Service manual

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SERVICE MANUAL

EV3

E-MO

E-TON POWER

Summary of content (101 pages)

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E-TON POWER EV3 E-MO SERVICE MANUAL
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E-MO SERVICE MANUAL 2009 by E-TON POWER TECH CO., LTD. First edition, April 2009 All rights reserved. Any reproduction or unauthorized use without the written permission of E-TON POWER TECH CO., LTD. is expressly prohibited.
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IMPORTANT This manual was produced by the E-TON POWER TECH CO., LTD., primarily for use by E-TON dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on E-TON vehicles should have a basic understanding of the mechanics and the techniques to repair these types of vehicles.
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TABLE OF CONTENTS GENERAL INFORMATION GEN INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ CONTROLLER SYSTEM CONT BATTERY/ CHARGER BAT CHA ELECTRICAL SYSTEM ELEC CHASSIS CHAS TROUBLESHOOTING TRBL SHTG – +
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CHAPTER 1 GENERAL INFORMATION GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MOTOR SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GEN INFO IDENTIFICATION OF SCOOTER GENERAL INFORMATION SCOOTER IDENTIFICATION FRAME SERIAL NUMBER is stamped on the The frame serial number chassis. TIP The fourth to the sixth digits of these numbers are for identifying the model; the remaining digits constitute the production number of the unit. MOTOR SERIAL NUMBER The serial number of the motor is stamped on the portion of the left section of the motor box. TIP Designs and specifications are subject to change without notice.
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GEN INFO IMPORTANT INFORMATION IMPORTANT INFORMATION REPLACEMENT PARTS 1. Use only genuine E-TON parts for all replacements. Use the oil and/or grease recommended by E-TON for assembly and adjustment. GASKETS, OIL SEALS AND O-RINGS 1. Replace all gaskets, seals and O-rings when overhauling the rim. 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. LOCK WASHERS/PLATES AND COTTER PINS 1.
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GEN INFO IMPORTANT INFORMATION CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture ĺ Dry with an air blower. Rust/stains ĺ Connect and disconnect several times. 3. Check: • all connections Loose connection ĺ Connect properly. TIP If the pin 1 on the terminal is flattened, bend it up. 4. • • • Connect: lead coupler connector TIP Make sure all connections are tight.
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GEN INFO SPECIAL TOOLS SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Tool NO. Tool name / Function Picture Tool name: SE3200-5BA0-0FA1 Six legs socket Function: To disassemble and assemble the nut of front fork component.
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GEN INFO SPECIAL TOOLS Tool NO. Tool name / Function Picture Tool name: SC9003-EGC2-0000 Testing interface software Function: Only for testing driver. Tool name: Testing interface connector SC9004-EGC2-0000 Function: Only for connecting the driver connector and USB connector of the computer. Tool name: Motor checking tool SC130A-EGC2-0FG1 Function: Testing the Hall data of motor. Tool name: Instrument panel check tools SC7200-EGC2-0FG1 Function: Only for testing the instrument panel quality.
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CHAPTER 2 SPECIFICATIONS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 MAINTENENCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 CONVERSION TABLE/ GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .
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SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Standard Item Dimensions Overall length Overall width Overall height Wheelbase Minimum ground clearance Minimum turning radius Basic weight Chassis Frame type Caster angle Trail Tire Size Size Manufacturer Manufacturer Type Type Tire pressure (cold tire) Maximum load* *Load in total weight of rider and accessories Brake Front brake Rear brake 1,550 mm (61.0 in) 650 mm (25.6 in) 1,000 mm (39.4 in) 1,050 mm (41.3 in) 115 mm (4.
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SPEC MAINTENANCE SPECIFICATIONS CHASSIS Standard Item Front suspension Front fork travel 50 mm (1.97 in) Rear suspension Shock absorber travel 30 mm (1.18 in) Front wheel Rim size Rim material Rim runout limit radial lateral Rear wheel Rim size Rim material Rim runout limit radial lateral Front drum brake Type Brake drum inside diameter 1.4 x 14" Aluminum 2.0 mm (0.08 in) 2.0 mm (0.08 in) 1.4 x 14" Aluminum 2.0 mm (0.08 in) 2.0 mm (0.08 in) Leading, trailing 85.0 mm (3.
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SPEC MAINTENANCE SPECIFICATIONS ELECTRICITY Standard Item Battery Type Battery capacity Li-ion Mn battery 48.0 V/ 10AH Lights X number Headlight Tail/ brake light Turn signal light 12V 35/ 35W X1 12V 21/ 5W X1 12V 10W X4 Fuse Fuse (main) Fuse (turn signal) 30A 10A Controller system Power input DC transformer output Driver output voltage current 48V ±10V 0A ~ 30A voltage current 12V ± 1V 7A ± 0.
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CONVERSION TABLE/GENERAL TIGHTENING TORQUE SPECIFICATIONS GENERAL TIGHTENING TORQUE SPECIFICATIONS CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.
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SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Part to be tightened Part Thread name size Q’ty Tightening torque Nm m•kg ft•lb Remarks Chassis Rear fork Nut M10 1 35 3.5 25.3 Front fork Nut M25 2 50 5.0 36.2 Rear shock absorber (up) Bolt M10 1 35 3.5 25.3 Bar footrest Controller system Bolt Bolt M8 4 25 2.5 18.1 M6 4 10 1.0 7.2 Horn Bolt M6 1 10 1.0 7.2 Hinge of seat Bolt M6 1 10 1.0 7.2 Body cover Bolt M6 24 4 0.4 2.
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SPEC CABLE ROUTING 1 2 Wire harness Cable brake, rear 3 4 5 Main switch lead Horn lead EMI coil 6 7 8 wire clamp Turn signal lead 12 pin connector 9 10 Starter controller lead DC 12V connecter 11 12 13 14 15 16 UVW motor three-phases connecter 6 pin connecter Positive battery lead Negative battery lead tail/brake light Turn light connector A B Main switch comp Horn C D EMI coil Turn signal relay 15 6 A B C 16 D 1 5 6 3 7 4 2 14 9 8 10 12 11 2-6 13
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SPEC CABLE ROUTING 1 Right turn light lead 2 Right brake lead 3 4 5 6 Cable brake, front Throttle lead Headlight lead Meter connector 7 Horn lead 8 Cable brake, rear 9 Left brake lead 10 Left turn light lead 8 2 1 3 10 9 6 5 7 8 1 3 2 4 9 10 2-7
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CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION/ PERIODIC MAINTENANCE/ LUBRICATION . . . . . . . . . . . . . . . . . . . . . 3-1 SIDE COVER/ BODY COVER/ HEADLIGHT/ METER REMOVE AND INSTALL . . . . . . 3-2 REMOVING THE SIDE COVER AND THE BODY COVER . . . . . . . . . . . . . . . . . . . . . . . 3-2 REMOVING SEAT/ BATTERY SEAT/ DRIVER ASSY/ BAR FOOTREST . . . . . . . . . . 3-3 REMOVING HEADLIGHT/ METER/ METER SIDE COVER . . . . . . . . . . . . . . . . . . . . . . .
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CHK ADJ INTRODUCTION/ PERIODIC MAINTENANCE/LUBRICATION PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable motorcycle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to motorcycles already in service as well as to new motorcycles that are being prepared for sale.
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SIDE COVER/ BODY COVER/ HEADLIGHT/ METER REMOVE AND INSTALL CHK ADJ REMOVING THE SIDE COVER AND THE BODY COVER T. T. R. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 4 Nm (0.4 m • kg, 2.9 ft • Ib) (X3) (X2) 3 2 1 (X2) 4 (X2) T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) (X6) (X2) 1 T. (X4) R. Order Job/Part Q’ty 1 2 Removing the side cover and the body cover Side cover Top cover (Rear) 2 1 3 Top cover (Front) 1 4 Bottom cover (Rear) 1 4 Nm (0.4 m • kg, 2.
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SIDE COVER/ BODY COVER/ HEADLIGHT/ METER REMOVE AND INSTALL CHK ADJ REMOVING SEAT/ BATTERY SEAT/ DRIVER ASSY/ BAR FOOTREST T. 1 R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) (X4) 4 7 T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 2 T. R. 25 Nm (2.5 m • kg, 18.08 ft • Ib) (X2) 6 (X4) 3 (X2) Order 5 1 Job/Part Q’ty Remarks Removing seat/ battery seat/ driver assy/ Remove the parts in the order listed.
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SIDE COVER/ BODY COVER/ HEADLIGHT/ METER REMOVE AND INSTALL CHK ADJ REMOVING HEADLIGHT/ METER/ METER SIDE COVER T. R. (X3) 4 Nm (0.4 m • kg, 2.9 ft • Ib) 2 (X2) T. R. 5 4 Nm (0.4 m • kg, 2.9 ft • Ib) 4 3 1 T. R. Order 4 Nm (0.4 m • kg, 2.9 ft • Ib) Job/Part Q’ty Removing headlight/ meter/ meter side cover 1 2 3 4 Front cap Meter Meter side (L) Headlight 1 1 1 1 5 Meter side (R) 1 Remarks Remove the parts in the order listed. For installation, reverse the removal procedure.
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REMOVING AND INSTALLING REAR BOTTOM COVER/ REAR FENDER CHK ADJ REMOVING REAR BOTTOM COVER/ REAR FENDER T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 3 T. R. 4 35 Nm (3.5 m • kg, 25.3 ft • Ib) (X4) 2 3 6 1 4 5 T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) T. R. Order Job/Part Q’ty Removing rear bottom cover/ rear fender 1 2 3 4 Rear bottom cover (L) Rear bottom cover (R) Cap A Cap B 1 1 2 2 5 6 Rear fender Main stand 1 1 25 Nm (2.5 m • kg, 18.
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ADJUSTING THE FRONT/REAR BRAKE CHECKING THE BRAKE SHOES CHK ADJ CHASSIS Front brake Adjusting the front/rear brake lever free play 1. Check • Clockwise (a) revolving will reduce free play. • Counterclockwise (b) revolving will increase free play. (b) (a) Adjusting nut TIP Before adjusting the front and rear brake, the front and rear brake linings should be checked. Rear brake NOT ICE რ Proper lever free play is essential to avoid excessive brake drag.
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ADJUSTING THE FRONT/REAR BRAKE CHECKING THE BRAKE SHOES CHECKING THE BRAKE SHOES A Wear limit line CHK ADJ 1. Operate the brake. 2. Check • brake shoes Wear indicators reaches the wear limit line ĺ Replace the brake shoes as a set. Refer to “REAR BRAKE” in chapter 7. Wear indicator 3. Adjust the front and rear brake lever free play after replace the brake shoes. A Front brake B B Rear brake Wear limit line Wear indicator Measure position. Brake lining wear limit a 1.0 mm (0.
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CHK ADJ CHECKING THE STEERING HEAD CHECKING THE STEERING HEAD WARNING Securely support the scooter so that there is no danger of it falling over. 1. Stand the scooter on a level surface. TIP • Please support by main stand. 2. Use a support put in the buttom of vehicle and raise the front wheel. 3. Check • steering shaft bushings and bearings Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness ĺ adjust the steering hand. Refer to “STEERING SYSTEM” in chapter 7. 4.
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CHECKING THE STEERING HEAD/ CHECKING THE FRONT FORK CHK ADJ d. Loosen the lower ring nut 1/2 turn counterclockwise then tighten it to specification with a steering nut wrench. T. R. Lower ring nut (final tightening torque) 12 Nm (1.2 m • kg, 8.7 ft • lb) e. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the front fork and check the upper and lower bearing. Refer to “STEERING HEAD” in chapter 7. T. f.
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CHECKING THE REAR SHOCK ABSORBER/ CHECKING THE TIRES CHK ADJ CHECKING THE REAR SHOCK ABSORBER 1. Stand the scooter on a level surface. 2. Check: • Oil leakage/ crack/ damaged ĺ 5HSODFH WKH rear shock absorber assembly. • Spring 'DPDJH ZHDU ĺ the rear shock absorber assembly. 5Hfer to 5($5 6+2&. $%625%(5 in chapter 7. • Bolts Loosen ĺ WLJKWHQ Upper/lower Bolts . T. Upper Bolt, 35 Nm (3.5 m • kg, 25.3 ft • lb) R. T. Lower Bolt, 35 Nm (3.5 m • kg, 25.3 ft • lb) R.
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CHK ADJ CHECKING THE TIRES/ CHECKING THE WHEELS • TIRE PRESSURE 1. Measure 7LUH SUHVVXUH 2YHU VSHFLILHG YDOXH ĺ $GMXVW 3 Maximum ORDG T.W.I. 2 4 98 kg 5HDU FrRQW T.W.I. * TRWDO weighW Rf rider anG DFFHVVRULHV NSD. NSD (2.25kg/cm 2 ) (2.25kg/cm 2 ) 1 2. Check: • Tire surfaces 'DPDJH ZHDU ĺ 5HSODFH WKH WLUH Minimum depth of thread of tires a 0.8 mm (0.03 in) 7KUHDG GHSWK 2 6LGH ZDOO 3 :HDU OLPLW OLQH 4 :HDU LQGLFDWRU 1 WARNING It is dangerous to ride with a worn-out tire.
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CHK ADJ REPLACING THE HEADLIGHT BULB REPLACING THE HEADLIGHT BULB 1. Remove • Headlight 1 . Refer to " REMOVING AND INSTALLING THE COVER". 1 • Opening the headlight bulb holder cover 2 . 2 3 • Remove headlight coupler 3 . • Loosen the screw of bulb fixer 4 and the fixer will open.
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REPLACING THE HEADLIGHT BULB/ REPLACING THE FRONT/ REAR TURN LIGHTS CHK ADJ 2. Change • Headlight bulb 5 (burned). 5 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 3. Install • Headlight bulb. New • Bulb fixer. • Headlight coupler. • Bulb holder cover. • Headlight. TIP • Make sure the triangle flange of bulb connect with coupler. • Make sure the bulb fixer infix to groove.
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REPLACING THE FRONT/ REAR TURN LIGHTS BULB/ REPLACING TAIL LIGHT BULB CHK ADJ WARNING Since the light bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 3 2. Install • • • • Bulb. New The turn light holder site. Lens. Left/ right turn light. TIP • Make sure the bulb infix to groove 3 . REPLACING THE TAIL LIGHT BULB 1. Remove • Lens 1 . • Bulb 2 . TIP 1 • Press the bulb in and counterclockwise a revolving will take it out. 2.
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CHAPTER 4 CONTROLLER SYSTEM MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 CHECK AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 REMOVING THE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CONT MOTOR CHECK AND TROUBLESHOOTING • When the rider control motor speed via acceleration handle, and if the motor can’t run and smoothly and the instrument panel sends out a warning signal, it is necessary to check the motor. Motor Controller Hall sensor Motor Hall sensor 1 2 3 4 Motor checking tool HALL Hall warning tone TIP • It is necessary to confirm relevant motorcycle components are free of failure or damage before testing.
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CONT MOTOR REMOVING THE MOTOR 2 ԦʳʳRemove the bolts 1 and rear bottom cover L 2 . 1 ԦʳʳRemove the band 1 and rear fender bolt 2 . 1 2 ԦʳʳRemove the rear fender bracket bolt 1 and rear fender 2 . 2 1 ԦʳʳRemove the bolts 1 and rear bottom cover R 2 . 2 1 ԦʳʳRemove the rear fender bolt 1 .
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CONT MOTOR • Remove brake cable adjusting bolt 1 . 1 • Remove brake cable set nut 1 to rear end. • Adjust the adjusting nut 2 to loosening position and fix the groove 3 across the brake drum. • Remove brake cable. 3 1 2 • Loosen set nuts on left and right motor and frame as illustrated. 1 • Remove motor three-phase circuit 1 and Hall connector 2 as illustrated. • Pull the three-phase circuit and Hall connector across frame gap. • Remove the motor.
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CONT MOTOR MOTOR INSTALLATION Dowel pin • Reverse the removal procedure for installation. NOTICE • It is necessary to confirm whether the regular and dowel pin are fastened tightly during brake cable installation. • It is necessary to check and adjust the brake clearance to maintain at 5~10mm. Regulator WARNING It is necessary to confirm whether brake indicator can light on and function regularly after adjusting brake.
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CONT DRIVER SPECIFICATION Voltage Power input Electric current 48 V ± 10 V 0 A ~ 30 A DC transfer output 12 V ± 1 V 7 A ± 0.5 A Motor driver output 48 V ± 10 V 25 A ± 1 A CHECK AND TROUBLESHOOTING • Check the fuse whether blow or not. Turn signal fuse 10 A Remove 1. Open the upper fuse cover. 2. Use a long nose pliers and pull out the fuse. Main fuse 30 A Check 1. Connect the pocket tester to the fuse and check the continuity.
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CONT DRIVER 2. Remove out wiring assembly after testing the driver according to the illustration and list below LQGLFDWHG E\ WKH VLJQ ³ Ɣ ´ 8VH D SRFNHW tester to measure. If there is any short-circuit VHQGLQJ RXW D ³%HHS´ WRQH RU D PHDVXUHPHQW YDOXH RI OHVV WKDQ LW FDQ EH MXGJHG DV failed. 3.
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CONT DRIVER LEV INTERFACE (TESTING INTERFACE) 1.
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CONT DRIVER • Fill in LEV in the selected frame for connecting to the COM port of the computer, such as filling 3 for COM 3 after clicking COM Created . TIP The COM port position has gotten by click my FRPSXWHU ĺ FOLFN ULJKW NH\ERDUG ĺ click contents ĺ FOLFN KDUGZDUH ĺ GHYLFH NHHSHU DIWHU LQVWDOO WKH WHVWLQJ LQWHUIDFH VRIWZDUH DQG FRQQHFW GULYHU and computer. 7KH VRIWZDUH RI :LQGRZV ;3 9LVWD are suitable for use the steps.
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CONT DRIVER • The controller will report the system status as shown in the selected frame. • If it is necessary to leave interface testing software after completing testing, please click on the selected frame COM Release , and click on COM Release ,and the switch off the software and pull off the plug to avoid software crash.
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CONT DRIVER STATUS Status: Unable to starting computer booting (there is no display on the panel instrument or beep tone continues). • Operate according the testing interface operation steps. If the illustration in the left still doesn’t appear, the driver shall be replaced. Status: If electricity shuts down during riding (the power and instrument panel display disappear) • Operate according the testing interface operation steps.
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CONT INSTRUMENT PANEL HOW TO READ INSTRUMENT PANEL ˉ ˊ ˋ 888888 8888.
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CONT INSTRUMENT PANEL b. After the instrument panel check tools are connected (move the panel and the 3 pin connector of main wiring and connect with the instrument panel check tools and panel connector), according to the instrument panel check tools instruction check whether the instrument panel can function regularly. If the instrument panel can’t function regularly, the panel instrument shall be replaced.
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CONT INSTRUMENT PANEL Eye Eye 8888.8 Trip 8888.8 888888 ODO Km/H Trip 20 888888 ODO Km/H 20 Left turn signal indicator LED Right turn signal indicator LED 3 pin connector 4 pin connector Headlight indicator LED 8888.8 Trip 888888 00 ODO Km/H LCD backlight b. Connect the instrument panel check tool and check whether the instrument panel can function regularly. If the instrument panel functions irregularly, it is necessary to replace with a new instrument panel. c.
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CONT INSTRUMENT PANEL c. If the instrument panel can function regularly, it is necessary to check whether the headlight and main wiring can function regularly. Please refer to Chapter 6 Wiring Diagram NO Yes Button A Testing Steps 4. There will sound beeper tone upon pressing Button A or Button B in the riding screen. Failure Status 1 • The button tone doesn’t sound upon pressing the left or right button in the riding screen. a.
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CHAPTER 5 BATTERY/CHARGER BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 HOW TO CHECK BATTERY RESIDUAL CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 REFERENCE VALUE FOR BATTERY RESIDUAL CAPACITY . . . . . . . . . . . . . . . . . . . . 5-2 CHECKING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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BAT CHA BATTERY – + HOW TO CHECK BATTERY RESIDUAL CAPACITY Read the battery residual capacity indicator or observe the indicator light on the battery box. From the battery residual capacity indicator in the display Turn the main switch to ON. The battery residual capacity icon in the display will light fully for few seconds. The battery residual capacity will be displayed then. Battery residual capacity How to read the battery residual capacity indicator light from the battery box 1.
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BAT CHA BATTERY – + e. Remove the battery to observe the indicator light on the battery box as illustrated in the following list. NOTICE The indicator light on the battery box One of the E-MO features is Li-ion Mn battery and its performance (electric capacity) will reduce gradually. The performance reduction speed will depend on usage. Repeating charging and discharging for about 500 times will reduce electric capacity to 70%~80% of the new product.
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BAT CHA BATTERY – + CHECKING BATTERY 1 Discharge 1. Press battery residual power display button 1 and observe whether LED light !!! 2 is on. If LED is not on, the battery might out of electricity. Please conduct the next step. 2 Indicator light 2. Plug on Charger plug and make the charger be OFF. Charging plug Charging outlet 3.
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BAT CHA CHARGER Power switch + INSTALLATION STEPS Electricity voltage switch 1. Make sure the charger is switched off. Connect the battery to output terminal. Select proper output wire suitable for the electricity current to act as the conducting wire between the battery and charger. 230 WARNING Each pole shall be connected correctly. Positive pole (+) shall be connected to (+) terminal and negative pole (-) shall be connected to (-) terminal.
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BAT CHA CHARGER – + The charging electricity current and voltage in each phase is shown as in the left. Start Charging Charging voltage 100% Charging current Phase 2 Phase 1 Fixed electricity current Fixed electricity voltage Floating charging Red Indicator light color Green Adjustment electricity Voltage button under the warn sticker, have already set up the voltage of charging suitable when dispatched from the factory, it will cause the damage of battery and charger to adjust by oneself.
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BAT CHA CHARGER – + TROUBLESHOOTING If the troubleshooting still can’t be attained after conducting the steps as in the following list, please contact the E-TON Co., Ltd. or the authorized dealer. Status No output electricity voltage Excessively low output electricity voltage Possible cause Solution Power switch is not turned to ON.
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CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ 6-1 WIRING DIAGRAM ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ 6-2 CHECKING SWITCH CONTINUITY ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ 6-3 CHECKING SWITCH CONTINUITY ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ
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ELEC ELECTRICAL COMPONENTS ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 2 3 4 5 6 Main switch Controller Battery Fuse Throttle Handle Motor 7 8 9 10 11 Switch Horn Meter Turn signal relay Charge 7 5 9 10 6 11 3 1 4 6-1 2 8 – +
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Br 21 R/W 16 LG 12V 10W R/W 12V 10W L/Y R/W L/Y 22 19 R/W Br/Y Br/Y R/W R/W 17 Br R/W R/W L/Y L/Y R/W 18 LG 12V 10W R/W Br G/Y R/W Br/Y Br/Y R/W G/Y 20 TURN SIGNAL SW R R PUSH PUSH L 9 12 Y/R Br/Y Br B/Y L/Y LG LG B/Y Y/R R/W R/W Y/R B/Y B/Y R/W ON OFF 13 ON OFF 11 14 HORN SW HEADLIGHT SW 10 LG L/Y B/Y Br Br/Y Y/R B/Y 15 12V 35W L/Y R/W Y/R L/Y G/Y B/Y Y/R Br/Y G/Y B/Y G/Y B/W Br/W G/B G/B Br/W Y/B Y/B R/W B/Y B/Y G G L Y Y/G Y/Br G/Y Br/B
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ELEC CHECKING SWITCH CONTINUITY – + CHECKING SWITCH CONTINUITY 0 Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Pocket tester x1 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
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ELEC CHECKING THE SWITCHES – + CHECKING THE SWITCHES Damage/wear Repair or replace. Properly connect. Improperly connected Incorrect continuity reading Replace the switch. Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
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CHECKING THE BULBS AND BULB SOCKETS ELEC – + CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Repair or replace the bulb, Damage/wear bulb socket or both. Properly connect. Improperly connected Repair or replace the bulb, No continuity bulb socket or both. a b TYPES OF BULBS The bulbs used on this scooter are shown in the illustration on the left.
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CHECKING THE BULBS AND BULB SOCKETS ELEC – + 2. Check: • bulb (for continuity) (with the pocket tester) Replace. No continuity TIP Before checking for continuity, set the pocket x 1” range. tester to “0” and to the “ a. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 2 , and check the continuity. b. Connect the positive tester probe to terminal 1 and the negative tester probe to terminal 3 , and check the continuity. c.
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Br 21 R/W 16 LG 12V 10W R/W 12V 10W L/Y R/W L/Y 22 19 R/W Br/Y Br/Y R/W R/W 17 Br R/W R/W L/Y L/Y R/W 18 LG 12V 10W R/W Br G/Y R/W Br/Y Br/Y R/W G/Y 20 TURN SIGNAL SW R PUSH L 9 12 B/Y L/Y LG Y/R Br/Y Br LG B/Y Y/R R/W R/W Y/R B/Y B/Y R/W ON OFF 13 ON OFF 11 14 HORN SW HEAD LIGHT SW 10 LG L/Y B/Y Br Br/Y Y/R B/Y 15 12V 35W L/Y R/W Y/R L/Y G/Y B/Y Y/R Br/Y G/Y B/Y G/Y B/Y R/W B/Y R/W G/Y B/W Br/W Y/B G/B Br/W G/B Y/B B/W B/Y G G L Y Y/
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ELEC LIGHTING SYSTEM TROUBLESHOOTING + 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Any of the following fail to light: headlight, and meter light. Check: 1. main fuse 2. battery 3. main switch 4. headlight switch 5. wiring connections Minimum open-circuit voltage 40.0 V or more at 20°C • Is the battery OK? ` YES NO • Clean the battery terminals. • Recharge or replace the battery.
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LIGHTING SYSTEM + 3. The tail/brake light fails to come on. CHECKING THE LIGHTING SYSTEM 1. The headlight fail to come on. 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” • Are the tail/brake light bulb and socket OK? 1. Headlight bulb and socket • Check the headlight bulb and socket for continuity.
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Br 21 R/W 16 LG 12V 10W R/W 12V 10W L/Y R/W L/Y 22 19 R/W Br/Y Br/Y R/W R/W 17 Br R/W R/W L/Y L/Y R/W 18 LG 12V 10W R/W Br G/Y R/W Br/Y Br/Y R/W G/Y 20 TURN SIGNAL SW R PUSH L 9 12 B/Y L/Y LG Y/R Br/Y Br LG B/Y Y/R R/W R/W Y/R B/Y B/Y R/W ON OFF 13 ON OFF 11 14 HORN SW HEAD LIGHT SW 10 LG L/Y B/Y Br Br/Y Y/R B/Y 15 12V 35W L/Y R/W Y/R L/Y G/Y B/Y Y/R Br/Y G/Y B/Y G/Y B/Y R/W B/Y R/W G/Y B/W Br/W Y/B G/B Br/W G/B Y/B B/W B/Y G G L Y Y/
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ELEC SIGNALING SYSTEM TROUBLESHOOTING • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? YES Check: 1. main fuse 2. turn signal fuse 3. battery 4. main switch 5. turn signal switch 6. wiring connections (of the entire signaling system) 4. Wiring • Check the entire signal system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the signaling system’s wiring properly connected and without defects? • Before troubleshooting, remove the following part(s): 1.Seat 2.
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ELEC SIGNALING SYSTEM + 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the blue/yellow connector at the horn terminal. • Connect a jumper lead to the horn terminal and ground the jumper lead. • Set the main switch to “ON”. • Does the horn sound? 1. Horn switch • Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the horn switch OK? YES – NO R/W L/Y Replace the left handlebar switch. 2.
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ELEC SIGNALING SYSTEM 2. The tail/brake light fails to come on. + • Set the main switch to “ON”. • Pull in the brake levers. • Measure the voltage (DC 1 2V) of red/white on the tail/brake light coupler (wire harn -ess side). • Is the voltage within specification? 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS” • Are the tail/brake light bulb and socket OK? YES – YES NO NO This circuit is OK.
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3. Voltage + • Set the main switch to “ON”. • Set the turn signal switch to “L” or “R”. • Measure the voltage (DC 12 V) on yellow/red at the turn signal relay coupler (wire harness side). • Is the voltage within specification? • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown. Positive tester probe Negative tester probe – ELEC SIGNALING SYSTEM red/white ground YES NO The turn signal relay is faulty and must be replaced. B/Y Y/R R/W 5.
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CHAPTER 7 CHASSIS FRONT WHEEL / REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 REMOVING THE FRONT/ REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CHAPTER 7 CHASSIS LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 LOWER BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 CHECKING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CHAS FRONT WHEEL / REAR WHEEL FRONT WHEEL T. R. 35 Nm (3.5 m • kg, 25.3 ft • lb) 1 2 5 3 6 7 6 5 4 Order 1 2 3 4 5 6 7 Job/Part Removing the front wheel Q’ty Hexagon flange bolt Collar B Front brake shoe plate Front wheel Oil seal Bearing Collar A 1 1 1 1 2 2 Remarks Remove the parts in the order listed. TIP Place the scooter on a suitable stand so that the front wheel is elevated. 1 For installation, reverse the removal procedure.
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CHAS FRONT WHEEL / REAR WHEEL REAR WHEEL T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 2 1 (x4) T. T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) R. 80 Nm (8.0 m • kg, 57.9 ft • Ib) 3 5 4 6 1 Order Job/Part Removing the rear wheel Q’ty Remarks Remove the parts in the order listed. TIP Place the scooter on a suitable stand so that the front wheel is elevated.
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CHAS FRONT WHEEL / REAR WHEEL REMOVING THE FRONT/ REAR WHEEL 1. Removing • Wheel bearings 1 • Collar 2 Remove the wheel bearings with a general bearing puller 3 . 2 General bearing puller 3 1 SA6100-A26-0FA1 1 NOT ICE რ Securely support the wheel to avoid damaging the brake disk. If the brake disk had damaged, please replace immediately. CHECKING THE FRONT/ REAR WHEEL 1. Checking • Wheels 2XW RI VKDSH ĺ UHSODFH • Rim Out of shape ĺ replace the wheel or check the bearings operation.
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CHAS FRONT WHEEL / REAR WHEEL ASSEMBLE THE FRONT/ REAR WHEEL 5 4 1. Install • Collar A 2 • Bearing 3 • Oil seal 4 • Collar B 5 • Front brake shoe plate 3 2 3 4 TIP • Put lithium soap base grease on the bearings and oil seal lips when installing. • Using the collar connect outside track of the bearing while installing. • Replacing the oil seal should use a new one. • Install oil seal with their manufacturer brands or numbers facing outwards.
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CHAS FRONT BRAKE / REAR BRAKE FRONT BRAKE T. R. 35 Nm (3.5 m • kg, 25.3 ft • lb) 1 6 7 8 2 Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the front brake Front fender Q’ty Front brake cable Front wheel Brake arm Brake indicator Felt seal Spring Brake shoe Brake arm cam Brake disk A 9 5 4 3 Remarks Remove the parts in the order listed. Please refer to " LOWER BRACKET " in cheaper 7. 1 1 1 1 1 1 2 1 1 For installation, reverse the removal procedure.
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CHAS FRONT BRAKE / REAR BRAKE REAR BRAKE T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) (x4) 6 1 7 3 8 2 9 5 4 T. R. Order 1 2 3 4 5 6 7 8 9 9 Nm (0.9 m • kg, 6.5 ft • Ib) Job/Part Removing the rear brake Front fender Bottom cover of rear fork (L/ R) Q’ty Remarks Remove the parts in the order listed. Please refer to " MOVING AND STALLING THE COVER " in cheaper 3.
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CHAS FRONT BRAKE / REAR BRAKE REMOVING THE FRONT/ REAR BRAKE ʳThe following procedure applies to each brake. brake and rear brake. 1. Removing • Brake arm 2 • Brake arm cam 3 2 TIP 3 When removing the brake arm, mark the position on the brake arm where it is aligned with the punch mark in the brake arm cam. CHECKING THE BRAKE DISK The following procedure applies to each brake. 1.
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CHAS FRONT BRAKE / REAR BRAKE 2 2 3. Measure • brake shoe lining thickness a 2XW RI VSHFLILFDWLRQ ĺ UHSODFH Measuring points 2 TIP Replace the brake shoes as a set if either is found to be worn to the wear limit. b Brake lining thickness 3.0 mm (0.12 in) : 1.5 mm (0.06 in) CHECKING THE BRAKE DRUMS The following procedure applies to each brake. 1. Check • brake drum inside diameter a 2XW RI VSHFLILFDWLRQ ĺ UHSODFH b Brake drum inside diameter 85.0 mm (3.35 in) : 86.0 mm (3.
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CHAS FRONT BRAKE / REAR BRAKE 2. Install • brake arm cam • brake arm 3 2 R. T. a 2 9 Nm( 0.9 m•kg, 6.5ft•lb) TIP 3 • Install the brake arm cam so its punch mark a is positioned as shown. • Align the punch mark in the brake arm cam with the mark on the brake arm. • Brake disk 4 • Rear brake cable • brake arm operation 8QVPRRWK RSHUDWLRQ ĺ UHSDLU B ˶ 4 TIP • When installing the brake disk, align the groove ˶ of the brake disk with the projection of ˷ the steering knuckle.
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CHAS SWINGARM SWINGARM T. R 2 4 Nm (0.4 m • kg, 2.9 ft • Ib) 5 3 1 6 4 7 9 T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 8 6 3 T. R. 35 Nm (3.5 m • kg, 25.3 ft • Ib) T. R. 25 Nm (2.5 m • kg, 18.1 ft • Ib) 2 1 Order Job/Part Removing the swingarm Q’ty 1 Cap A 2 2 Cap B 2 3 Rear bottom cover L/R 4 Rear fender bracket 1 5 Rear fender 1 6 Hexagon flange nut 2 7 Motor 1 8 Main stand Hexagon flange nut 1 9 Remarks Remove the parts in the order listed.
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CHAS SWINGARM REMOVE THE SWINGARM 1. Check • Swing arm free play a. Check the tightening torque of the pivot shaft nut. 35 Nm (3.5m •kg, 25 .3 ft • Ib) A Swingarm free play 1.0 mm (0.04 in) B b. Check the swingarm side play A by moving ing it from side to side. If side play is noticeable, check the spacer, bearings and frame pivot. c. Check the swingarm vertical movement B by moving it up and down.
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CHAS REAR SHOCK ABSORBER REAR SHOCK ABSORBER T. R. 1 35 Nm (3.5 m • kg, 25.3 ft • Ib) 2 3 1 Order Job/Part Removing the rear shock absorber Q’ty 1 Pin 2 2 Hexagon flange nut 1 3 Rear shock absorber 1 Remarks Remove the parts in the order listed. For installation, reverse the removal procedure.
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CHAS REAR SHOCK ABSORBER CHECKING THE REAR SHOCK ABSORBER 1. Check • Shock absorber rod Bends/damage ĺ replace the rear absorber assembly. • Shock absorber Oil leaks ĺ replace the rear absorber assembly. • Spring Fatigue ĺ replace the rear shock absorber assembly. INSTALL THE REAR SHOCK ABSORBER 1. Install • Shock absorber • Rear shock absorber upper bolt and nut 35 Nm (3.5m• kg, 25 .3 ft • Ib) • Rear shock absorber upper pin • Rear shock absorber lower bolt 35 Nm (3.5m• kg, 25 .
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CHAS STEERING SYSTEM HEADLEBAR 4 1 3 2 4 5 T. R. Order Job/Part 45 Nm (4.5 m • kg, 32.5 ft • lb) Q’ty Front brake cable Front cap Meter side L/ R Headlight Meter 1 2 3 4 5 Handle lever assembly (L) Handlebar grip (L) Handle lever comp (R) Left / right brake lever Handlebar Remarks Remove the parts in the order listed. Refer to "MOVING AND INSTALLING COVER " in cheaper 3. 1 1 1 1/1 1 For installation, reverse the removal procedure.
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CHAS STEERING SYSTEM REMOVING THE HANDLEBAR GRIP 1. Remove • Handlebar grip ϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰ Removing step : • Blow compressed air between the handlebar and handlebar grip, and gradually push the grip off the handlebar. ϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧ CHECKING THE HANDLEBAR 1. Check • Handlebar %HQGV GDPDJH ĺ UHSODFH WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar. INSTALLING THE HANDLEBAR 2 1. Handlebar 2 Tighten the bolt. R. T. 45 Nm( 4.
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CHAS STEERING SYSTEM INSTALL THE HANDLEBAR Reverse the removal procedure for installation and pay attention the following tips: 1 2 1. Clean • If the connection part of steering a touch with grease, should be clean. a WARNING • Install all cables should refer to "CABLE ROUTING" in cheaper 2. • Securely support the scooter so that there is no danger of it falling over. 2. Install • Handlebar 1 • Flange bolt 2 Align the lower handlebar holder with the upper groove of steering.
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CHAS LOWER BRACKET LOWER BRACKET T. 50 Nm (5.0 m • kg, 36.2 ft • lb) R. T. R. 12 Nm (1.2 m • kg, 8.7 ft • lb) 4 T. 5 R. 45 Nm (4.5 m • kg, 32.5 ft • lb) 6 7 3 8 1 9 9 2 8 3 10 11 Order Job/Part Q’ty Remove the lower bracket. Front wheel 1 2 3 4 5 6 7 8 9 10 11 Front fender Break hose holder Circle reflector Upper ring nut Lower ring nut Ball race cover Ball race upper Bearing ball Ball race outer Lower bracket Left/ right fork Remarks Remove the parts in the order listed.
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CHAS LOWER BRACKET REMOVING THE LOWER BRACKET 1. Remove • Ring nut 2 • Ball race cover 3 • Ball race upper 4 • Bearing ball 5 • Ball race outer 6 • Front fender assembly 2 7 2 6 5 3 4 5 TIP • Removing the ring nut by the steering nut wrench 7 . • Support the front fork safety and firmly, avoid topple and fall. • Do not lose the bearing ball inside of the bearing. 6 2. Remove • Front fender Please refer to "FRONT FROK" in cheaper 7. CHECKING THE LOWER BRACKET 1.
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CHAS LOWER BRACKET INSTALLING THE LOWER BRACKET 1. Install • Bearing ball 1 • Outer bearing race 2 2 1 NOTICE • Make sure the bearing ball size is correct. • Make sure the site of up and down while installing outer bearing race and upper bearing race. 2. Lubricate • Bearing ball 1 Please use lithium-soap-based grease to smear. Lithium-soap-based grease 5 1 4 2 3 2 1 3.
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CHAS LOWER BRACKET • Tighten the ring nut, please refer to "CHECKING STEERING HEAD " in cheaper 3.
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CHAS FRONT FORK FRONT FORK 1 1 T. R. 30 Nm (3.0 m • kg, 21.7 ft • Ib) 2 2 3 3 4 Order Job/Part Q’ty Remove the front fork. Remarks Remove the parts in the order listed. 1 Cap (L / R) 2 2 Nut (L / R) 2 3 Bolt (L / R) 2 4 Front fork (L / R) 2 For installation, reverse the removal procedure.
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CHAS FRONT FORK REMOVING THE FRONT FORK WARNING • Securely support the scooter so that there is no danger of it falling over. a a 1 1 2 2 3 1. Remove • Cap a • Nut (fork) 1 • Bolt 2 WARNING The fork spring would spring, should pay attention when remove the bolt. • Front fork (L/ R) 3 DISASSEMBLE THE FRONT FORK 1. Remove • Inner tube 1 • ʳDust seal 2 • Circlip • Oil seal 3 • Outer tube 1 2 NOTICE 4 Do not reuse the oil seal.
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CHAS FRONT FORK CHECKING THE FRONT FORK 1. Check • Inner tube :HDUV EHQGV GDPDJH ĺ UHSODFH WARNING Do not try to straighten an outer tube or an inner tube as this may dangerously weaken the tube. 2. Measure )RUN VSULQJ a $ERYH VSHFLILHG OLPLW ĺ UHSODFH a Fork spring free length 99.0 mm (3.90 in) : 94.0 mm (3.
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CHAS FRONT FORK 3. Install • Circlip 1 • Dust seal 1 TIP Couple the circlip correctly on the groove of the outer tube. 4. Check • Operation of inner tube 8QVPRRWK RSHUDWLRQ ĺ UHSODFH b b 1 1 2 2 3 INSTALLING THE FRONT FORK Reverse the disassembly procedure. The following points should be remembered. 1. Install • Front fork 3 2. Tighten R. T. 7-24 T • Nut (fork) 1 • Bolt 2 • Cap a 30 Nm(3.0 m•kg, 21.7 ft•lb) 30 Nm(3.0 m•kg, 21.
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CHAPTER 8 TROUBLE SHOOTING STARTING FAILURES ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ 8-1 Meter t has no display and no response ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ 8-1 Lasting meter warning tone ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ 8-1 Main switch "ON", turn handle bar the vehicle no
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TRBL SHTG TROUBLESHOOTING TIP The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts. STARTING FAILURES Meter t has no display and no response ԦʳʳHave not put the battery. ԦʳʳFaulty battery. ԦʳʳBattery protecting (turn off the main switch and wait about 15 seconds, turn on the main switch again).
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TRBL SHTG POOR BRAKING PERFORMANCE FAULTY LIGHTING OR SIGNALING SYSTEM Headlight does not light ԦʳʳWrong headlight bulb. ԦʳʳToo many electrical accessories. ԦʳʳHard charging. ԦʳʳFaulty battery. ԦʳʳIncorrect connection. ԦʳʳImproperly grounded circuit. ԦʳʳPoor contacts (main or light switch). ԦʳʳHeadlight bulb life expired. ԦʳʳWorn brake shoe lining. ԦʳʳIncorrect brake lever free play. ԦʳʳIncorrect brake shoe position. ԦʳʳWearing brake camshaft. ԦʳʳWorn or rusty brake drum.
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TRBL SHTG MESSAGE CODE Meter message codeΕwarning message(warning tone) drawing Message code 888888 8888.8 ODO Km/H Trip LOwv Battery residual capacity 88 Pow X Warning message (Warning tone) The following warning messages might display with a warning tone during riding status. Ϭ Warning and Cue signal Code Warning Indication Action Cause OVC2 OVC1 The controller detects increasingly high 1. Release the accelerator and let go of hands.
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TRBL SHTG Code SPD0 Operate code lock during riding. No operating code lock during riding can terminate this message. FAST Over speed warning. (over 52KM/HR) Reducing driving speed as soon as possible. LOWB Recharge battery as soon as possible. Low battery. Using Power mode during low battery residual The system will shift back to standard mode automatically and LOWP charge. will disappear. 1. This message will display to remind the rider that vehicle locking has already been 1.