User ManualTable of ContentsSCOOTER IDENTIFICATION1VEHICLE IDENTIFICATION NUMBER1MODEL LABEL1FEATURES1OUTLINE OF THE FI SYSTEM1FI SYSTEM1O2 sensor1IMPORTANT INFORMATION1PREPARATION FOR REMOVAL AND DISASSEMBLY1REPLACEMENT PARTS1GASKETS, OIL SEALS AND O-RINGS1LOCK WASHERS/PLATES AND COTTER PINS1BEARINGS AND OIL SEALS1CIRCLIPS1EQUIPMENT PREPARATION1CHECKING THE CONNECTIONS1SPECIAL TOOLS1GENERAL SPECIFICATIONS2ENGINE SPECIFICATIONS2CHASSIS SPECIFICATIONS2ELECTRICAL SPECIFICATIONS2GENERAL TIGHTENING TORQUE SPECIFICATIONS2TIGHTENING TORQUES2ENGINE2CHASSIS2LUBRICATION POINTS AND LUBRICANT TYPES2ENGINE2CHASSIS2CABLE ROUTING2INTRODUCTION3PERIODIC MAINTENANCE AND ADJUSTMENT3Periodic maintenance chart for the emission control system3Genela maintenance and lublication chart3COVER AND PANEL3SEAT AND TRUNK3FOOTREST BOARD3LEG SHIELD 1 ASSEMBLY AND LEG SHIELD 23ENGINE3ADJUSTING THE VALVE CLEARANCE3CHECKING THE ENGINE IDLING SPEED3ADJUSTING THE THROTTLE CABLE FREE PLAY3ADJUSTING THE SEAT SPRING FORCE3CHECKING THE SPARK PLUG3CHECKING THE IGNITION TIMING3MEASURING THE COMPRESSION PRESSURE3CHECKING THE ENGINE OIL LEVEL3CHANGING THE ENGINE OIL3CHANGING THE TRANSMISSION OIL3MEASURING THE ENGINE OIL PRESSURE3CLEANING THE AIR FILTER ELEMENT3CLEANING THE V-BELT CASE AIR FILTER ELEMENT3MANIFOLD3CHECKING THE FUEL HOSE3CHECKING THE BREATHER HOSES3CHECKING THE EXHAUST SYSTEM3CHECKING THE CANISTER AND ROLL OVER VALVE3CHASSIS3CHECKING THE FRONT BRAKE3ADJUSTING THE REAR BRAKE3CHECKING THE BRAKE FLUID LEVEL3CHECKING THE FRONT BRAKE PADS3CHECKING THE REAR BRAKE SHOES3CHECKING THE FRONT BRAKE HOSE3BLEEDING THE HYDRAULIC BRAKE SYSTEM3CHECKING AND ADJUSTING THE STEERING HEAD3CHECKING THE FRONT FORK3CHECKING THE TIRES3CHECKING THE WHEELS3CHECKING AND LUBRICATING THE CABLES3LUBRICATING THE LEVERS3LUBRICATING THE SIDESTAND3LUBRICATING THE CENTERSTAND3LUBRICATING THE REAR SUSPENSION3ELECTRICAL SYSTEM3CHECKING AND CHARGING THE BATTERY3CHECKING THE FUSES3REPLACING THE HEADLIGHT BULBS3ADJUSTING THE HEADLIGHT BEAMS3FRONT WHEEL AND BRAKE DISC4FRONT WHEEL4REMOVING THE FRONT WHEEL4CHECKING THE FRONT WHEEL4CHECKING THE BRAKE DISC4CHECKING THE SPEEDOMETER GEAR UNIT4ASSEMBLING THE FRONT WHEEL4INSTALLING THE FRONT WHEEL4ADJUSTING THE FRONT WHEEL STATIC BALANCE4REAR WHEEL AND REAR BRAKE4REMOVING THE REAR WHEEL4CHECKING THE REAR WHEEL4CHECKING THE REAR WHEEL DRIVE HUB4CHECKING THE BRAKE4ASSEMBLING THE BRAKE SHOES4INSTALLING THE REAR WHEEL4ADJUSTING THE REAR WHEEL STATIC BALANCE4FRONT BRAKE4FRONT BRAKE PADS4REPLACING THE FRONT BRAKE PADS4FRONT BRAKE MASTER CYLINDER4CHECKING THE FRONT BRAKE MASTER CYLINDER4CYLINDER4FRONT BRAKE CALIPER4DISASSEMBLING THE FRONT BRAKE CALIPER4CHECKING THE FRONT BRAKE CALIPER4CALIPER4FRONT FORK4REMOVING THE FRONT FORK LEGS4DISASSEMBLING THE FRONT FORK LEGS4CHECKING THE FRONT FORK LEGS4ASSEMBLING THE FRONT FORK LEGS4INSTALLING THE FRONT FORK LEGS4HANDLEBAR4REMOVING THE HANDLEBAR4CHECKING THE HANDLEBAR4INSTALLING THE HANDLEBAR4STEERING HEAD4HANDLEBAR BRACKET AND FRONT BRACKET4LOWER BRACKET4REMOVING THE LOWER BRACKET4CHECKING THE STEERING HEAD4INSTALLING THE STEERING HEAD4REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM4REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES4CHECKING THE REAR SHOCK ABSORBER ASSEMBLY4REMOVING THE SWINGARM4CHECKING THE SWINGARM4INSTALLING THE SWINGARM4ENGINE REMOVAL5LEADS AND HOSES5ENGINE5INSTALLING THE ENGINE5CYLINDER HEAD5REMOVING THE CYLINDER HEAD5CHECKING THE CYLINDER HEAD5INSTALLING THE CYLINDER HEAD5THE ROCKER ARMS AND CAMSHAFT5REMOVING THE ROCKER ARMS AND CAMSHAFT5CHECKING THE CAMSHAFT5SHAFTS5TIMING CHAIN GUIDES5CHECKING THE TIMING CHAIN TENSIONER5INSTALLING THE CAMSHAFT AND ROCKER ARMS5VALVES AND VALVE SPRINGS5REMOVING THE VALVES5CHECKING THE VALVES AND VALVE GUIDES5CHECKING THE VALVE SEATS5CHECKING THE VALVE SPRINGS5INSTALLING THE VALVES5CYLINDER AND PISTON5REMOVING THE CYLINDER AND PISTON5CHECKING THE CYLINDER AND PISTON5CHECKING THE PISTON RINGS5CHECKING THE PISTON PIN5CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE)5INSTALLING THE PISTON AND CYLINDER5BELT DRIVE5V-BELT CASE5V-BELT AND PRIMARY/SECONDARY SHEAVE5SECONDARY SHEAVE5REMOVING THE PRIMARY SHEAVE5REMOVING THE SECONDARY SHEAVE AND V-BELT5DISASSEMBLING THE SECONDARY SHEAVE5CHECKING THE CLUTCH SHOES5CHECKING THE V-BELT5CHECKING THE PRIMARY SHEAVE5CHECKING THE PRIMARY SHEAVE WEIGHTS5CHECKING THE SLIDER5CHECKING THE SECONDARY SHEAVE5ASSEMBLING THE PRIMARY SHEAVE5ASSEMBLING THE SECONDARY SHEAVE5SHEAVE5STARTER CLUTCH AND AC MAGNETO5STATOR COIL ASSEMBLY5STARTER CLUTCH5REMOVING THE AC MAGNETO5CHECKING THE STARTER CLUTCH5INSTALLING THE AC MAGNETO5OIL PUMP5CHECKING THE OIL PUMP5ASSEMBLING THE OIL PUMP5INSTALLING THE OIL PUMP5TRANSMISSION5CHECKING THE TRANSMISSION5CRANKSHAFT5CRANKSHAFT ASSEMBLY5DISASSEMBLING THE CRANKCASE5REMOVING THE CRANKSHAFT ASSEMBLY5CHECKING THE CRANKSHAFT AND CONNECTING ROD5CHECKING THE CRANKCASE5GUIDE(INTAKE SIDE)5CHECKING THE BEARINGS AND OIL SEALS5INSTALLING THE CRANKSHAFT ASSEMBLY5ASSEMBLING THE CRANKCASE5FUEL INJECTION SYSTEM6WIRING DIAGRAM6ECU’S SELF-DIAGNOSTIC FUNCTION6LIGHT BULB6SELF-DIAGNOSTIC FANCTION TABLE6TROUBLESHOOTING CHART6DIAGNOSTIC MODE6TROUBLESHOOTING DETAILS6THROTTLE BODY AND FUEL INJECTOR6FUEL TANK6FUEL INJECTOR AND FUEL HOSE6THROTTLE BODY6REMOVING THE FUEL TANK6REMOVING THE FUEL PUMP6CHECKING THE FUEL INJECTOR6CHECKING THE THROTTLE BODY6INSTALLING THE FUEL PUMP6INSTALLING THE FUEL TANK AND FUEL HOSE6OPERATION6CHECKING THE THROTTLE POSITION SENSOR6CHECKING THE ISC (IDLE SPEED CONTROL) VALVE6ELECTRICAL COMPONENTS7WIRING DIAGRAM7CHECKING SWITCH CONTINUITY7CHECKING THE SWITCHES7CHECKING THE BULBS AND BULB SOCKETS7TYPES OF BULBS7CHECKING THE CONDITION OF THE BULBS7CHECKING THE CONDITION OF THE BULB SOCKETS7IGNITION SYSTEM7CIRCUIT DIAGRAM7TROUBLESHOOTING7ELECTRIC STARTING SYSTEM7CIRCUIT DIAGRAM7STARTING CIRCUIT CUT-OFF SYSTEM OPERATION7TROUBLESHOOTING7STARTER MOTOR7CHECKING THE STARTER MOTOR7ASSEMBLING THE STARTER MOTOR7CHARGING SYSTEM7CIRCUIT DIAGRAM7TROUBLESHOOTING7LIGHTING SYSTEM7CIRCUIT DIAGRAM7TROUBLESHOOTING7CHECKING THE LIGHTING SYSTEM7SIGNALING SYSTEM7CIRCUIT DIAGRAM7TROUBLESHOOTING7CHECKING THE SIGNALING SYSTEM7STARTING FAILURE/HARD STARTING8ENGINE8FUEL SYSTEM8ELECTRICAL SYSTEMS8INCORRECT ENGINE IDLING SPEED8ENGINE8FUEL SYSTEM8ELECTRICAL SYSTEMS8POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE8ENGINE8FUEL SYSTEM8FAULTY CLUTCH8ENGINE OPERATES BUT SCOOTER WILL NOT MOVE8CLUTCH SLIPS8POOR STARTING PERFORMANCE8POOR SPEED PERFORMANCE8OVERHEATING8ENGINE8FUEL SYSTEM8CHASSIS8ELECTRICAL SYSTEMS8POOR BRAKING PERFORMANCE8FAULTY FRONT FORK LEGS8LEAKING OIL8MALFUNCTION8UNSTABLE HANDLING8FAULTY LIGHTING OR SIGNALING SYSTEM8HEADLIGHT DOES NOT COME ON8HEADLIGHT BULB BURNT OUT8TAIL/BRAKE LIGHT DOES NOT COME ON8TAIL/BRAKE LIGHT BULB BURNT OUT8TURN SIGNAL DOES NOT COME ON8TURN SIGNAL BLINKS SLOWLY8TURN SIGNAL REMAINS LIT8TURN SIGNAL BLINKS QUICKLY8HORN DOES NOT SOUND8Size: 9.04 MBPages: 338Language: EnglishOpen manual
