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HOOLIGAN 170i
GENUINE HOOLIGAN 170i User Manual
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Fuel
injection
systems
-4
* ISC measurement
＊
timing
when used
scoote
r occur:
1. Hard to start the engine
2. Engine I
dle speed is
unstable
3. Other unstable situation
T
o initialize the ISC, then the ISC reset to control zero point
※
program
Normal idle settings
：
1500rpm+100rpm
Cold idle speed increased to
：
1900rpm
76
75
77
Table of Contents
Table of Contents
2
Classification
2
Specifications
3
Scooter Specification
3
Information Summary and Preparation -1
3
Configuration
4
Handle Cover
4
Positions of Engine Number / Vehicle Identification Number
5
Rated Values
5
Positions of Engine Number
5
Torque
5
Code of Practice
6
Directions for Maintenance of the Engine Management System
6
Directions for General Maintenance
6
Directions During Maintenance
7
Special Tools
8
External Check
10
Trouble Shooting
10
Diagnosis Assist
10
Procedure to Maintain the Electronic Management System (EMS)
10
Engine Not Running or Slowly Running During Start-Up
11
Procedure for General Diagnoses
11
Engine Running but Start-Up Failing During Start-Up
11
Trouble of Hot Start
12
Trouble of Cold Start
13
Trouble of Start-Up Anytime Despite RPM Normal
14
Engine Mechanism
14
Start-Up Normal but Idle Speed too High
18
RPM Low or Stall During Acceleration
19
Acceleration Slow
20
Acceleration Powerless; Performance Bad
21
Information Summary and Preparation 1
21
Dismantle Bottom Cover of Luggage Comp/ Dismantle Battery Cover
22
Relations of Plastic Parts
22
Installation or Removal of External Components
22
Luggage Compartment
23
Rear Rack
23
Dismantle Middle Cover
24
Body Cover
24
Single Decomposition: Left / Right Body Cover
25
Single Decomposition: License Plate
25
Single Decomposition: Rear Lamp (9) and the License Plate
26
Single Decomposition: Reflector Holder
26
Battery Box
27
Single Decomposition
27
Body Cover-Lower
28
Cushion
28
Licence Plate Link Plate
28
Dismantle the Upper Cover
29
The Lower Cover of Handle
29
Speedometer /Speedometer Cover
30
Brake Master Cylinder / Haft Switch Assy Disassembly
31
Front Signallamp
32
Dismantle Windshield
33
Remove the Screws(2)- Figure
33
Single Decomposition: Turn Signal Front
34
Dismantle Front Fender
35
Dismantle Foor Step Floor Lower Cover
35
Dismantle Tank Lower Cover
37
Dismantle Step-Floor
38
Single Decomposition - Step-Floor
39
Fuel Tank
40
Fuel Pump/ Fuel Guage
40
Front Lower Cover / under Cover
41
Dismantle Front-Inner Cover
42
Single Decomposition – Front Inner Cover
43
Single Decomposition - GAS CAP BASE
44
Installation or Removal of External Components 2
45
Removable Front Inner Fender
45
Engine Oil
46
Check the Oil Level
46
Oil Replaced
46
Gear Oil
47
Volume
47
Air Cleaner
48
Recommended Service Cycle
48
Lcd Speedometer
49
Main Switch
50
Main Switch Cover Removable：
50
Fuel Tank Cap
50
Seatlock
51
Seat Lock / Fuel Tank Cover Adjustment
51
Battery Installation
51
12V Charging Power Switch
52
Spark Plug
52
Engine Timing Check / Adjustment
53
Demolition - Order
53
Adjustment - Camshaft Sprocket Position
53
Valve Clearance Check / Adjustment
54
Measurement - Valve Clearance
54
Throttle Cable Free Clearance Check / Adjustment
55
Brakes-Thin Check
55
Standard Values
55
Brake Fluid Check / Adjustment
56
Headlight Adjustment
57
Tire Pressure
57
Battery Check
58
Demolition
58
V-Belt - Air Sponge Cleaning
59
Fuse Check
59
View Confirmation
60
Gasoline Pipe Exclude Air and Inferiority Oil
60
Drain Valve
60
Cvt
61
CVT Installation Considerations
61
Compression Pressure Measurement
62
Measurement - Cylinder Pressure
62
Periodical Maintenance Table
63
The Exchange of Brake Fluid
64
Exhaust Control System
64
Feature of 2Nd-Stage EMS
65
Second-Generation Injection System
65
Fuel Injection System 4 65~81
65
Electronic Injection System Introduced
66
ECU (Electric Control Unit)
66
Crank Speed Sensor
67
Function of Crank Speed Sensor
67
Fault Phenomenon
67
Measurements to Determine
67
Measure Engine Temperature Sensor
68
Engine Temperature Sensor
68
The Engine Temperature Sensor Principle
68
Throttle Position Sensor (TPS)
69
Throttle Opening Degree Sensor (TPS) Principle
69
Maintenance Preliminary Gauge Connected
69
Intake Pressure Sensor
70
Intake Pressure Sensor Principle
70
Intake Pressure Sensor Measurement
70
Injector
71
Injector Measurement
71
Draining Cap of Injector
72
Bleed the Air
72
Drain the Gas
72
Overhaul of the Initial Impression Method and Connected
72
Fuel Pump
73
Fuel Pump Principle
73
The Fuel Pump Measurement
73
Fall down Sensor
74
Fall down Sensor Measurements
74
ISC (Idle Speed Control)
75
ISC Control Method
75
ISC Control Schematic
75
ISC Measurement
76
Timing When Used Scooter Occur
76
EMS System Repairing Tool
77
Pocket Tester Wiring
77
Use Spark Gauge
77
Injector Test Line Group Use
78
EMS Diagnostic
79
How to Use Quick Diagnostic
79
Clear the Defect Code Memory
81
Fuel Injection System 4
81
Disassembly of the Engine Assembly
82
Back Luggage
82
Engine / Reverse Differential Gear
82
Rear Brake Calipers
83
Remove the Air Cleaner
83
Throttle Assembly
84
Oil Cooler Hose Pipe
84
Rear Suspension
85
Remove the Engine Hanger
85
Rear Swingarm
86
Center Stand
86
Bracket Rear Cushion
86
Engine Disassembly
87
Cylinder Head Disassembly
87
Carburettor Models
88
VALVE Disassembly
90
Cylinder Head Installation Steps
90
Removing the Camshaft Holder
91
Cylinder Head - Timing Adjustment
91
Piston Rings Demolition
92
Cylinder Removal Procedure
92
Piston Ring Installation
93
Cylinder Installation Steps
94
CVT Removal Procedure
95
Remove the CVT Parts
95
Belt Pulley Comp, Driven Face Detachably
96
Crankcase Demolition
97
Drive Pulley, Starter Clutch. Driven Pulley
101
Engine Starts, but Vehicle Don’t Move
101
Can’t Reach High Speed, no Pick-Up
101
Measurement Data
101
Checking Driving Belt
102
Disassemble Slide Driving Plate Set
102
Check the Driving Pulley
102
Check Gasket Inner Dia Ofslide Driving Plate
102
Check Driving Spring Free Length
103
Check Clutch Driving Face
103
Checking Clutch
103
Cylinder Head and Valve
104
Unsmooth Idle Speed
104
Insufficient Compression Pressure
104
Abnormal Noise
104
The Operation Data Information
105
Check Cam Shaft
105
Check Cam Shaft Holder
105
When Installing
106
Lubrication System
107
Tighten the Oil Pump after Installation
108
Measurement Data (Hooligan 170I)
108
Reduction in Fuel Oil Volume
108
Engine Burning-Out
108
Cylinder and Piston
109
The Operation Notice
110
Data (Hooligan 170I)
110
Dismaniling Cylinder, Piston
111
Piston Outer Dia Measurement
111
Installing Cylinder and Piston
113
Installing Piston and Piston Rings
113
Installing Piston
113
Crankcase, Crankshaft
114
Engine Noise
114
Check Crankshaft
114
Final Transmission Mechanism
116
Engine Can be Started, but the Vehicle Doesn’t Move
116
Noise Occur When Running
116
Oil Leakage
116
Locking Torque
117
Check the Final Transmission Mechanism
118
Engine / Reverse Differential Gear 5
118
Front Wheel Measure
119
Front Wheel Demolition
119
Front Wheel -One Sealed Ball Bearing
120
Front Wheels - Brake Disc
121
Front Wheel – Meter Gear Assy
121
Front Wheel–Front Axle
121
Front Fork
122
Ball Bearing Disassembly
123
Ball Bearing Cage
123
The Front Fork Assembly Installation
124
Front Suspension Assembly
125
Rear Damper
125
Right Damper
125
Left Damper
125
Front Wheels - Brake Pad (Disc)
126
Rear Brake Pads
126
Removing the Rear Wheel
127
Shock Absorber / Brake System/Wheel 6
129
Tools: Pumping Unit
129
Brake Fluid Replacement
129
Denso Component Location
130
Locate the Position of the Main Wiring
131
Starter System
132
Check the Process
132
Fuse
133
Battery
133
Brake Safety Switch
134
Starting Motor
134
Starter Relay
134
Charging System
135
Check - Battery
135
A.C.G Check
136
Leakage Current Testing
136
Stop Light Switch
137
Light Switches and Line Checks
137
Bulb Check
137
Lamps Lighting System
137
Headlight / License Lamp Line Loop
138
Signal Lamp
140
Electrical Appliances Measurements
141
Horn
141
Fuel Guage
141
Control of Relays
142
The Main Purpose of the Fuse
143
Electronic Injection Version
143
Fuse Description
143
Associated with the Injection System and Fuse
144
Protection of the Microcomputer Controller
144
To Protect the Fuel Pump and Injector
144
Protecting Crystal Ignition System Line
144
Injection System Wiring Diagram
145
Line Color Injection System
145
Injection System Engine Misfire / no Injection
146
4
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GENUINE HOOLIGAN 170i Specifications
General
Brand
GENUINE
Model
HOOLIGAN 170i
Category
Scooter
Language
English
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