E-TON EV3 E-MO Service Manual
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E-TON EV3 E-MO Service Manual

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E-TON POWER
E V3
E-MO

SERVICE MANUAL

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Summary of Contents for E-TON EV3 E-MO

  • Page 1: Service Manual

    E-TON POWER E V3 E-MO SERVICE MANUAL...
  • Page 2 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.

  • Page 3: Important Information

    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.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CONTROLLER SYSTEM CONT – BATTERY/ CHARGER ELECTRICAL SYSTEM ELEC CHASSIS CHAS TRBL TROUBLESHOOTING SHTG...

  • Page 5: General Information

    CHAPTER 1 GENERAL INFORMATION GENERAL INFORMATION ............FRAME SERIAL NUMBER .

  • Page 6: Gen Info

    IDENTIFICATION OF SCOOTER INFO GENERAL INFORMATION SCOOTER IDENTIFICATION FRAME SERIAL NUMBER The frame serial number is stamped on the chassis. 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...

  • Page 7: Important Information

    IMPORTANT INFORMATION INFO 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.

  • Page 8: Checking The Connections

    IMPORTANT INFORMATION INFO 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 Dry with an air blower. Rust/stains Connect and disconnect sev- eral times.

  • Page 9: Special Tools

    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.
  • Page 10 INFO SPECIAL TOOLS Tool NO. Tool name / Function Picture Tool name: Testing interface software SC9003-EGC2-0000 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...
  • Page 11 CHAPTER 2 SPECIFICATIONS SPECIFICATIONS ............. . GENERAL SPECIFICATIONS .

  • Page 12: Spec

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Standard Item Dimensions Overall length 1,550 mm (61.0 in) Overall width 650 mm (25.6 in) Overall height 1,000 mm (39.4 in) Wheelbase 1,050 mm (41.3 in) Minimum ground clearance 115 mm (4.5 in) Minimum turning radius 1,600 mm (63.0 in) Basic weight 50 kg (110.2 lb)

  • Page 13: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS CHASSIS Standard Limit 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 1.4 x 14" Rim material Aluminum Rim runout limit radial 2.0 mm (0.08 in) lateral 2.0 mm...
  • Page 14 SPEC MAINTENANCE SPECIFICATIONS ELECTRICITY Standard Limit Item Battery Type Li-ion Mn battery Battery capacity 48.0 V/ 10AH Lights X number Headlight 12V 35/ 35W X1 Tail/ brake light 12V 21/ 5W X1 Turn signal light 12V 10W X4 Fuse Fuse (main) Fuse (turn signal) Controller system Power input...

  • Page 15: Conversion Table/ General Tightening

    CONVERSION TABLE/GENERAL SPEC TIGHTENING TORQUE SPECIFICATIONS GENERAL TIGHTENING TORQUE CONVERSION TABLE SPECIFICATIONS All specification data in this manual are listed This chart specifies tightening torques for stan- in SI and METRIC UNITS. dard fasteners with a standard ISO thread Use this table to convert METRIC unit data to pitch.

  • Page 16: Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Part Thread Part to be tightened torque Remarks Q’ty name size m•kg ft•lb Chassis Rear fork 25.3 See chapter 3 36.2 Front fork “ADJUSTING THE STEERING HEAD” Rear shock absorber (up) Bolt 25.3 18.1 Bar footrest Bolt...
  • Page 17 SPEC CABLE ROUTING Wire harness UVW motor three-phases connecter Cable brake, rear 6 pin connecter Main switch lead Positive battery lead Negative battery lead Horn lead tail/brake light EMI coil Turn light connector wire clamp Turn signal lead Main switch comp 12 pin connector Horn Starter controller lead...

  • Page 18: Cable Routing

    SPEC CABLE ROUTING Right turn light lead Right brake lead Cable brake, front Throttle lead Headlight lead Meter connector Horn lead Cable brake, rear Left brake lead Left turn light lead...

  • Page 19: Periodic Checks And Adjustments

    CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION/ PERIODIC MAINTENANCE/ LUBRICATION ..... SIDE COVER/ BODY COVER/ HEADLIGHT/ METER REMOVE AND INSTALL .

  • Page 20: Chk Adj

    • Check operation and correct if necessary. brake switches * Since these items require special tools, data and technical skills, have an E-TON dealer perform the service. • 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.

  • Page 21: Side Cover/ Body Cover/ Headlight/ Meter Remove And Install

    SIDE COVER/ BODY COVER/ HEADLIGHT/ METER REMOVE AND INSTALL REMOVING THE SIDE COVER AND THE BODY COVER 4 Nm (0.4 m kg, 2.9 ft 4 Nm (0.4 m kg, 2.9 ft • • • • (X3) (X2) (X2) (X2) (X6) 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 22: Removing Seat/ Battery Seat/ Driver Assy/ Bar Footrest

    SIDE COVER/ BODY COVER/ HEADLIGHT/ METER REMOVE AND INSTALL REMOVING SEAT/ BATTERY SEAT/ DRIVER ASSY/ BAR FOOTREST 10 Nm (1.0 m • kg, 7.2 ft • Ib) (X4) 6 Nm (0.6 m • kg, 4.3 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 23: Removing Headlight/ Meter/ Meter Side Cover

    SIDE COVER/ BODY COVER/ HEADLIGHT/ METER REMOVE AND INSTALL REMOVING HEADLIGHT/ METER/ METER SIDE COVER 4 Nm (0.4 m kg, 2.9 ft • • (X3) (X2) 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 24: Removing And Installing Rear Bottom Cover/ Rear Fender

    REMOVING AND INSTALLING REAR BOTTOM COVER/ REAR FENDER REMOVING REAR BOTTOM COVER/ REAR FENDER 4 Nm (0.4 m kg, 2.9 ft • • 35 Nm (3.5 m kg, 25.3 ft • • (X4) 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 25: Checking The Brake Shoe

    ADJUSTING THE FRONT/REAR BRAKE CHECKING THE BRAKE SHOES 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. Adjusting nut Before adjusting the front and rear brake, the Rear brake front and rear brake linings should be checked.
  • Page 26 ADJUSTING THE FRONT/REAR BRAKE CHECKING THE BRAKE SHOES CHECKING THE BRAKE SHOES Wear limit line 1. Operate the brake. 2. Check • brake shoes Wear indicators reaches the wear limit line Replace the brake shoes as a set. Refer to “REAR BRAKE” in chapter 7. Wear indicator 3.
  • Page 27 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. • Please support by main stand. 2. Use a support put in the buttom of vehicle and raise the front wheel.

  • Page 28: Checking The Froent Fork

    CHECKING THE STEERING HEAD/ CHECKING THE FRONT FORK d. Loosen the lower ring nut 1/2 turn counter- clockwise then tighten it to specification with a steering nut wrench. Lower ring nut (final tightening torque) 12 Nm (1.2 m • kg, 8.7 ft • lb) e.

  • Page 29: Checking The Rear Shock Absorber

    CHECKING THE REAR SHOCK ABSORBER/ CHECKING THE TIRES CHECKING THE REAR SHOCK ABSORBER 1. Stand the scooter on a level surface. 2. Check: • Oil leakage/ crack/ damaged rear shock absorber assembly. • Spring the rear shock absorber assembly. fer to chapter 7.

  • Page 30: Checking The Wheels

    CHECKING THE TIRES/ CHECKING THE WHEELS • TIRE PRESSURE 1. Measure Maximum 98 kg weigh f rider (2.25kg/cm ) (2.25kg/cm ) 2. Check: • Tire surfaces Minimum depth of thread of tires 0.8 mm (0.03 in) WARNING It is dangerous to ride with a worn-out tire. When tire wear is out of specification, replace the tire immediately.

  • Page 31: Replacing The Headlight Bulb

    REPLACING THE HEADLIGHT BULB REPLACING THE HEADLIGHT BULB 1. Remove • Headlight Refer to " REMOVING AND INSTALLING THE COVER". • Opening the headlight bulb holder cover • Remove headlight coupler • Loosen the screw of bulb fixer and the fixer will open.

  • Page 32: Replacing The Front/ Rear Turn Light Bulb

    REPLACING THE HEADLIGHT BULB/ REPLACING THE FRONT/ REAR TURN LIGHTS 2. Change • Headlight bulb (burned). 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 •...

  • Page 33: Replacing The Tail Light Bulb

    REPLACING THE FRONT/ REAR TURN LIGHTS BULB/ REPLACING TAIL LIGHT BULB WARNING Since the light bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 2. Install • Bulb. • The turn light holder site.
  • Page 34 CHAPTER 4 CONTROLLER SYSTEM MOTOR ............... . CHECK AND TROUBLESHOOTING .

  • Page 35: Cont

    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 •...

  • Page 36: Removing The Motor

    CONT MOTOR REMOVING THE MOTOR Remove the bolts and rear bottom cover L Remove the band and rear fender bolt Remove the rear fender bracket bolt and rear fender Remove the bolts and rear bottom cover R Remove the rear fender bolt...
  • Page 37 CONT MOTOR • Remove brake cable adjusting bolt • Remove brake cable set nut to rear end. • Adjust the adjusting nut to loosening position and fix the groove across the brake drum. • Remove brake cable. • Loosen set nuts on left and right motor and frame as illustrated.

  • Page 38: Motor Installation

    CONT MOTOR MOTOR INSTALLATION Dowel pin • Reverse the removal procedure for installation. N O T I C E • It is necessary to confirm whether the regular and dowel pin are fastened tightly during brake Regulator cable installation. • It is necessary to check and adjust the brake clearance to maintain at 5~10mm.

  • Page 39: Driver

    CONT DRIVER SPECIFICATION Electric Voltage current Power input 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 •...
  • Page 40 CONT DRIVER 2. Remove out wiring assembly after testing the driver according to the illustration and list below tester to measure. If there is any short-circuit failed. 3. Remove out wiring assembly after testing the driver according to the illustration and list below 4.

  • Page 41: Lev Interface (Testing Interface)

    CONT DRIVER LEV INTERFACE (TESTING INTERFACE) 1. Testing: Lev Interface (testing interface) Testing interface software SC9003-EGC2-0000 Panel N O T I C E connector List the all possible causes according to trouble- shooting and be sure to check and confirm all other causes shall be excluded before testing Driver driver according to testing interface...
  • Page 42 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 . The COM port position has gotten by click my click contents and computer.
  • Page 43 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.

  • Page 44: Status

    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) •...

  • Page 45: How To Read Instrument Panel

    CONT INSTRUMENT PANEL HOW TO READ INSTRUMENT PANEL Total mileage Signal code Vehicle speed unit Power mode 888888 8888.8 Trip Battery residual 8888 Status warning Km/H power signal Confirmation key Failure signal Button A Cancellation key Button B Speed Turn light signal Single trip odometer(reset to Headlight...
  • Page 46 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.
  • Page 47 CONT INSTRUMENT PANEL 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. 8888.8 8888.8 888888 888888 Trip Trip c.
  • Page 48 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 Testing Steps 4. There will sound beeper tone upon pressing Button A or Button B in the riding screen.
  • Page 49 CHAPTER 5 BATTERY/CHARGER BATTERY ..............HOW TO CHECK BATTERY RESIDUAL CAPACITY .

  • Page 50: Battery

    – 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 re- sidual capacity icon in the display will light fully for few seconds.

  • Page 51: Reference Value For Battery Residual Capacity

    – BATTERY e. Remove the battery to observe the indicator light on the battery box as illustrated in the following list. N O T I C E 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.

  • Page 52: Checking Battery

    – BATTERY CHECKING BATTERY Discharge 1. Press battery residual power display button Indicator light and observe whether LED light is on. If LED is not on, the battery might out of ele- ctricity. Please conduct the next step. 2. Plug on Charger plug and make the charger be Charging plug OFF.

  • Page 53: Charger

    – CHARGER INSTALLATION STEPS Power switch 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.

  • Page 54: Bat Cha

    – CHARGER The charging electricity current and voltage in each Start Charging phase is shown as in the left. Charging voltage 100% Charging current Phase 2 Phase 1 Fixed electricity Fixed electricity Floating charging current voltage Green Indicator light color WARNING Adjustment electricity Voltage button under the warn sticker, have already set up the voltage of charging...

  • Page 55: Troubleshooting

    – 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 Possible cause Solution Power switch is Turn to ON position not turned to ON.
  • Page 56 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS WIRING DIAGRAM CHECKING SWITCH CONTINUITY CHECKING SWITCH CONTINUITY CHECKING THE SWITCHES CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULBS CHECKING THE CONDITION OF THE BULB SOCKETS LIGHTING SYSTEM CIRCUIT DIAGRAM TROUBLESHOOTING CHECKING THE LIGHTING SYSTEM SIGNALING SYSTEM 6-10...

  • Page 57: Elec

    – ELEC ELECTRICAL COMPONENTS ELECTRICAL SYSTEM ELECTRICAL COMPONENTS Main switch Switch Controller Horn Battery Meter Fuse Turn signal relay Throttle Handle Charge Motor...
  • Page 58 – ELEC WIRING DIAGRAM...

  • Page 59: Checking Switch Continuity

    – ELEC CHECKING SWITCH CONTINUITY CHECKING SWITCH CONTINUITY Check each switch for continuity with the poc- ket tester. If the continuity reading is incorrect, Pocket tester check the wiring connections and if necessary, replace the switch. N O T I C E Never insert the tester probes into the cou- pler terminal slots.

  • Page 60: Checking The Switches

    – ELEC CHECKING THE SWITCHES CHECKING THE SWITCHES Damage/wear Repair or replace. Check each switch for damage or wear, proper Improperly connected Properly connect. connections, and also for continuity between the Incorrect continuity reading Replace the terminals. Refer to “CHECKING SWITCH CON- switch.
  • Page 61 – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear Repair or replace the bulb, bulb socket or both.
  • Page 62 – ELEC CHECKING THE BULBS AND BULB SOCKETS 2. Check: • bulb (for continuity) (with the pocket tester) No continuity Replace. Before checking for continuity, set the pocket tester to “0” and to the “ x 1” range. a. Connect the positive tester probe to termi- and the negative tester probe to ter- minal , and check the continuity.

  • Page 63: Lighting System

    – ELEC LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM Controller Meter Fuse Battery connection Battery box Main switch Head light switch Headlight Tail/brake light...
  • Page 64 – ELEC LIGHTING SYSTEM TROUBLESHOOTING 2. Battery • Check the condition of the battery. Any of the following fail to light: head- Refer to “CHECKING AND CHARGING light, and meter light. THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.
  • Page 65 – ELEC 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 1. Headlight bulb and socket for continuity.

  • Page 66: Signaling System

    – ELEC SIGNALING SYSTEM 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...
  • Page 67 – ELEC SIGNALING SYSTEM TROUBLESHOOTING 3. Main switch •Any of the following fail to light : turn • Check the main switch for continuity. signal light, brake light or an indicator Refer to “CHECKING THE SWITCHES”. light. • Is the main switch OK? •The horn fails to sound.
  • Page 68 – ELEC SIGNALING SYSTEM 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the blue/yellow connector at the horn terminal. 1. Horn switch • Connect a jumper lead to the horn terminal and ground the jumper lead. •...
  • Page 69 – ELEC SIGNALING SYSTEM 2. The tail/brake light fails to come on. • Set the main switch to “ON”. • Pull in the brake levers. 1. Tail/brake light bulb and socket • Measure the voltage (DC 1 2V) of red/white •...
  • Page 70 – ELEC SIGNALING SYSTEM 3. Voltage • Set the main switch to “ON”. • Set the turn signal switch to “L” or “R”. • Connect the pocket tester (DC 20 V) to the • Measure the voltage (DC 12 V) on turn signal relay coupler (wire harness side) yellow/red at the turn signal relay cou-...
  • Page 71 CHAPTER 7 CHASSIS FRONT WHEEL / REAR WHEEL ..........FRONT WHEEL .
  • Page 72 CHAPTER 7 CHASSIS LOWER BRACKET ............. 7-17 LOWER BRACKET 7-17...

  • Page 73: Chas

    CHAS FRONT WHEEL / REAR WHEEL FRONT WHEEL 35 Nm (3.5 m • kg, 25.3 ft • lb) Order Job/Part Q’ty Remarks Removing the front wheel Remove the parts in the order listed. Place the scooter on a suitable stand so Hexagon flange bolt that the front wheel is elevated.

  • Page 74: Rear Wheel

    CHAS FRONT WHEEL / REAR WHEEL REAR WHEEL 4 Nm (0.4 m kg, 2.9 ft • • (x4) 4 Nm (0.4 m kg, 2.9 ft 80 Nm (8.0 m kg, 57.9 ft • • • • Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed.

  • Page 75: Removing The Front/ Rear Wheel

    CHAS FRONT WHEEL / REAR WHEEL REMOVING THE FRONT/ REAR WHEEL 1. Removing • Wheel bearings • Collar Remove the wheel bearings with a general bearing puller General bearing puller SA6100-A26-0FA1 N O T I C E Securely support the wheel to avoid damaging the brake disk.

  • Page 76: Assemble The Front/ Rear Wheel

    CHAS FRONT WHEEL / REAR WHEEL ASSEMBLE THE FRONT/ REAR WHEEL 1. Install • Collar A • Bearing • Oil seal • Collar B • Front brake shoe plate • Put lithium soap base grease on the bearings and oil seal lips when installing. •...

  • Page 77: Front Brake / Rear Brake

    CHAS FRONT BRAKE / REAR BRAKE FRONT BRAKE 35 Nm (3.5 m • kg, 25.3 ft • lb) Order Job/Part Q’ty Remarks Removing the front brake Remove the parts in the order listed. Front fender Please refer to " LOWER BRACKET " in cheaper 7.

  • Page 78: Rear Brake

    CHAS FRONT BRAKE / REAR BRAKE REAR BRAKE 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft • • (x4) 9 Nm (0.9 m kg, 6.5 ft • • Order Job/Part Q’ty Remarks Removing the rear brake Remove the parts in the order listed.

  • Page 79: Removing The Front/ Rear Brake

    CHAS FRONT BRAKE / REAR BRAKE REMOVING THE FRONT/ REAR BRAKE The following procedure applies to each brake. brake and rear brake. 1. Removing • Brake arm • Brake arm cam When removing the brake arm, mark the position on the brake arm where it is aligned with the punch mark in the brake cam.

  • Page 80: Checking The Brake Drums

    CHAS FRONT BRAKE / REAR BRAKE 3. Measure • brake shoe lining thickness Measuring points Replace the brake shoes as a set if either is found to be worn to the wear limit. 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.

  • Page 81: Removing The Front/ Rear Brake

    CHAS FRONT BRAKE / REAR BRAKE 2. Install • brake arm cam • brake arm 9 Nm( 0.9 m•kg, 6.5ft•lb) • Install the brake arm cam so its punch mark is positioned as shown. • Align the punch mark in the brake arm cam with the mark on the brake arm.

  • Page 82: Swingarm

    CHAS SWINGARM SWINGARM 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 35 Nm (3.5 m kg, 25.3 ft • • 25 Nm (2.5 m kg, 18.1 ft • • Order Job/Part Q’ty Remarks...

  • Page 83: Remove The Swingarm

    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) Swingarm free play 1.0 mm (0.04 in) b. Check the swingarm side play by moving ing it from side to side.

  • Page 84: Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER REAR SHOCK ABSORBER 35 Nm (3.5 m kg, 25.3 ft • • Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. Hexagon flange nut Rear shock absorber For installation, reverse the removal pro- cedure.

  • Page 85: Checking The Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER CHECKING THE REAR SHOCK ABSORBER 1. Check • Shock absorber rod Bends/damage replace the rear absorber assembly. • Shock absorber Oil leaks replace the rear absorber assembly. • Spring Fatigue replace the rear shock absorber assembly. INSTALL THE REAR SHOCK ABSORBER 1.

  • Page 86: Steering System

    CHAS STEERING SYSTEM HEADLEBAR 45 Nm (4.5 m • kg, 32.5 ft • lb) Order Job/Part Q’ty Remarks Remove the parts in the order listed. Front brake cable Front cap Refer to "MOVING AND INSTALLING Meter side L/ R COVER " in cheaper 3. Headlight Meter Handle lever assembly (L)

  • Page 87: Removing The Handlebar Grip

    CHAS STEERING SYSTEM REMOVING THE HANDLEBAR GRIP 1. Remove • Handlebar grip Removing step : • Blow compressed air between the handlebar and handlebar grip, and gradually push the grip off the handlebar. CHECKING THE HANDLEBAR 1. Check • Handlebar WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar.
  • Page 88 CHAS STEERING SYSTEM INSTALL THE HANDLEBAR Reverse the removal procedure for installation and pay attention the following tips: 1. Clean • If the connection part of steering touch with grease, should be clean. WARNING • Install all cables should refer to "CABLE ROUTING"...
  • Page 89 CHAS LOWER BRACKET LOWER BRACKET 50 Nm (5.0 m • kg, 36.2 ft • lb) 12 Nm (1.2 m • kg, 8.7 ft • lb) 45 Nm (4.5 m • kg, 32.5 ft • lb) Order Job/Part Q’ty Remarks Remove the lower bracket. Remove the parts in the order listed.

  • Page 90: Removing The Lower Bracket

    CHAS LOWER BRACKET REMOVING THE LOWER BRACKET 1. Remove • Ring nut • Ball race cover • Ball race upper • Bearing ball • Ball race outer • Front fender assembly • Removing the ring nut by the steering nut wrench •...

  • Page 91: Installing The Lower Bracket

    CHAS LOWER BRACKET INSTALLING THE LOWER BRACKET 1. Install • Bearing ball • Outer bearing race N O T I C E • 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.
  • Page 92 CHAS LOWER BRACKET • Tighten the ring nut, please refer to "CHECKING STEERING HEAD " in cheaper 3. 7-20...

  • Page 93: Front Fork

    CHAS FRONT FORK FRONT FORK 30 Nm (3.0 m kg, 21.7 ft • • Order Job/Part Q’ty Remarks Remove the front fork. Remove the parts in the order listed. Cap (L / R) Nut (L / R) Bolt (L / R) Front fork (L / R) For installation, reverse the removal procedure.

  • Page 94: Removing The Front Fork

    CHAS FRONT FORK REMOVING THE FRONT FORK WARNING • Securely support the scooter so that there is no danger of it falling over. 1. Remove • Cap • Nut (fork) • Bolt WARNING The fork spring would spring, should pay attention when remove the bolt.

  • Page 95: Checking The Front Fork

    CHAS FRONT FORK CHECKING THE FRONT FORK 1. Check • Inner tube WARNING Do not try to straighten an outer tube or an inner tube as this may dangerously weaken the tube. 2. Measure Fork spring free length 99.0 mm (3.90 in) <limit>...

  • Page 96: Installing The Front Fork

    CHAS FRONT FORK 3. Install • Circlip • Dust seal Couple the circlip correctly on the groove of the outer tube. 4. Check • Operation of inner tube INSTALLING THE FRONT FORK Reverse the disassembly procedure. The following points should be remembered. 1.
  • Page 97 CHAPTER 8 TROUBLE SHOOTING STARTING FAILURES Meter t has no display and no response Lasting meter warning tone Main switch "ON", turn handle bar the vehicle no reaction POOR RIDING PERFORMANCE LIGHT ODES NOT LIGHT WHILE RIDING LOST ELECTRICITY SUDDENLY WARNING TONE POOR BRAKING PERFORMANCE FAULTY FRONT FORK LEGS...

  • Page 98: Trbl Shtg

    TRBL SHTG TROUBLESHOOTING 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 LIGHT ODES NOT LIGHT Meter t has no display and no response...
  • Page 99 TRBL SHTG POOR BRAKING PERFORMANCE FAULTY LIGHTING OR SIGNALING SYSTEM Headlight does not light Worn brake shoe lining. Incorrect brake lever free play. Wrong headlight bulb. Incorrect brake shoe position. Too many electrical accessories. Wearing brake camshaft. Hard charging. Worn or rusty brake drum. Faulty battery.
  • Page 100 TRBL SHTG MESSAGE CODE Meter message code warning message(warning tone) drawing Message code 888888 8888.8 Trip Km/H LOwv Battery residual capacity Warning message (Warning tone) The following warning messages might display with a warning tone during riding status. Warning and Cue signal Code Cause Action...
  • Page 101 TRBL SHTG Code Cause Action SPD0 Operate code lock during riding. No operating code lock during riding can terminate this message. Over speed warning. FAST Reducing driving speed as soon as possible. (over 52KM/HR) LOWB Recharge battery as soon as possible. Low battery.

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