GENUINE Blur 150 Service Manual Download Page 27

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10.Fuel indication malfunction

(a)wrong fuel level indication(when the main switch is “ON”)

fuse burn-out

battery has no power

main switch abnormal

circuit plug dropped off

main wiring disconnected

Float abnormal

Fuel gauge abnormal

electric plug dropped off

wrong connection

wire broken or short

circuit

Check and adjust

Trouble condition

The reason

Turn the signal lamp
On; check wiring of
battery

normal

Lamp dims, light
Not flash, not light

Remove the fuel gauge
Moving float up and
Down to check
The needle movement

Indicator moves

Indicator no motion

Do the short and opening
Circuit test on the fuel
Gauge plug which connect
To wire harness. Check the
indicator movement

Indicator
moves

Indicator on
motion

Check electric plug

good

abnormal

Summary of Contents for Blur 150

Page 1: ......

Page 2: ...Blur 150 220i Service Manual...

Page 3: ...Steering head bearing 4T Check looseness Adjust it if required A A A Rear absorber 4T Leaking and function check I I I Main Side Stand 4T Function check or replace it if required I L I L I L Nuts bol...

Page 4: ...periodically 1 Maintenance procedure of air clearer see page 33 2 Spark plug s checking please repair or replace if spark plug is dirty 3 Fuel system s checking please repair or replace if fuel pipe...

Page 5: ...nt BLUR 150 abbreviated as BLUR 150 is 4 stroke engine 4T 150cc displacement BLUR SS220i abbreviated as BLUR SS220 is 4 stroke engine 4T 220cc displacement At every section we illustrate each importan...

Page 6: ...nition timing 8 Throttle cables adjustment 9 Idle adjustment 10 Front brake adjustment 11 Rear brake adjustment 12 Tire Dismantling maintaining repairing and assembling operation A Plastic parts B BLU...

Page 7: ...ystem 5 Starting system 6 Switch operation 7 Wiring diagram I I I I BLUR 220 characteristics dismantle inspection 1 Engine dismantling 2 engine inspection 3 Electric system 4 Maintenance 5 Engine Mana...

Page 8: ...SK REAR 147 KG SPEEDOMETER 140 km hr WEIGHT TOTAL TOTAL 242 KG HEAD HI LO 12V 35W 35W TOP SPEED 87 km hr REAR 12V 5W FUEL CONSUMPTION 40 km l BRAKE 12V 21W PERFORMAN GRADIENT 24 LIGGHT SIGNAL 12V 10W...

Page 9: ...ASS TOTAL MASS TOTAL 294 KG HEAD LAMP 12V 60W 55W TOP SPEED 110 km hr TAIL LAMP 12V 5W FUELCONSUMPTION 33 km l BREAKING LAMP 12V 21W PERFORMA NCE HILL CLIMB 30 LIGHT TURNING LIGHT 12V 16W 4 TYPE C8E5...

Page 10: ...5 Troubleshooting 1 Difficult starting or starting 2 Weak acceleration 3 Engine running not smoothly low speed 4 Engine running not smoothly high speed 5 Clutch drive driven pulley 6 Handlebar steerin...

Page 11: ...ter dismantling please clean all parts involved or used for checking and grease all contact surfaces when reassembling 5 Use grease recommended by PGO 6 When removing the battery please disconnect the...

Page 12: ...9 1 1 6 Cylinder head bolt B Exhaust 2 8 2 0 2 3 7 Flange nut cam shaft holder 4 8 2 0 2 3 8 Gear oil drain bolt 1 8 1 7 2 0 9 Spark plug 1 10 1 2 1 3 10 Nut of fly wheel 1 12 5 0 6 0 11 Fixing nut cl...

Page 13: ...ine hanger bracket 2 10 4 5 5 0 11 Engine bolt engine hanger bracket 1 10 3 0 4 0 12 Hose bolt master cyl caliper 2 10 2 5 3 0 13 Front axle nut 1 12 4 5 5 5 14 Nut swing arm connecting rod 1 14 4 5 5...

Page 14: ...stroke motorcycle oil or SAE15W40 Auto Separated Lubrication BLUR 150 Total 900 c c Replacement 800c c BLUR220 Total 1400 c c Replacement 1000c c 3 1 Drive gear box BLUR 150 SAE85 140 Total 110 c c R...

Page 15: ...C Chassis appearance 1 Apply oil 1 2 2 Apply grease 3 4 5 6 7 8 1 2 3 4 5 6 7 8...

Page 16: ...D Wheel bearing Final transmission mechanism gear oil Speedometer gear clean grease...

Page 17: ...Leaking and function check I I I I I I Steering head bearing 4T Check looseness Adjust it if required I I I Rear absorber 4T Leaking and function check A A A Main Side Stand 4T Function check or repla...

Page 18: ...ake sure the engine runs smoothly NOTE 2 The exchange of brake fluid 1 After disassembling of brake main cylinder or caliper do change the new fluid 2 Check the fluid level often Refill if necessary 3...

Page 19: ...oke air trapped in intake manifold wrong ignition timing bad adjustment of carburetor s fuel adjusting screw carburetor fuel level too high malfunction of auto choke throttle valve open too largely Ch...

Page 20: ...buretor clean the dirt specification is not correct Check and Adjust Trouble condition The reason Start engine and open throttle Gradually check and inspect Engine can rotate up Engine can t rotate Up...

Page 21: ...combustion room ignition timing is too early too much carbon in the combustion room bad quality of the fuel clutch slip mixture is too lean ignition timing is too early Check the oil level in crankca...

Page 22: ...n coil faulty H V coil disconnect or short circuit main switch is abnormal A C generator malfanction hose is damaged air pipe is blocked or damaged Check and adjust Trouble condition The reason Check...

Page 23: ...level is too low fuel pipe fuel filter is blocked fuel pump faulty clean and wash it Check and adjust Trouble condition The reason Check ignition timing correct Not correct Check fuel pump Fuel suppl...

Page 24: ...out distorted or slipping weight roller worn out driving plate worn out driving plate spring distorted driving pulley shaft worn out driving belt worn out or slipping weight roller worn out driving p...

Page 25: ...r cracked 8 Brake disorder adjustment according to standard procedure brake lining worn out bake lining cam worn out brake cam worn out brake hub worn out brake lining worn out unknown materials attac...

Page 26: ...lug is loose or drop off main wiring disconnected wrong wire connection float faulty oil gauge switch disconnected or short circuit Float upward lamp Extinguishes oil tank distorted Float downward lam...

Page 27: ...n wire broken or short circuit Check and adjust Trouble condition The reason Turn the signal lamp On check wiring of battery normal Lamp dims light Not flash not light Remove the fuel gauge Moving flo...

Page 28: ...nside the fuel gauge electric plug drop off or loose wire broken or short circuit Check and adjust Trouble condition The reason Turn signal lamp on Check wiring of battery normal No motion Indicator m...

Page 29: ...ush worn out coil broken or short circuit starting motor wire broken circuit plug is loose drop off main wiring broken Check and adjust Trouble condition The reason Check brake switch Turn signal lamp...

Page 30: ...t return start relay capacitor melted or short circuit Check and adjust Trouble condition The reason Turn signal lamp On to check wi ring of battery normal Lamp dims no Flashing no light Starting Conn...

Page 31: ...on coil Check and adjust Trouble condition The reason Replace new spark Plug then check again Good sparking Weak sparking Or no sparking Check spark plug cap And H V cable is Loose or not Check the CD...

Page 32: ...then start engine Voltage remain The same Voltage goes up To normal value But after engine Stop the voltage Goes down again Check voltage rectifier Plug is loose or not good loosen Check the voltage B...

Page 33: ...ing table 2 Battery 3 Clean air cleaner 4 The final reduction mechanism oil 5 Spark plug 6 Compression pressure measurement 7 Ignition timing 8 Throttle cables adjustment 9 Idle adjustment 10 Front br...

Page 34: ...umn a clearance Clearance Front 10 20mm Rear 10 20mm Lever b movement of brake loose or damage Brake cable Change brake cable every 2 years Brake cam worn out a clearance between hub and lining b brak...

Page 35: ...amage condition Suspension arm Looseness on Connecting Part Oil leakage Damaged Condition Rear Damper Absorber Loose on ass y part Function Clutch and Shift mec hanism Gear oil leakage LH crank case T...

Page 36: ...eck the color of exhausting air Air cleaner Cylinder cy1inder head inlet pipe locking Condition Locking torque Cylinder head cold 1 0 1 2KG m Cam holder nut 2 0 2 3kg m BLUE150 220 Engine parts Compre...

Page 37: ...ile Judgement standard Remark Function Lamp system Dirty or broken Horn signal Lamp reflector Function lock Function Rear view mirror Dirty or broken License plate Dirty or damaged Dashboard Function...

Page 38: ...e assemble the battery please follow the opposite procedure of disassembling after recharging Note A The battery is totally sealed do not remove seal bolts when recharging B It s no need to add any el...

Page 39: ...r cleaner cover 2 Take out the air cleance filter 3 Clean the filter by the compressor air 4 Assemble the air cleance by the opposite procedure Note Do not start the engine when the air cleaner is Not...

Page 40: ...k the filling bolt e Locking torque 1 8kg m 5 Spark plug 1 Remove spark plug 2 Check the spark plug electrode and check if it is Burnt out or not and carbonized or not 3 Clean the electrode whether it...

Page 41: ...ng starting motor 5 seconds continuously measure the compression pressure 5 Compression pressure 150 220 cc 11 kg c 650rpm 6 when the compression pressure is too low check the following a cylinder hea...

Page 42: ...7 Throttle cables adjustment 1 check the clearance of throttle 2 Normal clearance 1 5 3 5mm 3 Adjust it by rotating the adjust nut change it if the throttle cables can t be adjusted BLUR150 220...

Page 43: ...check the clearance of front brake lever Clearance 10 20mm 2 if the clearance is beyond standard check whether a The air mix into the pipe caliper b The oil brake system is leaking 3 check the fluid...

Page 44: ...re pressure when it is too low The pressure is according to the carrier Driver passenger accessories and cruise Speed b Proper loading is very important for steering riding braking performance and saf...

Page 45: ...assembling operation 1 Lubrication system 2 Engine dismantling 3 Install Engine 4 Drive pulley starter clutch driven pulley 5 Cylinder head and valve 6 Cylinder and piston 7 AC generator 8 Final trans...

Page 46: ...1 Lubrication System...

Page 47: ...of muffler 2 Remove the AC flywheel magneto 3 Remove the AC generator coil 4 Tale off the locking bolts of the right crankcase cover 5 Remove the crankcase cover 6 Remove the washer lock pin 7 Remove...

Page 48: ...ft 3 Install the lock pin 4 Match the lock pin hole to the pump cover and install the oil pump cover 5 Put on the screws and tighten them 6 After installing turn the shaft lightly to assure installati...

Page 49: ...045 0 10 0 12 Oil pump Clearance between gear end and Oil pump body 0 045 0 10 0 12 Troubleshooting Reduction in fuel oil volume a Natural consumption b Leakage of fuel c Piston loop seizes or improp...

Page 50: ...tor cable 6 Remove the rear section of muffler dismantle the 2 bolts of rear brake caliper then remove the rear brake system assembly away from rear fork 7 Loosen bolts of upper lower engine hanger 8...

Page 51: ...4 Drive pulley starter clutch driven pulley A Troubleshooting B Measurement data C Driving pulley D Starter E Clutch driven pulley...

Page 52: ...ty Note No grease and oil should be distributed over driving belt and driving plate B Measurement data Item Standard value mm Limit of use mm The inner dia Of slide driving plate 24 011 24 052 24 10 T...

Page 53: ...C Driving Pulley 1 Take off the screws of left cover remove the left cover 2 Remove the lock nuts of driving Plate and the nuts of Starter gear And clutch 3 Take off the ramp plate Belt and clutch...

Page 54: ...n level ground increase the engine s speed slowly and notice the RPM at which the motorcycle begins to move forward Specified Engagement RPM 3100 300 rpm 6 Clutch LOCK UP inspection Apply the rear bra...

Page 55: ...belt width limit of use change it below 19mm 7 Disassemble slide driving plate set 1 Remove bush of slide driving plate 2 Remove screw and disassemble the cover of slide driving plate 3 Remove ramp pl...

Page 56: ...dition 4 Check the outer diameter of the contact surface of the movable driving plate limit of use change it below 23 94mm 9 Assemble the slide driving plate 1 Clean up the inside surface of slide dri...

Page 57: ...ck the wearing condition of the outer diameter of spindle comp and the inner diameter of bush and gear b Check the wearing condition of shaft of driven gear comp Gear sets and ratchet 9 Assembling the...

Page 58: ...the clutch follows the opposite procedure of dismantling 3 Checking clutch dismantling tool a Check clutch driving face Check clutch cover about its wearing condition And inner diameter measurement li...

Page 59: ...driving plate sets And measure outer diameter limit of use change it above 33 95mm e Check wearing condition of slide driven plate And measure its Inner diameter limit of use change it above 34 00mm...

Page 60: ...23 HEXAGON NUT 6 VALVE INLET 24 SHAFT EX ROCKER ARM 7 GASKET HEAD CYL 25 LOCK PIN 8 LOCK PIN D10 14L 26 CAMSHAFT HOLDER 9 HEXAGON FLANGE BOLT 27 PLAIN WASHER 10 STUD BOLT 28 HEXAGON FLANGE NUT 11 STUD...

Page 61: ...gh There is too much carbon accumulated in the combustion chamber 4 There is white fume coming out from the exhaust pipe The valve stem or valve guide pipe is worn out Valve stem s oil seal is damaged...

Page 62: ...ver and take off the cylinder head cover 4 Turn the flywheel counterclockwise and let the T mark on the flywheel point to the crankcase mark and make the round hole on the cam chain gear point upwards...

Page 63: ...e cylinder head are at parallel position convex part of cam shaft points upwards then install the cam shaft on the cylinder head 3 Install the cam chain onto the cam shaft gear 4 Install the locking p...

Page 64: ...d gasket 8 Remove cam chain guide Further dismantling Use the valve contracting tool to remove valve pin supporter the vlave spring collar valve spring and valve stem oil seal Notice Not to injure the...

Page 65: ...nd Piston ring 2nd ring 0 02 0 06 0 10 lst ring 0 10 0 25 0 50 2nd ring 0 10 0 25 0 50 Clearance of cutting section side ring 0 2 0 7 Piston outer diameter 57 470 57 490 57 400 Measuring location of p...

Page 66: ...ormal piston noise 1 Cylinder and piston worn out 2 Piston pin hole or Piston pin worn out 3 Connecting rod small end or bearing worn out d Abnormal piston or cylinder noise 1 Piston ring worn out or...

Page 67: ...ing c PISTON OUTER DIA MEASUREMENT 1 Measuring location Perpendicular to the piston pin hole down to 5mm 150CC form the piston skirt 2 The clearance between the piston and piston pin 3 Checking any we...

Page 68: ...position of the inner dia in X or Y direction d Checking the flatness of cylinder contact surface e Connecting rod small end inner diameter measurement Limit of use Roundness change it when above 0 0...

Page 69: ...on piston pin and piston pin clip b Installing piston 1 Fix the lock pin and gasket on the crankcase 2 Lubricate the Cylinder inner surface piston and piston rings by Motor Oil 3 Install the piston ri...

Page 70: ...7 A C Generator A Dismantling AC generator B Installing AC generator...

Page 71: ...antle the rear section of muffler 2 Remove fan cowl 3 Remove the M6 screws 4 Remove screws of flywheel magneto 5 Remove the AC flywheel magneto by special tool 6 Remove the flywheel 7 Remove the elect...

Page 72: ...B Installing AC generator To install please reverse the dismantling procedure Locking torque M6 1 0 1 2kg m M12 3 2 4 0kg m...

Page 73: ...ission 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 Gear burnt out Noise occur when running 1...

Page 74: ...B Disassemble the final transmission mechanism 1 Remove the rear wheel 2 Drain the oil in the gear box 3 Remove the bolt in the gear box cover Take off the gear box...

Page 75: ...ove the final reduction gear And idle gear 5 Clean up the gear box C Check the final transmission mechanism 1 Check the wearing condition of driving shaft and gears Gear teeth number 14 T 125CC 15 T 1...

Page 76: ...ition 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 lock...

Page 77: ...9 Crankcase Crankshaft A Disassembling diagram B Troubleshooting C Data D Remove crankcase and crankshaft E Check crankshaft F Assemble the crankcase...

Page 78: ...A Disassembling diagram Torque 1 0 1 2kg m B Troubleshooting 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...

Page 79: ...d vertical direction 0 04 Swingness of the crank shaft journal 0 03 0 10 D Remove the crankcase and crankshaft by the following procedures 1 Remove the engine 2 Remove the muffler 3 The carburetor 4 E...

Page 80: ...Change it when above 0 1mm Change it when above 0 1mm 3 Check the looseness of crankshaft bearing If it is loosen replace to a new one F Assemble crankcase 1 assemble crankcase according to the opposi...

Page 81: ...antling the float and nozzle CARBURETOR SPECIFICATIONS ITEM SPECIFICATION Model M2 150 Carburetor type KEIHIN CVK24 Bore size 24 mm I D NO 046 Idle r min 1700 100 Float height 18 0 0 5 mm Main jet 102...

Page 82: ...re present on the downstream side of the venturi A Negative pressure is admitted into the diaphragm chamber through an orifice provided in the piston valve Rising negative pressure overcomes the sprin...

Page 83: ...tered by the pilot screw and sprayed into the main bore through the pilot outlet port COASTING ENRICHMENT SYSTEM The coasting enrichment system is included in the slow system At the normal running ope...

Page 84: ......

Page 85: ...s the needle jet mixes with the air admitted through the main air jet and forms an emulsion The emulsified fuel then passes through the clearance between the needle jet and jet needle and is discharge...

Page 86: ...tent reaches upper part of The fuel pipe and mixes again with the air coming through a passage extending from main bore The two succesive mixings of fuel with air are such that proper fuel air mixture...

Page 87: ...e valve pushes up against the valve seat When this occurs no fuel enters the float chamber As the fuel level falls the float lowers and the needle valve unseats itself admitting fuel into the float ch...

Page 88: ...atio When the rider open the throttle grip quickly the intaken air volume becomes large and air velocity at the bottom of the throttle valve piston valve is slow and sucking volume of fuel is less The...

Page 89: ...ircuits in the carburetor body with a spray type cleaner and allow each circuit to soak if necessary to loosen dirt and varnish Blow the body dry using compressed air CAUTION after cleaning reassemble...

Page 90: ...as been connected NOTE To inspect the function check for change of temperature from the cold condition CAUTION FLOAT HEIGHT ADJUSTMENT To check the float height turn the carburetor upside down Measure...

Page 91: ...cleaner blocked 2 Mixed air is too dilute in the idle system Sparking unsteady while increasing speed 1 Ignition system malfunction 2 Air mixture is too dilute Difficult to start Ignition off Unstable...

Page 92: ...f fuel volume adjusting screws 1 After the engine is warm up adjust the stopping screw throttle of throttle valve to the standard rpm Idle rpm 1 700 100rpm 2 Adjust the fuel volume adjusting screws to...

Page 93: ...main jet and fuel adjusting screws Assemble the float valve float and float pin 4 Checking fuel level Note When the valve is too dirty or severely worn not the Valve base will not close completely th...

Page 94: ...k is crooked c The axle of front fork is crooked or the wheel is aslant 3 front wheel swings a wheel rim is distorted b bearing of front axle is loose c wheel spoke is distorted d Tire worn out e The...

Page 95: ...t of the speedometer cable 3 Remove the fixed screw of the speedometer cable on the front wheel 4 Pull out the damaged speedometer cable 5 To assemble the new cable please follow the opposite of disma...

Page 96: ...on front fork and handlebar 4 Take off the fixing bolt 5 Remove the nut and bolt of the front fork fixed on The handlebar 6 Take off the handle bar 7 When assembling please follow the opposite proced...

Page 97: ...t wheel follows the opposite procedure of dismantling Locking Torque M10 3 0 4 0kg m Note 1 Put the lock block of speedometer gear assy upon the extrusion of the front fork 2 Put the grease onto the g...

Page 98: ...ing is Loosen or any occurrence for noise Please change a new one 7 Front wheel rim checking 1 Check the swing of the front wheel rim 2 Limit of use Horizontal direction Change a new one when above 2...

Page 99: ...e container b Do not let the brake oil overflow from the master cylinder or container when assemble the master cylinder cover c Put the spanner upon the drain screw d Lock and unlock the screw several...

Page 100: ...a new one 4 Front shock absorber checking Check is there any unusual damage or worn out condition and whether the guide rod of the Front fork is crooked or not Fork oil type SAE 10W20 Capacity each s...

Page 101: ...semble the disk follows the disassembling procedure Locking torque M8 2 0 3 0kgm 6 Checking the front brake disk 4 0 mm BLUR 150 220 3 5 mm BLUR 150 220 7 Checking the front brake PAD a standard thick...

Page 102: ...adjustment of brake is not proper b The brake lining is dirty c The brake lining worn out d The cam of brake lining is worn out e The brake cam lever worn out f The wheel hub worn out or damage g The...

Page 103: ...Remove the locking nut of the rear wheel 3 Remove the rear wheel 4 To assemble the rear wheel please reverse the dismantling procedure D Checking the rear wheel a check the swingness of rear wheel b...

Page 104: ...1 Brake pad inspection for BLUR 150...

Page 105: ...84 F Rear absorber 1 Check the locking torque of rear absorber at lower upper 2 Both locking torque is 3 5 4 5 kg m 3 Oil leakage check is always necessary BLUR 150 220...

Page 106: ...is blocked c Auto cock and filter is blocked d The membrane of fuel pump is over swell 2 The membrance of auto cock is over extended a Fuel tank cover s ventilation hole is blocked b Fuel pipe is croo...

Page 107: ...2 Remove the fuel tank cover 3 Remove the fuel pipe 4 Remove the connecting terminal of the fuel gauge 5 Remove the fuel gauge 6 Remove the fixing blot of the fuel tank 7 Take off the fuel tank 8 When...

Page 108: ...em 1 the wiring diagram of recharge system 2 check A C flywheel magneto 3 Check regulator rectifier 4 Ignition system 1 the wiring of ignition 2 check spark plug 3 check H T cable and H V coil 4 check...

Page 109: ...der 5 Front rear brake switch is out of order 6 Starter relay is out of order 7 Wire disconnects or broken 8 Starting motor is out of order Currency is unstable 1 The wiring of batter connection is no...

Page 110: ...Battery 1 Check the cells of battery Always remove the battery negative Cable first then positive cable But connect the positive cable first then connect the Negative cable when assembling BLUR 150 2...

Page 111: ...ncy Please recharge 12V according to the following current and time Standard 0 9A 5 10Hr or Rapid 3A 60min 150 220cc NOTICE This battery is totally sealed Do not remove seal bolt when recharging Notic...

Page 112: ...ting Then increase the rpm slowly Assume the battery is fully charged situation Head Lamp Switch Recharging rpm 2 500rpm 6 000prm OFF DAY Under2 000rpm 0 6A MIN 1 5A MIN ON NIGHT Under2 000rpm 0 6A MI...

Page 113: ...ygen gasses produced at the positive electrode will immediately react With an active material lead at the negative electrode to turn back to water thus preventing water from losing PRECAUTION WHEN HAN...

Page 114: ...ng of electrolyte in even one cell will result in deteriorated performance and shortened life INSERTING CAP SEALING PLUG CAUTION To install the cap temporarily fit the cap to all the cells Lightly the...

Page 115: ...the battery voltage If the voltage reading is less than the 12 0V recharge the battery with a battery charger When recharging the battery remove the battery from the motorcycle Practice the standard c...

Page 116: ...3 Recharge system A Recharge system diagram for BLUR 150...

Page 117: ...e luggage box b Measure the resistance value of terminals 3 Check regulator Measure the resistance value between each terminal It should be in the specified range otherwise change a new one Yellow V S...

Page 118: ...ing or ignition 2 Check spark plug 3 Check the H V cable and H V coil by using the CDI tester 4 CDI sets checking Check with the CDI tester and please follow the instruction manual If the CDI test fai...

Page 119: ...5 The starting system 1 The wiring of starting 2 Make sure the Engine RUN OFF switch is in Run position 3 Check the safety switch by operating the brake lever and the brake lamps shall light on...

Page 120: ...nction well if above connection and both Red Black cable of staring motor have currency passing through 3 Dismantling the starting motor a Remove 2 screws on starting motor b Remove starting motor cab...

Page 121: ...Front section muffler 1 dismantle 2 castle nuts 2 take off front section oil cooler oil cooler oil cooler oil cooler 1 loosen 2 bolts remark there are 2 washers 2 dismantle the oil cooler Second Air...

Page 122: ...dismantle Cooling cowl Cooling cowl Cooling cowl Cooling cowl 1 dismantle 3 tapping screws 2 dismantle 1 upper hexagon bolt 3 take off upper cooling cowl 4 dismantle 1 lower hexagon bolt 5 take off lo...

Page 123: ...tensioner Chain tensioner Chain tensioner Chain tensioner 1 loosen the middle bolt 2 dismantle the spring 3 loosen 2 bolts of the body 4 dismantle the chain tensioner body 5 take off the packing Recov...

Page 124: ...ft holder Camshaft holder 1 loosen 4 nuts washers 2 dismantle the holder 3 dismantle 2 lock pins 4 dismantle the camshaft Cylinder head Cylinder head Cylinder head Cylinder head 1 loosen 2 hexagon bol...

Page 125: ...ntle 2 lock pins 4 take off the packing Piston Piston Piston Piston 1 dismantle 2 clips 2 dismantle piston pin 3 take off the piston Attention To prevent clip falling down the crankcase use clothes to...

Page 126: ...g fan Cooling fan Cooling fan Cooling fan 1 loosen 4 bolts 2 dismantle the fan Ge Ge Ge Generator outer nerator outer nerator outer nerator outer 1 Loosen 1 nut washer 2 use special tool turn the oute...

Page 127: ...r Generator stator Generator stator 1 loosen 2 bolts washers of pulser 2 dismantle the bracket of pulser 3 loosen 3 socket bolt 3 dismantle the stator Star Star Star Starting motor ting motor ting mot...

Page 128: ...e packing Attention Be careful of the surface don t defect it to avoid oil leaking Starting idle gear Starting idle gear Starting idle gear Starting idle gear 1 dismantle the shaft 2 dismantle the bod...

Page 129: ...ed air wrench to loosen nut or use the tool to fix the crankshaft Special tool one way clutch S620504G01 Sprocket of oil pump Sprocket of oil pump Sprocket of oil pump Sprocket of oil pump 1 dismantle...

Page 130: ...ankcase Right crankcase Right crankcase Right crankcase 1 loosen 2 bolts 2 dismantle the right crankcase 3 dismantle 2 lock pins 4 take off the packing Attention Be careful of the surface don t defect...

Page 131: ...BLUR 220 engine dismantle crankshaft from the left crankcase don t damage the oil impact the crankshaft...

Page 132: ...55 4 970 4 900 IN 5 000 5 012 5 30 Inner diameter of valve guide EX 5 000 5 012 5 30 IN 0 010 0 037 0 08 Clearance between valve stem and Valve guide EX 0 030 0 057 0 10 The inner dia Of slide driving...

Page 133: ...390 Measuring location of piston outer dia Down to 8 mm from the piston skirt Clearance b w piston and cylinder 0 025 0 035 0 10 Piston Piston ring Piston pin hole inner dia 16 004 16 010 16 040 Pist...

Page 134: ...1 6 3 Electric system Carburetor model electric General maintenance Engine Management System...

Page 135: ...m What is transistor ignition Transistor Ignition System Transistor a kind of semi conductor that can control electric current has the switch function Apply transistor to engine ignition control calle...

Page 136: ...tion controller Ignition coil DC generator with longer pulse flange TPS Throttle Position Sensor optional part of Carburetor Digital ignition controller ACG Ignition coil TPS Major components of Trans...

Page 137: ...Traditional C D I CDI Digital controller longer More coils Transistor ignition 5 4 3 2 1 item longer shorter ACG flange no yes CDI More coils Less coils Ignition coil yes no Digital controller yes no...

Page 138: ...p choke RPM 1000 OFF ON Control timing relay Headlamp switch 12V from battery Digital controller Green black fuse Headlamp choke carburetor diagram When engine speed 1000rpm the digital controller per...

Page 139: ...llow yellow yellow yellow yellow yellow yellow yellow yellow battery battery battery battery ground ground ground ground ground ground ground ground Charging to battery Charging to battery Charging to...

Page 140: ...7 Fuse wire white white Main fuse layout relay fuse layout reserved fuse layout Red white Red Red white Red black...

Page 141: ...8 BLUR 220 Electric parts battery relay fuse 15A Seat lamp controller Digital controller diode Remarks If dismantle the battery engine will cease fire...

Page 142: ...30cc 130cc 130cc 130cc Replace Replace Replace Replace 90cc 90cc 90cc 90cc Total Total Total Total 110cc 110cc 110cc 110cc Oil filter Oil filter Oil filter Oil filter 2 2 2 2nd nd nd nd filter filter...

Page 143: ...10 BLUR 220 Specified engine oil synthetic 1000ml...

Page 144: ...gear oil gear oil gear oil gear oil Drain of engine oil drain of gear oil Gear oil Gear oil Gear oil Gear oil filling filling filling filling Replace 110cc Replace 110cc Replace 110cc Replace 110cc t...

Page 145: ...1 park in flat area 1 park in flat area 1 park in flat area 2 keep in idle for 3 minutes 2 keep in idle for 3 minutes 2 keep in idle for 3 minutes 2 keep in idle for 3 minutes 3 3 3 3 cold down 3 minu...

Page 146: ...eplace the 2 Replace the 2 Replace the 2nd nd nd nd oil filter oil filter oil filter oil filter 1 dismantle the right lower cover 2 replace the filter keep the surface clean apply grease to the O ring...

Page 147: ...rews 1 loosen 8 screws 1 loosen 8 screws 2 dismantle the cover 2 dismantle the cover 2 dismantle the cover 2 dismantle the cover Take off the element Take off the element Take off the element Take off...

Page 148: ...CVT sponge CVT sponge Clean with compressed air or replace a new one 1 loosen 3 bolts 1 loosen 3 bolts 1 loosen 3 bolts 1 loosen 3 bolts 2 take off the sponge 2 take off the sponge 2 take off the spon...

Page 149: ...r 2 dismantle the cover 2 dismantle the cover 2 dismantle the cover 3 loosen 2 hexagon nuts 3 loosen 2 hexagon nuts 3 loosen 2 hexagon nuts 3 loosen 2 hexagon nuts Don Don Don Don t miss the lock pin...

Page 150: ...the words of belt facing to operator 1 keep the words of belt facing to operator 1 keep the words of belt facing to operator 2 push the belt to bottom 2 push the belt to bottom 2 push the belt to bot...

Page 151: ...le the right lower cover Loosen with the special tool Loosen with the special tool Loosen with the special tool Loosen with the special tool Spark plug Spark plug Spark plug Spark plug C7E carburetor...

Page 152: ...Dismantle the right lower cover Dismantle the right lower cover Dismantle the right lower cover You can see the ignition coil You can see the ignition coil You can see the ignition coil You can see t...

Page 153: ...sure 2 0 kg cm2 using limit of Disk using limit of Disk using limit of Disk using limit of Disk thickness thickness thickness thickness 3 5mm using limit of pad using limit of pad using limit of pad u...

Page 154: ...pin 2 take off the pin 2 take off the pin 3 take off the yoke 3 take off the yoke 3 take off the yoke 3 take off the yoke 4 dismantle the pads 4 dismantle the pads 4 dismantle the pads 4 dismantle the...

Page 155: ...sure 2 0 kg cm2 using limit of Disk using limit of Disk using limit of Disk using limit of Disk thickness thickness thickness thickness 3 5mm using limit of pad using limit of pad using limit of pad u...

Page 156: ...pin 2 take off the pin 2 take off the pin 3 take off the yoke 3 take off the yoke 3 take off the yoke 3 take off the yoke 4 dismantle the pads 4 dismantle the pads 4 dismantle the pads 4 dismantle the...

Page 157: ...1 Engine Management System Engine Management System Engine Management System Engine Management System EMS EMS EMS EMS...

Page 158: ...2 EMS index EMS units EMS diagnostic...

Page 159: ...3 Feature of PGO 2nd stage EMS feature 1 small light 2 integrity 3 accuracy 4 simple...

Page 160: ...injector coil Fuel supply ignition Engine temperature sensor Throttle position sensor Intake pressure sensor Crank speed sensor 5 sensors Oxygen sensor Oxygen sensor Oxygen sensor Oxygen sensor ISC I...

Page 161: ...ensor Oxygen sensor Oxygen sensor Engine temperature sensor Throttle position sensor Intake pressure sensor injector ISC coil Spark plug Crank speed sensor Electric control unit Electric control unit...

Page 162: ...6 EMS units...

Page 163: ...7 Throttle position sensor Intake pressure sensor injector Idle Speed Controller...

Page 164: ...8 FUEL PUMP COMP COIL COMP IGNITION O2 SENSOR TE SENSOR crankshaft ANGLE SENSOR...

Page 165: ...9 ECU ECU ECU ECU SAFETY SENSOR SIDE STAND AIAC ASSY SOLENOID...

Page 166: ...10 Important PIN no of ECU no of ECU no of ECU no of ECU ECU PIN 1 PIN 18 PIN 19 PIN 36 PIN...

Page 167: ...ECU Important PIN no of ECU no of ECU no of ECU no of ECU PIN NO function 11 Control pole of fuel pump 12 Control pole of headlamp relay 13 supply 5V voltage to sensors 16 Control pole of injector 18...

Page 168: ...12 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...

Page 169: ...erature sensor Engine temperature sensor Engine temperature sensor Engine temperature sensor function induct engine oil temperature then ECU knows engine is cold or hot theory different temperature va...

Page 170: ...Measure engine temperature sensor Measure engine temperature sensor Measure engine temperature sensor Measure engine temperature sensor T resistance K 20 18 800 K 40 1 136 K 100 0 155 K usually 1 5 5...

Page 171: ...le position sensor Throttle position sensor Throttle position sensor Throttle position sensor TPS function induct throttle angle provides the road load condition to ECU theory angle changes resistance...

Page 172: ...16 Throttle position sensor Throttle position sensor Throttle position sensor Throttle position sensor TPS Lb output Pu power 5V Gr ground Lb Gr throttle output V close 0 6 0 02V WOT 3 8 0 10V...

Page 173: ...Intake pressure sensor Intake pressure sensor Intake pressure sensor function induct intake air pressure ECU judge intake or compress stroke to decide injection ignition theory different pressure out...

Page 174: ...3 0 4 0 5 0 0 50 100 150 kPa Vcc V Intake pressure sensor Intake pressure sensor Intake pressure sensor Intake pressure sensor Pu output 5V G B output Gr ground G B Gr Press KPa output V 13 3KPa 0 5V...

Page 175: ...19...

Page 176: ...46 Wiring diagram for BLUR 150 4V...

Page 177: ...47 Wiring diagram for BLUR SS220I...

Page 178: ...48...

Page 179: ...49...

Page 180: ...to above figure sequence by sub assembly especially pay attention to followings Before dismantle front fender dismantle the front wheel assy First BLUR150 SS220I Windshield frt signal lamp cover shal...

Page 181: ...the upper with the inner cover Withdraw the windshield decorated cover Dismantle the handle upper cover Loosen 5 tapping screw under the handle Dismantle windshield turn signal front cover Loosen 1 t...

Page 182: ...n 3 LH 3 RH tapping screws of front inner cover Loosen 3 LH 3 RH tapping screws of front inner cover Loosen 1 machine screw in the middle of windshield Dismantle windshield front turn signal cover tog...

Page 183: ...he front wheel brake disc together Loosen screws at LH RH of front fender dismantle front fender Open the seat Loosen 3 bolts of rear luggage bracket dismantle it Loosen 4 bolts of front luggage compa...

Page 184: ...with finger withdraw the cover of rear luggage compartment Withdraw the rear luggage compartment Turn the tank inner cover counterclockwise a little bit dismantle it Dismantle the tank upper cover by...

Page 185: ...2 RH screws at the front upper section Loosen 2 LH 2 RH inner socket screws dismantle the keel cover Dismantle the LH RH lower cover Loosen 4 tapping screws on the top of LH RH lower cover Dismantle...

Page 186: ...pping screw in the front side Withdraw LH RH lower cver Dismantle other PP covers Dismantle the license plate Push the middle of quick plastic screw Loosen 2 screws at the rear of vehicle Withdraw the...

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GENUINE Blur 150, Service Manual

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