Motive Power PGO Service Manual

BR-150SERVICE MANUALManufactured by PGOof Motive Power Industry Co., Ltd

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3.1 OPERATION1.OPERATIONLAYOUT

2.. Digital Speedometer1.Symbol description••speed indication••high beam indicator••signal lamp indicator••reverse gear indicator••parking indicator••

13.2 Steering Inspection& AdjustmentDismantle•Lock tight thebolts of steeringhandle.•Torque:0.5 kg-m

2SteeringInspection•Inspect thecoupling jointknuckle.Maintenance•Add grease intouppersuspension armper 10,000kmfrom greasevalve.

3Inspection•Inspect theabsorber,functioncheck andoil leakagecheck.Inspection•Lock tight the nut oftie rod with steeringspindle support.•Inspect the cl

4Steering Inspection & AdjustmentSteering Inspection & Adjustment•Lock tight thebolt•Add grease intolower suspensionarm per10,000km.

5Steering Inspection & Adjustment•When checking the alignment of front wheel.•Keep the vehicle at flat surface•From the top view,wake sure:•C=D,an

13.3 Brake inspectionand adjustment•Brake system•Brakecylinder•Adjust the handbrake (to rear brakedisk)cable ifnecessary•Hand Park (Front end)•Loosen

ContentChapter 1 : Service notation¢ Specification¢ Locking torqueChapter 2: Engine dismantle & inspection¢ Engine dismantle¢ Engine inspection¢ T

2Brake adjustment•Hand Park (Caliperend)•Loosen nut#1•Adjust the cable tofrontto increasehand brake power.•Lock tight nut#2.1 2Brake inspection•Check

3Brake inspection and adjustment•Adjusting brakingpower.•Loosen nut•Adjust the length ofbolt, screw it in can getbigger brake power.•Lock the nut.fron

4Brake inspectionand adjustment•Specification of frontbrake caliper•Replace the pad ofdisk if necessary.Brake inspectionand adjustment•Specification o

5•Withdrawthe cap•Dismantlethe 4 nutsWheeldismantle (1)•You don’tneed todismantlethe wheelnutWheeldismantle (2)

6•Withdrawthe wheelWheeldismantle (3)•Withdrawthe cotterpin•Dismantlethe nut•Withdrawthe hubWheeldismantle (4)

14. Electric inspectionMain switchHeadlamp switchParking button12Vpower supplyHorn buttonSignal lamp switch•1.Operation panelPanel terminal wiring•Pan

PREFACEThis manualoffers all service specialists with the technologicalprocedures of maintenance, repairing for BR-150 show those whom mayconcern how

2Panel terminal wiring•Panelback2. Parts locationspeedometerSignal lamp

32. Parts locationRelayregulatorresistorIgnition coil2. Parts locationbatteryStarting safety device

42. Parts locationHead lampCDIOptional deviceReverse shifting safety deviceParking sensor

5Electric inspection•Check thecoupling,prevent losingconnection ofthe terminals.•Spray someanti-dust waxif necessary.Electric inspectionHead lamp &

62. Charging Adjustment of BR150•Start the engine, keep in idle speed, turn on theheadlamp.•Disconnect the red/white wire .•Use the pocket tester to m

73. Ignition•Ignition wiring•For CDI unit,you don’t haveto adjust theignition timing

1Engine Dismantle•Loosen the bolt ofconnecting rodwith upper swingarm.Engine Dismantle•Dismantle the nut•Withdraw the enginefrom the upperswing arm.

2Engine Dismantle•Loosen the bolt ofupper swing armwith the lowerswing arm rear.Engine Dismantle•Loosen 2bolts ofoil cooler

3OP ofReplacing RearEngine Hanger Collar for BR1501. Loosenthe locknut.1OP ofReplacing RearEngine Hanger Bush forBR150232.Dismantlethebolt3.Loosen the

BUGXTER SPECIFICATIONNameFRAME STEELTYPESUSPENSION SYSTEMDIMENSION FRONT SINGLE A ARMTOTAL LENGTH REAR SWING ARMTOTAL WIDTHTRANSMISSIONTOTAL HEIGHT RP

4Muffler DISASSEMBLY(1)•Loosen 2bolts ofmuffler withcylinder headMuffler DISASSEMBLY(2)•Loosen 1hexagon boltof mufflerwith LHcover•Removemuffler

5Air cleaner removal (1)•Loosen 9hexagonflange screwsof LH cover•Removeengine LHcoverAir cleaner removal (2)•Outside endis sponge,clean it ifnecessary

6MAGNETO DISASSEMBLY(1)•Loosen 2 hexagonscrews and 2 C-Rrecess pan hd.tapping screws•Remove fan coverMAGNETO DISASSEMBLY(2)•Loosen 4 hexagonscrews of

7MAGNETO DISASSEMBLY(3)•Loosen nut ofmagneto•When installing,tighten lock torqueis 5.5 kg-mMAGNETO DISASSEMBLY(4)•Pull out themagneto withspecial tool

8MAGNETO DISASSEMBLY(5)•Loosen 3hexagonscrews ofstator•RemovestatorStator flywheel cooling fanCYLINDER AND HEADDISASSEMBLY(1)•Loosen 1 hexagonscrew an

9CYLINDER AND HEADDISASSEMBLY(3)•Loosen 4 hexagonscrews of cylinderhead cover•Remove cylinderhead cover assy.CYLINDER AND HEADDISASSEMBLY(4)•Loosen 1

10CYLINDER AND HEADDISASSEMBLY(5)•Loosen 4 nuts ofcamshaft holder•Loosen 2 hexagonscrew of cylinderhead•Remove camshaftholder camshaftand cylinder hea

11ONE WAY CLUTCHDISASSEMBLY(1)•Loosen 8 hexagonscrews of RHcrankcasecover•Remove RHcrankcasecoverCYLINDER AND HEADDISASSEMBLY(2)•Loosen nut of oneway

12OIL PUMP DISASSEMBLY(1)•Loosen 2 C-Rrecess screws of oilseparator•Remove oilseparatorOIL PUMP DISASSEMBLY(2)•Loosen nut of oilpumpdriving gear•Remov

13OIL PUMP DISASSEMBLY(3)•Loosen 2 hexagonscrews of oil pump•Remove oil pumpCRANKSHAFT DISASSEMBLY(1)•Loosen 2 hexagonscrews of RHcrankcase•Remove RHc

1.1 The operation notice:1.Always replace gasket, O ring, cotter, pins and clip whenever reassembled.2.When tighten screws or nuts, lock tightly as pe

14CRANKSHAFT DISASSEMBLY(2)•Pull out crankshaftfrom LH crankcase•Remove camshaftchainCRANKSHAFT INSTALLATION(1)•Put camshaft chainin LH crankcase

15CRANKSHAFT INSTALLATION(2)•Assemblecrankshaft in LHcrankcase0.100.03Swingness of the crankshaft journal.0.04------Clearance of connectingrod big end

16CRANKSHAFT INSTALLATION(3)•Assemble RHcrankcase intocrankshaft•Tight 2 hexagonscrews•(torque is1.0kg-m)•Replace the oil sealand packing.CRANKSHAFT I

1Engine inspection•Enginelayout““ “35TUBE CYL.COMP.•Cylinderhead &cover

2•Cylinder head inspection•Different view ofcylinder headEngine inspectionDescriptionIN/EXStandard(mm)Lim it use(mm)Valve Clearance(Before warm up)IN

3Engine inspection•Valve train•Valve clearance•IN:0.08mm•EX:0.08mmCYLINDER & CYLINDER HEAD INSTALLATION•Installing camshaft,the valve timingshall

4CYLINDER & CYLINDER HEAD INSTALLATION•Ensure 2 line marksof camshaft parallelto cylinder headrefer to photo•And the hole shallbe in the toppositi

5Engine inspection•Oil lubricatedSystem (by pump& splash)•Make suretheoilpath is through &clean.Engine inspection•Intake& Exhaustsystem•In

6Engine inspection•Exhaust muffler•Make suretheflange#1 is welllocked with thecylinder head toavoid leakage.•Lock muffler at #4with engineLHcover.Engi

7Engine inspection•Pulse airsystem•Keep theair-inpath clean.•Keep thevacuumpipewell connectedto intakemanifold,•Never jam thevacuum pipe.Part name /de

1.2 TORQUE VALUE1. Engine:NO Locking location Q’TY Thread dia. (mm) Lockingtorque (kg-m) Remark1 Cylinder head bolt A (intake) 2 6 0.9~1.12 Cylinderhe

8Engine inspection•CylinderCYLINDER & CYLINDER HEAD INSTALLATION•Noticethe marksupon piston•“IN”mark shall inthe intake direction ; “EX”mark shall

9CYLINDER & CYLINDER HEAD INSTALLATION•Piston rings shallbe installedaccording to marks•1st ring is marked“1R”; 2nd ring is marked “RN”•The marks

1CVT TRANSMISSION DISASSEMBLY(1)•Loosen 9hexagonflange screwsof LH cover•Removeengine LHcover•Loosen nuts ofdriving pulley andclutch outer•When instal

2•Remove driveface,driving pulley assy.,driven pulley assy.,V-beltCVT TRANSMISSION DISASSEMBLY(3)CVTinspection dataIte mStandard value (mm ) Limit of

3CVTinspection dataBelt width Roller dia.Lining thickness OuterdiaFrt pulley diaSpring lengthEngine inspection•Transmission System•Primary:CVT•Final:r

4Engine inspection•TransmissionSystem•Reverse gearis engaged454.Dismantle 2 bolts5.Push thereversebox to right handapproximately 10mm.Driving chain di

56.Dismantle the bolt(#16)& nut.(#10)Lock torqueis:2.5 to 3.0 kg-mAndmake surepart #9can rotate in pivot #177.Replacethe collar (#17)8.Assemble th

69.Adjust thechain slackby this nut.Driving chain dismantle (4)10. Lock thelower nutsby :5.0 to 6.0 kg-m10Driving chain dismantle (5)

7•When installingthe lock pin ofdriving, keep theclose end forwardthe Drive direction.CloseendOpen endDriving chain dismantle (6)

2.4 Carburetor dismantle & inspection:1. dismantleò Remove:-carburetor assembly, pipes,cables and wiresò Remove:-high-tension wire2.adjustmentther

3.Locking Torque Standard (Chassis)No Locking location Qty Thread dia(mm)Kg-m Remark1 Wheel nut 16 10 6.02 Wheel axle nut 1 16 8.03 Front absorber bol

1CARBURETOR PRINCIPLEFuel levelFunctions:1.Fuel atomization2.Air/Fuel Ratio3.Engine OutputEngine inspection•CarburetorAssembly•Idleadjustment(stopscre

2(PJ)(SAJ)PilotScrew(PS)fuelRemarks:1.For 4 stroke engine,moreopening turns of PS,A/Fratio is richer.2.Clean the jets and bodywith compressed air.(MJ)

33.pilot screw assy.4.vacuum piston assy.5.jet needle8.cover13.main jet14.pilot jet15.float19.by-start cap20.auto by-start

1.3 In order to achieve safe riding, good performance andreduce pollution, please execute thefollowingrecommended maintenance table base upon average

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