GLUTGETOPERATIODN us 24 59 8525 ge Kes taro kia ME URS EM Khai ELDER 3 2 DRIVEN CLUTCH OPERATION ss priate 9c deed a A Tener MEAE BECA EC IE E Ld 3 2 OLUTCETGOMEREXPEODED VIE VV Sa debo d woe bee Mane
132. es The Continuously Variable Transmission CVT consists of three major assemblies 1 The Drive Clutch 2 The Driven Clutch 3 The Drive Belt The internal components of the drive clutch and driven clutch control engagement initial vehicle movement clutch up shift and backshift During the development of an Aeon the CVT system is matched first to the engine power curve then to average riding conditions and the vehicle s intended usage Therefore modifications or variations of components at random are never recommended Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning CVT MAINTENANCE INSPECTION Under normal operation the CVT system will provide years of trouble free operation Periodic inspection and maintenance is required to keep the system operating at peak performance The following list of items should be inspected and maintained to ensure maximum performance and service life of CVT components See CVT Overheating Diagnosis on page 3 4 for more information 1 Drive clutch rollers and bushings Driven clutch rollers pins and spring 2 Clutch sheave faces Clean and inspect for wear 3 CVT system sealing The CVT system is air cooled by fins on the drive clutch The fins create a low pressure area around the drive clutch The clutch cover must be sealed to ensure water and other contaminants entering the CVT area DRIVE CLU
133. es during regular maintenance Front brake master cylinder 1 Clean master cylinder reservoir cover thoroughly and remove the cover Rear brake master cylinder 2 If changing fluid remove old fluid from reservoir with a vacuum pump or similar tool Master cylinder cap 3 Add brake fluid to the indicated MAX level of reservoir 4 Begin bleeding procedure with the caliper that is farthest from the master cylinder Install a box end wrench on caliper bleeder screw Attach a clean clear hose to fitting and place the other end in a clean container Be sure the hose fits tightly on fitting Bubble y Brake bleeder valve i 5 Have an assistant slowly pump brake lever until pressure builds 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 15 tight or air may be drawn into master cylinder 7 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir CAUTION Maintain at least 1 5 cm of brake fluid in the reservoir to prevent air from entering the master cylinder 8 Tighten bleeder screw securely and remove bleeder hose Torque bleeder screw to 5 Nm 9 Repeat procedure Steps 5 8 for the remaining calipers 10 Add brake fluid to MAX level inside reservoir
134. ews and the clutch cover 5 Remove outer sheave from crankshaft 9 Remove and inspect the slide bushings and cam plate Replace any components that found to be worn excessively or appear abnormal Sie Bushing 3 34 CVT SYSTEM DRIVEN CLUTCH EXPLODED VIEW Oil Seal A Guide Roller DRIVEN CLUTCH REMOVAL NOTE This assembly utilizes a torque limiting system to prevent transmission damage Use care removing the clutch assembly as the torque limiting components become free and could fall apart Mark or note parts during disassembly 1 Hold the driven clutch housing then releasing the nut from 3 Pull the entire clutch off as an assembly 4 Set the driven clutch assembly on a flat surface Remove the cover Inspect components for excessive wear or damage Replace components as required CVT SYSTEM DRIVEN CLUTCH SERVICE DRIVEN CLUTCH DISASSEMBLY AND Driven Clutch Friction Pad INSPECTION Service Limit 2 mm 0 078 Driven Clutch Hub I D 1 Inspect the condition of the clutch drum Measure the inside Service Limit 153 0 2 mm diameter of th t90d intervals usi liper ee eld to check length of compression Inspect the condition and diameter of the drum lining If either E spring At full extension the measurement should be no less the measurements or the lining indicates excessive wear E than 130 mm If out of specification replace
135. ged in accordance 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 2 21 MAINTENANCE COOLING SYSTEM OVERVIEW The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels often during the break in period NOTE Overheating of engine could occur if air is not fully purged from system Coolant 50 50 is already premixed and ready to use Do not dilute with water COOLANT 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 recovery tank Recovery Tank Location COOLING SYSTEM With the engine at operating temperature the coolant level should be between the upper and lower marks on
136. gnets are damaged the Refer to ROLLOVER SWITCH at above If transmission starter must be replaced switch isn t correct repair or replace the main switch STARTER REASSEMBLY BRAKE LIGHT SWITCH 1 Place armature in field magnet casing Refer to BRAKE LIGHT SWITCH at above If brake light 2 Inspect and replace the O rings if damaged switch isn t continuity replace the brake light switch 3 Install case sealing O ring Make sure O ring is in good STARTING WIRE CONNECTION Refer to CIRCUIT DIAGRAM to check properly connect condition and not twisted on the case Lubricate the ends of the armature shaft and oil seal with a light film of grease and install housing the starting system If starting wires is poor continuity replace 4 Pushing back brushes while installing armature shaft Install the wires the coil spring behind brush 5 Reinstall starter motor housing screws and washers Make sure O rings are in good condition and seated in groove Tighten sufficiently 6 Reinstall the starter motor to the engine STARTER RELAY The starter relay consists of a simple 2 way circuit Power 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 starter motor to crank the engine 1 Remove the starter relay from the wire harness 2 Connect the pocket tes
137. hain is cam chain 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 smooth replace the one way clutch NOTE One way clutch components are not serviceable Replace the component as an assembly 10 To reattach the one way assembly apply Loctitet 272 to the retaining screw threads Torque to specification 4 76 ENGINE 3 Inspect oil sprocket rough movement Replace sprocket if 1 Remove the oil pump retaining screws rough movement 4 Inspect sprocket teeth for wear or damage 2 When install oil pump inner roller which the cover arrow must align the dot as above shows NOTE Oil pump is not a serviceable assembly Replace completed oil pump if excessively worn Inspect for Areas of Tooth Wear or Damage 5 Replace any worn or damaged parts 6 Inspect the chain for worn damage or missing rollers Replace chain anytime the oil pump is replaced or if excessively worn 4 77 ENGINE CRANKCASE DISASSEMBLY NOTE Engine must be removed from the frame to perform any crankcase or crankshaft removal NOTE The starter starter drive flywheel stator oil pump and transmission can be serviced with the engine in the frame CRANKCASE SEPARATION AND CAM CHAIN REMOVAL NOTE Stator housing flywheel and gears have are previously removed for this procedure U
138. he inlet and outlet ducting for obstructions Obstructions to air flow through the ducts will significantly increase CVT system operating temperatures The ATV should be operated in LOW RANGE if equipped when pulling or plowing heavy loads or if extended low speed operation is anticipated GENERAL RANGE OPERATION GUIDELINES Heavy loading basic operational speeds less than 10Km riding through rough terrain Swamps mountains etc low ground speeds po ground speeds speeds above 30Km Diagnosis of Clutch Drive Belt amp Cover Related Issues Heaving Loading onto the scooter when in high to low speed during loading of the scooter to eee petam Starting out going up a steep incline When starting out on an incline applying the brake and Driving at low RPM or low ground speed Drive at higher speed for cooler CVT operating At approximately 5 12 km temperatures and longer component life Insufficient warm up of exposed to low ambient Warm engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Continuous operation at the point of engagement initial vehicle movement increases CVT temperatures and component wear Stuck in mud or snow Reduce to Low RPM c
139. he load from the drive belt increases resulting in the belt rotating up toward the outer diameter of the drive clutch sheaves and downward into the sheaves of the driven clutch This action which increases the driven clutch speed is called up shifting Should the throttle setting remain the same and the vehicle is subjected to a heavier load the torque sensing driven clutch will close forcing the drive belt back up toward the outer diameter of the driven clutch This also forces the belt downward into the sheaves of the drive clutch This action which decreases the driven clutch speed is called back shifting In situations where loads vary and throttle settings are constant the drive and driven clutches are continually shifting to maintain optimum engine RPM At full throttle a perfectly matched CVT system should hold engine RPM at the peak of the power curve This RPM should be maintained during clutch up shift and backshift In this respect the CVT system is similar to a power governor Rather than vary throttle position as a conventional governor does the CVT system changes engine load requirements by either up shifting or back shifting 3 31 CVT SYSTEM CLUTCH COVER EXPLODED VIEW Driven Clutch VU Drive Clutch CVT EXPLODED VIEW Quter Sheave 3 32 CVT SYSTEM CVT OVERHEATING DIAGNOSIS During routine maintenance or whenever CVT system overheating is evident it s important to check t
140. head pipe could be damaged If the bearing race is not installed properly CAUTION Always replace the bearings and bearing races as a set 4 Install lower handlebar clamp into steering Jammed Whenever the steering head 15 disassembled then torque to 1000Nm replace the rubber seal Ring Nut of Steering Bearing Torque 10 Nm 7 ft Ibs 1 Inspect bearing race surface and steel ball pitting or damaged Jammed Nut of Steering Bearing Torque 600Nm 430 ft Ibs Jammed Nut of Lower Clamp 1000Nm 720 ft Ibs Stee Beanng Race 6 155 Steering Post Assembly 1 Position the two steering post blocks properly onto the 1 Elevate the vehicle off the ground to relieve the suspension handlebars load CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 Remove the front shock top cap from shock 2 Install the front block bolts first and evenly tighten bolts down Evenly torque the 2 front bolts to 15 18 Nm 11 13 ft Ibs 3 Install the rear bolts and tighten evenly Evenly torque the 2 rear bolts to 15 18 Nm 11 13 ft Ibs 4 Install the four handlebar bolts and pod bracket loosely into the blocks 5 Install the handlebar pod and screws NOTE There will be a slight gap on the backside of CAUTION the blocks after the procedure is performed
141. here e m OR Ro IU b e Era obe ule olo 4 52 DRIVESHAFT INSEEGQTIDIN 6 44 aso Coro eid dad EE Xy pe doro Ob eet Rees 4 52 COUNTER SHAFT INSPECTION s i32 41529 homed EO HE ed SO ast edo edes 4 52 FINAL SHARP GEAR INSPECTION ichs tied der eR ES og dde et todo Eds aute St ad edente 4 53 BEARINGANDOIE SEAL INSPECTION Reve EUNT AIDE RR RE NUES ey URP EVE eV EP 4 53 TRANSMISSION TROUBLESHOOTING 2523 Een RUP RE EI he aot P adr eT 4 53 4 42 ENGINE ENGINE SERVICE ENGINE EXPLODED VIEW 1 Cam Rocker Arm ENGINE ENGINE EXPLODED VIEW 2 Retainer Piston Pin n Piston Ring Set 4 44 ENGINE __ Valve Rocker Arm Press In Lubrication Shaft Spray Lubrication Con Rod Spray Lubrication Press In Lubrication Oil Passage Plug OIL FLOW DIAGRAM ENGINE ENGINE COOLING SYSTEM COOLING SYSTEM EXPLODED VIEW Filler Inlet from Cylinder aii ET Discharge to Pump Recovery Tank Coolant Flow Diagram Filler Neck Engiine Coolant Pump Expansion Tank Radiator Engine Thermostat Housing 4 46 ENGINE COOLING SYSTEM SPECIFICATIONS Condition Specification System Capacity 1200CC _ di Fan Switch Off Radiator Pressure Cap Relief Recommended Coolant Use only high quality antifreeze coolant mixed w
142. hese values vary with the temperature the condition ol Ihe battery plates and the electrolyte level 2 26 MAINTENANCE STEERING AND SUSPENSION SPARK PLUG SERVICE STEERING AND SUSPENSION 1 Remove seat and storage box The steering components should be checked periodically for loose fasteners and damage WARNING Replace any worn or damaged steering components A hot exhaust system and engine can cause serious Steering should move freely through the entire range of burns Allow engine to cool or wear protective travel without binding Check routing of all cables hoses gloves when removing the spark plugs and wiring to be sure the steering mechanism is not 2 Remove both spark plug caps restricted or limited 3 Clean plug area so no dirt and debris can fall into engine when plugs are removed HANDLE BAR INSPECTION 4 Remove spark plugs 1 Remove handlebar pod 5 Inspect electrodes for wear and carbon buildup Look fora 2 Check handlebar clamp sharp outer edge with no rounding or erosion of the electrodes 3 The upper handlebar holders should be installed with facing 6 Clean with electrical contact cleaner or a glass bead spark forward plug cleaner only CAUTION A wire brush or coated abrasive should not be used 7 Measure gap with a wire gauge Refer to specifications in the following illustration for proper spark plug type and gap gt Front Adjust gap if necessary by carefully bending the side e
143. i 2 24 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM CHECK WHEEL BATTERY MAINTENANCE bane Vane Oe CEL Se Keep battery terminals and connections free of corrosion If suitable stand under the frame T TUNE cleaning is necessary remove the corrosion with a stiff wire A WARNING brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with Serious injury may result if machine tips or falls clean shop towels Coat the terminals with dielectric grease or Be sure machine is secure before beginning this petroleum jelly service procedure Be careful not to allow cleaning solution or tap 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 large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable 2 Check both wheels damaged or out of round If wheel oil Call physician immediately OP CUP Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE Battery must be fully charged before use or
144. ide Cover x2 Chassis shield Front cab Battery cover Both kickstand covers Seat and luggage box Grab bar Latch Cover License plate mount Rear Fender Both side covers Both side veneers Floors Inner panel FRONT WHEEL AND BRAKE FRONT WHEEL EXPLODED VIEW Front Wheel Axle Front Caliper nu Speed Sensor Wheel Axle Pinch Bolt Front Disc Front Wheel Spacer 1 Elevate front end of the scooter off the ground to remove front wheel and brake from front fork Seal Hearing Sleeve Severe injury could occur if machine tips or falls Rearing 2 Remove front brake calipers Do not apply the brake Oil Seal lever when removing the brake calipers nuk speed seusorand Spacer 2 Inspect the axle hub main bearings for worn or damaged The bearing must be inspected visually and by turning feel The from front fork bearing should turn smoothly and quietly 4 Remove front wheel with disc assembly from front fork FRONT WHEEL DISASSEMBLY 1 Clean the surface of the front wheel hub 6 140 3 Remove oil seal slot screwdriver 2 Inspect front tire and wheel radial or lateral run out by dial 4 To prevent damaging the wheel place a rag between the gauge Replace if out of specification screwdriver and the wheel surface Front Wheel Lateral Limit 2 00mm Front Wheel R
145. ing Lack of lubrication Dirt entering engine through cracks in air filter or ducts Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup Worn rings piston or cylinder Excessive piston to cylinder clearance Worn valves guides or seals Restricted crankcase vent Air filter dirty or contaminated Low Compression Decompressor stuck Cylinder head gasket leak No valve clearance or incorrectly adjusted Cylinder or piston worn Piston rings worn leaking broken or sticking Bent valve or stuck valve Valve spring broken or weak Valve not seating properly bent or carbon accumulated on valve area Rocker arm sticking Backfiring Speed limiter system malfunction Fouled spark plug or incorrect plug or plug gap Map faulty lean condition Intake Exhaust system air leaks Ignition system faulty Spark plug cap cracked broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect Sheared flywheel key Poor connections in ignition system System wiring wet Cam lobe worn or Valve sticking Lean condition 4 92 ENGINE TRANSMISSION Vent Connect wi Air Cleaner Transmission Exploded View Final shaft Final gear t fa cm a shaft Drive shaft TRANSMISSION DISASSEMBLY NOTE Engine removal is not required to service 1 Remov
146. ing up a ring compressor on the piston assembly Verify that the ring 6 Check to make sure the rings rotate freely in the groove gaps are 120 apart from each other before installation when compressed by hand 7 Push the rings into the taper using a metallic blunt edge tool while holding the cylinder down PISTON INSTALLATION This will help push the piston past the ring taper into the CAUTION Do not re use cir clips Cir clips become cylinder deformed during the removal process Do not compress the new clip more than necessary to prevent loss of radial tension Severe engine damage may result if cir clips are re used or deformed during installation 1 Install a new cir clip on one side of the piston with the end gap facing or down 2 Apply clean engine oil to the piston rings ring lands piston 8 Up side down cylinder then place the blunt edge tool on pin bore piston pin and piston skirt cylinder Align it with cylinder Lubricate the connecting rod both ends and crankshaft main bearing area 3 IMPORTANT Install the piston on the connecting rod with the IN casting mark facing the intake side of engine The piston pin should be a push fit into the piston 4 Install the other cir clip with the gap facing up or down See Caution with Step 3 above Push the piston pin in both directions to make sure the clips are properly seated in the groove 4 83 ENGINE 9 Place piston into blunt edge tool Tensi
147. is may dangerously weaken it 1 Position the two steering post blocks properly onto the handlebars 9 Ensure the throttle grip operates smoothly 10 Install left hand grip weight There should be 1 3 0 04 0 12 in of clearance a between the throttle grip and the grip weight 2 Install the front block bolts first and evenly tighten the bolts down Evenly torque the 2 front bolts to 15 18 Nm 11 13 165 A FERE 3 Install the rear bolts and tighten evenly Evenly torque the 2 rear bolts to 15 18 Nm 11 13 ft lbs 4 Install the four handlebar bolts and pod bracket loosely into the blocks 5 Install the handlebar pod and screws 11 Install right hand grip weight There should be 1 3 mm 0 04 0 12 in of clearance a between the throttle NOTE There will be a slight gap on the backside 91 and the grip weight the blocks after the procedure is performed E E E Tae i 6 160 Throttle Freeplay Adjustment Inspection 1 Start the engine and warm it up thoroughly 2 Measure the distance the throttle pedal moves before the engine begins to pick up speed Free play should be 3 5 mm Adjustment 1 Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster 2 Loosen the adjuster lock nut 3 Rotate the boot to turn the adjuster until 3 5 mm of
148. iston pin O D Replace piston pin if out of round E T s LE p o PLE OF CROSS PATTERN PISTON INSPECTION 1 Measure piston outside diameter at a point 7mm up from the bottom of the piston at a right angle to the direction of the piston pin Piston Pin Measurement Locations 5 Measure connecting rod small end ID Replace crankshaft if out of round Piston Piston Pin 2 Subtract this measurement from the maximum cylinder measurement obtained earlier Piston to Cylinder Clearance Std 0 02 0 05 mm Limit 0 1 mm 4 71 ENGINE 6 Measure piston ring to groove clearance by placing the 3 If the installed gap measurement exceeds the limit replace ring in the ring land and measuring with a thickness gauge the rings If using new rings and the measurement is too Replace piston and rings if ring to groove clearance exceeds small file the ring ends to achieve the proper gap service limits NOTE Always check piston ring installed gap after re boring a cylinder or when installing new rings A Ring to groove clearance Piston re bored cylinder should always be scrubbed thoroughly with hot soapy water rinsed and dried completely Wipe cylinder bore with an oil rag immediately to remove residue and prevent rust PISTON RING INSTALLED GAP 1 Place each piston ring inside cylinder using piston to push ring squarely into place as shown Piston ring end gap install
149. ith distilled A TROUBLE DIAGNOSIS water in a 50 50 or 60 40 ratio depending on freeze protection Engine temperature is too height required in your area Water thermometer and temperature sensor don t work properly The thermostat 15 stuck to closed COOLING SYSTEM PRESSURE TEST 1 Remove the battery chamber cover that located under handlebar Insufficient coolant Water hose and jacket are clogged 2 Remove pressure cap and pressure test the cooling system Fan motor malfunction using a commercially available pressure tester The filler cap of radiator malfunction 3 The system must maintain 0 7 Bar 10 psi for five minutes or longer Engine temperature is too low If pressure loss is evident within five minutes check the Water thermometer and temperature sensor malfunction radiator hoses lamps and water pump seals for leakage Thermostat is stuck to open PRESSURE CAP TEST Coolant leaking yi WARNING Water Pump mechanical seal worn The o rings located on water pump thermostat and fan Never remove pr r when engine is Cap 9 thermo switch are deteriorated warm or hot The cooling system is under The water hoses are broken or aged pressure and serious burns may result Allow the engine and cooling system to cool before servicing 1 Remove pressure cap and test cap using a commercially available pressure cap test
150. ius at eens aoi as 2 16 STEERING HEAD INSPECTION 22 5 deo ROC RR HERES ead Br Lee dade sees 2 16 FRONTIER CHE PTT eh MAb rath cea 2 17 REAR SHOCK PRELOAD ADJUSTMENT 2 22004 0050244440 ea ete kk eek bled eek Pier bbeede rene nena 2 17 BRAKE SYSTEM cinis diu xa RORIS Re ee e Roda ceo 2 18 BRAKE FLUID INSPECTION so t daga PRA RS RAE DR EE Rd dee Stu da npa og up OS ard ts ara 2 18 BRAKE PAD ADISC INSPECTION ii dcum or och EVE ies re REA Mab d pod eot oe oe its 2 18 BRAKE HOSE ANB FEITTINGAINSPEGLTION ET nak PRECES 2 18 2 13 MAINTENANCE PERIODIC MAINTENANCE CHART PERIODIC MAINTENANCE OVERVIEW Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must b
151. lectrode 8 If 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 STEERING HEAD INSPECTION 10 Install spark plug and torque to specification 1 Position the scooter on level ground Recommended Spark Plug 2 Lightly turn the handlebar left and right NGK DPR7EA 9 3 There should be without any free play Spark Plug Gap 4 If there is excessive free play or the steering feels rough 0 7 09 mm inspect the steering head 222 MAINTENANCE 5 Remove handlebar lower clamp away 3 Hold the scooter upright and apply the front brake 6 Remove upper lock ring nut Push down hard on the handlebar several times and check if 7 Loosen the lower steering ring nut and then tighten it to the front fork rebounds smoothly specification with the steering nut wrench 4 If front fork rough movement repair or replace it REAR SHOCK PRELOAD ADJUSTMENT The rear shock absorber springs are adjustable by rotating the adjustment to change spring tension preload Wrench Suspension Spring Adjustment WS Steering Ring Nut 1 Position the scooter on a level surface 2 Stop the engine 3 Raise and safely support the rear of the scooter off the ground to allow the suspension to fully extend Steering Ring nut specification torque NOTE The tires should not be touching the ground 3
152. lers shoes and springs before reassembly Transmission Inspect transmission operation and adjust linkage if necessary Exhaust Replace exhaust gaskets Seal connections if desired with high temp sealant After running the engine verify all bolted exhaust connections are tight and in good condition Engine Mount Torque Front Mount 80Nm Rear Mounts lower shock 30Nm O Rear Wheel shaft Nut 130Nm Engine Break In Period 4 Cycle Engine Break In Period is defined as the first 10 hours of engine operation or a full tank of fuel Use only Season Synthetic Oil or API certified oil Use fuel with a minimum octane of 87 R M 2 method Change break in oil and filter at 20 hours or 100 miles whichever comes first Radiator System Use only 50 coolant water 50 Ethylene Glycol and 50 water in radiator do not fill only water CAUTION Do not bent or squeeze each wires or hose Route all cables and wires in accordance with the routine layout ENGINE LUBRICATION Oil Type 0 40W Synthetic oil Capacity Approximately 1800 cc Drain Plug Screen Fitting 20 Nm Oil Pressure Specification Continuous oil flows out of stator housing plughole at Idle RPM 0W 40 Synthetic WARNING Cil temperature can cause serious injury and damage Wear the proper safety gear when performing these procedures NOTE Due to the engine assembly having a majority of
153. link Code 35 The blink light stat twinkling 3 times then light off for 1 5 seconds and twinkling 5 times EX_Blink Code 15 Light on 0 5 Sec 4 Sec _ a 40 Digits m ET e Digits 5 Tip SQ Blink Starting Light off 1 5 Sec Light c off 0 5 Sec T off 4 Sec 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 factory For example if blink code shows as number 21 The blink code should be like below There is 4 secconds light off between prime and fail blink code PRIME CODE 55 BLINK CODE 21 10 Digits Digits 0 5Sec Light off 1 5Sec Light off 4 Sec Light off 4 Sec 0 5 sec Off BLINK CODE 24 Light off 1 5 MORE THAN 1 FAILS BLINK CODE If there are two fail blink codes like 21 and 32 The light should twinkle prime code 55 first than 21 and 32 Cycle repeat just 21 and 32 Shows as below Blink Code Repeat 21 6 32 45 OFF 1 55 OFF 45 OFF 1 55 OFF 45 OFF BLANK CODE 21 32 5 116 ELECTRONIC FUEL INJECTION EFI TROUBLESHOOTING Fuel Starvation Lean Mixture Symptoms Hard start or no start bog backfire popping through intake exhaust hesitation detonation low power spark plug erosion engine runs hot surging high idle idle speed erratic No fuel in tank Restricted tank vent or routed improperly Fuel lines
154. ll battery with electrolyte to upper level marks on case 3 Set battery aside to allow for acid absorption and stabilization for 30 minutes 4 Add electrolyte to bring level back to upper level mark on case NOTE This is the last time that electrolyte should be added If the level becomes low after this point add only distilled water 7 183 ELECTRICAL 5 Charge battery at 1 10 of 15 amp hour rating Examples 1 10 of 9 amp battery 9 amp 1 10 of 14 amp battery 1 4 amp 1 10 of 18 amp battery 1 8 amp recommended charging rates 6 Check specific gravity of each cell with a hydrometer to assure each has a reading of 1 270 or higher BATTERY TERMINALS TERMINAL BOLTS Use corrosion resistant grease on battery bolts See Battery Installation CONVENTIONAL BATTERY INSPECTION REMOVAL The battery is located under the seat and the right rear fender see page 9 20 Inspect the battery fluid level When the battery fluid nears the lower level remove the battery and fill with distilled water only to the upper level line To remove the battery Maintain between upper and lower level marks 1 Disconnect holder strap and remove covers 2 Disconnect battery negative black cable first followed by the positive red cable CAUTION Whenever removing or reinstalling the battery disconnect the negative black cable first and reinstall the negative cable last 3 Remove the battery
155. ly charged battery 7 185 ELECTRICAL CONVENTIONAL BATTERY OFF SEASON 3 Install battery in vehicle with positive terminal toward the STORAGE front Coat threads of battery bolt with a corrosion resistant To prevent battery damage during extended periods of dielectric grease non use the following basic battery maintenance items must 4 Connect battery cables be performed A WARNING Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water avoid the possibility of explosion connect positive Rinse with lots of fresh water after cleaning NOTE Do not red cable first and negative black cable last get any of the baking soda into the battery or the acid 5 After connecting the battery cables install the cover on the will be neutralized battery and attach the hold down strap Using a wire brush knife remove any corrosion from the 6 Install clear battery vent tube from vehicle to battery vent cables and terminals A WARNING Make sure that the electrolyte is at the proper level Add Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion Vent should be routed away from frame and body to prevent contact with electrolyte Avoid skin contact with electrolyte as severe burns could result If electrolyte contacts the vehicle frame disconnected or store in
156. ly due to the design of the injectors the high fuel pressure the use of filters and the detergent additives in the gasoline The valve needle in the injector is opened electro magnetically Symptoms that could be caused by dirty clogged injectors and the pressure in the fuel rail forces fuel down through the include rough idle hesitation stumble during acceleration or inside The director plate at the tip of the injector see inset triggering of fault codes related to fuel delivery Injector contains a series of calibrated openings which directs the fuel clogging is usually caused by a buildup of deposits on the into the intake port in a cone shaped spray pattern director plate restricting the flow of fuel resulting in a poor The injector is opened and closed once for each crankshaft spray pattern Some contributing factors to injector clogging revolution however only one half the total amount of fuel include dirty air filters higher than normal operating needed for one firing is injected during each opening The temperatures short operating intervals and dirty incorrect or amount of fuel injected is controlled by the ECU and poor quality fuel Cleaning of clogged injectors is not determined by the length of time the valve needle is held open recommended they should be replaced Additives and higher also referred to as the injection duration or pulse width It grades of fuel can be used as a preventative measure if may
157. m Seal Valve Valve amp Valve Spring Assembly ENGINE 3 To check for bent valve stems mount valve in a drill or use V blocks and a dial indicator 4 Check end of valve stem for flaring pitting wear or damage A 8 Subtract valve stem measurement to obtain stem to guide clearance Stem to guide clearance Limit gt 0 10mm 5 Inspect split keeper groove for wear or flaring of the keeper NOTE Be sure to measure each guide and valve seat area B combination individually NOTE The valves cannot be re faced or end ground 9 Replace valve and or guide if clearance is excessive They must be replaced if worn bent or damaged NOTE If valve guides are replaced valve seats must 6 Measure diameter of valve stem with a micrometer in three be reconditioned Refer to Valve Seat Reconditioning places and in two different directions six measurements total for procedure Replace if excessive wear is evident VALVE SEAT RECONDITIONING Valve Seat Inspection Inspect valve seat in cylinder head for pitting burnt spots roughness and uneven surface If any of the above conditions exist the valve seat must be reconditioned the valve seat 15 cracked the cylinder head must be replaced Valve Stem OD LIMIT Intake Valve Limit 4 975mm Exhaust Valve Limit 4 955mm n UU Hmm Too Narrow 7 Measure valve guide inside diameter at the top middle and end of the guide using a
158. m engine and main harness 5 Connect an ohmmeter between and terminals A resistance value of 0 7 1 3 2 at room temperature 25 TI should be obtained 6 Connect an ohmmeter between the A and B terminals A resistance value of 7K 1 3K at room temperature 25 TT F should be obtained IGNITION COIL REPLACEMENT 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 Coil Retaining Bolt Torque 8 Nm 71 in 105 DIAGNOSTIC CODES NOTE The EFI diagnostic mode is intended to quickly view the cause of the Check Engine light To recall blink codes fail codes from the ECU 1 Verify the key switch is off and the transmission is in neutral with the parking brake applied 2 Turn the key switch ON and OFF 3 times within 5 seconds and leave the key switch in the ON position on the third turn The word Wait will appear as the ECU searches for blink codes 3 Any blink codes stored in the ECU will display a numerical blink code one at a time in numerical order on the instrument cluster display 4 The word End and or the number 61 will display after all of the codes have been displayed or if no codes are present 5 114 ELECTRONIC FUEL INJECTION DIAGNOSTIC BLINK CODES CHART
159. mal function codes as below P0112 IAT grounded P0113 IAT short open P0117 CLT grounded P0118 CLT short open 2 Engine in idle mode 3 In take air temperature within specified range 4 Engine temperature within specified range 5 Diagnostic tool in connection KWF Digoust Tool ON Bee 1 CORPORATION Histor Raci Idle RPM Adjust LAC sacan arl On flag IdleRPMErr 10 rpm RPM 7 1610 rpm CLC 0 00 percent BLM 0 00 percent lACCommDuty 21 9 percent Cyl1ExpectMAP 43 40 kPa SA 0SA Toil_Physical 114 degC idx 39 degC Baro 102 kPa VBatt_idx 13 0 V AFR 14 3 AFR Log Contig St 5 130 ELECTRONIC FUEL INJECTION PreBLM Learn This function can be used when it exceeds 10 of control under engine fully warm up ad BON I DiagTool PreBLMEnF eq ON Fuel3 PreBLMEn On Pul PEERS on icon of Enable or Disablai Fuel BLMEn Off flag BLM 3 91 percent PreBLM 0 00 percent A dm count H Physical 101 degC IAT_idx 22 degc exceed 10 percent 102 AFR 14 6 AFR Convert Log File 1 Press Convert Log File under Not connected condition Tool CITE POHREAT ECEN I Liteon Group The Lite On Group is one of Talwan s leading m
160. mbly Do not disassemble pump Replace entire component 1 Inspect the oil pump sealing surface on the crankcase Apply a liberal amount of engine oil to the surfaces and pump 2 Install pump as shown Torque screws to specified torque F s NOTE not use gasket sealer the pump mating surfaces PISTON RING INSTALLATION NOTE Apply clean engine oil to all ring surfaces and ring lands Always check piston ring installed gap before rings are installed on piston If the piston has been in service clean any accumulated carbon from 1 Place the oil control ring expander in oil ring groove with the end gap facing forward The expander has no up or down marking and can be installed either way The ends should butt squarely together and must not overlap 2 Install the oil ring top rail with the end gap at least 30 from the end of the expander 4 82 ENGINE 3 Install the bottom rail with the gap at least 30 from the end of the expander on the side opposite the top rail gap Top Ring Profile Second Ring Profile um 5 Place dowel pins in crankcase and install a new 4 Install the second ring with the mark facing up cylinder base gasket Position the end gap toward the rear intake side of the piston 6 Lubricate the piston and rings with assembly lube and install 5 Install the top ring with the chamfered edge fac
161. mpared to its ECU If the maximum RPM limit 8500 is exceeded the ECU programming for determining the fuel and ignition suppresses the injection signals cutting off the fuel flow This requirements during operation process repeats it self in rapid succession limiting operation to the preset maximum IAT TEST ECU SERVICE The IAT is a sealed non serviceable assembly If fault code Never attempt to disassemble the ECU It is sealed to prevent diagnosis indicates a problem within this sensor test as damage to internal components Warranty is void if the case 15 follows opened or tampered with in any way All operating and control functions within the ECU are pre set No internal servicing or readjustment may be performed Inlet air temperature signal B Ground if m Pel problem is encountered and you determine the ECU to be n la inc egy T r gu e i i i faulty contact the AEON Service Department for specific handling instructions Do not replace the ECU without factory authorization The relationship between the ECU and the throttle position sensor TPS is very critical to proper system operation If the TPS is faulty or the mounting position of the TPS to the 1 Disconnect IAT 2 wire harness connector on the left hand throttle body is altered the TPS must be re initialized see TPS side of throttle body boot Initialization for procedure if requir
162. n be serviced or removed with the engine installed in the frame 1 Flywheel 2 Alternator Stator 3 Starter Motor Starter Drive 4 Oil pump 5 Rocker Arms 6 Throttle Body 7 Injector and all EFI system 8 Transmission 9 Valve gap adjustment The following components require engine removal for service 1 Cam Chain and Sprockets 2 Cylinder Head 3 Cylinder 4 Piston Rings 8 Crankcase 9 Transmission 10 Valves NOTE Cam chain service requires crankshaft removal as the chain is located on the pto side of the engine NOTE Crankshaft components are not serviceable Replace crankshaft as an assembly ENGINE REMOVAL IMPORTANT Some engine repair procedures can be performed without removing the scooter engine assembly from the vehicle WARNING Always wear safety glasses and proper shop clothing when performing the procedures in this manual Failing to do so may lead to possible injury or death 1 Clean work area 2 Thoroughly clean the scooter engine and chassis 3 Disconnect battery cables 4 Drain engine oil 5 Drain radiator water 6 Open the seat then remove the luggage box 7 Remove all chassis protect shield both bottom cover both foot well and both side cover 8 Disconnect spark plug high tension lead 9 Disconnect all electric and EFI wires from the engine 10 Disconnect radiator tubes 11 Lift middle of body frame by jack 4 54 ENGINE 12 Remove the
163. nctional For bleed air bubble completely Remove radiator cap and start engine while engine is cold then press water hose softly by hand to bleeding Turn the throttle repeatedly until the coolant surface becomes stable 4 48 Water pump repair Water hose clogged Replace thermo unit Replace thermostat Refill coolant and check again Ensure the coolant hose not twist and kink while air bubble bleeding ENGINE COOLANT REPLACEMENT 1 The cooling system can be serviced on the motorcycle 2 Remove radiator pressure cap which located under handlebar Radiator Pressure Cap 3 Remove recovery cap which located under footrest 4 Place a water pan under the water pump remove the drain bolt to drain out the coolant 5 Reinstall the drain bolt 6 Refill system with the coolant and bleed out the air bubbles COOLING SYSTEM BLEEDING PROCEDURE WARNING Always wear safety glasses and proper shop clothing when performing the procedures in this manual Failing to do so may lead to possible injury or death 4 49 CAUTION Use caution when performing these procedures Coolant may be hot and may cause severe injury or 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 overheats and no apparent leaks in the cooling sy
164. ne data ECU version Malfunction code Malfunction history Malfunction record Freeze frame DIT DIAGNOSTIC HARNESS ECU Terminal IGN 1 with ignition key switch Grund J pi20 5 118 ELECTRONIC FUEL INJECTION DIAGNOSTIC TOOL Diagnostic Tool PC interface cable RS232 USB Conversion Cable SYSTEM LOGIN Plug 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 Password Memorize Faseword 1 Connection and Convert Log File will be shown before connection Press Connection to start 5 119 ELECTRONIC FUEL INJECTION E Tool L Connect Disconnect L CORPORATION L Convert Log Fila Liteon Group OS QN x The Lite On Group is of Taiwan s leading manufacturers Many of our products have been ranked in first place globally The Lite On Group has approximately 50 thousand employees and annual turnover of over USS 5 2 billion Language of interface Langue 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 Connection 5 120 ELECTRONI
165. nstallation of new seals is bearing in a freezer prior to installation will assist the assembly process 1 Install bearing so numbers are visible disassembled 2 Drive or press the new bearing into the crankcase using the 1 Inspect both the crankshaft and the crankcase diameter proper driver where bearing is installed location Replace crankshaft if it is CAUTION out of specification Press only on outer race of bearing to prevent bearing damage 3 Install new seals with the lip facing in CAUTION Press only on outer diameter to prevent damage ENGINE REASSEMBLY 4 80 ENGINE CRANKSHAFT AND OIL CHAIN INSTALLATION Lubricate all bearings with clean engine oil before assembly 1 Support the crankcase on blocks 4 Install 3 bolts circled from the right side crankcase NOTE Use care not to damage the crankshaft end 5 Loop the cam chain through the chain room and secure with mechanic s wire NOTE Use care not to damage the crankshaft end WARNING 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 hold it in place 4 81 ENGINE OIL PUMP AND CHAIN INSTALLATION 5 Install oil pump shield NOTE pump is not a serviceable asse
166. nt and spring which can cause loss of oil pressure resulting in severe 5 Inspect stator coils and pick up Replace complete stator if any one coil or engine damage pick up burnt 1 Remove the oil passage plunge joint flywheel nut and washer ONE WAY CLUTCH REMOVAL INSPECTION 1 Remove the hex bolts that attach the one way drive clutch to the flywheel Stick with Loctite 272 2 Install Flywheel Puller 3 Remove 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 Gear 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 4 75 ENGINE 3 Inspect one way rollers connect surface Replace one way roller if it worn or damaged Roller One Way Clutch Screw Torque 10 Nm 4 Inspect one way clutch gear connect surface against with OIL PUMP DRIVE SPROCKET REMOVAL one way roller Replace one way clutch gear if it worn or INSPECTION damaged 1 Remove the oil pump shield 5 Install the one way clutch onto flywheel and push the one way gear into one way clutch 6 Turn the one way gear counterclockwise to check that 2 The outer chain is oil and water pump drive chain The one way clutch and one way gear well engagement inner c
167. of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection 2 Straight water or antifreeze may cause the system to freeze corrode or overheat COOLING SYSTEM HOSES 1 Inspect all hoses for cracks deterioration abrasion or leaks Replace if necessary Discharge to Pump Recovery Tank 2 Check tightness of all hose clamps CAUTION Do not over tighten hose clamps at radiator or radiator fitting may distort causing a restriction to coolant flow Radiator hose clamp torque is 4 Nm 36 in Ibs RADIATOR 1 Check radiator air passages for restrictions or damage 2 Carefully straighten any bent radiator fins 3 Remove any obstructions with compressed air or low pressure water CAUTION Washing the vehicle with a high pressure washer could damage the radiator fins and impair the radiators effectiveness Use of a high pressure washer is not recommended COOLANT DRAIN 1 Remove front windshield and floor 2 Slowly remove the pressure cap to relieve any cooling system pressure 3 Place a suitable drain pan underneath the discharge hose on the LH side of the radiator 4 Drain the coolant from the radiator by removing the lower engine inlet hose from the Radiator discharge hose Properly dispose of the coolant 5 Allow coolant to completely drain 2 23 MAINTENANCE WHEELS AND TIRES TIRE PRESSURE
168. oner Blade Mounting Bolt Torque 10 Nm 7 4 ft Ibs CYLINDER INSTALLATION NOTE Clean the gasket surfaces on the crankcase and cylinder Remove all traces of old gasket material and apply a new base gasket 1 Install the dowel pin s Install an new base gasket onto the mating surface and install the piston into cylinder 10 Use non metallic rod to push piston until piston through NOTE Route cam chain through the cylinder chain the tool to cylinder room and secure it holding it up while rotating the engine to avoid damage to the chain drive sprocket teeth or tensioner blade 2 Apply clean engine oil liberally to the bore and tapered area of the cylinder Place the cylinder on to the studs 3 Install the cam chain guide and dowel pins into the cylinder Verify the bottom end is seated properly in the crankcase E s 4 Pull cam chain through cylinder chain room and TENSIONER BLADE INSTALLATION 1 Install the tensioner blade and tighten the mounting bolt to specified torque 4 84 ENGINE 5 Position crankshaft at Top Dead Center TDC on 4 Install the cam according to the Cam Shaft compression stroke Timing procedure Verify the cam chain is in place around the crankshaft gear NOTE Verify camshaft timing procedure before installing the rocker shaft assembly CAMSHAFT TIMING CAUTION Serious engine damage may result if the camshaft is not prope
169. or and magnet are located on front right wheel FREE Speedometer sensor TURN SIGNAL 1 When the switch is pushed to the position there should be continuity between the Br W amp DG wires 2 When the switch is pushed to the gt position there should be continuity between the Br W amp DB wires 7 167 ELECTRICAL Speedometer Signal Description Tachometer Fuel gauge Water temperature gauge Hazard indicat P azard indicator i li Coolant temp PAZ OFI Turn shes High Beam NN N 2 YOI o9 c Mileage Counter ADS Se _ ADJ Button service indicator SEL Button warning light SPEEDOMETER CIRCUIT TERMINALS 2 il PIN 1 Coolant Gauge PIN 2 W B Petrol Gauge Lr PIN 3 NO WIG Qan DID UID Light Light Switch PIN 7 B Y R P M Sensor PIN 8 L R Hazard Controller PIN 9 DB Signal Lamp LH F amp R PIN 10 DG Signal Lamp RH F amp R PIN 11 0 Light Light Switch PIN 12 O B Blink Lamp EFI Mal PIN 13 R2 Hazard Controller ir IDB LLAW I Y PIN 14 Br L Horn PIN 15 Ground n in T PIN 16 Gr Tachometer 4 3 SENSOR PIN 6 R P M Sensor E 8 7 168 ELECTRICAL BRAKE LIGHT SWITCH Brake lever utilizes an electrical brake switch that sends voltage
170. or fuel injectors restricted Fuel filter plugged Fuel pump inoperative Air leak in system ntake air leak throttle shaft intake ducts airbox or air cleaner cover ncorrect throttle stop screw adjustment Rich Mixture Symptoms Fouls spark plugs black sooty exhaust smoke rough idle poor fuel economy 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 incorrect njector failure Poor Idle Symptom Idle Too High If greater than 1300 RPM when engine is warm Throttle stop screw set incorrect Throttle cable sticking improperly adjusted routed incorrectly Symptom Idle Too Low if less than 900 RPM when engine is warm Plugged air filter Leaking injector rich condition Belt dragging Throttle stop screw tampering Symptom Erratic Idle Throttle cable incorrectly adjusted Air Leaks dirty injector e TPS damaged or adjusted Tight valves gnition timing incorrect Belt dragging Dirty air cleaner Engine worn e Spark Plug fouled Throttle stop screw set incorrectly out of sync with ECU 5 117 ELECTRONIC FUEL INJECTION KWP DIAGNOSTIC TOOL KWP Diagnostic Tool that transfer ECU diagnosis data to PDA or computer by K Line There are 7 majors mode to monitor engine system failure Engi
171. otor starter relay brake light switch and ECU and kick stand switch If the main switch is START position the starter motor can be operated only if 1 The kickstand on ground kickstand tough ground Or 2 The brake lever is not pressed the brake light switch is closed IF THE STARTING MOTOR FAILS TO OPERATE FOLLOWING PROCEDURE TO CHECKING FUSE Ensure fuse main ignition signaling system continuity If broken replace the fuse BATTERY Check the battery condition The open circuit voltage should be 12 8 V or more at 20 C 68 F If battery less than 11 8V inspect regulator and stator recharge or replace the battery 7 174 ELECTRICAL STARTER MOTOR STARTER MOTOR DISASSEMBLY The starter motor is a complete service part If it is determined NOTE Use only electrical contact cleaner to clean that the starter motor is the failed part replace as needed starter motor parts Other solvents may leave a 1 Connect the battery terminal and starter motor cable2 residue or damage internal parts and insulation 2 Using a jumper connect start motor terminal and frame ground 3 Check the operation of the starter motor WARNING This check is likely to produce sparks so be sure that no flammable gas or fluid is in the vicinity CAUTION A wire that is used as a jumper wire must have the equivalent capacity or more as that of the battery wire otherwise the jumper
172. p SEALED LOW MAINTENANCEBATTERY CHARGING 2 Disconnect battery negative black cable first followed by the positive red cable If battery voltage is 12 8 V or less the battery may need recharging When using an automatic charger refer to the A CAUTION charger manufacturer s instructions for recharging When Whenever removing or reinstalling the battery i tant t ch the followi USNS IESE USS TIS OWNS SEN disconnect the negative black cable first and for recharging reinstall the negative cable last NOTE Always verify battery condition before and 1 2 3 Remove the battery SEALED LOW MAINTENANCE BATTERY INSTALLATION 1 Clean battery cables and terminals with a stiff wire brush charging times carefully Stop charging if the battery Corrosion be removed using solution of one cup water hours after the end of charging WARNING An overheated battery could explode causing severe injury or death Always watch becomes very warm to the touch Allow it to cool l and one tablespoon baking soda Rinse well with clean water before resuming charging hl and dry thoroughly BATTERY CHARGING REFERENCE TABLE State off VOLTAGE ACTION CHARGE TIME 2 Route the cables correctly 3 Reinstall battery attaching positive red cable first and then the negative black cable Coat terminals and bolt 100 12 8 13 0 None FULL threa
173. pite aa kts Wee hos aaa ese PU bee ane eee eae ee 4 4 ENGINE EXPLODED VIEWS 25 Gee ERE URN PUE d e E dma Rud SURE 4 5 Ol FLOW DIAGRAM owe cic ce See Sawa a Pek Ea ee oe Be ee Ee dri ac dele dre ia tcd s 4 6 ENGINE COOLING SYSTEM eee eee eee es 4 7 COOLING SYSTEM EXPLODED VIEW 24252 84 59 Rod adt e E ds Ete SER ta shee eds bn Ge Pee ieee es 4 7 COOLING SYSTEM SPECIFICATIONS iu or ree Pre M eke Pee o coepta 4 7 COOLING SYSTEM PRESSURE TEST nice ead ue a ue w ae Bie a LE eds 4 8 PRESSURE CAP TEST cu stehe ect UR doe been Rt Seed eae em ae mee peed as Sra aoe 4 8 TOU BER SIS hs EE ad ratur Do cea eee ee nce ae 4 8 COOLING SYSTEM FAILURE 2 eee 4 9 COOLANT REPLACEMENT suia ih cen me RS RO sus bane 4 10 ROAR s s ou ier eda Sete eee A Soe oes en as as 4 12 STAG Cora we wie ek Sone aise ee ae See Re ean E E area 4 12 FAN THENMO SVT CR 4d our hee aa aucem UH ware Feat eran Soe iab dts 4 12 VATE R EUM Sound A ieee ve aS 4 13 LOP END DISASSEMBLY
174. pping is not required with an interference angle 10 Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve Proper Seat Contact On Valve Face stem Ifthe indicated seat contact 15 at the top edge ofthe valve 11 Rotate the valve rapidly back and forth until the cut sounds face and contacts the margin area B it is too high on the valve smooth Lift the valve slightly off of the seat rotate 1 4 turn face Use the 30 cutter to lower the valve seat and repeat the lapping process Do this four to five times until Iftoo low use the 60 or 75 cutter to raise the seat the valve is fully seated and repeat process for the other valve When contact area is centered on the valve face measure seat 12 Clean cylinder head valves and camshaft oil supply width passages thoroughly Ifthe seat is too wide or uneven use both top and bottom 13 Spray electrical contact cleaner into oil passages and dry cutters to narrow the seat using compressed air If the seat is too narrow widen using CYLINDER HEAD ASSEMBLY the 45 cutter and re check contact point on the valve face CAUTION and seat width after each cut Wear eye protection during assembly NOTE Assemble the valves one at a time to maintain proper order Bottom 60 or 79 Seat 45 or 46 1 Install new valve seals on valve guides E e NOTE When using an interferen
175. r is up to the MAX line inside reservoir and install reservoir cap 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 Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Allow pads and disc to cool sufficiently during the procedure Do not allow pads or disc to become hot or warping may result Repeat this procedure 10 times BRAKE SQUEAL POOR BRAKE PERFORMANCE Air in system Water in system brake fluid contaminated Caliper or disc misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc and or friction pads ncorrectly adjusted stationary pad Worn or damaged master cylinder or components Damaged break pad noise insulator Brake pads dragging Brake caliper dragging PEDAL VIBRATION Disc damaged Disc worn run out or thickness variance exceeds service limit CALIPER OVERHEAT BRAKES DRAG Compensating port plugged Pad clearance set incorrectly Brake pedal binding or unable to return fully Residue build up under caliper seals Operator riding brakes BRAKE LOCK Alignment of caliper to disc Caliper pistons sticking Improper assembly of brake system components 6 153 Steering Shaft Exploded View Race Woodruff Key steering Shaft 1 Support scooter by Main stand
176. rly timed to the crankshaft CYLINDER HEAD AND CAMSHAFT IMPORTANT CAMSHAFT TIMING NOTE INSTALLATION In order to time the camshaft to the crankshaft the NOTE Clean the gasket surfaces on the cylinder piston must be precisely located at Top Dead head and cylinder Remove all traces of old gasket Center TDC This can be accomplished using one of material two methods 1 Install the dowel pin s and a new cylinder head gasket Install the cam chain over the crankshaft When the stator housing is removed use Method 1 This method uses the camshaft gear marks and the crankshaft keyway to establish TDC It is important to note that this method can only be used when the stator housing is removed and the crankshaft keyway is in view The camshaft sprocket alignment marks are parallel to the gasket surface and camshaft lobes are pointing down The cam chain plate links are not used to time the camshaft 2 Pull the cam chain through the cylinder head chain room When the stator housing is installed use Method 2 and secure with mechanic s wire This method establishes accurate Top Dead Center 3 Place the cylinder head on the cylinder TDC by aligning the single mark on the flywheel with the notch in the timing inspection hole see Method 2 The camshaft sprocket alignment marks are parallel to the gasket surface and camshaft lobes are pointing down The cam chain plate links are not used to time the camshaft 4 85 ENGINE
177. ry Cail 110 du 5000 at 20 C 68 F STATOR COIL 1 Resistance Value of Each Stator Leg Measure the resistance value of each of the three stator legs Y1 to Y2 Y1 to Y3 and Y2 to Y3 Each should measure 0 3 1 2 ohms When measuring any of the Yellow wires to ground the Secondary coil resistance reading should be infinite open 5 3 6 7 kQat 20 C 68 F NOTE If there are any significant variations in ohm s 6 If ignition coil resistance reading overdue specified replace readings between the three legs it is an indication the ignition coil that one of the three stator legs maybe weak or failed MAIN SWITCH Refer to KEY MAIN SWITCH 2 Resistance Value of Stator Leg to Ground Measure the resistance value of each of the stator legs to PICKUP COIL ground Y1 to Ground Y2 to Ground and to Ground 1 Disconnect the A C stator coupler from the wire harness 2 Connect the multi meter 100 to the pickup coil NOTE Any measurement other than Infinity open Will indicate a failed or shorted stator leg terminal 3 Measure AC Voltage Output of Each Probe L blue terminal Stator Leg at Charging RPM with a voltmeter set to Volts Probe G green terminal AC 3 Check the pickup coil for the specified resistance 4 Place the red lead on the tester in the 10A jack 5 Turn the selector dial to the Volts AC position 6 Start the engine and let it idle 7 Separ
178. ry case is dark and the cell caps are not removable SEALED LOW MAINTENANCE BATTERY NOTE All Low Maintenance batteries are fully since there is no need to check electrolyte level charged and tested at the factory before NEVER attempt to add electrolyte or water to a Low installation Expected shelf life varies upon storage Maintenance battery Doing so will damage the case and conditions As a general rule before placing the shorten the life of the battery Refer to the Battery Activation battery into service check the battery condition and Maintenance Video PN 9917987 for proper instruction and charge accordingly _ 9 gly on servicing Low Maintenance batteries 7 180 ELECTRICAL NEVER attempt to add electrolyte or water to a Low SEALED LOW MAINTENANCE BATTERY Maintenance battery Doing so will damage caseand INSPECTION REMOVAL shorten the life of the battery Refer to the Battery The battery is located under left handlebar and inside of inspection cover Maintenance Video PN 9917987 for proper instruction on servicing Low Maintenance batteries Inspection Cover How To service a Low Maintenance battery 1 Remove battery from the vehicle 2 Test battery with a voltage meter or load tester to determine battery condition This will determine the length of time required to charge the battery to full capacity Refer to capacity table 3 Charge battery using a variable rate charger 1 Disconnect holder stra
179. s barometric Pressure Sensor CroutLow input ves barometric Pressure Sensor CroutHigh put ves 9 iake Air Temp Sensor Stort Grud 65 iake Air Temp Sensor Open orShotGreuto ECU ves _ Temperature Sensor Shot To Groma ves _ sr Engine Temperature Sensor Open or Sotto Batey YES poes SSN Openorshon creatora ws _ esse muros _ u o oasensor Open or w _ e osoena e w _ 18 fuet Pump Open orStertoBatey wo ner ston creuttoGouns Instr Open or stertoaatey anon cor stor creuttoGrouns ws 5 anon Open or Storaatey ws _ s Lamp ster Grout Ground wes pregnoste Lamp Open or _ as speedometer Shor mo s speedometer Open or ShortoBatey pos Postion Sensor Open J _ s Openorsrorosatey wo _ shor CrouttoGrond 3s jMeArConwmersronOmutbGmed mo fe Ar Convoler Open or stort Batey mo LC NN 5 115 ELECTRONIC FUEL INJECTION BLINK CODE BREAKOUT DIAGRAMS BLINK CODE RECOGNITION The blink code is 10 digits numbers The blink light location on left of the speedometer display screen as show above For example while B
180. s Over But Fails to Start No fuel Fuel injector carbon built Fuel pressure less than 250kpa Fuel pump inoperative restricted Tank vent or fuel hose plugged Engine flooded Low compression high cylinder leakage No spark Spark plug fouled Spark plug coil lost power O Without valve clearance Engine Does Not Turn Over Dead battery O Starter motor does not turn O Engine seized rusted or mechanical failure One way clutch components damaged or sliding Engine Runs But Will Not Idle Restricted throttle pilot system Air mixture screw misadjusted Idle speed control valve failure Low compression O Crankcase breather restricted Air filter restriction Oxygen sensor connects corrosion or short circuit Engine Idles But Will Not Accelerate Spark plug fouled weak spark O Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Incorrect or restricted fuel injector O Reverse speed limiter limiting speed Map fault Incorrect ignition timing Restricted exhaust system Cam Lobe worn Engine Has Low Power Spark plug fouled Restricted exhaust muffler Dirty carburetor Cam lobe worn Too much engine oil in crankcase TROUBLESHOOTING CVT not operating properly Cylinder piston ring or valve wear or damage check compression Piston Failure Scor
181. sat for a while before removing the dipstick IMPORTANT Do not run the machine and then check the dipstick 3 Remove dipstick and wipe dry with a clean cloth 4 Reinstall the dipstick completely and screw it to the end NOTE Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent 7 Remove the dipstick and check the oil level Maintain the oil level between the Upper and Lower range Add oil as indicated by the level on the dipstick Do not overfill see NOTE below Crankcase Drain Plug Torque 20 Nm 15 ft Ibs Oil Filter Torque 5 Nm 45 in 105 2 19 MAINTENANCE NOTE A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full mark change the oil immediately E 8 Reinstall dipstick and seat lever lock OA Oda e 14 4 ENGINE OIL AND FILTER SERVICE Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart Always change the oil filter whenever changing the engine oil Engine oil Filter Can Location WARNING 10 Install new filter can and turn by hand until filter gasket Personal injury can occur when handling used oil Contacts the sealing surface then turn an additional 1 2 turn Hot oil can cause burns or skin damage 11 Remo
182. se care during the removal process 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 Remove 3 flange bolts yellow arrows from the right side crankcase 2 Separate crankcase using a hydraulic tool or by pressing on the pto end of the crankshaft using special tool NOTE Tap on one side of the crankcase with a soft face hammer Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crankcase halves separate evenly ENGINE 3 Watch the gap along the crankcase mating surface and separate the crankcase evenly 4 Once the crankshaft bearing is free from the case the crankshaft and cam chain can be removed by hand for service CRANKSHAFT REMOVAL 1 Remove right hand crankcase with soft faced hammer 2 Press the crankshaft out Use care not to damage the crankshaft oil passage on the right end crankshaft end NOTE Use care not to damage the crankshaft end CRANKSHAFT CAM amp OIL CHAIN SPROCKET INSPECTION 1 Inspect the crankshaft main bearings and cam and oil pump chain sprocket for wear or damage NOTE Due to extremely 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 rac
183. sential to engine operation constantly monitoring the rotational speed RPM and position of the crankshaft 2 Connect an ohmmeter between the pin terminals leading from the Blue and Green wires A resistance value of 110 5000 at room temperature 25 77 should be obtained El A ferromagnetic 23 tooth is mounted on the flywheel During rotation an AC pulse is created within the sensor for each passing tooth The ECU calculates engine speed from the time interval between the consecutive 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 ECU FUEL INJECTOR 5 107 ELECTRONIC FUEL INJECTION 3 If the resistance is correct Test the main harness circuit between the sensor connector terminals and the corresponding pin terminals at the ECU see wiring diagram Check the sensor mounting air gap flywheel ring gear for damage or run out and flywheel key Follow the CPS Replacement procedure to inspect CPS and flywheel ring gear for damage 4 If the resistance is incorrect follow the CPS Replacement procedure CPS Resistance Specification 10 Remove 2 retains bolts and the CPS 110 5000 25 77 F 11 Install new sensor CPS REPLACEMENT 12 Torque the CPS retaining bolt to specification Removal 1 Safely support the rear of the vehicle off the
184. sheave and cam plate off crankshaft as an assembly NOTE When removing primary sliding sheave and cam plate assembly hold cam plate and sliding sheave together This prevents the rollers from falling out of the assembly 7 Holding the clutch shoe assembly with the holding tool tighten the clutch shoe assembly nut to 90Nm with the locknut 3 Remove cam plate wrench 4 Inspect surface of roller weight for wear or damage The outside diameter is 23 2mm service limit is 22 7mm E Holding E Tooling 8 Hold the clutch housing with the holding tooling tighten the clutch housing nut to 50Nm 5 Inspect surface of slide sheave slide bushing and cam plate for wear pitting or damage k Tooling 3 38 CVT SYSTEM 6 Inspect belt contacting surface of both sheave for wear or damage DRIVE CLUTCH ASSEMBLY 1 Install the V belt onto the drive 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 sheave with the rotor holding tool install washer and nut tighten the drive clutch nut to 100 Drive Clutch Drive Clutch Lock Nut Torque 100 Nm 74ft Ibs 3 39 ENGINE CHAPTER 4 ENGINE SERVICE 53 9 x 9E tg Shy ba ea eee ECHO RR UR RR 4 4 ENGINE EXPLODED iynin ihn bg dde
185. ssembly 8 After tensioner installation rotate engine at least two revolutions 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 view sprocket Use a wire to pull the chain up through the cylinder and cylinder head and to hold it in place Secure the chain 3 Apply grease or molybdenum disulfide grease to the camshaft main journals and cam lobes Lubricate automatic compression release mechanism with clean engine oil 4 Orientate the camshaft with the lobes facing downward 5 Disconnect the wire securing the cam chain and loop the cam chain over the sprocket while verifying the cam is inserted with the alignment marks parallel to the gasket surface 6 Check all cam timing marks to verify proper cam timing and install the rocker arm assembly Torque the cylinder stud nuts to specification NOTE Do not rotate engine until tensioner and rocker assembly is installed 7 Install the tensioner and rocker assembly 8 After tensioner installation rotate engine at least two revolutions and re check marks timing 4 86 ENGINE ROCKER SHAFT ARM INSTALLATION 7 Adjust valves according to the VALVE 1 Assemble arms shafts and decompression components into CLEARANCE ADJUSTMENT PROCEDURES cam support Page4 39 8 Install rocker cover and torque bolts to specifica
186. stem are found 1 Park motorcycle with center stand 2 Remove recovery bottle cap and fill bottle to the full line 3 Slightly loosen the bleed hose bypass hose to let air escape 5 NE 4 Close bleed hose 5 Start the engine and let it idle for 5 10 minutes or until the thermostat opens and allows coolant to flow through the system Bubbles will escape continuing 6 Until fan start the temperature will cool down and coolant be sucked into coolant system 7 Squeeze the coolant lines by hand to help purge the system of air NOTE If there is air in the system you will see air bubbles forming through the radiator filler neck ENGINE 8 Add coolant to the radiator filler neck if the level goes 9 Repeat 6 to 8 step If no bubbles are seen at the filler neck down 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 coolant level indicating that coolant has been pulled into the system Fill the recovery bottle only after you have completely filled the cooling system at the radiator filler neck 11 Repeat this procedure if overheating still occurs WARNING Be sure to install the pressure cap before shutting off the engine Coolant may spit out of the radiator Thermo switch fan Cooling fan Engine coolant outlet pipe Radiator Thermostat N
187. t the engine when the cables are loose or poorly SPECIAL TOOLS connected to the battery terminals Part Number Tool Description Never disconnect battery while engine is running 07100201 000 Diagnostic Tool PC Cable Never use a battery boost pack to start the engine Missing Cable RS232 USB Conversion Do not charge battery with key switch on Missing KWP Diagnostic Software Always disconnect negative battery cable lead before qe charging battery Missing Fuel pressure gauge Always unplug ECU from the wire harness before SERVICE NOTES For more convenient and accurate testing of EFI components performing any welding on the unit it is recommended dealers utilize the KWP Diagnostic Tool Software dealer only or testing may be done manually using 5 99 ELECTRONIC FUEL INJECTION the procedures provided ELECTRONIC FUEL INJECTION SYSTEM EFI SYSTEM EXPLODED VIEW 1 2 3 1 1 4 5 6 7 amp 9 Electronic Control Unit ECU Intake Air Temperature IAT Crankshaft Position Sensor CPS Fuel Injectors Fuel Pump Fuel Pump Regulator Engine Coolant Sensor ECT Throttle Position Sensor TPS Throttle Body Ignition Coil 0 Rollover Sensor 1 Idle Air Control Valve Crank Wheel Heated 02 sensor Encine Temp Sensor ETS Inlet Air Temp Sensor E Check Engine Engine Speed Light MIL 5 100 Throttle Position Throt
188. ter 1 and the battery 12 V to the starter relay terminals 3 Connect Battery terminal with relay G R wire Connect Battery terminal with relay Br wire 2 4 Connect multi meter probe with relay R terminal 9 Connect multi meter probe with ground terminal 5 Check the starter relay for continuity If relay is in continuity replace the start relay 7 177 ELECTRICAL Charging Circuit Pick Up CPS 10 Fuse IF THE BATTERY IS NOT CHARGED FOLLOWING 3 Refer to KEY MAIN SWITCH at above and ensure fuse PROCEDURE TO CHECKING continuity If broken replace the fuse MAIN FUSE 1 The main fuse box is located in left panel and above air cleaner which be fasten on left frame CURRENT DRAW KEY OFF CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running Damage will occur to light bulbs and speed limiter Connect an ammeter in series with the negative battery cable 2 A 15 Amp fuse protects the main electrical system a 30 Check for current draw with the key off Amp fuse protects charging system two 10 Amp fuses If the draw is excessive loads should be disconnected from the protects the light and EFI system a 5 Amp fuse protects system one by one until the draw is eliminated Check ignition system component wiring as well as the component for partial shorts to ground to eliminate the draw 7 178 ELECTRICAL Current Dr
189. ter With lights on charging should occur at or below 2000 RPM not perform this test longer than required to obtain a reading or the alternator stator windings may overheat Do not exceed idle rpm during this test To Calculate Available Alternator Output I P E 150W 12V 12 5 Amps Current in Amps P Power in Watts E Electromotive Force Volts Alternator Current Output Minimum of 5 AC Amps 1 Maximum alternator output will be indicated on the meter It is not necessary to increase engine RPM above idle 2 Place the red lead on the tester in the 10A jack 3 Turn the selector dial to the AC amps position 4 Connect the meter leads to the wires leading from the alternator see schematic for proper wiring colors 5 Start the engine and let it idle Reading should be a minimum of 5 at idle OBATTERY IDENTIFICATION NOTICE It is important to identify what type of battery you have installed in your ATV Different types of batteries require different service procedures Proper servicing and upkeep of your battery is very important for maintaining long battery life Your ATV may have a Conventional Battery or a Sealed Low Maintenance Battery To identify which type of battery your ATV has refer to the illustration below and 9 Turn the lights on and lock parking brake to keep brake light follow the correct service and charging procedures that follow On in the manual 7 179 ELECTRIC
190. the brake system BRAKE BURNISHING PROCEDURE It is required that a burnishing procedure be performed after A WARNING installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph If brake pads are contaminated with grease oil or Gradually apply brakes to stop machine Allow pads and disc liquid soaked do not use the pads Use only new to cool sufficiently during the procedure Do not allow pads or clean pads disc to become hot or warping may result Repeat this procedure 10 times 1 Install caliper and torque mounting bolts to specification PAD REMOVAL 1 Elevate and support rear of vehicle CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls Front caliper Bolt Torque 30 Nm 21 7 ft Ibs 2 Install brake line and tighten securely with a line wrench 2 Remove the two caliper mounting bolts and lift caliper off the brake disc NOTE When removing caliper be careful not to Torque the banjo bolt brake hose to the proper torque specification 3 Perform brake bleeding procedure as outlined earlier in this damage brake line Support caliper so as not to kink chapter or bend brake line 4 Install wheel and torque wheel nuts to specification 3 Push caliper piston into the caliper bore slowly and remove caliper from swing arm 6 152
191. the coolant recovery bottle If not perform the following procedure 1 Position the vehicle on a level surface 2 Remove the rubber mat from the left floor 3 View the coolant level in the recovery bottle 4 If the coolant level is below the MIN line inspect the coolant level in the radiator NOTE If overheating is evident allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system WARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can cause severe burns The engine must be cool before removing the pressure Cap 5 Remove the inspection cover from the cab 6 Remove the pressure cap Using a funnel add coolant to the top of the filler neck 7 Reinstall the pressure cap Radiator pressure Cap Location his l Radiator Pressure Cap 2 22 MAINTENANCE NOTE Use of a non standard pressure cap will not allow the recovery system to function properly 8 Remove recovery bottle cap and add coolant using a funnel 9 Fill recovery bottle to MAX level with Anti Freeze Coolant or 50 50 or 60 40 mixtures of antifreeze and distilled water as required for freeze protection in your area 10 Reinstall the recovery bottle cap 11 If coolant was required start engine and check for leaks Make sure radiator fins are clean to prevent overheating COOLANT STRENGTH TYPE 1 A 50 50 or 60 40 mixture
192. the life of the bulb and the luminous the left flux will be adversely affected If the headlight bulb 1 Bulbs A and B are used for headlights and usually use a bulb gets soiled thoroughly clean it with a cloth holder which must be detached before removing the bulb The Imgistened with alcohol lacquer thinner majority of these bulbs can be removed from their respective socket by turning them counterclockwise 7 169 ELECTRICAL WARNING Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down 2 Inspect bulb for continuity with the multi meter If discontinuity Replace the bulb NOTE Before checking for continuity set the multi meter to 0 and to 0 1 range 3 Connect the tester positive probe to terminal and the tester negative probe to terminal 2 and check the continuity 4 Connect the tester positive probe to terminal and the tester negative probe to terminal and check the continuity 5 If either of the readings indicates no continuity replace the bulb BULB SOCKETS INSPECTION 1 Install a good bulb into the bulb socket 2 Connect the multi meter probes to the respective leads of the bulb socket 3 Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket 7 170 ELECTRICAL EMS 120 10 12V Power 2 Kay Arma
193. three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test 7 184 ELECTRICAL CONVENTIONAL BATTERY OCV OPEN OPEN CIRCUIT VOLTAGE CIRCUIT VOLTAGE TEST State of charge Conventional Low Maintenance Lead acid Type Battery voltage should be checked with a digital 100 12 60V 12 70V Multi tester Readings of 12 6 volts or less require further 75 Charged 12 40V 12 50V battery testing and charging See charts and 50 Charged 12 10V 12 20V Load Test on below 11 8V 12 0V Less than Less than 11 9V NOTE Lead acid batteries should be kept at or neara SPECIFIC GRAVITY full charge as possible Electrolyte level should be State of charge Conventional kept between low and full marks If the battery is lead acid Type stored or used in a partially charged condition or 1 275 0 with low electrolyte levels hard crystal sulfating will vni 50 Charged 1 175 form on the plates reducing the efficiency and 25 Charged 1 135 service life of the battery 0 Charged Less than 1 100 Less than 1 115 CONVENTIONAL BATTERY SPECIFIC Al ty read Subtract 01 from the specific gravity readin GRAVITY TEST Mes ce A tool such as a Battery Hydrometer can be used to measure electrolyte strength or specific gravity As the battery goes CONVENTIONAL BATTERY LOAD TEST through the charge discharge cycle the electrolyte goes from a
194. tion CAM CHAIN TENSIONER INSTALLATION 1 Using a small flat blade screwdriver turn the tensioner clockwise to retract the plunger B all the way into the tensioner body Exhaust 2 Install and tighten rocker shaft locking plate Tighten 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 liberally to the valve springs cam chain rocker arms and camshaft 6 Install cylinder head nuts and torque to specification 2 With the plunger retracted install the tensioner assembly Cylinder Head Torque Procedure with a new gasket and tighten the bolts to specification Tensioner Bolt Torque 10 Nm 7 4 ft Ibs 3 Install the tensioner cap Torque cap to specification Tensioner Cap Torque 10 Nm 7 4 ft Ibs 4 Slowly rotate engine two to three revolutions and re check Torque 22Nm 16ft lbs cam timing once chain 15 tight 4 87 ENGINE 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 Crankshaft Keyway UP 4 88 ENGINE CAMSHAFT TIMING METHOD 2 Method 2 Camshaft Timing Using Flywheel TDC Mark Sprocket marks aligned with gasket surface at TDC on compression stroke cam lobes facing downw
195. tle Sensor TPS Manifold Pressure Sensor or lanition Coils Injectors A FUEL PUMP Catahtc Converter ELECTRONIC FUEL INJECTION EFI SYSTEM COMPOMENT LOCATIONS 4 Fuel Injectors Fuel Rail 1 Electronic Control Unit ECU Attached to the fuel rail located in the intake track of the Located bottom of the seat right side attaching on mainframe cylinder head Fuel 4 j d 1422 12 Fuel Injector 2 Intake Air Temperature IAT 5 Fuel Pump Located in the rubber intake boot between the air box and throttle Located bottom of the frame behind the fuel tank and next body the relief valve Fuel Pump 3 Crankshaft Position Sensor CPS 6 Fuel Pump Regulator Located in the magneto cover between the engine and Located bottom of the frame behind the fuel tank and next transmission the fuel pump 5 101 ELECTRONIC FUEL INJECTION 7 Throttle Body Located between the rubber air box boot and the manifold id Throttle Body 8 Throttle Position Sensor TPS Located on the right hand side of the throttle body rdi UP 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 Valve Located in the rubber intake boot between the air box and throttle body
196. to the programming in the 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 in overall engine condition and operating environment so it will be able to maintain the ideal air fuel ratio During certain operating periods such as cold starts warm up acceleration etc a richer air fuel ratio is automatically calculated by the ECU check of itself each of the sensors and system performance If a fault is detected the ECU turns on the Check Engine light in the speedometer and stores the fault code in its fault memory Depending on the significance or severity of the fault normal operation may continue or Fail Safe operation slowed speed richer running may be initiated A technician can determine the cause of the Check Engine light by initiating the Blink Code sequence or by using Digital EFI Diagnostic Software INTAKE AIR TEMPERATURE 5 105 ELECTRONIC FUEL INJECTION The ECU requires a minimum of 5 0 volts to operate The IAT OPERATION OVERVIEW memory in the ECU 15 operational the moment the battery Mounted in the throttle body intake boot cables are connected To prevent engine over speed and Air passing through the intake is measured by the IAT and possible failure a delimiting feature is programmed into the relayed temperature readings to the ECU and co
197. tton to select correct COM port Wane fool will update to 10701 8129 1004260110_819 Please Check connection engine state stall and power carefully Elapsed time sec Please Click Download rid ECU count WTI CD amp 07 POS Book small Enem Ti Y Ti 1 L Ll hu 7 T act T 1 B rir E EB Kk WPConfig Contig 1 Port 2 Baud Rate gar Configuration Negtive Response Table About 5 fedhis Warming This tool will update ECM to 10701 5129 1004260110 519 n BUSS SS Please Check connection engine state stall and power carefully ales sm SR Please Click Download x Rss 58 3x Elapsed time sec Riis 38025 coun Suec 929 q mans Ri 5 135 ELECTRONIC FUEL INJECTION Note While update program the Elapsed time stop at 4 5 sec Means wrong COM port choose Please repeat step 6 7 CAUTION Ensure your battery has enough power capacity while update your ECU program Do not crank or ignition scooter while updating ECU program Or ECU may be destroyed 5 136 6 BODY COVER 474 uu ett tes qute eee eee eee ee eee es 6 3 BODY COVER EXPLODED VIEW Rope fever Scu a ein ens a ale bud Med ee a Ge lara a 6 3 BODY COVER DISASSEMBLY PRODEGUNRE 4412194
198. uel2 DEEn DECELERATION MODE ENABLE It refers to the operation conditions that less fuel will be supplied to engine combustion so as to avoid AFR from too rich Fuel1 OSFCOEn OVER SPEED FUEL CUT OFF MODE ENABLE This is used for engine protection from over speed operation MisSyncCnt MISSING COUNTER DETECTION The gap between target wheel and crank sensor is 0 8mm nominal Missing count 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 This refers to the accumulated time after the engine being started most lately AFR TARGET AFR This refers to the AFR values set up in the ECU The target AFR value will normally be 14 6 except the conditions of starting transient and power mode IdleDesRPM IDLE DESIGN RPM TARGET This refers to target revolution in idle condition It will vary according to different ambient and engine temperatures IdleRPMErr DELTA OF IDLE DESIGN RPM This refers to the difference between actual and target rpm values Fuel3 PumpOn FUEL PUMP STATUS This is the indication whether the fuel pump is in operation Cyl1FinalVE FINAL VOLUMETRIC EFFICIENCY 5 125 ELECTRONIC FUEL INJECTION This refers to the efficiency of intake air volume Cyl1MAP_idx INDICATION VALUE OF MANIFOLD PRESSURE This refers to the default value set up in the ECU The
199. ult parts removed and wrap any open joints with plastic if they Do not overfill the tank The tank is at full capacity when Will remain open for any length of time New parts should be the fuel reaches the bottom of the filler neck removed from their protective packaging just prior to Leave room for expansion of fuel installation Never start the engine or let it run in an enclosed area Clean any connector before opening to prevent dirt from Gasoline powered engine exhaust fumes are poisonous entering the system and can cause loss of consciousness and death in a Although every precaution has been taken to prevent water short time intrusion failure avoid direct water or spray contact with Do not smoke or allow open flames or sparks in or near System components the area where refueling is performed or where gasoline Do not disconnect or reconnect the wiring harness connector is stored to the control unit or any individual components with the gasoline seek medical attention immediately the ECU If you spill gasoline on your skin or clothing Do not allow the battery cables to touch opposing terminals immediately wash with soap and water and change When connecting battery cables attach the positive red cable clothing to positive battery terminal first followed by negative Always stop the engine and refuel outdoors or in a black cable to negative battery terminal well ventilated area Never star
200. ve dipstick and fill sump with 1800cc 0W 40 synthetic oil 8 Start the engine and let it idle for one to two minutes Recommended Engine Oil 12 Stop the engine and inspect for leaks Synthetic SAE 0W 40 Above 0 C 32 F 13 Re check the oil level on the dipstick and add oil as Semi Synthetic SAE 20W 40 Below 0 C 32 F necessary to bring the level to the upper mark on the dipstick i Position ons level surface 14 Dispose of used oil and oil filter properly 2 Clean area around oil drain plug at bottom of engine ENGINE BREATHER HOSE INSPECTION The engine is equipped with a breather hose Inspect the breather hose for possible kinks or wear The hose is form fitted for a proper fit Follow the breather hose from the side of the air cleaner to the engine valve cover Hot oil can cause serious burns to skin Do not allow hot oil to come in contact with skin 3 Place a drain pan beneath engine crankcase and remove the NOTE Make sure line is not kinked or pinched drain plug 4 Allow oil to drain completely 5 Replace the sealing washer on drain cap NOTE The sealing 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 Ibs 7 Place shop towels beneath oil filter Using Oil Filter Wrench turn the oil filter counter clockwise to remove it 8 Using a clean dry cloth clean filter sealing surface on the crankcase
201. vehicle speed The friction applied to the brake pads will cause the pads to wear As these pads wear the piston within the caliper moves further outward and becomes self adjusting Fluid from the reservoir fills the additional area created when the caliper piston moves outward Brake fluid level is critical to proper system operation Too little fluid will allow air to enter the system and cause the brakes to feel spongy Too much fluid could cause brakes to drag due to fluid expansion Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston assembly As the temperature within the hydraulic system changes this port compensates for fluid expansion or contraction 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 reservoir Do not fill the reservoir beyond the MAX LEVEL line When servicing brake systems use DOT3 or DOT 4 Brake Fluid WARNING Once a bottle is opened use what is necessary and discard the rest in accordance with local laws Do not store or use a partial bottle of brake fluid The brake fluid is hygroscopic and it means that it rapidly absorbs moisture This causes the boiling temperature of the brake fluid to drop which can lead to early break fade and the possibility of serious injury Dirt dust or imbed

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