Motive Power Industry BLUR 150 Service Manual Download

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Dismantle 1 tapping 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 license plate.

Summary of Contents for BLUR 150

Page 1: ......

Page 2: ...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 3: ...ition timing 48 8 Throttle cables adjustment 48 9 Idle adjustment 49 10 Front Rear brake adjustment 49 11 Tire 50 4 Dismantling maintaining repairing and assembling operation 51 A Plastic parts 51 B B...

Page 4: ...ystem 131 5 Starting system 132 5 BLUR 220 characteristics dismantle inspection 134 1 Engine dismantling 134 2 engine inspection 144 3 Electric system 146 4 Maintenance 153 5 Engine Management System...

Page 5: ...G BRA KE REAR DISK 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...

Page 6: ...4 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 HORN DC 12V FUEL 92 UNL...

Page 7: ...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 steering...

Page 8: ...er 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 9: ...1 6 0 4 0 6 5 Screw chain extensioner 2 6 0 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 N...

Page 10: ...bolt engine 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...

Page 11: ...stroke motorcycle oil or SAE15W40 Auto Separated Lubrication BLUR 150 Total 1000 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 12: ...C Chassis appearance 1 Apply oil 1 2 1 2 3 4 5 6 7 8 2 Apply grease 3 4 5 6 7 8 8...

Page 13: ...D Wheel bearing Final transmission mechanism gear oil Speedometer gear clean grease 9...

Page 14: ...ng and function check A A A Main Side Stand 4T Function check or replace it if required I I I I Nuts bolts fasteners 4T Tighten it if required I L I L I L Battery 4T Recharge the battery it required C...

Page 15: ...2 Check the fluid level often Refill if necessary 3 Change the oil seal of main cylinder and caliper every two years 4 Change the brake fluid hose every four years 11...

Page 16: ...nder body has sand hole bad action of auto choke air trapped in intake manifold wrong ignition timing bad adjustment of carburetor s fuel adjusting screw carburetor fuel level too high malfunction of...

Page 17: ...eed valve malfunction 2T engine Clean the carburetor clean the dirt specification is not correct Start engine and open throttle Gradually check and inspect Engine can rotate up Engine can t rotate Up...

Page 18: ...ombustion 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 Oil level is normal Oil level is...

Page 19: ...y CDI out of order AC magnet abnormal ignition 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 i...

Page 20: ...level is too low fuel pipe fuel filter is blocked fuel pump faulty clean and wash it Check and adjust Check ignition timing correct Not correct Check fuel pump Fuel supply system good unsmoothly Check...

Page 21: ...ut 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 pul...

Page 22: ...cracked Handlebar operates heavily Front and rear wheel swings Handlebar astrayed to one direction Trouble condition Damper is too soft Damper is too hard Damper has abnormal noise Trouble condition...

Page 23: ...g 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 lamp...

Page 24: ...mal electric plug dropped off wrong connection wire broken or short circuit normal Lamp dims light Not flash not light Remove the fuel gauge Moving float up and Down to check The needle movement Indic...

Page 25: ...side the fuel gauge electric plug drop off or loose wire broken or short circuit Check and adjust Trouble condition Turn signal lamp on Check wiring of battery normal No motion Indicator moves good Mo...

Page 26: ...h worn out coil broken or short circuit starting motor wire broken circuit plug is loose drop off main wiring broken Check and adjust Check brake switch Turn signal lamp No to check wiring Of battery...

Page 27: ...rmal Lamp dims no Flashing no light Starting Connect motor to the starting motor to Battery directly Running normal Runing slowly Kick the kickstarter lever Easy to kick Difficult to kick Trouble cond...

Page 28: ...ts or sockets defective CDI Defective ignition coil 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 CDI...

Page 29: ...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 Between chassis and The red...

Page 30: ...diagnoses or reparation Diagnosis assist 1 Make sure of no engine related trouble records 2 Make sure of any offered troubles 3 Follow the said procedure to complete inspections and find no any uncon...

Page 31: ...tor not running or slowly running No Repeat the said step 2 Engine running but start up failing during start up General trouble location 1 Oil tank empty 2 Fuel pump 3 RPM sensor 4 Ignition coils 5 En...

Page 32: ...high voltage flash blue white No Repair the ignition system Yes Correct circuits or replace the sensor No Next step 3 Press the engine temperature sensor connector and start the engine check if the e...

Page 33: ...the engine successfully started Or install a series connected resistor 2500 in lieu of the engine temperature sensor at the engine temperature sensor connector Observe if the engine is successfully st...

Page 34: ...mable to specifications No Adjust or change the spark plug Yes Correct circuits or replace the sensor 5 Press the engine temperature sensor connector and start the engine check if the engine is succes...

Page 35: ...change Yes Cleaning 4 Check the air throttle and the idle air bypass for any carbon deposition No Next step Yes Replace the defective nozzle 5 Disassemble the nozzle and check any leakage or jam in t...

Page 36: ...ir bypass for any carbon deposition No Next step Yes Correct circuits or replace any sensor 4 Press the engine temperature sensor connector and start the engine to check any instability of the idle sp...

Page 37: ...ss for any carbon deposition No Next step Yes Correct circuits or replace any sensor 4 Press the engine temperature sensor connector and start the engine to check any instability of the idle speed dur...

Page 38: ...tep 2 Check if the engine s output power is increased with the load applied use the EMS diagnosis tester to check any change in the ignition advance angle duration of fuel injection and air input No R...

Page 39: ...eakage No Next step Yes Clean relevant parts 3 Remove the ISC and check the air throttle the ISCand the idle air bypass for any carbon deposition No Next step Yes Correct circuits or replace any senso...

Page 40: ...or replacement Yes Clean relevant parts 4 Remove the ISC and check the air throttle the ISCand the idle air bypass for any carbon deposition No Next step Yes Next step 5 Check the inlet pressure senso...

Page 41: ...ement Yes Clean relevant parts 4 Remove the ISC and check the air throttle the ISCand the idle air bypass for any carbon deposition No Next step Yes Next step 5 Check the inlet pressure sensor the air...

Page 42: ...No Repair the ignition system Yes Next step 5 Check the spark plug in the cylinder and its model and gap conformable to specifications No Adjustment or replacement Yes Clean relevant parts 6 Remove th...

Page 43: ...checking 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 Fro...

Page 44: ...n 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 brake...

Page 45: ...age 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 Tra...

Page 46: ...k 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 Compress...

Page 47: ...e 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 Lo...

Page 48: ...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 ele...

Page 49: ...move air 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 BLUR 220 Note Do not start the engine when the ai...

Page 50: ...cking torque 1 8kg m Draining Filling Bolt Note Be sure the crankcase tire or wheel are cleaned if there is grease oil on it 5 Spark plug 1 Remove spark plug 2 Check the spark plug electrode and check...

Page 51: ...g 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 head...

Page 52: ...gage compartment 2 Remove right body cover 3 Remove the fan case 4 Check with ignition timing lamp keep the engine running at 1 700 100 r p m the checking mark should lay in 30 apart From F mark 5 ign...

Page 53: ...ocedure 10 front Rear brake adjustment 1 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 br...

Page 54: ...t for steering riding braking performance and safety c Never carry any parcel unfastened d Load the heaviest parcel on the center of vehicle balancing the weight on both sides e Beware of the weight l...

Page 55: ...e the plastic parts according to above figure sequence by sub assembly especially pay attention to followings Before dismantle front fender dismantle the front wheel assy First BLUR150 SS220I Windshie...

Page 56: ...he 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 tap...

Page 57: ...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 toget...

Page 58: ...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 compart...

Page 59: ...th 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 re...

Page 60: ...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 qu...

Page 61: ...ing 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 l...

Page 62: ...ssembling 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 transm...

Page 63: ...1 Lubrication System 59...

Page 64: ...f 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 s...

Page 65: ...t 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 installatio...

Page 66: ...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 imprope...

Page 67: ...or 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 R...

Page 68: ...4 Drive pulley starter clutch driven pulley A Troubleshooting B Measurement data C Driving pulley D Starter E Clutch driven pulley 64...

Page 69: ...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 The...

Page 70: ...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 66...

Page 71: ...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 brake...

Page 72: ...t rubber 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 7 Disassemble slide driving plate set 1 Remove bush of slide...

Page 73: ...ition 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 driv...

Page 74: ...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 st...

Page 75: ...e clutch follows the opposite procedure of dismantling Locking torque M12 4 0 5 5kg m 3 Checking clutch dismantling tool a Check clutch driving face Check clutch cover about its wearing condition And...

Page 76: ...riving plate sets And measure outer diameter zlimit of use change it above 33 95mm e Check wearing condition of slide driven plate And measure its Inner diameter zlimit of use change it above 34 00mm...

Page 77: ...3 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 78: ...h 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 79: ...er 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 80: ...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 2 Turn the flywheel to make the T mark pin c...

Page 81: ...gasket 8 Remove cam chain guide Notice Not to injure the contact Surface of the cylinder Avoid any object dropping info the engine Further dismantling Use the valve contracting tool to remove valve pi...

Page 82: ...d 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 pi...

Page 83: ...rmal 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 c...

Page 84: ...carbon in the groove of the Don t make piston ring worn out or damaged piston ring c PISTON OUTER DIA MEASUREMENT 1 Measuring location Perpendicular to the piston pin hole down to 5mm 150CC form the p...

Page 85: ...position of the inner dia in X or Y direction d Checking the flatness of cylinder contact Limit of use Roundness change it when above 0 005mm Cylindrility change it when above 0 005mm surface Limit of...

Page 86: ...n 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 rin...

Page 87: ...7 A C Generator A Dismantling AC generator B Installing AC generator 83...

Page 88: ...tle 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 electri...

Page 89: ...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 85...

Page 90: ...ion mechanism D Assemble the final transmission mechanism A Troubleshooting zEngine can be started but the vehicle doesn t move 1 Gear worn out or cracked 2 Gear burnt out zNoise occur when running 1...

Page 91: ...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 87...

Page 92: ...ve 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 15...

Page 93: ...tion 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 locki...

Page 94: ...9 Crankcase Crankshaft A Disassembling diagram B Troubleshooting C Data D Remove crankcase and crankshaft E Check crankshaft F Assemble the crankcase 90...

Page 95: ...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 91...

Page 96: ...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 Eng...

Page 97: ...the crankshaft journal Limit of use A B Change it when above 0 1mm Change it when above 0 1mm B A 3 Check the looseness of crankshaft bearing If it is loosen replace to a new one F Assemble crankcase...

Page 98: ...tling 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 J...

Page 99: ...esent on the downstream side of the venturi A Negative pressure is admitted into the diaphragm chamber d through an orifice e provided in the piston valvec Rising negative pressure overcomes the sprin...

Page 100: ...ed by the pilot screw g and sprayed into the main bore through the pilot outlet port i COASTING ENRICHMENT SYSTEM The coasting enrichment system is included in the slow system At the normal running op...

Page 101: ...97...

Page 102: ...he needle jet g mixes with the air admitted through the main air jet h and forms an emulsion The emulsified fuel then passes through the clearance between the needle jet g and jet needle i and is disc...

Page 103: ...content reaches upper part of The fuel pipe and mixes again with the air coming through a passage extending from main bore h The two succesive mixings of fuel with air are such that proper fuel air mi...

Page 104: ...lve d pushes up against the valve seat When this occurs no fuel enters the float chambere As the fuel level falls the float clowers and the needle valve d unseats itself admitting fuel into the float...

Page 105: ...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 throttle...

Page 106: ...use han dling and storage y Clean all jets with a spray type carburetor cleaner and dry them using compressed air y Clean all circuits of the carburetor thoroughly not just the perceived problem area...

Page 107: ...has been connected NOTE To inspect the function check for change of temperature from the cold condition CAUTION 78 FLOAT HEIGHT ADJUSTMENT To check the float height turn the carburetor upside down Mea...

Page 108: ...eaner blocked 2 Mixed air is too dilute in the idle system zSparking unsteady while increasing speed 1 Ignition system malfunction 2 Air mixture is too dilute zDifficult to start Ignition off Unstable...

Page 109: ...fuel volume adjusting screws Note Fuel volume adjusting screws have been set up properly before sale thus there is no need for self adjustment However when dismantling a record of the turning loop has...

Page 110: ...or Cleaning Note zAvoid any damage on the jets and the fuel adjusting screws zBefore dismantling record the number of turning loops zNo screwing in movement by force to avoid any damages Note When the...

Page 111: ...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 wh...

Page 112: ...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 dismant...

Page 113: ...n 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 procedur...

Page 114: ...heel 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 grea...

Page 115: ...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 zHorizontal direction Change a new one when above 2 0m...

Page 116: ...ntainer 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 tim...

Page 117: ...ing 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 side 95 CC BLUR 150 220 Tube fixing scre...

Page 118: ...mble 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 thickne...

Page 119: ...justment 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 op...

Page 120: ...emove 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 ve...

Page 121: ...1 Brake pad inspection for BLUR 150 117...

Page 122: ...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 150 220 118...

Page 123: ...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 crooke...

Page 124: ...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 r...

Page 125: ...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 C...

Page 126: ...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 yCurrency is unstable 1 The wiring of batter connection is not...

Page 127: ...attery 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 150 220...

Page 128: ...y 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 Notice...

Page 129: ...g 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 MIN 1...

Page 130: ...roduced 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 HANDLING BATTERY...

Page 131: ...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 thereaft...

Page 132: ...e battery voltage If the voltage reading is less than the 12 0V recharge the battery with a battery charger y When recharging the battery remove the battery from the motorcycle y Practice the standard...

Page 133: ...3 Recharge system A Recharge system diagram for BLUR 150 129...

Page 134: ...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 b...

Page 135: ...g 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 faile...

Page 136: ...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 132...

Page 137: ...tion 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 cable...

Page 138: ...gine 2 take off engine assembly Front section muffler 1 dismantle 2 castle nuts 2 take off front section oil cooler 1 loosen 2 bolts remark there are 2 washers 2 dismantle the oil cooler Second Air In...

Page 139: ...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 lower cooling cowl 135...

Page 140: ...der head cover 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 Recover the chain tensioner 1 di...

Page 141: ...holder 1 loosen 4 nuts washers 2 dismantle the holder 3 dismantle 2 lock pins 4 dismantle the camshaft Cylinder head 1 loosen 2 hexagon bolts 2 dismantle cylinder head 3 dismantle 2 lock pins 4 take...

Page 142: ...nder 3 dismantle 2 lock pins 4 take off the packing 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 cover th...

Page 143: ...he engine lower hanger Cooling fan 1 loosen 4 bolts 2 dismantle the fan Generator outer 1 Loosen 1 nut washer 2 use special tool turn the outer counterclockwise lock the inner bolt clockwise 3 dismant...

Page 144: ...4 Generator stator 1 loosen 2 bolts washers of pulser 2 dismantle the bracket of pulser 3 loosen 3 socket bolt 3 dismantle the stator Starting motor 1 loosen 2 hexagon bolts 2 dismantle starting moto...

Page 145: ...l leaking Starting idle gear 1 dismantle the shaft 2 dismantle the body One way Clutch 1 loosen the nut washer with special tool 2 dismantle the one way clutch Attention 1 the thread of nut is left ha...

Page 146: ...pump 1 dismantle E clip washer 2 dismantle the sprocket chain 3 dismantle the sprocket of crankshaft Oil pump 1 loosen 2 bolts 2 dismantle oil pump body Attention There is a lock pin in the shaft of...

Page 147: ...g Attention Be careful of the surface don t defect it to avoid oil leaking Crankshaft 1 dismantle the crankshaft assembly including a ball bearing in the left side 2 take off the timing chain Attentio...

Page 148: ...limit mm Inspection data Item standard mm Camshaft valves Standard mm Using limit mm Clearance between adjuster tapped Screw and valve stem Before warm up IN EX 0 08 Compression pressure throttle open...

Page 149: ...0 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 Piston...

Page 150: ...is transistor ignition Transistor Ignition System z Transistor a kind of semi conductor that can control electric current has the switch function z Apply transistor to engine ignition control called...

Page 151: ...f Transistor ignition z Digital ignition controller z Ignition coil z DC generator with longer pulse flange z TPS Throttle Position Sensor optional part of Carburetor Digital ignition controller ACG I...

Page 152: ...em parts Traditional CDI BLUR 220 transistor 1 2 3 4 5 TPS no yes Digital controller no yes CDI yes no ACG flange shorter longer Ignition coil Less coils More coils Traditional C D I CDI Digital contr...

Page 153: ...e carburetor diagram zWhen engine speed 1000rpm the digital controller permits the relay to conduct the circuit To headlamp choke RPM 1000 OFF ON Control timing relay Headlamp switch 12V from battery...

Page 154: ...5 Charging system diagram 3 phase DC generator Regula tor yellow yellow yellow battery ground ground Charging to battery Battery feedback voltage 150...

Page 155: ...6 Fuse wire white white Main fuse layout relay fuse layout reserved fuse layout Red white Red Red white Red black 151...

Page 156: ...7 BLUR 220 Electric parts relay fuse 15A battery Seat lamp controller Digital controller diode Remarks If dismantle the battery engine will cease fire 152...

Page 157: ...lace 1000cc Total 1400cc Replace 800cc Total 1000cc Gear oil Replace 110cc Total 130cc Replace 90cc Total 110cc Oil filter 2 nd filter 2 nd filter Air element Wet paper bigger Wet paper CVT sponge Cir...

Page 158: ...9 BLUR 220 Specified engine oil synthetic 1000ml 154...

Page 159: ...10 Engine oil gear oil Drain of engine oil drain of gear oil Gear oil filling Replace 110cc total 130cc 155...

Page 160: ...il filling gauge replacement 1000cc total 1400cc Check the oil level 1 park in flat area 2 keep in idle for 3 minutes 3 cold down 3 minutes 4 take off the gauge 5 when lower the lowest limit add oil t...

Page 161: ...12 Replace the 2nd oil filter 1 dismantle the right lower cover 2 replace the filter keep the surface clean apply grease to the O ring before installing 157...

Page 162: ...13 Air element 1 loosen 8 screws 2 dismantle the cover Take off the element Don t forget to install the black rubber packing back to the element 158...

Page 163: ...14 CVT sponge Clean with compressed air or replace a new one 1 loosen 3 bolts 2 take off the sponge 159...

Page 164: ...15 CVT dismantle 1 loosen the outer bolts 2 dismantle the cover 3 loosen 2 hexagon nuts Don t miss the lock pin falling into the crankcase 160...

Page 165: ...16 CVT install notes 1 keep the words of belt facing to operator 2 push the belt to bottom 3 lock the nuts Rotation direction 161...

Page 166: ...17 Spark plug Dismantle the right lower cover Loosen with the special tool Spark plug C7E carburetor or CR7E EMS model 162...

Page 167: ...18 Ignition coil Dismantle the right lower cover You can see the ignition coil clearly 163...

Page 168: ...19 Front brake system Service data tire pressure 2 0 kg cm2 using limit of Disk thickness 3 5mm using limit of pad thickness to groove bottom 164...

Page 169: ...20 Replace the front pads 2 1 3 dismantle 1 dismantle clip 2 take off the pin 3 take off the yoke 4 dismantle the pads install reverse procedure of dismantle 165...

Page 170: ...21 Front brake system Service data tire pressure 2 0 kg cm2 using limit of Disk thickness 3 5mm using limit of pad thickness to groove bottom 166...

Page 171: ...22 Replace the rear pads dismantle 1 dismantle clip 2 take off the pin 3 take off the yoke 4 dismantle the pads install reverse procedure of dismantle 1 2 3 167...

Page 172: ...5 Engine Management System EMS 168...

Page 173: ...EMS index EMS units EMS diagnostic 169...

Page 174: ...Feature of PGO 2nd stage EMS feature 1 small light 2 integrity 3 accuracy 4 simple 170...

Page 175: ...A ECU Control unit injector coil Fuel supply ignition Engine temperature sensor Throttle position sensor Intake pressure sensor Crank speed sensor 5 sensors Oxygen sensor ISC Idle speed control 2nd ai...

Page 176: ...EMS structure B ECU Oxygen sensor Engine temperature sensor Throttle position sensor Intake pressure sensor injector ISC coil Spark plug Crank speed sensor Electric control unit 172...

Page 177: ...EMS units 173...

Page 178: ...Throttle position sensor Intake pressure sensor injector Idle Speed Controller 174...

Page 179: ...FUEL PUMP COMP COIL COMP IGNITION O2 SENSOR TE SENSOR crankshaft ANGLE SENSOR 175...

Page 180: ...ECU SAFETY SENSOR SIDE STAND AIAC ASSY SOLENOID 176...

Page 181: ...Important PIN no of ECU ECU PIN 1 PIN 18 PIN 19 PIN 36 PIN 177...

Page 182: ...U Important PIN 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 Control pole of coil 19 Input vo...

Page 183: ...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 179...

Page 184: ...Engine temperature sensor function induct engine oil temperature then ECU knows engine is cold or hot theory different temperature vary resistance 180...

Page 185: ...Measure engine temperature sensor T resistance K 20 18 800 K 40 1 136 K 100 0 155 K usually 1 5 5 5 K 181...

Page 186: ...Throttle position sensor TPS function induct throttle angle provides the road load condition to ECU theory angle changes resistance changes 182...

Page 187: ...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 183...

Page 188: ...Intake pressure sensor function induct intake air pressure ECU judge intake or compress stroke to decide injection ignition theory different pressure outputs different resistance 184...

Page 189: ...Intake pressure sensor 0 0 1 0 2 0 3 0 4 0 5 0 0 50 100 150 kPa Vcc V Pu output 5V G B output Gr ground G B Gr Press KPa output V 13 3KPa 0 5V 120 KPa 3 4V 185...

Page 190: ...Intake pressure sensor average resistance in ambient wire R K Pu Gr 2 4K G B Gr 2 4K Pu output 5V G B output Gr ground 186...

Page 191: ...Oxygen sensor function induct the A F ratio feedback to ECU and decide the injection time modify to the best 14 7 ratio others there is heater inside help it reach the working temperature quickly 187...

Page 192: ...Oxygen sensor W heater 12V 2 couple 8 Gr ground B output 188...

Page 193: ...injector function inject the gas mixed with air theory control the opening time interval to decide the gas amount 189...

Page 194: ...injector time msec Gas amou nt feeding R B output 12V Br W output 12V each terminal virus ground is 12V injecting 190...

Page 195: ...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 191...

Page 196: ...Fuel pump function pumping the gas to injector and keep the constant pressure as 3kgf cm2 theory the regulator keeps constant pressure regulator filter pump 192...

Page 197: ...Fuel pump R B output 12V B ground R B B voltage 12V resistance 1K 193...

Page 198: ...l down sensor function when vehicle fall down more than 65degree then EMS cut off the power and cease the engine theory there is ball mechanism inside the sensor act by gravity and conduct the wiring...

Page 199: ...Fall down sensor power degree output ground OFF any OFF ON 65 ON ON 65 OFF to recover the sensor function after fall down 1 turn OFF the key 2 turn ON the key O input 12V Bl W output B grounding 195...

Page 200: ...ISC Idle Speed Control W ISC A R B ISC B G ISC B Gr ISC A ISC unit R A A 80 B B 80 196...

Page 201: ...is at idle ECU refer the sensors and decide how much air is required then tell the ISC to act forward or backward sample when cold engine ECU tell ISC enrich the by pass air to increase the engine sp...

Page 202: ...ISC Idle Speed Control ISC Step motor ISC By pass air Throttle body engine Throttle valve Air flow 198...

Page 203: ...nitialization timing 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 204: ...ick diagnostic 2 wide open throttle turn on the key the ISC sounds da da 3 release the throttle after the ISC stop acting 4 turn off the key finish initialization Wide open ISC act Key ON Release thro...

Page 205: ...EMS fuses 7 5A 10A 5A 1A 10A 15A 201...

Page 206: ...5A 10A 15A protect the units when extra current occurs 1A Y G B protect the ECU 5A R W G B protect fuel pump injector 7 5A O G B protect ignition wiring EMS 10A O Dg protect EMS system wiring 15A R W...

Page 207: ...6 EMS diagnostic 203...

Page 208: ...Quick diagnostic part no S320840G01 name quick diagnostic 204...

Page 209: ...use quick diagnostic 1 Prepare quick diagnostic 2 Open the rubber cover beside the battery 3 Plug in the quick diagnostic 4 turn on the key 5 wait for about 8 seconds 6 observe the EMS led on dash boa...

Page 210: ...PC diagnostic PC diagnostic assy S320891G01 S320838G01 software adapter connect cable PC software KEIHIN adapter connect cable PGO vehicle RS232 or USB 206...

Page 211: ...PC diagnostic part number S320891G01 name software adapter software adapter 207...

Page 212: ...PC diagnostic part number S320838G01 name connect cable 208...

Page 213: ...ong 6 short Crankshaft position sensor Always on ECU Always off System is all right 1 long 1 short Engine temperature sensor 3 long 3 short injector 0 long 9 short Intake manifold pressure sensor 0 lo...

Page 214: ...at 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 wot EMS led on Key ON EMS le...

Page 215: ...7 EMS system Repairing tool 211...

Page 216: ...pocket tester wiring pocket tester wiring part no S905310005 212...

Page 217: ...Ignition gauge connect minimum distance 6mm Plug cap ground 213...

Page 218: ...Fuel pressure gauge fuel pressure gauge part no S905330008 214...

Page 219: ...Connect to the vehicle measure the fuel pressure standard 3kgf cm2 usage 1 dismantle the hose to injector 2 connect the gauge assembly to the pipe 3 turn on the key 4 read the pressure 215...

Page 220: ...8 General Electric units 216...

Page 221: ...BLUR 220 HELMET CASE ASSY BR ELECTRICALS COMPONENT MAIN RELAY FUEL PUMP INJECTOR RELAY DIODE luggage lighting lamp CONTROL FUSE BATTERY 12V9A HEAD LAMP CONTROL 217...

Page 222: ...Signal flasher relay LED within the leg shield cover dismantle the leg shield cover first 218...

Page 223: ...regulator within the right body cover dismantle 1 luggage comp 2 rear rack 3 body cover 219...

Page 224: ...Fuel gauge dismantle 1 middle cover below the middle cover 220...

Page 225: ...Measure the fuel gauge gray output black ground gray black F 4 10 E 80 90 221...

Page 226: ...Starting relay within the right body cover dismantle 1 luggage comp 2 middle cover 3 rear rack 4 body cover 222...

Page 227: ...EMS relays dismantle 1 luggage comp 2 middle cover 3 rear rack 4 body cover within the right body cover 223...

Page 228: ...EMS relays wiring A EMS system Dg O Gr B Bl W B fuel pump injector R W R W R B Db C headlamp O O Y W Y A B C 224...

Page 229: ...Control of relays Relay 15A theory use small current to control big current Usage fuel pump injector EMS whole system headlamp Big current Small current ECU 225...

Page 230: ...Measure the relays use the pocket tester 1 find the control coil 2 fit 12V to the control coil 3 the relay sounds ka 4 measure the resistance disconnect NG connected OK DC 12V 1 2 4 226...

Page 231: ...6 Wiring diagram Wiring diagram for BLUR 150 4V 227...

Page 232: ...Wiring diagram for BLUR SS220I 228...

Page 233: ...229...

Page 234: ...230...

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