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GENUINE HOOLIGAN 170i User Manual

GENUINE HOOLIGAN 170i
146 pages
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HOOLIGAN 170I SERVICE MANUAL
This manual offers all service specialists with the technological procedures of
maintenance, repair, and troubleshooting for the Hooligan 170i.
Four-Stroke Cycle, 168CC , 2-valve, electronic injection, Oil-cooled
engine.
1

Table of Contents

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GENUINE HOOLIGAN 170i Specifications

General IconGeneral
BrandGENUINE
ModelHOOLIGAN 170i
CategoryScooter
LanguageEnglish

Summary

Information Summary and Preparation

1-1 Specifications

Details the technical specifications for the Hooligan 170i scooter.

1-2 Configuration

Illustrates the external configuration and component labels of the motorcycle.

1-4 Torque

Provides torque values for various bolts and nuts used in body and engine assembly.

1-5 Code of practice

Outlines essential rules and best practices for performing maintenance procedures safely and correctly.

1-6 Special tools

Lists and illustrates various specialized tools required for maintenance and repair tasks.

1-7 Trouble shooting

Provides systematic procedures for diagnosing and resolving common engine and EMS issues.

Installation or Removal of External Components

Relations of plastic parts

Illustrates the interrelationships and positions of various plastic components on the vehicle.

Body cover

Details the steps for dismantling and removing the main body cover panels.

Brake master cylinder / Haft switch assy disassembly

Details the disassembly of the brake master cylinder and handlebar switch assemblies.

Fuel tank

Details the procedure for removing and installing the fuel tank assembly.

Dismantle front-inner cover

Details the procedure for removing the front inner cover assembly.

Check & Adjust

3-1 Engine oil

Covers checking and replacing the engine oil, including volume and procedure.

3-3 Air cleaner

Explains how to check, clean, and replace the air cleaner element.

3-7 Battery installation

Provides step-by-step instructions for installing the motorcycle battery correctly.

3-10 Engine timing check / adjustment

Covers the procedure for checking and adjusting the engine's timing mechanism.

3-11 Valve clearance check / adjustment

Details how to check and adjust the valve clearance for optimal engine performance.

3-13 Brakes-thin check

Details how to check the thickness of brake pads for wear and replacement.

3-16 Tire

Covers checking tire pressure, tread depth, and specifications for wear.

3-19 Fuse check

Details how to check and replace fuses using a multimeter.

3-22 Compression pressure measurement

Explains how to measure engine compression pressure for diagnostic purposes.

Fuel injection systems

4-1 Second-generation injection system

Introduces the features and structure of the second-generation Electronic Fuel Injection (EFI) system.

4-2.2 Crank speed sensor

Explains the function, location, and measurement of the crank speed sensor.

4-2.3 Engine temperature sensor

Describes the principle, fault phenomena, and measurement of the engine temperature sensor.

4-2.4 Throttle position sensor (TPS)

Details the TPS principle, measurements, and troubleshooting for idle speed issues.

4-2.7 Fuel pump

Details the fuel pump's location, principle, measurement, and troubleshooting for clogging.

4-3 EMS system Repairing tool

Lists and illustrates essential repair and diagnostic tools for the EMS system.

4-4 EMS diagnostic

Details how to use the quick diagnostic tool for EMS system troubleshooting and defect code reading.

Engine / Reverse differential gear

5-1 Disassembly of the engine assembly

Covers the steps for disassembling the engine assembly, including back luggage and muffler.

Separation of the engine and the frame

Guides the process of separating the engine from the vehicle's frame.

5-2.1 Cylinder head disassembly

Covers the steps for disassembling the cylinder head, including fan cover and cooling cowl.

5-2.2 Cylinder removal procedure

Covers the steps for removing the cylinder, piston pin, and piston rings.

5-2.4 crankcase demolition

Details the procedure for dismantling the crankcase, including fan, flywheel, and stator removal.

5-3 Drive pulley, starter clutch. driven pulley

Details the drive pulley, starter clutch, and driven pulley components and their measurement data.

5-3.4 Cylinder and piston

Details the troubleshooting, data, dismantling, and installation of cylinder and piston assemblies.

5-3.5 Crankcase, Crankshaft

Provides troubleshooting and data for crankcase and crankshaft components, including measurements.

5-3.6 Final transmission mechanism

Covers troubleshooting, disassembly, and checking of the final transmission mechanism.

Shock absorber / brake system/wheel

6.1 Front wheel demolition

Covers the steps for removing the front wheel, including brake bolts and axle.

6.1.2 Front wheel -One sealed ball bearing

Explains the demolition, check, and installation of the front wheel's sealed ball bearing.

6.2 Front fork

Covers the steps for disassembling the front fork, including handle bar and steering components.

6.5 Rear damper

Details the demolition and installation procedures for the rear damper (both right and left).

6.6 Front wheels - brake pad (disc)

Details the disassembly, measurement, and installation of front wheel brake pads.

6.8 Brake fluid replacement

Provides instructions for replacing brake fluid using a pumping unit, with safety warnings.

Denso unit

Denso component location

Illustrates the locations of various Denso electrical components on the vehicle.

starter system

Details the process for checking the starter system components: fuse, battery, switch, motor, and relay.

7-2 Charging system

Explains how to check the battery, A.C.G., and charging lines for proper operation.

7-3 Leakage current testing

Provides a method for testing leakage current using an ammeter to identify short circuits.

7-4 Lamps lighting system

Covers electrical checks for bulbs, switches, and lighting circuits.

7-5 electrical appliances measurements

Details measurements for electrical appliances like main switch, horn, and fuel gauge.

7-6 Control of relays

Explains relay function, usage, and measurement procedures using a pocket tester.

7-7 Fuse Description

Details fuse types, ratings, and their specific purposes in protecting circuits.

7-8 Associated with the injection system and fuse

Details how fuses protect the injection system components and associated failure phenomena.

7-9 Injection system wiring diagram

Presents the wiring diagram for the injection system, including line color coding.

7-9.1Injection system engine misfire / no injection

Provides a checklist for diagnosing engine misfire or no injection issues in the system.

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