GENUINE HOOLIGAN 170i Service Manual

Text of GENUINE HOOLIGAN 170i User Guide:

• GENUINE HOOLIGAN 170i, 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. Remove the bolts (6), take out the front lower cover(5). ＊install According to the reverse procedure as above ○ 1 ○ 2 41

• GENUINE HOOLIGAN 170i, 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). 127

• Engine / Reverse differential gear -5 5. Loosens bolts (5), remove the bolts (3) * 2 Remove the inner chain adjuster (2) and washers (4) 6. Remove the screws (10) 6.1 Remove the screws (12) camshaft LOCK PIN camshaft holder Torque values: Parts 3-

• GENUINE HOOLIGAN 170i, 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. Remove the air cleaner screws、Washer (3/4/5)。 83

• Engine / Reverse differential gear -5 7. Remove the cylinder head / cylinder head gasket ＊Gaskets can not be reused VALVE disassembly Remove the following: 1. Use the valve compressor tool, compressed the steam valve 2. Remove the cotter valve，Relax the valve removal tool，The order to remo

• GENUINE HOOLIGAN 170i, Engine / Reverse differential gear -5 1. 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. Notch between the rings can not overlap and must be spaced。Upper-left 1.3 nicked, upper-right section 2.4 nicked . Cylinder installation steps: Installed in a

• GENUINE HOOLIGAN 170i, 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 　 2.The spark plug no ignition with the fuel injector fuel injection 　 EMS light is on six long and six short(Crank angle perception circuit is broken or open circuit). * Measurements to determine: The measured crank angle percept

• GENUINE HOOLIGAN 170i, 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. D. Assemble the final transmission mechanism please follow the opposite procedure of disassembling.After locking the drain bolt, refill 110cc of gear oil SAE90. 118

• GENUINE HOOLIGAN 170i, 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) 65

• GENUINE HOOLIGAN 170i, Engine / Reverse differential gear -5 c.Checking the flatness of cylinder contact surface. d.Connecting rod small end inner diameter measurement. Limit of use : change it when above 0.05mm. Limit of use : change a new one when above 15.060mm. 112

• GENUINE HOOLIGAN 170i, Engine / Reverse differential gear -5 B.The operation data information (BF3-168) Description IN/EX Standard Value (mm) Limit of use (mm) Clearance between adjuster tapped Screw and valve stem (Before warm up) IN 0.08 － EX 0.08 － Compression pressure(throttle open full) 11kg/650rpm Height of the cam’s convex part IN 26.625 26.23 EX 26.53 26.13 Inner diameter of rocker arm shaft IN 10.00~10.015 10.10 EX 10.00~10.015 10.10 Outer diameter of rocker arm shaft IN 9.972~9.987 9.91 EX 9.972~9.987 9.91 Valve base angle IN&EX 1.0 1.8 Outer diameter of valve stem IN 4.

• GENUINE HOOLIGAN 170i, Check & Adjust -3 3-2 Gear oil Volume: Total oil volume: 110c.c. Oil volume replaced: 90c.c. Service cycle: Every1800 mile Check the oil level: 1. Place a graduated cup under the drain plug bolt prior to removal of the bolt. 2. Check the oil volume after the gear oil is evacuated. Oil replaced 1. Place a vessel under the drain plug bolt; remove and clean the bolt. 2. Install the bolt with the gear oil evacuated. 3. Op

• GENUINE HOOLIGAN 170i, Information Summary and Preparation -1 1-3 Positions of engine number / vehicle identification 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 10mm nut 3.0~4.0kg-m 10mm bolt 3.0~4.0kg-m Pin / bolt 1.5~2.0kg-m 12mm bolt 5.0~6.0kg-m Body / Engi Type Torque (kg-m) Type Torque (kg-m) Type Torque (kg-m) Disk Front axle Handlebar Engine hanger Brake caliper Joint bolt (brake hose) Brake pump assembly Rear axle Front shock abs

• GENUINE HOOLIGAN 170i, 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

• Denso unit -7 c: Brake safety switch e: Starting motor f: starter relay Measurement - switch actuation, continuity > Tools: multimeter use multimeter measure the probe is connected to the switch pin . Measurement line color pr

• GENUINE HOOLIGAN 170i, Fuel injection systems -4 4-3 EMS system Repairing tool ＊pocket tester wiring part no.：S905310005 ＊ Use spark gauge Injector test line group: S905310005 ＊connect ＊minimum distance 6mm 火星 塞帽 接地 Plug cap. ground 77

• 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 pro

• GENUINE HOOLIGAN 170i, 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. 43

• 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 rev

• GENUINE HOOLIGAN 170i, 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. ＊ Fall down sensor measurements: 74

• GENUINE HOOLIGAN 170i, Fuel injection systems -4 4-2 Electronic injection system introduced 4-2.1 ECU (electric control unit) * Location ＊Important PIN no.# of ECU Fault phenomenon: 　 EMS lights lit 　 vehicle can not start 1 PIN 18 PIN 19 PIN 36 PIN 66

• GENUINE HOOLIGAN 170i, 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). 7. A. Remove the bolts (17), take out the oil pump (16). B.Remove the screws (13, 15), take out the right crankcase (14). When installing oil pump, oil pump on the arrow toward the crank shaft hole.※ Torque: Parts 3、5- 0.9~1.1kg-m Torque: Parts 13、15、17- 0.9~1.1kg-m 99

• 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 t

• GENUINE HOOLIGAN 170i, 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. Procedure for general diagnoses: No. Operating Procedure Detection Results Subsequent Steps 1 Check the air filter for any jam. Yes Check the air intake system. No Next step 2 Connect a fuel pressure gauge before the fuel inlet of the nozzle; start the engine to check the fuel pressure at 300kPa or so during the idle status. Yes Ne x t step No Repair t

• GENUINE HOOLIGAN 170i, Engine / Reverse differential gear -5 8. 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 100

• GENUINE HOOLIGAN 170i, 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. Remove the nut / washer (3/4), separated Reflectors(2). ＊install- According to the reverse procedure as above. Single decomposition: Reflector holder ＊dismantle-

• GENUINE HOOLIGAN 170i, Engine / Reverse differential gear -5 8.Tighten the oil pump after installation. Troubleshooting: Reduction in fuel oil volume Engine burning-out a.Natural consumption a.Zero or too low oil pressure b 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) item Standard Value ( mm ) Limit of use (

• GENUINE HOOLIGAN 170i, Check & Adjust -3 3-8 Spark plug Check: 1. Use a spark plug socket to remove the spark plug. 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. Specific model: CR7HSA NGK or similar substitute Spark plug gap: 0.6~0.7mm 3-9 12V Charging power switch 1.Function: Supply 12V DC voltage, the charging power. 2.Restrictions on Us

• GENUINE HOOLIGAN 170i, 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. Procedure for general diagnoses: No. Operating Procedure Detection Results Subsequent Ste p s 1 Check the air filter for any jam. Yes Check the air intake system. No Next step 2 Connect a fuel pressure gau

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