Motive Power PGO Service Manual

1 PREFACE This service manual contains chief instructions in connection with service and maintenance of PGO TIGRA motorcycle and is also one technica

Information Summary and Preparation 1 10  Tool name: Water pump shaft SC seal kit Functions: Install SC seals on the wate

Information Summary and Preparation 1 11 1-7 Procedure to maintain the Electronic Management System (EMS)  Systematic procedure to

Information Summary and Preparation 1 12 (1) Engine not running or slowly running during start-up General trouble location: 1. Batter

Information Summary and Preparation 1 13 (3) Trouble of hot start General trouble location: 1. Water in fuel; 2. Fuel pump; 3. Engine

Information Summary and Preparation 1 14 (4) Trouble of cold start General trouble location: 1. Water in fuel; 2. Fuel pump; 3. Engin

Information Summary and Preparation 1 15 (5) Trouble of start-up anytime despite RPM normal General trouble location: 1. Water in fue

Information Summary and Preparation 1 16 (6) Start-up normal but idle speed unstable anytime General trouble location: 1. Water in fu

Information Summary and Preparation 1 17 (7) Start-up normal but idle speed unstable during warm-up General trouble location: 1. Wate

Information Summary and Preparation 1 18 (8) Start-up normal but idle speed unstable with warm-up finished General trouble location:

Information Summary and Preparation 1 19 (9) Start-up normal but idle speed unstable or stall with load such as front lamp applied Ge

Contents 2 This manual is a service manual for PGO Tigra Series with details specifying skills to disassemble or install various mechanisms, basic ma

Information Summary and Preparation 1 20 (10) Start-up normal but idle speed too high General trouble location: 1. Air throttle and i

Information Summary and Preparation 1 21 (11) RPM low or stall during acceleration General trouble location: 1. Water in fuel; 2. Inl

Information Summary and Preparation 1 22 (12) Acceleration slow General trouble location: 1. Water in fuel; 2. Inlet pressure sensor

Information Summary and Preparation 1 23 (13) Acceleration powerless; performance bad General trouble location: 1. Water in fuel; 2.

Information Summary and Preparation 1 24 1) PCODE List No. PCODE UAES Description 1 P0107 Inlet pressure sensor to GND short-circ

Installation or Removal of External Components 2 25 Front & rear covers (handlebar) 1. Front cover → Front lamp assembly → Rear cover → Dash

Installation or Removal of External Components 2 26 Removal and installation of body cover & lower cover 2. Storage compartment → Luggage c

Installation or Removal of External Components 2 27 Removal of body cover and license plate 2-1 License plate and left & right body cover as

Installation or Removal of External Components 2 28 3. Left & right air breathers (front inner panel) → Windshield → Front air deflector cov

Installation or Removal of External Components 2 29 4. Front inner panel cover → Front inner panel ◙ Remove 4 speed rivets on the fr

3 1-1 Configuration Water tank / fan Auxiliary water tank Front brake disk Fro

Installation or Removal of External Components 2 30 6. Front inner fender ◙ Remove the set screw / nut on the handlebar. ◙ 1

Check & Adjustment 3 31 1) Gear oil Vo l u m e Total oil volume: 110c.c. Oil volume replaced: 90c.c.

Check & Adjustment 3 32 3) Engine oil Vo l u m e Total oil volume: 1000c.c. Oil volume replaced: 800c.

Check & Adjustment 3 33 3) Air filter Recommended service cycle: Check: Every 1000 km Change: Every 6000 km or l

Check & Adjustment 3 34 6) Spark plug Check 1. Use a spark plug socket to remove the spark plug. 2. Check the s

Check & Adjustment 3 35 8) Back-play of throttle cable Check Turn the right grip and check movement of the throt

Check & Adjustment 3 36 9) Brake system Brake lever Check the back-play by pressing the brake lever for any inco

Check & Adjustment 3 37 Change of a front brake pad Tool to change a brake pad: 1. Allen wrench 2. 12” T-type

Check & Adjustment 3 38 4. Take out the brake shoe with pins removed. 5. Check if the thickness of each

Check & Adjustment 3 39 Change the rear brake pad Brake pad ☉ Remove set screws fixing the rear brake

Information Summary and Preparation 1 4 1-2 Positions of engine number / vehicle identification number:

Check & Adjustment 3 40 Change brake oil Steps: 1. Loose the drain plug bolt. 2. Use an oil pump to draw used o

Check & Adjustment 3 41 11) Check / adjust timing Check: 1. Align the flywheel “T” mark to a triangular sign on

Check & Adjustment 3 42 12) Driving belt / clutch lining 1. Check the driving belt for any chaps or wear; replac

Check & Adjustment 3 43 15) Steering lever system Use the center stand to support the motorcycle and make the fr

Lubrication System 4 44 Lubrication system diagram 曲軸箱 Oil lines inside a cran

Lubrication System 4 45 1) Cleaning of filter screen A. Remove the oil filter screen cover B. Remove the oil filt

Lubrication System 4 46 3) Oil filter Change A. Remove 3 set screws on the oil filter cover and take out the cover.

Disassembly of the Engine Assembly 5 47 1) Separate the engine from the vehicle body Procedure: 1. Remove the luggage compartme

Disassembly of the Engine Assembly 5 48 4. Disassemble the engine’s throttle cable and vacuum tube

Disassembly of the Engine Assembly 5 49 8. Remove calipers and fuel hose clips 9. Remove set bolts for shock absorbers

Information Summary and Preparation 1 5 1-3 Specifications: (以下表格內容不需翻譯) 國 產 機 器 腳 踏 車 規 格 表 廠 牌 摩 特 動 力 車

Cylinder Head 6 50 Removal and disassembly 1. Remove the cylinder head Procedure: A. Remove 4 set screws on th

Cylinder Head 6 51 E. Remove the cylinder head, cylinder head gaskets and 2 dowel pins.

Cylinder Head 6 52 2. Disassemble the cylinder head A. Use a wrench to remove set screws on the camshaft mount

Cylinder Head 6 53 F. Loose bolts on the temperature controller; remove the temperature controller cover and t

Cylinder Assembly 7 54 Disassemble the cylinder Remove the cylinder head for the steps as follows: A. Sequentially

Cylinder Assembly 7 55 Measurement and check 1. Visually check the external of the piston or replace it with a n

Cylinder Assembly 7 56 2. Installation of the cylinder 1. Install dowel pins and cylinder gaskets on the crankc

V Belt Driver 8 57 Left cover / drive belt assembly A. Remove 3 set screws on the left cover cap and take out it.

V Belt Driver 8 58 Limit sizes of parts A. Balancing ball: Standard outer diameter=18.0mm; limit size>17.40mm

Crankcase & Crankshaft 9 59  Right crankcase cover A. Remove 3 set screws on the water pump cover and take out par

Information Summary and Preparation 1 6 1-4 Code of practice: 1. Any clamp or cotter pin removed shall be replaced with a new one. 2

Crankcase & Crankshaft 9 60  Disassembly and installation of the engine oil pump sprocket: Disassembly of the engi

Crankcase & Crankshaft 9 61  Engine oil filter A. Remove 3 set screws on the engine oil filter cover and take ou

Crankcase & Crankshaft 9 62 Crankcase  Left crankcase Remove 11 set screws on the crankcase; place the inner chain

Crankcase & Crankshaft 9 63 3. Securely fix the right crankcase with the puller hammer installed for the bearing pu

Crankcase & Crankshaft 9 64 Installation of the crankcase  Method (1) Install the bearing and the engine oil pump s

Crankcase & Crankshaft 9 65  Method (2) Separate the bearing and the engine oil sprocket 1. Use the fixture to in

Final Speed Gear 10 66 Final drive gear Steps for removal: 1. Remove the drain plug bolt and drain the gear oil

Fuel Injection System 7 67 Configuration and performance of parts in the MSE3.0 gasoline engine’s electronic control

Fuel Injection System 7 68 11-1 ECU Principle: Electronic Control Unit (ECU) is the brain of the whole electron

Fuel Injection System 7 69 ECU Pin ISA-TEV +canister purge(TEV) TEV (IS

Information Summary and Preparation 1 7 prior to a connector removed or connected. 3. During any operation to simulate the thermal s

Fuel Injection System 7 70 11-2 Intake manifold pressure sensor Function: Monitor absolute pressures (kPa) in the

Fuel Injection System 7 71 11-3 Temperature sensor Function: The sensor is used to provide information about water

Fuel Injection System 7 72 11-4 LSF Lambda sensor Principle: When a ceramic tube’s temperature is up to 350℃, the

Fuel Injection System 7 73 Fault diagnosis A variety of signals from different sensors, actuators, power amplifiers

Fuel Injection System 7 74 11-5 Electromagnetic fuel nozzle Function: Subject to ECU, the fuel nozzle injects atomiz

Fuel Injection System 7 75 11-6 DKG (Throttle sensor) Function: The sensor can provide information about a throttle

Fuel Injection System 7 76 Principle: The idle sped actuator is composed of electromagnetic coils, armature iron, an

Fuel Injection System 7 77 ① Airflow direction conformable to spec. during installation; ② Check and replace the idl

Fuel Injection System 7 78 Fig. 2-34, Electric circuits of an intake temperature sensor ③ To inspect the

Cooling System 12 79 Cooling system diagram

Information Summary and Preparation 1 8 Body / Engine Type Torque (kg-m) Type Torque (kg-m) Type Torque (kg-m)Disk Front axle Bra

Cooling System 12 80 System maintenance  Regular maintenance  Every 1000km: Check if the coolant level in the

Cooling System 12 81 Change coolant  Steps to change water coolant (simplified): 1. In order to avoid burn and

Cooling System 12 82 7. During the coolant temperature gradually increased to the circulating temperature, some

Cooling System 12 83 Water tank / fan Check 1. Check the water tank and the fan for any damaged or deformed

Cooling System 12 84 Thermostat Function: Control temperature of water coolant for the engine running at the bes

Cooling System 12 85 Water pump  Steps to disassemble a water pump 1. Take out the water pump cover. 2. Loo

Cooling System 12 86 3. Screw the water pump impeller in place with the water pump shaft and the washer install

Cooling System 12 87  Sealing performance of the cooling system 1. Change the water tank cover with a specifi

Charge, Ignition, and Start-up 13 - 88 - Notices for operation: 1. Sequentially disconnect cables on the battery’s terminal

Charge, Ignition, and Start-up 13 89 Check: 1. Battery  Voltage check A. Use a multi-meter or a voltage meter to test a

Information Summary and Preparation 1 9 1-6 Service tools  Summary of service tools  Tool na

Charge, Ignition, and Start-up 13 90 ACG charge performance  Use a clamp meter to test charge performance by turning the r

Charge, Ignition, and Start-up 13 91 4. Ignition system Check the ignition system 1. Measure the first circuit (Red) &a

92 Chassis 14 92  Remove the rear wheel  Removal A. Remove the seat assembly; disconnect the Lambda sensor

Exhaust Emission Control System 9 107Letter of guarantee for the exhaust emission control system Motive Power, Inc. warranties the exhaust

Exhaust Emission Control System 9 108 1. Evaporative Emission Controller (EEC) Principle: Make any HC inside t

Exhaust Emission Control System 9 109 2. Regular maintenance table for the exhaust emission control system Item Content First 300km (1 mon