1. Manuals
  2. Brands
  3. GENUINE Manuals
  4. Scooter
  5. HOOLIGAN 170i
  6. Service manual

GENUINE HOOLIGAN 170i Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the HOOLIGAN 170i and is the answer not in the manual?

Questions and answers

bluegarage
May 3, 2025

I need to remove the muffler. How do I access the 2 nuts that hold the exhaust pipe flange to the engine?

0
1 comments:
Mr. Anderson
May 17, 2025

To access the two nuts that hold the exhaust pipe flange to the engine on a GENUINE HOOLIGAN 170i, you need to:

1. Remove the front lower cover and under cover:
- Remove self-tapping screws (1), (2), and (7), and hex bolts (4).
- Take out the under cover (3).
- Remove bolts (6) and take out the front lower cover (5).

This exposes the engine area, allowing access to the exhaust pipe flange and its mounting nuts.

This answer is automatically generated

0

Related Manuals for GENUINE HOOLIGAN 170i

Summary of Contents for GENUINE HOOLIGAN 170i

  • Page 1 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.

  • Page 2: Table Of Contents

    Contents This manual is a service manual for Hooligan 170i with details specifying skills to disassemble or install various mechanisms, basic maintenance (check and adjustment) of components, notices for operation, and configuration of colored electrical wires in connection with the motorcycle in which there are 7 chapters and as references of users or mechanics during service.

  • Page 3: Information Summary And Preparation 1

    Information Summary and Preparation -1 1-1Specifications SCOOTER SPECIFICATION BRAND Genuine FRAME STEEL TUBE Hooligan 170i MODEL FRONT TELESCOPE SUSPENSION LENGTH REAR UNI-ABSORBER 1870 mm 2.65~0.81 WIDTH REDUCTION 710 mm 9.262 HEIGHT REDUCTION 1155 mm WHEEL BASE CLUTCH CENTRIFUGAL 1285 mm...
  • Page 4 Information Summary and Preparation -1 1-2 Configuration HANDLE COVER SPEEDOMETER HANDLE COVER GRIP(L/R) REAR LUGGAGE FR SIGNAL LAMP(R/L) BRACKET WIND SHIELD REAR SIGNAL HEAD LIGHT COMP REAR SUSPENSION muffler SIDE STAND ASSY CENTER STAND ASSY FRONT WHEEL FRONT INNER COVER LEVER(L/R) SEAT BODY COVER,L/R...
  • Page 5 Information Summary and Preparation -1 1-3 Positions of engine number / vehicle identification number: Vehicle identification number Positions of engine number 1-4 Torque Rated values Type Torque (kg-m) Type Torque (kg-m) 5mm bolt 0.4~0.5kg-m 6mm nut 1.0~1.4kg-m 6mm bolt 0.9~1.1kg-m 8mm nut 2.0~3.0kg-m 8mm bolt 1.8~2.5kg-m...
  • Page 6 Information Summary and Preparation -1 1-5 Code of practice: 1. Any clamp or cotter pin removed shall be replaced with a new one. 2. Any part to be replaced shall be manufactured by Motive Power. 3. Make sure of any assembled component securely fastened and formally activated. 4.
  • Page 7 Information Summary and Preparation -1 2) Directions during maintenance 1. Do not arbitrarily remove any part or connector of the Electronic Management System from its initial position; avoid any accidental damage or foreign object such as water and greasy dirt to enter into any connector and affect a properly running Electronic Management System.

  • Page 8: Special Tools

    Information Summary and Preparation -1 1-6 Special tools 1. Front fork - Bearing cage 2. Brake oil-pumping unit 3. Bearing puller tool disassembly, tools 4. Clutch compression tool 5. Fixator 6. feeler gauge 7. Bearing Striking Tools 8.Cylinder pressure gauge 9.
  • Page 9 Information Summary and Preparation -1 16. spark plug gap gauge 17.EMS diagnostics - dedicated 18. Hose clamp removal tool 19. Fuel injector cleaning tool 20. Oil seal removal tool - small 21. Dial gauge + Magnetic Base 22. Oil seal removal tool - Large 23.

  • Page 10: Trouble Shooting

    Information Summary and Preparation -1 1-7 Trouble shooting Procedure to maintain the Electronic Management System (EMS)  Systematic procedure to diagnose any troubles for reparation Items to be checked first prior to any diagnoses for engine troubles: 1. Make sure of the engine trouble indicator normally running; 2.
  • Page 11 Information Summary and Preparation -1 (1) Engine not running or slowly running during start-up General trouble location: 1. Battery; 2. Start motor; 3. Main wiring or power switch; 4. Engine mechanism. Procedure for general diagnoses: Detection Operating Procedure Subsequent Steps Results Check the voltage between two battery terminals with a Next step...
  • Page 12 Information Summary and Preparation -1 (3) Trouble of hot start General trouble location: 1. Water in fuel; 2. Fuel pump; 3. Engine temperature sensor; 4. Ignition coils Procedure for general diagnoses: Detection Operating Procedure Subsequent Steps Results Next step Connect a fuel pressure gauge before the fuel inlet of the nozzle; start the engine to check the fuel pressure at 300kPa or so.
  • Page 13 Information Summary and Preparation -1 (4) Trouble of cold start General trouble location: 1. Water in fuel; 2. Fuel pump; 3. Engine temperature sensor; 4. Nozzle; 5. Ignition coils; 6. Air throttle and & idle air bypass; 7. Engine mechanism. Procedure for general diagnoses: Detection Operating Procedure...
  • Page 14 Information Summary and Preparation -1 (5) Trouble of start-up anytime despite RPM normal General trouble location: 1. Water in fuel; 2. Fuel pump; 3. Engine temperature sensor; 4. Nozzle; 5. Ignition coils; 6. Air throttle and & idle air bypass; 7. Air intake; 8. Ignition timing; 9. Spark plug; 10.
  • Page 15 Information Summary and Preparation -1 (6) Start-up normal but idle speed unstable anytime General trouble location: 1. Water in fuel; 2. Nozzle; 3. Spark plug; 4. Air throttle and idle air bypass; 5.Air intake; 6. ISC; 7. Ignition timing; 8. Spark plug; 9. Engine mechanism. Procedure for general diagnoses: Detection Operating Procedure...
  • Page 16 Information Summary and Preparation -1 (7) Start-up normal but idle speed unstable during warm-up General trouble location: 1. Water in fuel; 2. Engine temperature sensor; 3. Spark plug; 4. Air throttle and idle air bypass; 5. Air intake; 6. Idle governor; 7. Engine mechanism. Procedure for general diagnoses: Detection Operating Procedure...
  • Page 17 Information Summary and Preparation -1 (8) Start-up normal but idle speed unstable with warm-up finished General trouble location: 1. Water in fuel; 2. Engine temperature sensor; 3. Spark plug; 4. Air throttle and idle air bypass; 5. Air intake; 6. ISC; 7. Engine mechanism. Procedure for general diagnoses: Detection Operating Procedure...
  • Page 18 Information Summary and Preparation -1 (9) Start-up normal but idle speed unstable or stall with load such as front lamp applied General trouble location: 1. ISC 2. Nozzle. Procedure for general diagnoses: Detection Operating Procedure Subsequent Steps Results Clean relevant parts. Remove the ISC and check the air throttle, the ISCand the idle air bypass for any carbon deposition.
  • Page 19 Information Summary and Preparation -1 (11) RPM low or stall during acceleration General trouble location: 1. Water in fuel; 2. Inlet pressure sensor & air throttle sensor; 3, Spark plug; 4. Air throttle & idle air bypass; 5. Air intake; 6.ISC ; 7. Nozzle; 8. Ignition timing; 9. Exhauster.
  • Page 20 Information Summary and Preparation -1 (12) Acceleration slow General trouble location: 1. Water in fuel; 2. Inlet pressure sensor and air throttle sensor; 3. Spark plug; 4. Air throttle and idle air bypass; 5. Air intake; 6. ISC ; 7. Nozzle; 8. Ignition timing; 9. Exhauster.
  • Page 21 Information Summary and Preparation -1 (13) Acceleration powerless; performance bad General trouble location: 1. Water in fuel; 2. Inlet pressure sensor and air throttle sensor; 3. Spark plug; 4. Ignition coils; 5. Air throttle and idle air bypass; 6. Air intake; 7. ISC ; 8. Nozzle; 9. Ignition timing;...

  • Page 22: Installation Or Removal Of External Components 2

    Installation or Removal of External Components- 2 Relations of plastic parts ＊inclined parts could be dismantle directly Steering upper LH & RH step Luggage comp.Rear rail Leg shield lower Steering lower Middle cover Step floor LH & RH body cover Front fender Lower cover of Inner cover...

  • Page 23: Rear Rack

    Installation or Removal of External Components- 2 Luggage compartment  ＊dismantle- 1.open seat. 2. Remove the bolts (2)，take out the luggage compartment(1). ＊install- According to the reverse procedure as above.  Rear rack ＊dismantle- 1. Remove the bolts/ Washer(7/8)，Take out the rear rack(6).
  • Page 24 Installation or Removal of External Components- 2 Dismantle middle cover  ＊dismantle- 1. Remove the bolts(5)，take out the middle cover (4). ＊install- According to the reverse procedure as above. Body cover  ＊dismantle- 1. Remove the screws(2)- Figure 1. 2.Remove the screws(3)- Figure 2. 3.
  • Page 25 Installation or Removal of External Components- 2 Single decomposition: Left / Right Body Cover ＊dismantle- 1. Remove the self-tapping screws (6), separation the rear lamp (1) with the left / right body cover (5/4). 2. Separate left / right body cover and the left / right cover (2/3). ＊install- According to the reverse procedure as above.
  • Page 26 Installation or Removal of External Components- 2 Single decomposition: Rear lamp (9) and the license plate (1) Combination ＊dismantle- 1. Remove the self-tapping screws (10), separation rear lamp (9). 2. Remove the self-tapping screws (6/8), separating left / right signal lamp(5/7). 3.
  • Page 27 Installation or Removal of External Components- 2 Battery box  ＊dismantle- 1. Remove the screws(11)，take out the fuse box. 2. Remove the screws(10)，take out the Battery box(9). ＊install- According to the reverse procedure as above. Single decomposition: ＊dismantle- 1. Remove the screws，take out the diagnose adaptor(2). 2.
  • Page 28 Installation or Removal of External Components- 2 Body cover-lower  ＊dismantle- 1. Remove the screws(13)，take out the Body cover-lower (16). ＊install- According to the reverse procedure as above. Cushion  ＊dismantle- 1.Remove the wire clip，take out the Cushion. ＊install- According to the reverse procedure as above. Licence plate link plate ...
  • Page 29 Installation or Removal of External Components- 2 Dismantle the upper cover  ＊dismantle- 1.Remove the screws(2/3/4)，take out the upper cover (1). ＊install- According to the reverse procedure as above. The lower cover of handle  ＊dismantle- 1.Remove the screws(3)，take out the lower cover of handle(2).
  • Page 30 Installation or Removal of External Components- 2 speedometer /speedometer cover  ＊dismantle- 1.Remove the screws(5/6)，take out the speedometer(1). 2.Remove the screws(3)，take out the speedometer cover(2). ＊install- According to the reverse procedure as above.
  • Page 31 Installation or Removal of External Components- 2 Brake master cylinder / Haft switch assy disassembly  ＊dismantle Step- 1.The brake fluid extraction was complete, remove the joint bolt (11) and copper gasket(10), remove the brake master cylinder (6/8) screws and take out the brake master cylinder(6/8)- Figure ( 1.2). 2.Remove the bolts (4) and right haft switch fixing screws (7),take out the grip(9)、...
  • Page 32 Installation or Removal of External Components- 2 5.Install the brake hose, place the hose fixed at A. ＊install- According to the reverse procedure as above. front signallamp  ＊dismantle- 1.Remove the screws(3) ,take out the fixed plate(1). ＊install- According to the reverse procedure as above.

  • Page 33: Remove The Screws(2)- Figure

    Installation or Removal of External Components- 2 Dismantle Windshield  ＊dismantle- 1.Remove the screws(2)- Figure 1. 2. Remove the screws(3)- Figure 2. Figure 1 Figure 2 3. Remove the screws(4/5/6/7)，take out the Windshield(1)- Figure 3. Figure 3 Parts 2: U TYPE SPRING NUT...
  • Page 34 Installation or Removal of External Components- 2 Single decomposition: turn signal front ＊dismantlep- 1.Remove the screws(3/5)，take out the turn signal (2/4). ＊install- According to the reverse procedure as above. Single decomposition: ＊dismantle- 1.Remove the screws (5)，take out the head light (4). 2.Remove the screws (3)，take out the headlamp ornament frame (2).
  • Page 35 Installation or Removal of External Components- 2 Dismantle front fender  ＊dismantle- 1.Remove the screws(13/14)，take out the front fender(12)、speedmeter cable clip comp (11/16). ＊install- According to the reverse procedure as above. Dismantle Foor step floor lower cover  ＊dismantle- 1.Remove the screws(4/5)，take out the foorstep floor lower cover(1/2). ＊install- According to the reverse procedure as above.
  • Page 36 Installation or Removal of External Components- 2 NOTE: ＊dismantle- release rear withdraw the Foor step floor lower cover as arrow direction ＊install Foor step floor lower cover- Pressed into two fixed points...
  • Page 37 Installation or Removal of External Components- 2 Dismantle Tank lower cover  ＊dismantle- Remove the screws(4/7)，take out the tank lower cover(3). ＊install- According to the reverse procedure as above.
  • Page 38 Installation or Removal of External Components- 2 Dismantle step-floor  ＊dismantle- 1. Remove the screws(2) – Figure 2.Remove the rubber plug (5)- Figure 3.Remove the screws(4)，take out the step-floor(2) – Figure ＊install- According to the reverse procedure as above. Figure Note: ＊Dismantle- a.pull up the rear section...
  • Page 39 Installation or Removal of External Components- 2 ＊Install- Single decomposition - Step-floor Parts2: U TYPE SPRING NUT...
  • Page 40 Installation or Removal of External Components- 2 Fuel tank  ＊dismantle- 1. Remove the screws(5)，take out the support holder of step foor(3/4). 2. Loosen the clip(5)，take out the gasoline hose(4). 3.Use needle-nose pliers to remove the clip(7) , take out the three way assy(6). 4.
  • Page 41 Installation or Removal of External Components- 2 FRONT LOWER COVER / UNDER COVER  ＊dismantle- 1. Remove the self-tapping screws (1). 2.Remove the self-tapping screws (2). ○ ○ 3. Remove the self-tapping screws (7) and hex bolts (4), take out the under cover (3). 4.
  • Page 42 Installation or Removal of External Components- 2 Dismantle front-inner cover  ＊dismantle- 1. Remove the screws (8). 2. Use the magnet burglar key, remove the magnet burglar lock assy(3). 2.dismantle the fuel cap cover turn counterclockwise 3. Remove the screws (1)，take out the gas cap base. and pull out.
  • Page 43 Installation or Removal of External Components- 2 Single decomposition – front inner cover ＊dismantle Step- 1. Remove the bolts (6), take out the side reflectors (5). 2. Remove the self-tapping screws (8), separated front inner cover-upper (7) and front inner cover-lower (1). ＊Install- According to the reverse procedure as above.
  • Page 44 Installation or Removal of External Components- 2 Single decomposition - GAS CAP BASE ＊dismantle Step- 1. Remove the Phillips head screw (5), take out the Gas cap fixing plate-B (4). 2. Remove the Phillips head screw (3), take out the Gas cap fixing plate-A (2). 3.Remove the Phillips head screw (7), take out the Gas cap fixing plate-C (6).
  • Page 45 Installation or Removal of External Components- 2  Removable front inner fender ＊dismantle Step: 1.Remove the front fork assembly (see 6-2). 2.Remove the bolts (2) ，take out the front inner fender (1). ＊ install According to the reverse procedure as above.
  • Page 46 Check & adjust -3 3-1 Engine oil Volume: Total oil volume: 1000c.c. Oil volume replaced: 800c.c. Service cycle: Every1800 mile Check the oil level:  Park the motorcycle on a horizontal surface for check.  Start the engine for 3-minute running and stop it for another 3-minute;...
  • Page 47 Check & Adjust -3 3-2 Gear oil Volume: Total oil volume: 110c.c. Filling orifice bolt Oil volume replaced: 90c.c. Service cycle: Every1800 mile Drain plug bolt Check the oil level:  Park the motorcycle on a horizontal surface for check. Drain plug bolt 1.
  • Page 48 Check & Adjust -3 3-3 Air cleaner Recommended service cycle: Check: Every1800 mile Change: Every3600mile or less than 3600 mile in the event of filth. Check / Change 1. Remove 8 set screws on the air filter cover. 2. Check packing for filth or damage; clean packing with high-pressure air gun.
  • Page 49 Check & Adjust -3 3-4 LCD SPEEDOMETER 1. 轉速表 2. 方向燈指示燈 3. 遠光燈指示燈 4. 機油更換指示燈 首次 500KM 亮起 重設後 1000KM 亮起 5. 汽油量表 6. 速度表 7. 總里程/單次里程 8. 噴射系統指示燈 9. ADJUST 鍵 10. SELECT 鍵 function display SELECT ADJUST result mode Click Mile...
  • Page 50 Check & Adjust -3 3-5 Main switch 1.All the power is cut off, the key can be pulled out at this position(B). 在此位置時鎖匙可以拔出 2. ON：電源接通，引擎可以發動 2.The power is ON, engine can be started, the key can not be pulled out at this position (A).

  • Page 51: Battery Installation

    Check & Adjust -3 Seatlock: Push the key and turn counterclockwise to open the seat. Seat lock / Fuel tank cover adjustment a- Seat lock lever cable. b- Tank cover lever cable. Adjustment screws: Tank cover lever cable (b) Clockwise: Tighten Counterclockwise: loosen Seat lock lever cable (a) Battery installation...

  • Page 52: Spark Plug

    Check & Adjust -3 3-8 Spark plug Check: 1. Use a spark plug socket to remove the spark plug. 0.6~0.7mm 2. Check the spark plug for damage, filth, or carbon deposition. 3. Use carbon remover or a steel brush to clean any filth or deposited carbon.
  • Page 53 Check & Adjust -3 3-10 Engine timing check / adjustment 1. Demolition - order > Please refer to the engine disassembly. Check – timing ›Clockwise rotation of the flywheel, the flywheel "T" mark aligned with the instructions on the right crankcase cover ribs above.
  • Page 54 Check & Adjust -3 3-11 Valve clearance check / adjustment 1. Remove - order > Please refer to chapter 7 cylinder head. Note .1). Valve clearance adjustment, measurement adjustments in the cold when. .2) Measurement and adjustment, go to your piston top dead center position. 2.Measurement - valve clearance >...
  • Page 55 Check & Adjust -3 3-12 Throttle cable free clearance check / adjustment 1.Check - > Check the idle speed is too high. > Rotate up and down the right grip, check the throttle cable clearance. Whether large or small, please adjust exceeded the standard value.
  • Page 56 Check & Adjust -3 3-14 Brake fluid check / adjustment 1. Check - brake master cylinder > Brake oily (View Mirror 2/3) whether the amount of high oil And between the low oil level (MIN). > Out of range -> add or reduce the amount of oil. Adjustment: >...

  • Page 57: Tire Pressure

    Check & Adjust -3 3-15 Headlight adjustment Adjustment: Remove the windshield ; Turn the adjustment screw using a Phillips screwdriver, the average adjustment left / right screw. The beam to be projected could be changed by moving the reflecting plane’s angle upward or downward.
  • Page 58 Check & Adjust -3 3-17 Battery check 1. Demolition - > Battery cable > First demolition of the battery cable (-) negative, then split the battery lead (+) positive. 2 check - battery voltage Tools: multimeter Ways: (+) red probe is connected to the positive terminal (-) black Probe is connected negative terminal method State...
  • Page 59 Check & Adjust -3 3-18 V-belt - air sponge cleaning 1. Demolition - > Remove of clamp bolt (1) Loosen. > Remove the breather pipe ( 2). > Remove to remove the fixed plate (3). > Remove the sponge (4). 2.
  • Page 60 Check & Adjust -3 3-20 drain valve Gasoline pipe exclude air and inferiority oil: 1.dismantle the under cover. 2.找到汽油管洩壓閥 2.find the drain valve. 3.開啟電源鎖開關 3.turn on the key. 4.壓下汽油管洩壓閥 4.press the drain valve, fuel drained & air bleed. 汽油與空氣會從洩壓管排出 5.repeat #3~#4, until fuel is clean. 5.重複...
  • Page 61 Check & Adjust -3 3-21 CVT ※The counterweight Roller Installation Notes 1.put the driving face as below. 3.the close end face to left. 2.install the upper roller. 4.install the others. CVT Installation Considerations-  Press the v-belt into the driven pulley as deep as possible. ...
  • Page 62 Check & Adjust -3 3-22 Compression pressure measurement 1. Demolition - > Spark Plugs NOTE Removable spark plugs, use compressed air to clean around Prevent dirt drop the spark plug hole. Make sure that the compression pressure → 2. Measurement - cylinder pressure combustion chamber whether coke, if less than the minimum value Standard value: 10 ±...
  • Page 63 Check & Adjust -3 PERIODICAL MAINTENANCE TABLE In order to achieve safe riding, good performance and reduce pollution, please execute the recommended maintenance accordingly. Model MONTHS/DISTANCE(IN KM)FOR CHECKING Item Checking Content 1 or 3 or 6 or 9 or 12 or 18 or 200 mile 1800...
  • Page 64 I: inspect, or replace if necessary L: lubricate R: replace 2. Items with “*” mark indicate our recommendation to have it done by GENUINE dealer. NOTE 1： For 4T engine, the engine oil shall be changed completely after run-in period 200mile or one month later. This can make sure the engine runs smoothly.

  • Page 65: Fuel Injection System 4

    Fuel injection systems -4 4-1 Second-generation injection system Feature of 2nd-stage EMS ＊feature 1.small, light 2.integrity 3.accuracy 4.simple EMS structure (A) EMS structure (B)
  • Page 66 Fuel injection systems -4 4-2 Electronic injection system introduced 4-2.1 ECU (electric control unit) * Location ＊Important PIN no.# of ECU 1 PIN 18 PIN 19 PIN 36 PIN Fault phenomenon: EMS lights lit 　 vehicle can not start 　...
  • Page 67 Fuel injection systems -4 4-2.2 Crank speed sensor * Location Function of Crank speed sensor: ＊ function：induct the engine speed, tell ECU to control inject fuel & ignition. ＊ theory：calculate the interval time of each flange on the outer. Fault phenomenon: 1.vehicle can not start 　...
  • Page 68 Fuel injection systems -4 4-2.3 Engine temperature sensor * Location ＊ The engine temperature sensor principle Functions: sensing engine temperature to determine the hot and cold car conditions, the fuel injection quantity and ignition timing Correction compensation. Principle: the use of high and low temperature, resulting in a change in resistance. Measure engine temperature sensor: * Fault phenomenon: The cold car hard to start, can not be judged as the hot and cold car.
  • Page 69 Fuel injection systems -4 4-2.4 Throttle position sensor (TPS) * Location ＊ throttle opening degree sensor (TPS) principle 1. functions: sensing the throttle opening to determine the driving situation, determine the amount of fuel injectionAnd ignition timing. 2. principle: the use of the variable resistor, changes in the measured angle. ＊throttle opening sensor (TPS) measurements Fault phenomenon: idle speed high to 3000rpm or so throttle unresponsive.
  • Page 70 Fuel injection systems -4 4-2.5 Intake pressure sensor ＊Location * Intake pressure sensor principle: function：induct intake air pressure, ECU judge intake or compress stroke to decide injection & ignition. theory：different pressure outputs diferent resistance. * intake pressure sensor measurement: ＊ fault phenomenon: Idle speed will be lower than 1300rpm 　...
  • Page 71 Fuel injection systems -4 4-2.6 Injector ＊Location * Injector principle function：inject the gas, mixed with air. theory：control the opening time interval to decide the gas amount. Injector measurement: ＊ Impedance:12Ω±10％...
  • Page 72 Fuel injection systems -4  Draining cap of injector ＊bleed the air Used when replace the fuel pump,pipe…etc. ＊drain the gas The gas inside the pipe may become poor quality after storage, drain it before start the engine. * Fault phenomenon: Thevehicle difficult to start, or can not be launched.

  • Page 73: Fuel Pump

    Fuel injection systems -4 4-2.7 Fuel pump ＊Location ＊ Fuel pump principle features: gasoline tank suction and control the nozzle gas pressure 3kgf/cm2 Principle: pressure adjustment allows gas pressure to maintain stability * The fuel pump measurement Nozzle internal line or external line break or open circuit photo into a spray ,The nozzle does not fuel injection. If there is no fault code generation does not have a line problem, should be able to determine for nozzle clogging.
  • Page 74 Fuel injection systems -4 4-2.8 Fall down sensor ＊Location ＊Fall down sensor Function: vehicles and dumping more than 65 degrees for any reason, you can cut off the power turn off. Principle: the use of gravity to make the ball move position touch sensor vehicle dumping.
  • Page 75 Fuel injection systems -4 4-2.9 ISC (Idle Speed Control) ＊Location  ISC control method When the engine at idle, the ECU will make reference to the other sensor signals, to calculate how much idle bypass air and Notice to the stepper motor to control the amount of bypass air volume in order to control and maintain the engine idle speed.
  • Page 76 Fuel injection systems -4 Normal idle settings ： 1500rpm+100rpm Cold idle speed increased to ： 1900rpm * ISC measurement ＊timing when used scooter occur: 1. Hard to start the engine 2. Engine Idle speed is unstable 3. Other unstable situation To initialize the ISC, then the ISC reset to control zero point ※...
  • Page 77 Fuel injection systems -4 4-3 EMS system Repairing tool ＊pocket tester wiring part no.：S905310005 ＊ Use spark gauge ＊connect ＊minimum distance 6mm 火星 Plug cap. 塞帽 接地 ground Injector test line group: S905310005...
  • Page 78 Fuel injection systems -4 ＊Injector test line group use The Injector will open with the relay Frequency of injection (recommend the use of LED Direction light relay. 油管 Tubing 12V battery 12V電瓶 ＊fuel pressure gauge part no.：S905330008 ＊measure the fuel pressure standard 3kgf/cm2 ＊usage...
  • Page 79 Fuel injection systems -4 4-4 EMS diagnostic part no.：S320840G01 name：quick diagnostic How to use quick diagnostic: 1. Prepare quick diagnostic 2. Open the rubber cover inside the luggage comp. 3. Plug in the quick-diagnostic 4.turn on the key 5.wait for about 8 seconds 6.observe the EMS led on dash board...
  • Page 80 Fuel injection systems -4 name：connect cable Quick diagnostic table-...
  • Page 81 Fuel injection systems -4 Clear the defect code memory: 1.plug quick diagnostic into vehicle seat 2.wide open the throttle, turn on the key 3.after the EMS led off, release the throttle 4.don’t turn off the key until EMS led on again. 5.turn on the key to confirm again.

  • Page 82: Engine / Reverse Differential Gear 5

    Engine / Reverse differential gear -5 5-1 Disassembly of the engine assembly Removing the steps: 一.Back luggage 1. Remove the screws (2), take out the Back luggage 二. Muffler 1. Remove the nut / screw / washer (26/28/29/30), take out the Muffler (31) and packing (25)
  • Page 83 Engine / Reverse differential gear -5 三. Rear brake calipers 1. Remove the screw (19/23), take out the rear brake calipers and brake hose clamp . 四. Remove the air cleaner 1.Remove the”EEC TUBE“and “PCV TUBE”。 2. Turn loose clip。 3.
  • Page 84 Engine / Reverse differential gear -5 Remove the 、 、 、 、 。 A.C.G temperature sensor O2 sensor Starter motor Starter motor lion wiring terminals 五 Throttle assembly 六 Remove the throttle assembly screws * 2 七. Oil cooler hose pipe 1.
  • Page 85 Engine / Reverse differential gear -5 八. Rear suspension 1.Remove the left and right rear suspension screws(7) Torque values: REAR SUSPENSION (upper):4.7~5.5kg-m REAR SUSPENSION (under):2.0~3.0kg-m 九. Remove the engine hanger Remove the engine hanger * 1 fixed nut Remove the engine hanger * 1 mounting bolts Torque values: Engine hanger:4.0~5.0kg-m Separation of the engine and the frame...
  • Page 86 Engine / Reverse differential gear -5 十二. Rear Swingarm 1. Use the slotted screwdriver , remove the Rubber (10). 2 .Remove the flat washer / nut (7/8/9), take out the Rear Swingarm (6). 3. Remove the screw(3)，take out the Engine lower hanger (2). 十三.
  • Page 87 Engine / Reverse differential gear -5 5-2 Engine disassembly 5-2.1 Cylinder head disassembly 1. Remove the screw (10/11)，take out the fan cover (8) Torque values(10、11):0.9~1.1kg-m 2. Remove the cooling cowl (1.2) * 4 screws Torque values:0.9~1.1kg-m...
  • Page 88 Engine / Reverse differential gear -5 3. BF3-150 Carburettor models A.Remove the fixing screws (4), take out the Remove the bolts (5,8), removing the tube comp (7), separator (3). washers (9) and the cooling cowl (1) B. Check the cylinder head gasket (5) is deformed, replace if necessary.
  • Page 89 Engine / Reverse differential gear -5 5. Loosens bolts (5), remove the bolts (3) * 2 Remove the inner chain adjuster (2) and washers (4) Torque values: Parts 3- 0.9~1.1kg-m Parts4- 0.9kg-m 6. Remove the screws (10) 6.1 Remove the screws (12) 6.2.
  • Page 90 Engine / Reverse differential gear -5 7. Remove the cylinder head / cylinder head gasket cylinder head gasket Lock pin cylinder head ＊Gaskets can not be reused VALVE disassembly Remove the following: 1. Use the valve compressor tool, compressed the steam valve cotter valve ，...
  • Page 91 Engine / Reverse differential gear -5 Removing the camshaft holder: Disassembly: 1 .Use 5mm screws, remove the valve rocker shaft . 2. Remove (intake and exhaust) valve rocker. Cylinder head - timing adjustment: 1. clockwise rotation of the flywheel to the flywheel of the "T" markon the。The prospective the crankcase on the instructions ribs.
  • Page 92 Engine / Reverse differential gear -5 5-2.2 Cylinder removal procedure 1. Remove the chain guide member (7). 2. Remove the cylinder (6) and washers (5). 3. Using needle-nose pliers to remove C-type retaining ring (3). 4.Remove the piston pin (8), the piston (2) and the positioning pin (4). Piston rings demolition: Use the left and right hand thumb piston ring openings distraction, the order to remove the piston rings.
  • Page 93 Engine / Reverse differential gear -5 Piston ring installation: ★ Install oil scraper ring - spacer ring joints shall be concave upward 1.Install the oil scraper ring - spacer ring, ring 3 and 4 of the ring. 2.Side upward install piston rings (2) - iron gray. 3.Side upward install the piston ring (1) - Metallic Silver.
  • Page 94 Engine / Reverse differential gear -5 Each Piston rings nicked need to detach the 120 degrees. 2. Piston ring nicked and the piston pin hole can not be a straight line. 3. Piston ring nicked are installed are toward the top of the piston. 4.
  • Page 95 Engine / Reverse differential gear -5 5-2.3 CVT removal procedure 1. Remove the screws (22) and remove the left side cover (21) and retaining pin (19). Torque values: Parts 22- 0.9~1.1kg-m 2. Remove the CVT parts Torque values:: Parts 16- 5.0~6.0kg-m Remove the nut (16), sequentially removed - A.driven face (17)
  • Page 96 Engine / Reverse differential gear -5 Installation Notes: ， ， Weight roller is not the same at both ends Please coated end is mounted on the the face movable drive trench right side To Weight roller life and prevent face movable drive of abnormal wear. Triangles Install the slide piece to the pamp plate pressed into the triangle facing upwards.
  • Page 97 Engine / Reverse differential gear -5 5-2.4 crankcase demolition 1. Remove the screws (1) ，take out the fan(3) . Torque values: Parts 1: 0.9~1.1kg-m 1. Remove the screws(1) take out the flywheel (3) (electric plate puller to remove the flywhee 3.
  • Page 98 Engine / Reverse differential gear -5 4. Remove the screws(15.16.17.18.19)，take out the right crankcase cover (14) Torque: Parts 15.16.17.18.19- 0.9~1.1kg-m A. Remove the oil filter cover (6) 17mm. B. Remove the oil strainer (3), spring (4) and O-ring (5). * Installation must check whether the deformation of the O-ring and replace if necessary.
  • Page 99 Engine / Reverse differential gear -5 6. A. Remove the screws(5), take out the oil separator(4). B. Remove the screws(3), take out the sprkt oil pump drive (1) and oil pump drive chain(2). Torque: Parts 3、5- 0.9~1.1kg-m 7. A. Remove the bolts (17), take out the oil pump (16). B.Remove the screws (13, 15), take out the right crankcase (14).
  • Page 100 Engine / Reverse differential gear -5 Remove the right crankcase cover. Remove the Crankcase gasket (13) 、 crankshaft (11) 、 chain camshaft (10) 、 lock pin(12). Oil pump above the arrow (mark) toward the ※ crank shaft hole...
  • Page 101 3. Weight roller worn out. 4. Driving plate dirty. Note: No grease and oil should be distributed over driving belt and driving plate. B.Measurement data ( Hooligan 170i) Standard value ( mm ) Limit of use ( mm ) Item The inner dia.
  • Page 102 Engine / Reverse differential gear -5 1.Checking driving belt (1)check driving belt is cracked or notrubber and fiber is loosened or not also check if they are extraordinary worn out. (2)driving belt width: limit of use:change it below 19mm 2.Disassemble slide driving plate set. (1)Remove bush of slide driving plate.
  • Page 103 Engine / Reverse differential gear -5 4.Checking clutch: dismantling tool a.Check clutch driving face. Check clutch cover about its wearing condition And inner diameter measurement. limit of use: change it above 125.5mm b.Check clutch lining wearing condition and measure the lining thickness. limit of use : change it below 1.5mm.
  • Page 104 Engine / Reverse differential gear -5 5-3.2 Cylinder head and valve A.Trouble shooting B.The operation data information A.Troubleshooting. If the cylinder head is malfunctioned, usually it can tell from the measurement of the compression pressure or from the noise that comes from the upper part of the engine. 1.Unsmooth idle speed -Compression pressure is too low.
  • Page 105 Engine / Reverse differential gear -5 B.The operation data information (BF3-168) Standard Value Limit of use Description IN/EX (mm) (mm) Clearance between adjuster tapped 0.08 － Screw and valve stem 0.08 － (Before warm up) Compression pressure(throttle open full) 11kg/650rpm 26.625 26.23 Height of the cam’s convex part...
  • Page 106 Engine / Reverse differential gear -5 WHEN INSTALLING: A.The mark “EX” on the cam shaft holder is the exhaust rocker arm, one-way stopper. Install the exhaust rocker arm, the inlet rocker arm, and the rocket arm shaft. NOTICE: a. The tangen angle of the heat side of intake valve’s rocker arm shaft is to match with the bolt of the cam holder.
  • Page 107 Engine / Reverse differential gear -5 5-3.3 Lubrication System Lubrication System Diagram Assembly: 1. Install the inner and outer of the oil pump. 2. Install the oil pump shaft. Note: The notch of the oil pump shaft should comply With the notch of the inner gear. 3.
  • Page 108 Leakage of fuel b.Blockage in oil route c.Piston loop seizes, or improperly install-ation c.Did not use the fuel oil recommended d.Worn out of valve’s oil seal Measurement data (Hooligan 170i) Standard Value Limit of use item ( mm )
  • Page 109 Engine / Reverse differential gear -5 5-3.4 Cylinder and piston A.Trouble shooting B.The Operation notice C.Data D.Dismaniling cylinder, piston E.Installing cylinder, piston...
  • Page 110 3. Dismantle cylinder and cylinder head by screw driver. Do not injure the contact surface. 4. Cylinder inner surface and piston outer face can’t be injured. Contact Surface should lubricate by specified oil. C.Data (Hooligan 170i) Part name /description Standard value( mm )
  • Page 111 Engine / Reverse differential gear -5 D. Dismaniling cylinder, piston a. Dismantling piston 1.Remove the piston pin clip. NOTICE: Dot’ drop the clip into the crankcase. 2.Remove the piston pin and take off the piston. 3.Check piston, piston pin, piston ring. 4.Remove the piston ring NOTICE: NOTICE: Don’t make piston ring worn out or damaged...
  • Page 112 Engine / Reverse differential gear -5 c.Checking the flatness of cylinder contact surface. Limit of use : change it when above 0.05mm. d.Connecting rod small end inner diameter measurement. Limit of use : change a new one when above 15.060mm.
  • Page 113 Engine / Reverse differential gear -5 D.Installing Cylinder and piston a.Installing piston and piston rings 1.Lubricate the piston rings by motor oil. NOTICE: a. Be careful not to scratch the piston and not to break the piston ring. b.The mark (on the ring) should be upward when installing. c.after installing, the ring should be smoothly rotated.
  • Page 114 Engine noise: 1. The bearing of final transmission mechanism is loosen. 2. Crank pin of bearing is slack. 3. The bearing of gear box is loosen. B.Data (Hooligan 170i) Item Stardard value(mm) Limit of use.(mm) Clearance of connecting rod big end 0.10~0.35...
  • Page 115 Engine / Reverse differential gear -5 1. Check the looseness of crankshaft bearing. If it is loosen, replace to a new one.
  • Page 116 Engine / Reverse differential gear -5 5-3.6 Final transmission mechanism A.Troubleshooting. B.Disassemble the final transmission mechanism. C.Check the final transmission mechanism. D.Assemble the final transmission mechanism. A.Troubleshooting Engine can be started, but the vehicle doesn’t move. 1. Gear worn-out or cracked. 2.
  • Page 117 Engine / Reverse differential gear -5 Remove the bolt(3)，take out the bracket rear cushion (2). Locking torque: M8*P1.25*40L: 2.0~3.0kg-m 4.Remove the bolt(4.5.6.7.8) ，take off the gear box cover. Locking torque: Parts4:M8*P1.25*50L: 2.5~2.8kg-m Parts5:M8*P1.25*45L: 2.5~2.8kg-m Parts6:M8*P1.25*40L: 2.5~2.8kg-m Parts7:M8*P1.25*30L: 2.5~2.8kg-m Parts8:M8*P1.25*150: 2.5~2.8kg-m 5.Remove the final reduction gear(9)，...
  • Page 118 Engine / Reverse differential gear -5 C.Check the final transmission mechanism 1.Check the wearing condition of driving shaft and gears. 2.Check the wearing condition of idle gear shaft and idle gears. 3.Check the wearing condition of the final reduction gear 4.Check the wearing condition of the oil seal and bearing.

  • Page 119: Shock Absorber / Brake System/Wheel 6

    Shock absorber / brake system/wheel - 6 6.1 Front wheel demolition Steps: 1. Remove the "5" front brake bolts * 2. 2. Remove the front axle nut "6". 3.Remove the "5" front axle "4" spacer ring"3" code table gear and "2" wheels. Torque: Parts5- 5.0~6.0kg-m 6.1.1 Front wheel measure Measuring -...
  • Page 120 Shock absorber / brake system/wheel - 6 6.1.2 Front wheel -One sealed ball bearing >Demolition - Tool: Bearing Removal Tool Demolition of oil seal tool Specification: Sealed ball bearing 6201 1) Use Oil seal tool demolition oil seal demolition. 2) Use of the bearing removal tool will hammer out the single sealed ball bearings.
  • Page 121 Shock absorber / brake system/wheel - 6 6.1.3 Front wheels - Brake disc Measurement – 1.Thickness: Standard values:3.6mm Use limits: 3.1mm ≦ Beyond the limits - replace 2.lost roundness: 0.3mm ≧ Beyond the limits - replace 6.1.4 Front wheel – Meter gear assy Check - ›Speed meter gear”1”...
  • Page 122 Shock absorber / brake system/wheel - 6 6.2 Front fork >Disassembly - Step- 1. Remove the Handle bar. 2. Remove the Front wheel. 3. Remove the front fender. 4. Remove the screws with washers (15),take out the clip (14). 5. Using the front fork disassembly tool，Remove the steering shaft lock nut (5)and Upper ring-shape nut(4). 6.
  • Page 123 Shock absorber / brake system/wheel - 6 6.2.1 Ball bearing disassembly Check - ›Ball bearing cage Rupture, deformation → replacement. › Upper ring-shape nut、Upper bearing cage、Lower bearing cage、Inner bearing cage Wear, deformation → replacement. Note: Ball bearing cage and Bearing Rupture depression deformation will cause handle tube rotating flow, and body shaking unstable.
  • Page 124 Shock absorber / brake system/wheel - 6 6.3 The front fork assembly installation Installation – 1.Ball bearing gage (up / down) for Smear the butter. Note: Ball bearing gage direction, the installation can no be wrong . 2. front fork assembly installation- Front damper can be installed in accordance with demolition reverse (See the chapter 6.2).
  • Page 125 Shock absorber / brake system/wheel - 6 6-4 Front suspension assembly Demolition - 1.Remove the brake caliper mounting bolts "2". 2 mounting bolts of the front wheels "3" removed, take out the front Axle,spacer , meter gear,front wheels. 3 Remove the front fender fixed bolts "5". 4.
  • Page 126 Shock absorber / brake system/wheel - 6 6.6 Front wheels - brake pad (disc) >Disassembly - Step 1. Remove the screws of the brake calipers * 2. 2. will push the piston back. Step2 Step1 3. Remove the screw. 4 Remove the yoke springs and brake pads. >Measurement - brake pad- Step3...

  • Page 127: Removing The Rear Wheel

    Shock absorber / brake system/wheel - 6 6.7 Removing the rear wheel 1.Remove the nut / screw / washer (26/28/29/30), take out the muffler (31) and packing (25). 2.Remove the screw (19/23), take out the rear brake calipers and brake hose clamp . 3.Remove the left and right rear suspension screws(7).
  • Page 128 Shock absorber / brake system/wheel - 6 4.1Use the slotted screwdriver , remove the Rubber (10). 4.2 Remove the flat washer / nut (7/8/9), take out the Rear Swingarm (6). 4.3Remove the screw(3)，take out the Engine lower hanger (2). 4.4 Remove the rear wheel (4).
  • Page 129 Shock absorber / brake system/wheel - 6 6.8 Brake fluid replacement- Tools: pumping unit 1.Relax the drain screw. 2.Vacuum pumping unit, taking the dirty oil. 3.Open above the brake master cylinder, pour new oil. 4.Use vacuum pumping unit, out of the air brake tubing. Please add brake fluid at the same time, do not let the oil cup is taking the time to suck Into the air.
  • Page 130 Denso unit -7 Denso component location- 1.FLASHER RELAY ASSY (10) 2.HORN (11) 3.IGNITION(MAIN) SWITCH(12) 4.TOPPLE SWITCH (13) 1.FUEL PUMP (11) 1.RELAY (16) 2.STARTER RELAY (17) 3.IGNITION COIL (18) 4. REGULATE RECTIFIER(20) (20) 1. ECU(3) 1. DIAGNOSE ADAPTOR (2) 2. FUSE BOX (3)
  • Page 131 Denso unit -7 Locate the position of the main wiring-...
  • Page 132 Denso unit -7 starter system: Check the process: fuse → b. Battery → c. start switch → d. start motor → e start relay → f.one-way clutch Check the process: Project Handle 1. Battery (check the voltage) 12V- Please replace or recharge 2.Fuse:(check 15A) KEY the ON ∞-Replace 3.Main switch (KEY ON) Check the line color: Red / White (12V)→...
  • Page 133 Denso unit -7 4.staring switch (ON) check the wire color: orange (12V)→ light blue (12V) 0V- Replace the staring switch or line barrier 5. To starter relay check the wire color: green / white (-), light blue (12V), red (12V),black (12V) light blue，red=0V- check the line is open circuit。...
  • Page 134 Denso unit -7 c: Brake safety switch Measurement - switch actuation, continuity > Tools: multimeter use multimeter measure the probe is connected to the switch pin . Measurement line color probe stalls Judgment conduction normal switch Ω ∞ replace e: Starting motor Check - start the motor actuator is normal ─...
  • Page 135 Denso unit -7 7-2 Charging system Check the process: a:battery → b:A.C.G → c: charging line check a. battery Check - Battery > Tools: multimeter Measurement: Voltage: at20 ℃ when 12.8V or more Insufficient voltage → recharged or replaced Measurement the A.C.G, connect a voltmeter (hook table or pointer).
  • Page 136 Denso unit -7 b:A.C.G check Check- Tools: multimeter The measurement-A.C.G rechargeable coil impedance Measurement line color probe stalls Judgment Y(1) 0.8±0.2Ω Ωx1 at20° Y(2) Y(1) 0.8±0.2Ω Ωx1 Y(3) at20° Y(2) 0.8±0.2Ω Ωx1 Y(3) at20° c: Charging line inspection Check - >...
  • Page 137 Denso unit -7 7-4 Lamps lighting system 7-4.1- Bulb check Check - filament whether disconnection Measurement: > Tools: Three multimeter stalls: Ωx1 Method: Three multimeter measuring rod connected to the three-pin bulb ∞ → replace (—) Measurement: (Figure 13-2) (＋)LO >...
  • Page 138 Denso unit -7 7-4.3 Headlight / license lamp line loop(Electronic injection version) Check the process: Project Handle 1. Check the lamp tungsten is not blown Replacing the Lamp。 2. Battery (check the voltage) 12V- Please replace or recharge。 3. Main switch (KEY ON) check the line color - orange (12V), Red/White (12V) 0V- Replace the main switch or lines open circuit。...
  • Page 139 Denso unit -7 Blue, brown / white> 0V-check line is open circuit black line with frame is not turned on - lines open ( Repeat check) circuit。...
  • Page 140 Denso unit -7 7-4.5 Signal lamp Check the process: Project Handle 1. Check the lamp tungsten is not blown Replacing the Lamp. 2. Battery (check the voltage) 12V- Please replace or recharge. 3. Main switch (KEY ON) check the line color - orange (12V), Red/White (12V) 0V- Replace the main switch or lines open circuit.
  • Page 141 Denso unit -7 7-5 electrical appliances measurements ›Main switch Tools: multimeter Stalls: DC 20V › line Key position Red / Orange Green Gray White 330Ω/12V ○ ○ ○ ○ Anti-theft voltage: main switch install a resistor (330Ω) in the gray wire with the middle of the green line, a signal voltage is connected to the ECU, ECU without receiving this voltage or voltage at the same time, the vehicle will not start ›Horn Tool:Battery、multimeter...
  • Page 142 Denso unit -7 7-6 Control of relays ＊ (Relay) 15A ＊theory： use small current to control big current ＊Usage： fuel pump & injector EMS whole system headlamp ＊ Relay measurement ＊use the pocket tester 1.find the control coil 2.fit 12V to the control coil 3.the relay sounds “ka”...
  • Page 143 Denso unit -7 7-7 Fuse Description (Electronic injection version)- ＊ Location ＊dismantle 1.luggage comp. 2.battery cover ＊at the right of battery Description ＊ ＊ The main purpose of the fuse ＊ (FUSE) 1A / 5A / 7.5A / 10A / 15A protect the units when extra-current occurs 1A ：...
  • Page 144 Denso unit -7 7-8 Associated with the injection system and fuse- 1A: Protection of the microcomputer controller (ECU)  such as the fuse burned  failure phenomenon: Unable to launch, no fuel pump actuator  whether the apparent failure code: no EMS lamp does not light when the main switch is turned on 5A: to protect the fuel pump and injector 　...
  • Page 145 Denso unit -7 7-9 Injection system wiring diagram Line color injection system 1 gray -. Ground 2 pink-ECU provides 5V voltage 3 red / white - the battery voltage 4 Orange – main switch (KEY ON)
  • Page 146 Denso unit -7 7-9.1Injection system engine misfire / no injection CHECK 1. Check whether the vehicle lights EMS fault lights? Troubleshooting. 2. Check the battery voltage has 12.3V? Replace or recharge batteries. 3. Check the fuse if there is broken wire? Fuse broken wire replace with new one.

Table of Contents

Save PDF