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Aeon
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350cc
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ELECTRONIC FUEL INJECTION
5-120
2 Eight options includin
g
“
Engi
ne Data
”
,
“
ECU Version
”
,
“
Idle RPM Adjust
”
,
“
PreBLM
Learn
”
,
“
Malf Code
”
,
“
Malf Hi
story
”
,
“
Malf Reco
rd
”
and
“
Freeze Frame
”
wil
l be shown
after pressing
“
Start Con
nection
”
119
121
Table of Contents
Main Page
Default Chapter
1
Default Chapter
1
Service Manual
1
General Information
2
Understanding Manual Safety Labels and Directions
2
Chapter 1
5
Model Information
5
Engine Serial Number Location
5
Vehicle Identification Number Location
5
VIN Identification
5
General Specification
6
Urban 350 I
6
Model: URNAN 350I
7
Specifications
7
Conversion Table
8
Glossary of Terms
9
Maintenance
12
Table of Contents
12
Periodic Maintenance Chart
14
Chapter 2
14
Periodic Maintenance Overview
14
Severe Use Definition
14
Maintenance Chart Key
14
Maintenance Interval
15
Periodic Maintenance and Lubrication Chart
15
Frame, Nuts, Bolts and Fastener Inspection
16
General Vehicle Inspection and Maintenance
16
Maintenance Quick Reference
16
Standard Fastener Torques
16
Standard Torque Specifications
16
Fuel and Intake System
17
Fuel Line
17
Gasket, Oil Seals and O-Rings
17
Preparation for Removal Procedures
17
Replacement Parts
17
Fuel Pump/ Fuel Filters/ Pump Regulator
18
Throttle Free Play Adjustment
18
Throttle Inspection
18
Vent Line
18
Air Cleaner Service
19
Engine Oil Level
19
Engine Breather Hose Inspection
20
Engine Oil and Filter Service
20
Engine Mount Locations
21
Transmission Lubricant Change
21
Coolant Level Inspection
22
Cooling System Overview
22
Coolant Drain
23
Coolant Strength/ Type
23
Cooling System Hoses
23
Radiator
23
Tire Pressure Measurements
24
Wear Indicator
24
Wheels and Tires
24
Battery Maintenance
25
Check Wheel
25
Electrical and Ignition System
25
Battery Installation
26
Battery off Season Storage
26
Battery Removal
26
Handle Bar Inspection
27
Spark Plug Service
27
Steering and Suspension
27
Steering Head Inspection
27
Front Fork
28
Rear Shock Preload Adjustment
28
Brake Fluid Inspection
29
Brake Hose and Fitting Inspection
29
Brake Pad/Disc Inspection
29
Brake System
29
CVT System
30
CVT System Overview
31
Chapter 3
31
Cvt Maintenance / Inspection
31
Drive Clutch Operation
31
Driven Clutch Operation
31
Clutch Cover Exploded View
32
CVT Exploded View
32
Cvt Overheating / Diagnosis
33
Drive Clutch Removal
34
Driven Clutch Exploded View
35
Driven Clutch Removal
35
Driven Clutch Disassembly and Inspection
36
Driven Clutch Service
36
CVT Belt Inspection
37
Driven Clutch Assembly
37
Drive Clutch Disassembly and Inspection
38
Drive Clutch Service
38
Drive Clutch Assembly
39
Engine
40
Cam/Rocker Arm
43
Crank Case
43
Engine Exploded View
43
Engine Service
43
Cylinder/Cylinder Head
44
Piston/Crankshaft
44
Oil Flow Diagram
45
Chapter 4
46
Cooling System Exploded View
46
Coolant Flow Diagram
46
Engine Cooling System
46
Cooling System Pressure Test
47
Cooling System Specifications
47
Pressure Cap Test
47
Trouble Diagnosis
47
Cooling System Failure Elimination Chart
48
Coolant Replacement
49
Cooling System Bleeding Procedure
49
Fan Thermo Switch
51
Radiator Check
51
Thermostat Checking
51
Water Pump
52
Top End Disassembly
53
Accessible Components
54
Engine Removal
54
Piston Identification
54
Left Hand Engine Mount
55
Engine Installation Note
56
Engine Lubrication
56
Oil Flow Test
56
Cam Chain Tensioner Inspection
57
Cam Chain Tensioner Removal
57
Rocker Arm/ Shaft Disassembly and Inspection
57
Camshaft Removal and Inspection
59
Camshaft Inspection
61
Cylinder Head Removal
61
Cylinder Head Warp Inspection
62
Cylinder Head Disassembly
63
Valve Inspection
63
Cylinder Head Reconditioning
64
Valve Seat Reconditioning
64
Cylinder Head Assembly
66
Bottom-End Disassembly
67
Valve Sealing Test
67
Cylinder Removal
68
Cam Chain Follower / Tensioner Blades
69
Cylinder Inspection
69
Piston Removal
69
Cylinder Hone Selection / Honing Procedure
70
Honing to Deglaze
70
Piston Inspection
71
Piston Ring Installed Gap
72
Alternator/Stator/Oil Pump Exploded View
73
Starter Drive Gear Removal/Inspection
73
Flywheel Removal / Inspection
75
One-Way Clutch Removal / Inspection
75
Oil Pump Drive Sprocket Removal/ Inspection
76
Oil Pump Removal
77
Crankcase Disassembly
78
Crankcase Separation and Cam Chain Removal
78
Crankshaft Removal
79
Crankshaft/Cam & Oil Chain/Sprocket Inspection
79
Bearing/ Seal Installation
80
Crankcase Inspection
80
Crankcase Oil Strainer Inspection
80
Engine Reassembly
80
Crankshaft and Cam/Oil Chain Installation
81
Oil Pump and Chain Installation
82
Piston Ring Installation
82
Piston Installation
83
Cylinder Installation
84
Tensioner Blade Installation
84
Camshaft Timing
85
Cylinder Head and Camshaft Installation
85
Important Camshaft Timing Note
85
Camshaft Installation - Timing Method
86
Cam Chain Tensioner Installation
87
Cylinder Head Torque Procedure
87
Rocker Shaft/Arm Installation
87
Camshaft Timing with Stator Housing Removed
88
Camshaft Timing Using Flywheel TDC Mark
89
Exhaust Valve Clearance Adjustment
90
Flywheel Installation
90
Intake Valve Clearance Adjustment
90
Starter Drive Assembly
90
Spark Plug Fouling Troubleshooting
91
Stator Housing Installation
91
Backfiring
92
Engine Does Not Turn over
92
Engine Has Low Power
92
Engine Runs but will Not Idle
92
Excessive Smoke and Carbon Buildup
92
Low Compression
92
Piston Failure- Scoring
92
Troubleshooting
92
Transmission Disassembly
93
Transmission Exploded View
93
Counter Shaft/Gear Inspection
94
Drive Shaft Inspection
94
Transmission Inspection
94
Bearing and Oil Seal Inspection
95
Final Shaft/Gear Inspection
95
Transmission Troubleshooting
95
Electronic Fuel Injection
96
Service Information
99
Chapter 5
99
Special Tools
99
Service Note
99
Electronic Fuel Injection System
100
EFI System Exploded View
100
Crankshaft Position Sensor (Cps)
101
EFI System Component Locations
101
Electronic Control Unit (Ecu)
101
Fuel Pump
101
Fuel Pump Regulator
101
Intake Air Temperature (Iat)
101
10. Ignition Coil
102
11. Idle Air Control Valve
102
12.Rollover Sensor
102
13. O2 Sensor
102
Engine Coolant Temperature Sensor (Ect)
102
Throttle Body
102
Throttle Position Sensor (Tps)
102
Fueltank
103
Efi Information
104
Fuel Flow Chart
104
Fuel Tank Exploded View
104
EFI Operation Overview
105
ECU Replacement
106
ECU Service
106
IAT Operation Overview
106
IAT Test
106
CPS Operation Overview
107
CPS Test
107
Fuel Injector
107
IAT Replacement
107
CPS Replacement
108
Fuel Injector Operation Overview
108
Fuel Injector Service
109
Fuel Injector Test
109
Fuel Injector Replacement
110
Fuel Pump Operation Overview
110
Fuel Pump Test
110
Fuel Pressure Regulator Operation Overview
111
Fuel Pressure Regulator Replacement
111
TPS Test Procedure
111
ECT Operation Overview
112
TPS Replacement
112
ECT Sensor Replacement
113
ECT Sensor Test
113
General Troubleshooting
113
Ignition Coil Operation Overview
113
Diagnostic "Blink Codes"
114
Ignition Coil Replacement
114
Ignition Coil Test
114
Diagnostic "Blink Codes" Chart
115
Blink Code Breakout Diagrams
116
Blink Code Recognition
116
More than 1 Fails Blink Code
116
Prime Code
116
EFI Troubleshooting
117
Diagnostic Harness
118
KWP Diagnostic Tool
118
Diagnostic Tool
119
System Login
119
Engine Data
121
Engine Parameter Definition
121
RPM (Engine Running Speed)
121
Manifold Pressure
122
Idle Design Rpm Target
125
Afr Choke Counter
126
Air Flow Correction Mode
126
Analog to Digital of Clt Sensor
126
Analog to Digital of Iat Sensor
126
Idle Mode Afr Choke
126
Idle Spark Angle Correction
126
Indication Value of Manifold Pressure
126
Initial Leaning Value of Throttle Position
126
Run Mode Afr Choke
126
Blm Cell Number
127
Recording of Engine Operation Parameters
127
ECU Version
128
Malf Code
128
Freeze Frame
129
Malf Record
129
Idle RPM Adjust
130
Malf History
130
Convert Log File
131
Preblm Learn
131
Appendix
134
Update ECU Program
134
Body Frame
137
Body Cover Exploded View
139
Front Wheel and Brake
140
Front Wheel Disassembly
140
Front Wheel Exploded View
140
Remove the Front Wheel
140
Front Brake Disc Inspection
141
Front Wheel Inspection
141
Front Wheel Adjusting and Wheel Static Balance
142
Front Wheel Hub Assembly
142
Front Wheel Installation
143
Rear Wheel and Brake Exploded View
144
Remove the Rear Wheel
144
Rear Wheel Installation
145
Brake Exploded View
146
Brake System
146
Brake System Service Notes
146
Brake Noise Troubleshooting
147
Brake System Inspection
147
Hydraulic Brake System Operation
147
Brake Bleeding / Fluid Change
148
Brake Master Cylinder
150
Installation
150
Master Cylinder Removal
150
Front Brake Caliper
151
Pad Assembly / Installation
151
Pad Inspection
151
Pad Removal
151
Brake Burnishing Procedure
152
Caliper Installation
152
Pad Removal
152
Rear Brake Caliper
152
Brake Burnishing Procedure
153
Brake Lock
153
Brake Squeal / Poor Brake Performance
153
Caliper Overheat (Brakes Drag)
153
Pad Assembly / Installation
153
Pad Inspection
153
Pedal Vibration
153
Troubleshooting
153
Steering Shaft Removal
154
Steering Shaft Inspection
155
Steering Shaft Installation
155
Front Fork Removal
156
Steering Post Assembly
156
Front Fork Assembly
157
Front Fork Inspection
157
Handlebar
159
Hnadlebar Exploded View
159
Inspection
161
Throttle Freeplay Adjustment
161
Electrical
162
Electrical System Service Note
164
General Information
164
Wires Color Letter List
164
Switch Service
165
Chapter 7
165
Check the Connection
165
Check the Switch
165
Check a Switch Shown in the Manual
166
Headlight Switch
166
Beam Switch
166
Key/ Main Switch
166
Hazard Switch
167
Horn
167
Speedometer Sensor and Magnet
167
Speedometer/Odometer
167
Turn Signal
167
Speedometer Circuit
168
Speedometer Signal Description
168
Brake Light Switch
169
Bulb Inspection
169
Types of Bulbs
169
Bulb Sockets Inspection
170
Battery
172
Fuse
172
Ignition Circuit
172
RPM Limiter Specifications
172
Ignition Coil Resistance
173
Main Switch
173
Stator Coil
173
◎ ◎ ◎ ◎ Pickup Coil
173
Battery
174
Fuse
174
Starting Circuit Operation
174
Voltage Drop Test
174
Starter Motor Disassembly
175
Starter Motor Service
175
Armature Test
176
Starter Brush Inspection / Replacement
176
Brake Light Switch
177
Main Switch
177
Rollover Switch
177
Starter Reassembly
177
Starter Relay
177
Starting Wire Connection
177
Charging Circuit
178
Main Fuse
178
◎ ◎ ◎ ◎ Current Draw - Key off
178
Battery Identification
179
Battery Check
180
Sealed Low Maintenance Battery
180
Battery Charging Reference Table
181
Sealed Low Maintenance Battery Charging
181
Sealed Low Maintenance Battery Inspection/Removal
181
Sealed Low Maintenance Battery Installation
181
Sealed Low Maintenance Battery Testing
181
Sealed Low Maintenancebattery Charging
181
Sealed Low Maintenance Battery - OCV - Open Circuit Voltage Test
182
Sealed Low Maintenance Battery off - Season Storage
182
Conventional Battery Activation/ Svc
183
Sealed Low Maintenance Battery Charging Procedure
183
Battery Terminals/ Terminal Bolts
184
Conventional Battery Installation
184
Conventional Battery Testing
184
Conventional Battery Load Test
185
Conventional Battery OCV - Open Circuit Voltage Test
185
Conventional Battery Specific Gravity Test
185
Conventional Battery Charging Procedure
186
Conventional Battery Off-Season Storage
186
Headlight
187
Light System
187
Taillight and License Lamp
187
Cooling System
188
Thermo Switch
188
Troubleshooting
189