E-TON EV3 E-MO Service manual

E-TON POWER
EV3
E-MO
SERVICE MANUAL
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.
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. Repair and maintenance work attempted by anyone without this knowledge
is likely to render the vehicle unsafe and unfit for use.
E-TON POWER TECH CO., LTD., is continually striving to improve all of its models. Modifications
and significant changes in specifications or procedures will be forwarded to all authorized E-TON
dealers and will appear in future editions of this manual where applicabe.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations:
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
WARNING
A WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
NOTICE
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
TIP
A TIP provides key information to make procedures easier or clearer.
* Product and specifications are subject to change without notice.
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
–
+
CHAPTER 1
GENERAL INFORMATION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MOTOR SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
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.
1-1
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. Replace all lock washers/plates
and cotter pins after removal. Bend lock tabs along
the bolt or nut flats after the bolt or nut has
been tightened to specification.
or
BEARINGS AND OIL SEALS
1. Install the bearings
and oil seals
with
their manufacturer brands or numbers facing
outwards. (In other words, the stamped letters
should be on the side exposed to view.) When
installing oil seals, apply a light coating of
lightweight lithium base grease to the seal
lips. Put oil on the bearings when installing.
NOTICE
Do not use compressed air to spin the bearings dry. This will damage the bearing surface.
1-2
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.
5. Check:
• continuity (with the pocket tester)
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps 1 to 3.
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-3
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.
Tool name:
SA6100-A26-0FA1
Bearing inner puller set
Function:
To disassemble the bearing of front wheel.
Specification:
8‚ 10‚ 12‚ 15‚ 17‚ 20‚ 22‚ 25‚ 30‚ 32/ mm
Tool name:
Oil seal & bearing installer set
SA6100-A26-0FA2
Function:
Used for installing the bearing of the front
wheel and oil seal.
Specification:
27, 32, 35, 40, 42, 45, 47, 48, 52, 58,
64/ mm
SD4712-EGC2-0FA1
Tool name:
Tire valve driver
Function:
To disassemble and assemble an air
needle in the inner tube of a tire.
Specification:
Double head (6.2mm& 5.4mm)
SD4711-EGC2-0FA1
Tool name:
Tire lever component
Function:
To disassemble and assemble the inner
tube of a tire.
Specification:
11 inch and 15 inch.
1-4
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.
1-5
CHAPTER 2
SPECIFICATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
MAINTENENCE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
CONVERSION TABLE/ GENERAL TIGHTENING
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
CHASSIS TIGHTENING TORQUES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
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 (4.5 in)
1,600 mm (63.0 in)
50 kg (110.2 lb)
Steel tube FRAME
24°00'
73.5 mm (2.9 in)
front
rear
front
rear
front
rear
2.25-14 27B
2.25-14 27B
MAXXIS
MAXXIS
C-109R-X
C-109R-X
front
rear
98kg (215 LBS )
225 kPa (2.25 kgf/cm 2,32 psi)
225 kPa (2.25 kgf/cm 2,32 psi)
type
operation
type
operation
Drum brake
Right hand operation
Drum brake
Left hand operation
2-1
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 (3.35 in)
Lining thickness
3.0 mm (0.12 in)
Shoe spring free length
46.3 mm (1.82 in)
Rear drum brake
Type
Brake drum inside diameter
Limit
Leading, trailing
85.0 mm (3.35 in)
Lining thickness
3.0 mm (0.12 in)
Shoe spring free length
46.3 mm (1.82 in)
2-2
---86.0mm
(3.39 in)
1.5mm
(0.06 in)
------86.0mm
(3.39 in)
1.5mm
(0.06 in)
----
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 ± 0.5A
voltage
current
48V ± 10V
25A ± 1A
Charger
Voltage range
115V/ 230V
Motor
Type
48V Brushless DC Motor
2-3
Limit
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. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
Ex.
METRIC
MULTIPLIER
IMPERIAL
** mm
x
0.03937
=
** in
2 mm
x
0.03937
=
0.08 in
SPEC
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
Multiplier
Imperial unit
m · kg
m · kg
cm · kg
cm · kg
7.233
86.794
0.0723
0.8679
ft · lb
in · lb
ft · lb
in · lb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/h
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Torque
3)
Volume/
Capacity
cc (cm
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (Imp liq.)
cu · in
qt (Imp liq.)
gal (Imp liq.)
Misc.
kg/mm
kg/cm2
Centigrade
(°C)
55.997
14.2234
9/5+32
lb/in
psi (lb/in2)
Fahrenheit
(°F)
A: Distance between flats
B: Outside thread diameter
A
(nut)
2-4
B
(bolt)
General tightening
torques
Nm
m · kg
ft · lb
10 mm
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94
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
2.9
Battery seat
Bolt
M6
4
4
0.4
2.9
Rear wheel axle
Nut
M14
2
80
8.0
57.9
Rear shock absorber (down)
Bolt
M10
1
35
3.5
25.3
Main stand
Bolt
M8
2
25
2.5
18.1
Rear fender bracket
Bolt
M6
1
10
1.0
7.2
Body cover
Bolt
M6
3
4
0.4
2.9
Body cover
Bolt
M6
2
4
0.4
2.9
Handle bar
Nut
M10
1
45
4.5
32.5
Front shock absorber (down)
Bolt
M10
1
35
3.5
25.3
Body cover
Bolt
M6
4
4
0.4
2.9
Bolt
M6
2
4
0.4
2.9
Bolt
M6
2
6
0.6
4.3
Bolt
M6
2
9
0.9
6.5
Rear fork
Front fork
Handle bar
Speedometer comp
Seat
Hinge of seat
Brake disk
Front brake arm cam/ brake arm
2-5
See chapter 3
“ADJUSTING THE
STEERING HEAD”
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
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
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 . . . . . . . . . . . . . . . . . . . . . . . 3-4
REMOVING AND INSTALLING REAR BOTTOM COVER/ REAR FENDER . . . . . . . . . 3-5
ADJUSTMENT FRONT/REAR BRAKE FREE PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
CHECKING THE BRAKE SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
CHECKING THE STEERING SYSTEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
CHECKING THE FROENT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
CHECKING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
REPLACING THE HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
REPLACING THE FRONT/ REAR TURN LIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
REPLACING THE TAIL LIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
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.
All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
ODOMETER READING (km)
ITEM
No.
CHECKS OR MAINTENANCE JOB
1
Brake (drum)
• Check operation and adjust brake lever free play.
• Checking and replace the hose if necessary.
2
Tires
• Check tread depth and for damage.
• Replace if necessary.
3
Wheel bearings
4
Front fork
5
• Check bearing play and steering for roughness.
Steering bearings • Replace if necessary.
• Lubricate with lithium-soap-based grease.
6
Rear shock absorber • Check operation and for oil leakage.
assembly
• Replace if necessary.
7
Main stand
• Check operation and lubricate.
8
Battery
• Check battery box for cracks or damage.
• Clean
9
• Make sure that all nuts, bolts and screws are
Chassis fasteners
properly tightened.
First 500km 3000km 5500km 8000km 10500km 13000km 15500km ANNUAL
or
or
or
or
or
or
or
CHECK
1 month 3 month 6 month 9 month 12 month 15 month 18 month
Every 1,000km
• Check bearing for looseness or damage. Replace
if necessary.
• Check operation and correct if necessary.
• Replace if necessary.
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
Every 12,000km
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
¥
10
Moving parts
and cables
• Lubricate.
¥
¥
¥
11
Wheels
• Check runout and for damage, and replace if
necessary.
¥
¥
¥
12
Lights, signals
and switches
• Check operation and correct if necessary
• Adjust headlight beam.
¥
¥
¥
¥
¥
¥
¥
¥
13
Front and rear
brake switches
• Check operation and correct if necessary.
¥
¥
¥
¥
¥
¥
¥
¥
¥
* Since these items require special tools, data and technical skills, have an E-TON dealer perform
the service.
TIP
• After 15,500 mileages has been reached or 18 months has been past, an additional maintenance
shall be conducted in every 2,500 km or 2 months.
• It should check and replace ahead of time in a dirt area or rainy day.
• Please check and replace ahead of time after by long riding distance or heavy load.
• Replace the brake cable every two years or if cracked or damaged. If find the cracks or damage,
should replace the new one immediately.
3-1
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, 2.9 ft • Ib)
Remarks
Remove the parts in the order listed.
For installation, reverse the removal procedure.
3-2
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.
bar footrest
1
Seat
2
Battery
1
3
Battery seat
1
4
Driver assy
1
5
6
Bar footrest
Frame vin plate
1
1
7
Horn
1
For installation, reverse the removal procedure.
3-3
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.
3-4
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, 18.1 ft • Ib)
Remarks
Remove the parts in the order listed.
For installation, reverse the removal procedure.
3-5
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.
(b)
(a)
Adjusting nut
Dowel pin
TIP
Must confirm adjusting nut and dowel pin clench
the teeth.
Adjusting nut
2. Measure
• front and rear brake lever free play a .
Out of specification ĺ Adjust.
a
Front and rear brake lever free play
5 ~ 10 mm (0.20 ~ 0.39 in)
3. Adjust
• front and rear brake lever free play
• Loosen or tighten the nuts until the specified
front brake lever free play is obtained.
WARNING
After the brake is adjusted, must confirm
braking lights action are normal.
3-6
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 (0.04 in)
a
3-7
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. Remove
• Front cap
• Meter
• Side cover (L)
• Headlight
• Side cover (R)
Refer to "FRONT FORK" in chapter 7.
1
5. Adjust
• Steering head
2
a. Remove the upper ring nut 1 .
b. Loosen the lower ring nut 2 .
c. Use a steering nut wrench
the lower ring nut 2 .
3
and tighten
T.
R.
Lower ring nut (initial tightening torque)
35 Nm (3.5 m • kg, 25.3 ft • lb)
3
TIP
2
Install a ring nut wrench on the steering nut wrench
3 and tighten by verticality and get the tightening
torque.
3-8
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. Hold the lower ring nuts with a ring nut wrench
and tighten the upper ring nut with a steering
nut wrench.
Upper ring nut
50 Nm (5.0 m • kg, 36.2 ft • lb)
R.
6. Install
• Side cover (R)
• Headlight
• Side cover (L)
• Meter
• Front cap
CHECKING THE FRONT FORK
1. Stand the scooter on a level surface.
2. Check
• Front fork
6FUDSHGDPDJHĺUHSODFH
3. Operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement ĺ Replace
Refer to “FROENT FORK” in chapter 7.
WARNING
• Securely support the scooter so that there
is no danger of it falling over.
• If there is any abnormal sound, please
replace immediately.
3-9
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 ĺ5HSODFHWKH
rear shock absorber assembly.
• Spring
'DPDJHZHDUĺthe rear shock absorber
assembly.
5Hfer to5($56+2&.$%625%(5in
chapter 7.
• Bolts
Loosen ĺWLJKWHQ
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.
WARNING
The rear shock absorbers can't disassemble,
improper one overhaul can cause performance reduce.
CHECKING THE TIRES
• TIRE CHARACTERISTICS
The tire characteristic effect the operation of
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because is unable to measure its characteristic
of tire, may lead to the danger happen while
riding, so not propose using.
Manufacturer
Front
MAXXIS
Rear
MAXXIS
Size
2.25-14
27B
2.25-14
27B
Type
C-109R-X
C-109R-X
WARNING
Ride conservatively after installing a tire to
allow it to seat itself properly on the rim.
3-10
CHK
ADJ
CHECKING THE TIRES/ CHECKING THE WHEELS
• TIRE PRESSURE
1. Measure
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4
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(2.25kg/cm 2 )
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1
2. Check:
• Tire surfaces
'DPDJHZHDUĺ5HSODFHWKHWLUH
Minimum depth of thread of tires a
0.8 mm (0.03 in)
7KUHDGGHSWK
2 6LGHZDOO
3 :HDUOLPLWOLQH
4 :HDULQGLFDWRU
1
WARNING
It is dangerous to ride with a worn-out tire.
When tire wear is out of specification, replace
the tire immediately.
1
CHECKING THE WHEELS
1.Check:
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2. WKLOH DGMXVWing and UHSODFLQJWhe ZKHHOV, SOHDVe
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2
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WARNING
Never attempt to make any repairs to the wheel.
TIP
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DOZD\VEDODQFHWKHZKHHO
2
3-11
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.
4
3-12
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.
NOTICE
Avoid touching the glass part of the headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the life of the bulb
and the luminous flux will be adversely affected.
If the headlight bulb gets soiled, thoroughly
clean it with a cloth moistened with alcohol
or lacquer thinner.
REPLACING THE FROENT/ REAR TURN
LIGHT BULB
3
1
1. Remove
• Lens 1 .
• Turn light holder site 2 .
• Bulb 3 .
2
2. Replace
• Bulb (burned).
a
TIP
• Counterclockwise a revolving the bulb will take
it out.
3-13
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. Replace
• Bulb (burned).
WARNING
Since the light bulb gets extremely hot, keep
flammable products and your hands away
from the bulb until it has cooled down.
a
2
3. Install
• Bulb.
• Lens.
b
TIP
• Press the bulb in and clockwise b revloving
will insert into the holder site.
• Make sure the bulb infix to groove.
3-14
CHAPTER 4
CONTROLLER SYSTEM
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
CHECK AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
REMOVING THE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
CHECK AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
LEV INTERFACE (TESTING INTERFACE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
HOW TO READ INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
CHECK AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
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.
• It is necessary to confirm the connector between
the motor and controller is loosened or damaged.
1. Testing on check tools
• Remove the Hall sensor between the motor and
controller.
• Connect motor Hall sensor 1 and the Hall sensor
2 on the check tools and switch on the power
of check tool 3 .
• Turn the rear wheel by hand to confirm whether
the Hall indicator (U, V, W) 4 can function norm
ally by conducting the checking steps as in the
following:
a. How to confirm Hall sensor signal functions
regularly :
• Turn the rear wheel by hand. If none of Hall
signal indicators doesn’t remain on light-on
or light-off and every indictor remains on
flashing, the Hall signal can function normally.
b. How to confirm Hall Sensor signal function
irregularly :
• Turn the rear wheel by hand. If any of Hall
signal indicator remains on light-on or lightoff and any indicator doesn’t remain on flashing,
the Hall signal functions irregularly. Please
replace the motor.
c. If the instrument panel sends out a warning
tone or warning signal :
If the instrument panel sends out a warning
tone, the control system can’t detect the
signals of motor Hall Sensor and the motor
Hall Sensor functions irregular.
The check procedures are as below:
• When the instrument panel sends out a warning
tone and the Hall sensor sends out a warning
signal (as illustrated in the left), please check
whether motor Hall sensor and controller Hall
sensor is loosened or there is poor contact.
• If wiring is regular, but there still sends out a
warning signal during riding, Please replace
the motor.
Motor checking tool
SC130A-EGC2-0FG1
X
4-1
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 .
1
4-2
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.
2
WARNING
1
When failed, the precise circuits and electronic
component in the motor must be replaced or
repaired by the authorized dealer immediately
and are forbidden to be removed and decomposed
by the rider to insure riding safety.
4-3
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.
4-4
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.
TIP
6HWWKHSRFNHWWHVWHUVHOHFWRUWRŸ[
• If an Avometer displays “’ ”, please replace the
fuse.
Installation
Turn the main switch to “OFF”.
• Install a new fuse of the same specification
and press the fuse to the bottom.
• Close and press the fuse folder cover tightly.
• Turn the main switch to “ON” and confirm each
circuit system can function regularly.
• If the fuse blows out quickly again, please
check each circuit system.
WARNING
• Never use the fuse of a different specification
or other metal to replace the fuse.
• Using the fuse exceeding the specified capacity
will lead to wiring over-heating or blowing out.
4-5
CONT
DRIVER
2. Remove out wiring assembly after testing the
driver according to the illustration and list below
LQGLFDWHGE\WKHVLJQ³Ɣ´8VHDSRFNHW
tester to measure. If there is any short-circuit
VHQGLQJRXWD³%HHS´WRQHRUDPHDVXUHPHQW
YDOXHRIOHVVWKDQLWFDQEHMXGJHGDV
failed.
3. Remove out wiring assembly after testing the
driver according to the illustration and list below
LQGLFDWHGE\WKHVLJQ³ż´,IWKHUHLVQRWDQ\
VKRUWFLUFXLWZLWKRXWVHQGLQJRXWD³%HHS´WRQH
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FDQEHMXGJHGDVIDLOHG
4. Remove out wiring assembly after testing the
driver according to the illustration and list below
LQGLFDWHGE\GLJLWDOYDOXHDQGXVHDSRFNHW
tester to conduct ohmmeter measurement.
If the measurement value exceeds the corresSRQGLQJYDOXHLWFDQEHMXGJHGDVIDLOHG
WARNING
When failed, the precise circuits and electronic
component in the controller must be replaced or
repaired by the authorized dealer immediately
and are forbidden to be removed and decomposed
by the rider to insure riding safety.
Data for controller cable outlet
Fuse
Controller
Plug
R
R
Y
G
B
W
Br
W
B
Y
R
W
Blue
G
W
Y
W
W
BrW GB
BW YB
GY BrB
G
Blue
B
W
P
ȝPSRURVLW\
ZDWHUUHSHOOHQWFRYHU
BW
YG YBr
Terminal
Comparison list for controller cable outlet
Cable outlet
3
serial
4
5
6
7
8
9 10
12
13
14
16
1&2
6
3kŸ~10kŸ 3kŸ~10kŸ 3kŸ~10kŸ 120kŸ~140kŸ
"_" indicates exemStion of testing.
4-6
CONT
DRIVER
LEV INTERFACE (TESTING INTERFACE)
1. Testing: Lev Interface (testing interface)
Testing interface software
SC9003-EGC2-0000
Ꮪ।൷ᙰ
Panel
connector
NOTICE
List the all possible causes according to troubleshooting and be sure to check and confirm all
other causes shall be excluded before testing
driver according to testing interface
Driver
ᦀ೯ᕴ൷ᙰ
connector
How to operate testing interface
• Remove frontal fender
• Remove the connector between instrument
panel and driver (as illustrated in the left) and
connect the 4 pin connector of the testing interface
with the driver connector and the other end
connects with the UBS connector of the computer.
• Inert the key to switch on the power.
Please install the testing interface software and
testing interface driver by first use.
Testing interface
ᛀྒྷտ૿൷ᙰ
connector
ᛀྒྷտ૿൷ᒵ
Testing
interface
wiring
USB ൷ᙰ
USB
connector
Testing interface connector
SC9004-EGC2-0000
• Start the testing interface software on the
software as illustrated in the following:
4-7
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
FRPSXWHUĺFOLFNULJKWNH\ERDUGĺclick contents
ĺFOLFNKDUGZDUHĺGHYLFHNHHSHUDIWHULQVWDOO
WKHWHVWLQJLQWHUIDFHVRIWZDUHDQGFRQQHFWGULYHU
and computer.
7KHVRIWZDUHRI:LQGRZV;39LVWD
are suitable for use the steps.
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ZLQGRZZLOODSSHDUDVLOOXVWUDWHGLQWKHOHIW
3OHDVHFRQILUPZKHWKHUWKHZLULQJFRQQHFWLRQ
is installed completely and COM port setting is
correct.
• After successful on-line connection, please
click on the frame Get
.
4-8
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.
4-9
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. If the system report like in illustration
in the left still doesn’t appear, the driver shall
be replaced.
• If the system report appears, connect the
instrument panel connector with the driver and
start the booting. After successful booting, turn
the rear wheel slowly. If the electricity shuts
down, the driver shall be replaced.
Status: Operate the throttle switch after the booting
but the vehicle doesn’t respond.
• Operate according the testing interface operation
steps. After the system report status appear,
turn the handle throttle. The turn range is bigger
as the digits in the selected frame become
bigger. If the digits don’t change as the throttle
switches on or off, the driver shall be replaced.
Status: The vehicle can’t run smoothly and suffers.
• Operate according the testing interface operation
steps. After the system report status appear,
turn the rear wheel slowly. The selected frame
will also change. If the selected frame doesn’t
change as the rear wheel turns, it means
unchanged or the change doesn’t proceed as
in the sequence in the following list, the driver
shall be replaced.
Hall logic list
Order
˄
˅
ˆ
ˇ
ˈ
ˉ
4-10
U-Phase Hall
Voltage
V-Phase Hall
Voltage
W-Phase Hall
Voltage
CONT
INSTRUMENT PANEL
HOW TO READ INSTRUMENT
PANEL
ˉ
ˊ
ˋ
888888
8888.8
Trip
88
8888
˄ˇ
ˌ
ODO
Km/H
mph
˅
˄ˇ
Pow
Yes
1 Total mileage
2 Vehicle speed unit
3 Battery residual
power
4 Failure signal
5 Cancellation key
6 Speed
7 Single trip
odometer(reset to
zero)
˄ˈ
˄
ˆ
NO
X
ˇ
ˈ
˄˃
˄˄
˄˅
8 Signal code
9 Power mode
10 Status warning
signal
Confirmation
key
11
12 Button A
13 Button B
14 Turn light signal
15 Headlight
˄ˆ
CHECK AND TROUBLESHOOTING
EV3 instrument panel owns simple functions and
can display only status output, button input and
odometer accumulation. Except that the headlight,
turn signals are accessed from the electricity
signal of lamps, all other signals, such as speed,
electricity volume, unit (kilometers or miles),
warning status are all provided by controller via
RS232.
4 testing steps are described in the following to
confirm whether instrument panel can function
regularly or not. Each testing item describes how
to judge irregular function and to make troubleshooting.
push
888888
8888.8
ODO
Km/H
mph
Trip
8888
Standby
screen
88
Pow
8888.8
Yes
NO
Trip
X
Riding
screen
1ʳ
888888
ODO
Km/H
00
Booting screen
Testing steps
1. After switching on the power of electric vehicle,
the instrument panel beeper shall sound and
LCD shall display booting screen (as illustrated
in the left) and the backlight is on. It will enter
into the standby screen. Press Button A ˄ ,
it will enter into riding screen.
Troubleshooting 1
3-Pin Connector
4-Pin Connector
• There is no response and no screen on LCD
after starting booting.
a. Check whether 4-pin connector is installed
correctly. Make sure the installation is completed
properly.
4-11
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.
Panel connector
Main wiring
connector
Instrument panel
check tools
ˢˡʳ
Instrument
panel line
Spee
d/ Ba
ttery ˢ˙˙ʳ
ˢˡ˂ʳ
ˢ˙˙ʳ
˖˟˘˔
˥ʳˢ˗
ˢʳ
c. If the panel instrument can function regularly, use
the electricity meter to measure electricity + (brown/
white), - (black/white)electricity voltage at two ends
of main wiring terminal of 4-Pin connector. Check
whether electricity voltage of main wiring 12 V can
function regularly. If the electricity voltage of main
wiring 12 V functions irregularly, check the main
distribution wirings.
Instrument panel check tools
SC7200-EGC2-0FG1
Failure status 2
• There appears broken or uneven-shading words
on LCD after booting.
a. Connect the instrument panel check tool to confirm
whether the panel instrument can function regularly.
If the instrument panel functions irregularly, it is
necessary to replace with a new instrument panel.
Failure status 3
• After booting, instrument panel LCD backlight is
insufficient or irregular.
a. Connect the instrument panel check tool to confirm
whether the panel instrument can function regularly.
If the instrument panel functions irregularly, it is
necessary to replace with a new instrument panel.
Failure status 4
• After booting, the instrument panel LCD functions regularly but the beeper doesn’t sound or sound irregularly.
a. Check beeper connection wire or connector is installed
properly. Make sure the installation is completed
properly.
b. When poor contact is confirmed but beeper still sound
irregularly, the beeper shall be replaced.
Failure Status 5
• After booting, LCD still keeps on displaying booting
screen and can’t enter into standby screen.
a. Check 4-pin connector is installed properly.
Make sure the connector is installed properly.
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. If the instrument panel can function regularly, and
the wiring connector is installed properly, it is necessary
to check whether the controller can function regularly.
Please refer to testing steps for the controller.
Failure status 6
• In booting screen, press the left button but it is always
unable to enter into the riding screen.
a. Check 4-pin connector is installed properly.
Make sure the connector is installed properly.
4-12
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. If the instrument panel can function regularly, and the
wiring connector is installed properly, it is necessary to
check whether the controller can function regularly.
Please refer to testing steps for the controller.
Testing steps
2. Switch on a turn signal in riding screen. The icon
“Eye” and turn signal indicator LED shall flash.
Failure Status 1
• Switch on turn signal in the riding screen, but the
turn signal LED doesn’t flash regularly.
a. Check 3-pin connector is installed properly. Make
sure the connector is installed properly.
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. If the instrument panel can function regularly, it
is necessary to check whether the turn signal
and main wiring can function regularly. Please
refer to Chapter 6 signal system.
• Switch on turn signal in the riding screen, but
the turn signal LED doesn’t flash regularly.
a. Check 3-pin connector is installed properly. Make
sure the connector is installed properly.
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. If the instrument panel can function regularly, it
is necessary to check whether the turn signal
and main wiring can function regularly. Please
refer to Chapter 6 wiring diagram.
Failure Status 2
• Switch on the turn signal in riding screen and
the turn signal LED flashes but the icon “Eye”
in the LCD functions irregularly.
a. 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.
Testing Steps
3. Switch on the headlight and LCD backlight and
the headlight indicator LED will be on.
Failure Status 1
• Switch the headlight in the riding screen but the
headlight indicator LCD doesn’t switch on.
a. Check 3-pin connector is installed properly. Make
sure the connector is installed properly.
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.
4-13
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.Restart the booting to make sure the beeper
can make booting sound effects.
b. If there is no booting sound effect, check whether
the beeper wiring, connector, the beeper can
function regularly.
c. If there is booting sound effect and the beeper can
function regularly but there is still no button tone
upon pressing the left or right button in the riding
screen. Connect the instrument panel check
tool to make sure the instrument panel can function
regularly. If the instrument panel functions irregularly,
it is necessary to replace with a new instrument panel.
X
Button B
Headlight
indicator LED
8888.8
Trip
888888
00
ODO
Km/H
LCD
backlight
Testing Steps
5. Switch on the headlight in the riding screen and the
LCD backlight and the headlight indicator LED
be on.
Failure Status 1
• Switch on the headlight in the riding screen but
the headlight indicator LCD isn’t on.
a.Check 3-pin connector is installed properly.
Make sure the connector is installed properly.
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. 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.
Failure Status 2
• Switch on the headlight in the riding screen and
the headlight indicator LCD is on but the LCD
backlight isn’t on.
a.Connect the instrument panel check tool to
check whether the instrument panel can function
regularly. If the instrument panel functions
irregularly, it is necessary to replace with a new
instrument panel.
4-14
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Testing charging
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
CHARGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
INSTALLATION STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
CHARGING ELECTRICITY CURRENT AND OPERATION
ENVIRONMENT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
MAINTENANCE AND TESTING STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
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. Remove the battery
a. Turn the main switch to OFF
b. Lift the seat
Pull the buckle 1 on the seat rear upwards
and lift the seat rear upwards to open the seat.
1
Key
Battery housing
c. Use the key to open the battery protection cover
and open the battery cover by hand carefully.
NOTICE
The battery protection cover will be bounced off
upwards by the spring.
d. Hold the battery handle and pull the battery out.
5-1
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.
REFERENCE VALUE FOR BATTERY RESIDUAL CAPACITY
Battery residual
capacity(%)
Screen
Bright
Light signals
Flash
Green
Red
Situation
Only 2 sections of battery residual capacity
flash on the instrument panel or red light on
the battery means nearly no battery residual
capacity. Riding shall be stopped and charging
shall be conducted immediately.
Only 2 sections of battery residual capacity
on the instrument panel or 1 green light on
the battery means battery is nearly out of
charge and charging shall be conducted soon.
0 ~ 24
25 ~ 39
Only 4 sections of battery residual capacity
on the instrument panel or 2 green light on
the battery means less than half battery
residual capacity. Charging shall be conducted
soon.
Only 6 sections of battery residual capacity
on the instrument panel or 3 green light on
the battery means about 1/2 battery residual
capacity. Battery capacity shall be noticed
during riding.
40 ~ 54
55 ~ 69
70 ~ 84
There are 8 sections of battery residual capacity
on the instrument panel or 4 green light on
the battery means sufficient battery capacity.
85 ~ 100
There are 10 sections of battery residual capacity
on the instrument panel or all green light on
the battery means sufficient battery capacity.
ϡʳPress
on the battery box to display light signal.
TIP
Before replacing the battery, use E-Mo Charger
to charge the battery completely. If the battery is
not charged completely, the indicator can’t display the battery residual capacity correctly.
5-2
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. Use an ammeter to measure the output on the
positive and negative poles of the battery and
stay the probe on the output terminal for 10
seconds and observe whether electricity voltage is over 36V.
If the electricity voltage is less than 36V, please
replace the battery immediately.
Testing charging
1. Plug on the charger plug and make the charger
be OFF. Switch on the charger and observe
whether the charger indicator 1 light illumi-!!!!
nates in red.
1
2. Use an ammeter to measure charging signal.
Use the red probe of the ammeter to test the
positive pole of the battery; the black probe to
test the negative pole of the battery and then
observe whether electricity voltage is more
than 40V and keeps on increasing. If the electricity voltage is less than 40V, please use an
ammeter to measure the negative and positive
poles of the battery to observe whether the
electricity voltage is more than 40V. If not,
please replace with a new charger. If yes,
please replace with a new battery.
5-3
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. Output positive and negative poles
shall avoid short circuit.
Charging outlet
LED
+V -V
2. Use selection switch to adjust the AC input
electricity voltage range 115/230V according
to local electricity voltage. Factory default is
preset to be 115V(Taiwan).
3. After the electricity power is connected, turn
the power switch (0/-) to ON(-). Check whether
the LED light illuminates in red (in charging
status). Green light indicates it is already fully
charged.
Terminal
WARRANT IS VOID IF
STICKER IS BROKEN
ᐺᄤྤய
–
NOTICE
Θ This battery can charge for the lithium battery
of this vehicle.
Charger
Θ This charger shall be kept in drafty and dry
Power cable
and shall avoid exposure to rain or snow.
Θ The length of conducting wire connecting
Θ
Input terminal
Θ
Charging outlet
Charging plug
Θ
Θ
Battery
Power outlet
Charger
Power switch
5-4
the battery to the charger shall be kept as
short as possible to avoid lengthening the
time for full charge due to excessive voltage reduction.
Make sure the charging electricity voltage
and electricity current complying with battery
specification.
Both new and old battery can’t be charged
in parallel connection.
Make sure the charger is switched off upon
plugging into or off the conducting wire.
2-year warranty is provided for the charger
except damage caused by improper usage.
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.
Warranty is void if sticker is broken.
ᐺᄤྤய
ʳʳ
WARRANT IS VOID IF
STICKER IS BROKEN
LED
WARRANT IS VOID IF
STICKER IS BROKEN
ᐺᄤྤய
WARNING
+V ʳʳʳ-V
CHARGING ELECTRICITY CURRENT AND
OPERATION ENVIRONMENT TEMPERATURE
100
80
1. PB-360 Charger can charge with the maximum
electricity current at the temperature under 40°.
The maximum electricity current will be reduced
automatically at the temperature higher than 40°
as shown in the left.
70
60
40
30
-20
10
20
30
40
50
60
70
к
Environment temperature °C
MAINTENANCE AND TESTING STEPS
1. Set the DC voltage of ammeter to over 100V.
2. The charger shall not be connected with the
battery. Switch on the charger and the charger
shall illuminate in green.
3. Use the red probe of the ammeter to contact
the positive pole (P1) and the black probe to
contact the negative (P2) as shown in the left.
4. The displaying voltage range of the ammeter
is about 54.9±0.3V
5. If the electricity voltage is not within the range
mentioned above, adjust SVR1. The electricity
reduces back to 54.9±0.3V as shown in the left.
6. If troubleshooting still can’t be attained after
conducting the steps mentioned above, it means
the product is already damaged.
ᐺᄤྤய
P1 (+V)
P3 (-V)
WARRANT IS VOID IF
STICKER IS BROKEN
workload %
90
P2 (-V)
5-5
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.
Incorrect connection of
electric pole
(output fuse burned out)
115/230VAC Incorrect
selection on switch
Turn to ON position
115/230VAC Incorrect
selection on switch
Turn the switch to
the correct position
Replace the fuse
Maintenance and repair
is needed.
The battery charging still Battery is aged or damaged Replace with new battery
can’t reach the floating
charging phase (in green Select wire of proper diameter Excessively narrow
light)
output wire diameter
5-6
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 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 THE SWITCHES 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 6-4
CHECKING THE BULBS AND BULB SOCKETS 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 6-5
CHECKING THE CONDITION OF THE BULBS 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 6-5
CHECKING THE CONDITION OF THE BULB SOCKETS 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 6-6
LIGHTING SYSTEM 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 6-7
CIRCUIT 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 6-7
TROUBLESHOOTING 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 6-8
CHECKING THE LIGHTING SYSTEM 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 6-9
SIGNALING SYSTEM 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 6-10
CIRCUIT 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 6-10
TROUBLESHOOTING 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 6-11
CHECKING THE SIGNALING SYSTEM 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 6-12
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
–
+
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 Gr
Br
B/W
L
Y
B/W
Br/W G/B B/W Y/B
Y/Br Y/G
Br/B G/Y
R/W
B/Y
R/W
G/Y
B/W Gr
Y/B B/W G/B Br/W
Br/Y
LG
Br
2
3
1
7
ON
OFF
Y/Br
Y/G
Y/Br
Y/G
Y/Br
B/W L/W
G/W
Br/W Y/W
L/W B/W
G/W
Y/W Br/W
Br/B
Br/Y
Y/B
L
L
G/B
G/B
Y/B
Y
G
B/W
Br/W
Br/W
Y
12V 10W
Br/Y
R/W
Br/Y
12V 21/5W
R/W
B/W
B/W
B/W
B
B
5
W/Pu
R
R
Br/B
W/Pu
LG
Y/Br
Br/W
B/W
G
Y/G
L/W
L/W
Br/W
B/W
Y/W
G/W
Y/G
Gr
Y/W
6-2
G/W
Gr
R
LG
Gr Br/B
8
30A
10A
Br/B Gr B/W
B/W
6
Or
Br/Y
Or
Br
4
B
Controller
Meter
Motor
Fuse
Battery connection
Battery box
Main switch
Throttle handle
Turn signal switch
Horn switch
Headlight switch
Turn signal relay
Front brake light switch
Rear brake light switch
Front turn signal light (R)
Front turn signal light (L)
Rear turn signal light (R)
Rear turn signal light (L)
Head light
Tail/brake light
Horn
Protective choke coil
B Black
Br Brown
G Green
Gr Gray
L Blue
LG Light Green
Or Orange
R Red
Y Yellow
Br/B Brown/Black
B/W Black/White
B/Y Black/Yellow
Br/W Brown/White
Br/Y Brown/Yellow
G/B Green/Black
G/W Green/White
G/Y Green/Yellow
L/W Blue/White
R/W Red/White
W/Pu White/Purple
Y/B
Yellow/Black
Y/Br Yellow/Brown
Y/G Yellow/Green
Y/L
Yellow/Blue
Y/R
Yellow/Red
Y/W Yellow/White
Color Code
22
21
20
18
19
17
15
16
11
12
13
14
10
1
2
3
4
5
6
7
8
9
WIRING DIAGRAM
ELEC
–
+
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.
TIP
• Before checking for continuity, set the pocket tester to “0” and to the “ x1” range.
• When checking for continuity, switch back
and forth between the switch positions a
few times.
The terminal connections for switches (e.g.,
trun signal switch, horn switch) are shown in
an illustration similar to the one on the left.
The switch positions a are shown in the far
left column and the switch lead colors b are
shown in the top row in the switch illustration.
b
Br Y/R LG
a
R
PUSH
L
TIP
“ — ” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows
that:
There is continuity between brown and yellow/red
when the switch is set to “ R ”.
6-3
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”.
1
2
Br Y/R LG
3
L/Y B/Y
R
PUSH
L
ON
OFF
Br/Y B/Y
ON
OFF
Y/R Br/Y Br
Br Br/Y Y/R
B/Y Y/L LG
LG Y/L B/Y
4
G/Y
B/Y
5
G/Y
B/Y
6
Y/Br
Y/Br
Y/G
Y/G
7
8
Y/Br Y/G
ON
OFF
30A
1 Turn signal switch
2 Horn switch
3 Headlight switch
4 Front brake switch
5 Rear brake switch
6 Main switch
6-4
7 Main fuse
8 Turn signal fuse
10A
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.
• Bulbs a and b are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulbs c is used for turn signal and
tail/brake lights and can be removed from
the socket by pushing and turning the bulb
counterclockwise.
• Bulbs d and e are used for meter and
indicator lights and can be removed from
their respective socket by carefully pulling
them out.
c
d
e
CHECKING THE CONDITION OF THE
BULBS
The following procedure applies to all of the
bulbs.
1. Remove:
• bulb
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled
down.
NOTICE
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the terminal in the coupler.
• Avoid touching the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the glass,
the life of the bulb, and the luminous flux
will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it
with a cloth moistened with alcohol or
lacquer thinner.
6-5
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. If either of the readings indicate no continuity, replace the bulb.
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of the
bulb sockets.
1. Check:
• bulb socket (for continuity)
(with the pocket tester)
Replace.
No continuity
TIP
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity, replace the bulb socket.
6-6
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/G Y/Br
G/Y Br/B Gr
L
Y
B/W
Br/W G/B B/W Y/B
Y/Br Y/G
Br/B G/Y
R/W
B/W Gr
Y/B B/W G/B Br/W
Br/Y
LG
Br
2
3
1
7
ON
OFF
Y/Br
Y/G
Y/Br
Y/G
Y/Br
B/W L/W
G/W
Br/W Y/W
L/W B/W
G/W
Y/W Br/W
Br/B
Br
Y/B
L
L
G/B
G/B
Y/B
G
B/W
Br/W
Br/W
G
12V 10W
Br/Y
R/W
Br/Y
12V 21/5W
R/W
B/W
B/W
B/W
B
B
5
W/Pu
R
R
Br/B
W/Pu
Br/Y
Y/Br
Br/W
B/W
Y
Y
Y/G
L/W
L/W
Br/W
B/W
Y/W
G/W
Y/G
Gr
Y/W
6-7
G/W
Gr
R
LG
Gr Br/B
8
30A
10A
6
4
Br/B Gr B/W
B/W
Or
LG
B
Br/Y
Or
Br
LIGHTING SYSTEM
ELEC
1
2
4
5
6
7
–
+
LIGHTING SYSTEM
CIRCUIT DIAGRAM
Controller
Meter
Fuse
Battery connection
Battery box
Main switch
11 Head light switch
19 Headlight
20 Tail/brake light
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.
TIP
• Before troubleshooting, remove the following part(s):
1.Seat
2.Cap,front
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
• Troubleshoot with the pocket tester.
1. Main fuse
• Check the fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 4.
• Is the fuse OK?
YES
–
YES
NO
Replace the main switch.
NO
4. Headlight switch
• Check the headlight switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the headlight switch OK?
Replace the fuse.
YES
NO
The headlight switch is
faulty. Replace the left
handlebar switch.
5. Wiring
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly connected and without defects?
6-8
YES
NO
Check the condition of
each of the lighting system’s circuits. Refer to
“CIRCUIT DIAGRAM”.
Properly connect or
repair the lighting
system’s wiring.
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.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the headlight bulb and socket OK?
YES
YES
–
ELEC
NO
NO
Replace the
tail/brake light bulb,
socket or both.
Replace the headlight
bulb, socket or both.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
2. Voltage
• Connect the pocket tester (DC 20 V) to the
headlight couplers as shown.
12V 35W
1
2
R/W
G/Y
• Set the main switch to “ON”.
•Measure the voltage (DC12V) on the
tail/brake light coupler (tail/brake light
side).
• Is the voltage within specification?
Br/Y R/W
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) on the
headlight coupler (wire harness side).
• Is the voltage within specification?
YES
This circuit is OK.
This circuit is OK.
1
Br/Y
R/W
R/W Br/Y
YES
red/white 1
brown/yellow 2
2
G/Y
Br/Y
red/white 1
brown/yellow 2
12V 21/5W
Positive tester probe
Negative tester probe
Positive tester probe
Negative tester probe
NO
Wiring circuit from
the main switch to
the headlight light
coupler is faulty and
must be repaired.
6-9
NO
Wiring circuit from
the main switch to
the tail/brake light
coupler is faulty and
must be repaired.
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/G Y/Br
G/Y Br/B Gr
L
Y
B/W
Br/W G/B B/W Y/B
Y/Br Y/G
Br/B G/Y
R/W
B/W Gr
Y/B B/W G/B Br/W
Br/Y
LG
Br
2
3
1
7
ON
OFF
Y/Br
Y/G
Y/Br
Y/G
Y/Br
B/W L/W
G/W
Br/W Y/W
L/W B/W
G/W
Y/W Br/W
Br/B
Br
Y/B
L
L
G/B
G/B
Y/B
G
B/W
Br/W
Br/W
G
12V 10W
Br/Y
R/W
Br/Y
12V 21/5W
R/W
B/W
B/W
B/W
B
B
5
W/Pu
R
R
Br/B
W/Pu
Br/Y
Y/Br
Br/W
B/W
Y
Y
Y/G
L/W
L/W
Br/W
B/W
Y/W
G/W
Y/G
Gr
Y/W
6-10
G/W
Gr
R
LG
Gr Br/B
8
30A
10A
6
4
Br/B Gr B/W
B/W
Or
LG
B
Br/Y
Or
Br
SIGNALING SYSTEM
ELEC
1
2
4
5
6
7
9
10
12
13
14
15
16
17
18
20
21
22
–
+
SIGNALING SYSTEM
CIRCUIT DIAGRAM
Controller
Meter
Fuse
Battery connection
Battery box
Main switch
Turn signal switch
Horn switch
Turn signal relay
Front brake light switch
Rear brake light switch
Front turn signal light (R)
Front turn signal light (L)
Rear turn signal light (R)
Rear turn signal light (L)
Tail/brake light
Horn
Protective choke coil
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.Cap,front
3.Bottom cover,front
YES
Check the condition
of each of the
signaling system’s
circuits.
Refer to “CHECKING THE SIGNALING SYSTEM”.
• Troubleshoot with the pocket tester.
1. Main fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” in chapter 4.
• Is the fuse OK?
NO
Replace the fuse.
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 5.
Minimum open-circuit voltage
40.0 V or more at 20°C
• Is the battery OK?
• Clean the battery
terminals.
NO
Replace the main
switch.
TIP
YES
+
3. Main switch
•Any of the following fail to light : turn
signal light, brake light or an indicator
light.
•The horn fails to sound.
YES
–
NO
• Recharge or
replace the
battery.
6-11
NO
Properly connect or
repair the signaling
system’s wiring.
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. Voltage
• Connect the pocket tester (DC 20 V) to the
horn connector at the horn terminal as
shown.
Positive tester probe
Negative tester probe
YES
red/white
ground
R/W
NO
Replace the horn.
4. Voltage
L/Y
• Connect the pocket tester (DC 20 V) to the
horn connectors as shown.
Positive tester probe
Negative tester probe
R/W
red/white
ground
L/Y
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown at
the horn terminal.
• Is the voltage within specification?
YES
NO
The wiring circuit from
the main switch to the
horn connector is faulty
and must be repaired.
• Set the main switch to “ON”. Push horn
switch
• Measure the voltage (DC 12V) of blue/yellow
at the horn terminal.
• Is the voltage within specification?
YES
This circuit is OK.
6-12
NO
The wiring circuit or
horn switch is faulty
and must be repaired.
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.
The wiring circuit
from the main
switch to the
tail/brake light coupler is faulty and
must be repaired.
Replace the
tail/brake light bulb,
socket or both.
2. Brake light switches
• Check the brake light switches for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the brake light switch OK?
YES
3. The turn signal light, turn signal indicator
light or both fail to blink.
1. Turn signal indicator light bulb and socket
• Check the turn signal light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the turn signal light bulb and socket
OK?
NO
Replace the brake
light switch.
3. Voltage
YES
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
as shown.
Replace the turn
signal light bulb,
socket or both.
red/white
green/yellow
G/Y
2. Turn signal switch
1
Br/Y
12V 21/5W
Br/Y
Positive tester probe
Negative tester probe
NO
R/W
• Check the turn signal switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the turn signal switch OK?
2
G/Y
YES
NO
R/W
Replace the left
handlebar switch.
6-13
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. Voltage
R/W Y/R B/Y
+
-
1
• Connect the pocket tester (DC 20 V) to the
turn signal light connector or meter coupler
(wire harness side) as shown.
• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) on red/white
at the turn signal relay coupler (wire harness side).
• Is the voltage within specification?
YES
Right turn signal light
Positive tester probe
Negative tester probe
Left turn signal light
Positive tester probe
Negative tester probe
red/white 1
brown 3
red/white 1
light green 2
NO
The wiring circuit from
the main switch to the
turn signal relay coupler
is faulty and must be
repaired.
1 R/W
1 R/W
12V 10W
Br
12V 10W
LG
3
2
4. Voltage
• Set the main switch to “ON”.
• Set the turn signal switch to “L” or “R”.
• Measure the voltage (DC 12 V) of the light
green 2 or brown 3 at the turn signal
light connector (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
yellow/red
ground
YES
NO
B/Y Y/R R/W
This circuit is OK.
R/W Y/R B/Y
-
+
1
6-14
The wiring circuit
from the turn signal
switch to the turn
signal light connector is faulty and
must be repaired.
CHAPTER 7
CHASSIS
FRONT WHEEL / REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
REMOVING THE FRONT/ REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
CHECKING THE FRONT/ REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
CHECKING THE FRONT/ REAR WHEEL AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
ASSEMBLE THE FRONT/ REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
INSTALL THE FRONT/ REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
FRONT BRAKE / REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
REMOVING THE FRONT/ REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
CHECKING THE BRAKE DISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
CHECKING THE BRAKE SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
CHECKING THE BRAKE DRUMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
REMOVING THE FRONT/ REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
REMOVE THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
CHECKING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
INSTALL THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
HEADLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
REMOVING THE HANDLEBAR GRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
CHAPTER 7
CHASSIS
LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
LOWER BRACKET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
CHECKING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
INSTALLING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
REMOVING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
DISASSEMBLE THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
ASSEMBLING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
INSTALLING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
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.
7-1
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.
1
2
3
4
5
6
Rear bottom cover L/R
Rear fender
Rear fender bracket
Rear brake shoe plate
Hexagon flange bolt
Rear wheel
1/1
1
1
1
1
1
For installation, reverse the removal procedure.
7-2
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
2XWRIVKDSHĺUHSODFH
• Rim
Out of shape ĺ replace the wheel or check the
bearings operation.
• Tire
'DPDJHZHDUĺ5HSODFH
Please refer to “CHECKING THE TIRES” in
chapter 3.
WARNING
Ride conservatively after installing a tire to
allow it to seat itself properly on the rim.
CHECKING THE FRONT/ REAR WHEEL AXLE
1. Checking
• Front wheel axle 2
• Rear wheel axle 3
'DPDJHZHDUĺ5HSODFH
Roll the wheel axle on a flat surface and check.
WARNING
Do not attempt to straighten a bent wheel axle.
• Front/ rear wheel axle
If the wheel axle could shake or the tire unsmooth
RSHUDWLRQĺUHSODFHWKHZKHHOEHDULQJV
NOT
ICE
რ
• Do not strike the center race of the bearings
to avoid damaging the bearings.
• Securely support the wheel to avoid damaging
the brake disk. If the brake disk had damaged,
please replace immedicately.
• Oil seal
'DPDJHZHDUĺ5HSODFH
7-3
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.
˔
˔ Install the front wheel
˕ Install the rear wheel
INSTALL THE FRONT/ REAR WHEEL
For installation, reverse the removal procedure and
following procedure applies to all the front/ rear
wheel.
˕
1. Lubricate
• Front wheel axle
• Wheel bearings
• Oil seal lips
Lithium-soap-based grease
2. Install
• Front wheel
• Rear wheel
2
3
3. Tighten
• Front wheel axle 4
• Front wheel axle nut
4
T.
R.
2
35 Nm (3.5 m•kg, 25.3 ft•lb)
• Rear wheel axle 5
• Rear wheel axle nut
T.
R.
80 Nm (8.0 m•kg, 57.9 ft•lb)
NOT
ICE
რ
Before tightening the wheel axle nut, push down
hard on the handlebar several times and check
if the front fork rebounds smoothly.
5
3
WARNING
Make sure the brake cable is routed properly.
7-4
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.
7-5
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.
1
1
1
1
1
1
2
1
1
Rear wheel
Rear brake cable
Brake arm
Brake indicator
Felt seal
Spring
Brake shoe
Brake arm cam
Brake disk B
For installation, reverse the removal procedure.
7-6
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. Checking
• Brake disk A
• pivot pin
• Brake arm cam
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• Felt seal
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CHECKING THE BRAKE SHOES
The following procedure applies to each brake.
1. Checking
• Brake shoes 2
• Brake shoe spring 3
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3
2
TIP
When replacing the brake shoes, replace the
brake shoe springs at the same time.
• brake shoe lining surface
*OD]HGDUHDVĺUHPRYH
Use coarse sandpaper.
TIP
After using sandpaper, wipe off the polished particles
with a cloth.
7-7
CHAS
FRONT BRAKE / REAR BRAKE
2
2
3. Measure
• brake shoe lining thickness a
2XWRIVSHFLILFDWLRQĺUHSODFH
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)
<Limit>: 1.5 mm (0.06 in)
CHECKING THE BRAKE DRUMS
The following procedure applies to each brake.
1. Check
• brake drum inside diameter a
2XWRIVSHFLILFDWLRQĺUHSODFH
b
Brake drum inside diameter
85.0 mm (3.35 in)
<Limit>: 86.0 mm (3.39 in)
INSTALLING THE FRONT AND THE REAR
BRAKES
Reverse the “Removal” procedure.
Note the following points.
1. Lubricate
• brake camshaft
• pivot pin
Lithium-soap-based grease
NOTICE
During installation, lightly grease the brake
camshaft and the pivot pin. Wipe off the excess
grease.
7-8
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
8QVPRRWKRSHUDWLRQĺUHSDLU
B
˶
4
TIP
• When installing the brake disk, align the groove
˶ of the brake disk with the projection of ˷
the steering knuckle.
• Check that the brake shoes are properly positioned.
˷
C
4
B Front fork.
C Swing arm.
˶
˷
3. Adjust
• front brake
• rear brake
Refer to “ADJUSTING THE FRONT BRAKE
REAR BRAKE”
in chapter 3.
7-9
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.
1/1
1
7-10
Removing 6 pin connector and rear brake
cable before remove motor.
Refer to "REAR SHOCK ABSORBER" in
cheaper 7.
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. If vertical movement
is tight or rough, or if there is binding, check
the spacer, bearings and frame pivot.
2. Remove
• Pivot shaft nut
• Pivot shaft
• Swingarm
CHECKING THE SWINGARM
1. Check
• Swingarm
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2. Check
• Pivot shaft
Roll the axle on a flat surface.
%HQGVĺUHSODFH
WARNING
Do not attempt to straighten a bent pivot shaft.
3. Clean
• Pivot shaft
• Spacer
Recommended cleaning solvent
Kerosene
7-11
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.
7-12
CHAS
REAR SHOCK ABSORBER
CHECKING THE REAR SHOCK ABSORBER
1. Check
• Shock absorber rod
Bends/damageĺreplace the rear absorber
assembly.
• Shock absorber
Oil leaks ĺ replace the rear absorber assembly.
• Spring
Fatigueĺreplace 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 .3 ft • Ib)
• Rear shock absorber lower pin
TIP
When installing the rear shock absorber assembly
assembly, press backward the vehicle slightly.
7-13
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.
7-14
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
%HQGVGDPDJHĺUHSODFH
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( 4.5 m•kg, 32.5 ft•lb)
2. Install
• Handlebar grip 3
Refer to "MAINTAINENCE FRONT BRAKE" in
cheaper 3.
TIP
3
Before installing the handlebar grip,should be
put oil on the left headlebar grip.
7-15
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.
• Handle lever assembly (L)
• Handlebar grip (L)
• Handle lever comp (R)
• Left / right brake lever
TIP
Lubricate the inside of the throttle grip with a thin
coat of lithium soap base grease and install it
onto the handlebar.
7-16
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.
Refer to "FRONT WHEEL/ REAR WHEEL".
1
1
2
1
1
1
1
2
2
1
1/1
For installation, reverse the removal procedure.
7-17
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. Washing the bearing ball with solution.
2. Check
• Bearing ball
3LWWLQJGDPDJHĺUHSODFH
3. Check
• Lower bracket 2
3LWWLQJEHQGVGDPDJHĺUHSODFH
2
WARNING
Do not attempt to straighten a bent lower bracket
as this may dangerously weaken the lower
bracket.
7-18
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. Install
• Front fender assembly
• Ball race outer 1
• Bearing ball 2
• Ball race upper 3
• Ball race cover 4
• Ring nut 5
TIP
Holding the front fender assembly until tighten.
4. Tighten
• Ring nut
ϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰϰ
Tighten steps :
• Tighten the ring nut 1 with the ring nut wrench
2 .
3
1
2
T.
R.
Lower ring nut (initial tightening torque)
35Nm (3.5m • kg, 25.3ft • lb)
Lower ring nut (final tightening torque)
12Nm (1.2m • kg, 8.7ft • lb)
Upper ring nut
50 Nm (5.0 m • kg, 36.2 ft • lb)
TIP
Install a ring nut wrench on the steering nut wrench
3 and tighten by verticality and get the tightening
torque.
7-19
CHAS
LOWER BRACKET
• Tighten the ring nut, please refer to "CHECKING
STEERING HEAD " in cheaper 3.
2
3
ϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧϧ
7-20
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.
7-21
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.
• Wiper 4
3
NEW
7-22
CHAS
FRONT FORK
CHECKING THE FRONT FORK
1. Check
• Inner tube
:HDUVEHQGVGDPDJHĺUHSODFH
WARNING
Do not try to straighten an outer tube or an
inner tube as this may dangerously weaken
the tube.
2. Measure
‡)RUNVSULQJ a
$ERYHVSHFLILHGOLPLWĺUHSODFH
a
Fork spring free length
99.0 mm (3.90 in)
<limit> : 94.0 mm (3.70 in)
ASSEMBLING THE FRONT FORK
5HYHUVHWKHGLVDVVHPEO\SURFHGXUH%HDULQ
PLQGWKHIROORZLQJSRLQWV
2
1
,QVWDOO
‡)RUNVSULQJ
‡6SULQJZDVKHU
‡0LQLVSULQJ
• Washer
• Inner tube
1
2
&RPELQHWKHLQQHUWXEHZLWKRXWHUWXEH
2
3
4
1
,QVWDOO
‡2LOVHDO 1 NEW
3
8VHDKDPPHUDQGFRQGXLWIRULQVWDOO
2
WKHRLOVHDO
4 Outer tube.
TIP
%HIRUHLQVWDOOLQJWKHRLOVHDODSSO\OLWKLXPVRDS
EDVHJUHDVHWRWKHRLOVHDOOLSV
7-23
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
8QVPRRWKRSHUDWLRQĺUHSODFH
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, 21.7 ft•lb)
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 reaction 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
POOR RIDING PERFORMANCE 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
LIGHT ODES NOT LIGHT 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
WHILE RIDING LOST ELECTRICITY SUDDENLY 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
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 ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ 8-1
POOR BRAKING PERFORMANCE 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 8-2
FAULTY FRONT FORK LEGS 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 8-2
HORN DOES NOT SOUND 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 8-2
FAULTY LIGHTING OR SIGNALING SYSTEM 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 8-2
ˁ
Headlight does not light 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 8-2
Light bulb burnt out 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 8-2
Turn signal does not light 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 8-2
Turn signal remains lit 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 8-2
Turn signal blinks slowly 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 8-2
Turn signal blinks quickly 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 8-2
MESSAGE CODE 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 ˁ ˁ 8-3
Meter m essage code Εwarning message(warning tone) drawing ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ ˁ 8-3
Warning and Cue signal 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 8-3
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).
ԦʳʳBattery contact bad connection.
ԦʳʳBlown, damaged or incorrect fuse.
ԦʳʳWiring contact bad connection or damage.
ԦʳʳFaulty main switch.
ԦʳʳFaulty meter.
ԦʳʳFaulty driver.
LIGHT ODES NOT LIGHT
ԦʳʳDriving modes is set standard mode.
ԦʳʳWiring contact bad connection or damage.
ԦʳʳBurnt-out light bulb.
WHILE RIDING LOST ELECTRICITY
SUDDENLY
ԦʳʳDriving modes is set
ԦʳʳFaulty main fuse.
ԦʳʳFaulty
ԦʳʳFaulty
Lasting meter warning tone
ԦʳʳWiring contact bad connection or damage.
ԦʳʳFaulty driver.
ԦʳʳFaulty meter.
standard mode.
battery.
driver.
WARNING TONE
E-MO will notify vehicle operation and movement
starts by sending out warning tone.
ϬʳWarning
Main switch "ON", turn handle bar the
vehicle no reaction
ԦʳʳWiring contact bad connection or damage.
ԦʳʳFaulty handle bar switch.
ԦʳʳFaulty motor.
ԦʳʳFaulty driver.
tone list
O: Tone
X: No tone
Vehicle operation
POOR RIDING PERFORMANCE
contact bad connection or damage.
ԦʳʳFaulty motor.
ԦʳʳFaulty driver.
ԦʳʳBrake drag.
Main switch ON
O
Press an operation button
O
Password decode
O
Wrong password
O
No operation for 30 seconds
O
10% battery residual volume
O
Warning and warning message
O
Main switch OFF
X
ԦʳʳWiring
8-1
Warning
tone
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.
ԦʳʳDust or water on the brake drum.
ԦʳʳOil or grease on the brake drum.
ԦʳʳWorn brake cable wire.
ԦʳʳWorn brake spring.
ԦʳʳWorn brake camshaft and brake lever.
Light bulb burnt out
ԦʳʳWrong light bulb.
ԦʳʳFaulty battery.
ԦʳʳImproperly grounded circuit.
ԦʳʳPoor contacts (main or light switch).
ԦʳʳLight bulb life expired.
FAULTY FRONT FORK LEGS
ԦʳʳBent or damaged inner tube.
ԦʳʳBent or damaged outer tube.
ԦʳʳDamaged fork spring.
ԦʳʳBent or damaged damper rod.
ԦʳʳIncorrect oil viscosity.
ԦʳʳIncorrect oil level.
Turn signal does not light
ԦʳʳImproperly grounded circuit.
ԦʳʳFaulty battery.
ԦʳʳBlown, damaged or incorrect fuse.
ԦʳʳFaulty turn signal switch.
ԦʳʳFaulty turn signal relay.
ԦʳʳDamaged or faulty wire harness.
ԦʳʳBurnt-out turn signal bulb.
HORN DOES NOT SOUND
ԦʳʳFaulty battery.
ԦʳʳBlown, damaged or incorrect fuse.
ԦʳʳFaulty main switch / horn switch.
ԦʳʳImproperly adjusted horn.
ԦʳʳDamaged or faulty horn.
ԦʳʳFaulty wire harness.
Turn signal remains lit
ԦʳʳFaulty turn signal relay.
ԦʳʳFaulty battery.
ԦʳʳBurnt-out turn signal bulb.
Turn signal blinks slowly
ԦʳʳFaulty turn signal relay.
ԦʳʳFaulty battery.
ԦʳʳIncorrect turn signal bulb.
ԦʳʳPoor contacts (main or light
Turn signal blinks quickly
ԦʳʳFaulty turn signal relay.
ԦʳIncorrect turn signal bulb.
8-2
switch).
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. Wait until the message
disappears then continue on driving.
electric current. The power of the motor
disappears while the warning message 2. If the warning message does not disappear, or if this warning message
appears a lot, take the motor to the service station for check up.
and warning sound are given out.
OV T
The controller detects increasingly high
1. Wait for the controller to cool down before driving continues.
temperature. The power of the motor
2. If the warning message does not disappear, or if this warning message
disappears while the warning message
appears a lot, take the motor to the service station for check up.
and warning sound are given out.
OV V
The controller detects increasingly high 1. Restart.
voltage. The power of the motor disappears 2. If the warning message does not disappear, or if this warning message
while the warning message and warning
appears a lot, take the motor to the service station for check up.
sound are given out.
LOWV
The controller detects decreasingly low 1. Restart.
voltage. The power of the motor disappears
2. If the warning message does not disappear, or if this warning message
while the warning message and warning
appears a lot, take the motor to the service station for check up.
sound are given out.
STL1
Strong resistance (stalling) at startup or 1. Release the accelerator and let go of hands. Wait until the message
during moving. The power of the motor
disappears then continue on driving.
disappears while the warning message 2. If the warning message does not disappear, or if this warning message
and warning sound are given out.
appears a lot, take the motor to the service station for check up.
NO B
This message appears when the battery Residual capacity of battery is around 10%.
is completely exhausted to remind the
Recharge the battery as soon as possible.
user to recharge the battery.
CHAR
Remind that the battery is charging.
Wait for the battery to be fully charged.
FULL
Remind that the battery charging has
already completed.
Remove the battery charger.
8-3
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. Rider can switch off safely.
set success fully.
LOWP
LOCK
Indication FAIL
Cause
Action
2.This message will display on restarting to
remind that the vehicle locking has already 2. Press confirmation button and input password to unlock the vehicle.
been set success fully.
Wrong password.
Re-enter the password.
OLD
On setting vehicle locking password, this
message will display to remind the rider to
input old password if an old password has Enter the old password.
already existed.
NEW
ON setting vehicle locking password, this
message will display to remind the rider to
input a new password if there are no password Enter the new password.
was set up in system or already enter the
correct password.
PUSH
During standby mode, this message will display to remind the user to press confirmation Press confirmation button A.
button to enter into riding page.
PRES
TPS0
After starting. This message will display to
remind the rider if the vehicle still stays in Release throttle handle and press confirmation button to enter into
standby page but the rider intends to turn around riding page.
handlebars.
After PRESS is conducted, this message
will display to remind the rider if the confirmation Release throttle handle and press confirmation button to enter into
button is pressed before handle bar is not riding page.
yet released.
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