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Motive Power Industry Bugxter BR-150, Service Manual, Page: 33 / 75

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Motive Power Industry Bugxter BR-150 Service Manual Download Page 33

ENGINE INSPECTION 4

CYLINDER & CYLINDER HEAD INSTALLATION

• Ensure 2 line marks 

of camshaft parallel 
to cylinder head

（

refer to photo

）

• And the hole shall 

be in the top 
position

（

refer to photo

）

Line marks in

camshaft

Hole in camshaft

CYLINDER & CYLINDER HEAD INSTALLATION

• Installing camshaft 

holder

，

“EX”

mark shall face to 
exhaust valve

• Tighten 4 nuts 

crossly, lock torque 
is 2.0 kg-m

Summary of Contents for Bugxter BR-150

Page 1: ...SERVICE MANUAL Manufactured by Motive Power Industry Co Ltd...

Page 2: ...ismantle n Engine inspection n Transmission dismantle inspection n Carburetor adjustment Chapter 3 Chassis inspection n Operation n Steering inspection adjustment n Brake inspection adjustment n Insta...

Page 3: ...SERVICE MANUAL Manufactured by Motive Power Industry Co Ltd...

Page 4: ...ismantle n Engine inspection n Transmission dismantle inspection n Carburetor adjustment Chapter 3 Chassis inspection n Operation n Steering inspection adjustment n Brake inspection adjustment n Insta...

Page 5: ...oncern how to maintain in detail repair change parts troubleshoot and reassemble etc At every important section we illustrate by assembly explosion diagrams and photographs if necessary please check t...

Page 6: ...RSONS 110KG BRAKE SYSTEM VEHICLT PERFORMANCE FRONT DISC BRAKE TOP SPEED 70KM H REAR DRUM BRAKE FUEL CONSUMPTION 25KM L LIGHT CLIMBING ABILITY 25 HEAD LIGHT H L 12V 35W 35W 2 TAIL LIGHT 12V 5W CYCLE 4...

Page 7: ...tling please wash all parts necessary for checking and grease all contact surface when reassembling 5 Use grease recommended by P G O 6 When removing battery please dismantle the negative pole first w...

Page 8: ...tch outer 1 12 5 0 6 0 9 Nut driven plate 1 12 5 0 6 0 10 Nut driving plate 1 12 5 0 6 0 11 Spark plug 1 10 1 2 1 3 12 Nut drive clutch 1 22 9 0 10 0 Left thread 13 Screw inner chain adjuster 1 6 0 4...

Page 9: ...suspension arm 2 8 3 0 8 Tie rod nut 4 10 5 0 9 Roll cage bar 6 8 4 0 10 Rear swing arm lower 2 12 6 0 11 Engine hanger with frame 2 10 3 5 4 5 12 Engine hanger with engine 1 10 3 5 4 5 13 Rear absorb...

Page 10: ...I C A L I C A L Steering joint rod Check looseness Adjust it if required I I I Absorber Leaking and function check I I I I Parking Function check or replace it if required I I I I I I I Nuts bolts fa...

Page 11: ...LOCKING TORQUE 1 1 2 3 4 5 6 7 8...

Page 12: ...LOCKING TORQUE 2 9 10 11 12 13 14 15...

Page 13: ...LOCKING TORQUE 3 16 17 18 19 20 21...

Page 14: ...ENGINE DISMANTLE 1 Engine Dismantle Loosen the bolt of connecting rod with upper swing arm Engine Dismantle Dismantle the nut Withdraw the engine from the upper swing arm...

Page 15: ...ENGINE DISMANTLE 2 Engine Dismantle Loosen the bolt of upper swing arm with the lower swing arm rear Engine Dismantle Loosen 2 bolts of oil cooler...

Page 16: ...DISMANTLE 3 OP of Replacing Rear Engine Hanger Collar for BR150 1 Loosen the lock nut 1 OP of Replacing Rear Engine Hanger Bush for BR150 2 3 2 Dismantle the bolt 3 Loosen the nut Lock torque is 11 0...

Page 17: ...ENGINE DISMANTLE 4 Muffler DISASSEMBLY 1 Loosen 2 bolts of muffler with cylinder head Muffler DISASSEMBLY 2 Loosen 1 hexagon bolt of muffler with LH cover Remove muffler...

Page 18: ...NTLE 5 Air cleaner removal 1 Loosen 9 hexagon flange screws of LH cover Remove engine LH cover Air cleaner removal 2 Outside end is sponge clean it if necessary Inside end is paper element replace it...

Page 19: ...ENGINE DISMANTLE 6 MAGNETO DISASSEMBLY 1 Loosen 2 hexagon screws and 2 C R recess pan hd tapping screws Remove fan cover MAGNETO DISASSEMBLY 2 Loosen 4 hexagon screws of cooling fan Remove cooling fan...

Page 20: ...MANTLE 7 MAGNETO DISASSEMBLY 3 Loosen nut of magneto When installing tighten lock torque is 5 5 kg m MAGNETO DISASSEMBLY 4 Pull out the magneto with special tool part no S620402G01A tool should be tig...

Page 21: ...8 MAGNETO DISASSEMBLY 5 Loosen 3 hexagon screws of stator Remove stator Stator flywheel cooling fan CYLINDER AND HEAD DISASSEMBLY 1 Loosen 1 hexagon screw and 2 tapping screws of cooling cowl 2 Remov...

Page 22: ...DISASSEMBLY 3 Loosen 4 hexagon screws of cylinder head cover Remove cylinder head cover assy CYLINDER AND HEAD DISASSEMBLY 4 Loosen 1 hexagon screw of chain adjuster Loosen 2 hexagon screws fixed in...

Page 23: ...EAD DISASSEMBLY 5 Loosen 4 nuts of camshaft holder Loosen 2 hexagon screw of cylinder head Remove camshaft holder camshaft and cylinder head CYLINDER AND HEAD DISASSEMBLY 6 Remove cam chain guide comp...

Page 24: ...Y 1 Loosen 8 hexagon screws of RH crankcase cover Remove RH crankcase cover CYLINDER AND HEAD DISASSEMBLY 2 Loosen nut of one way clutch with special tool part no S620401G015 Remove one way clutch com...

Page 25: ...INE DISMANTLE 12 OIL PUMP DISASSEMBLY 1 Loosen 2 C R recess screws of oil separator Remove oil separator OIL PUMP DISASSEMBLY 2 Loosen nut of oil pump driving gear Remove oil pump driving gear and cha...

Page 26: ...ENGINE DISMANTLE 13 OIL PUMP DISASSEMBLY 3 Loosen 2 hexagon screws of oil pump Remove oil pump CRANKSHAFT DISASSEMBLY 1 Loosen 2 hexagon screws of RH crankcase Remove RH crankcase with plastic hammer...

Page 27: ...ENGINE DISMANTLE 14 CRANKSHAFT DISASSEMBLY 2 Pull out crankshaft from LH crankcase Remove camshaft chain CRANKSHAFT INSTALLATION 1 Put camshaft chain in LH crankcase...

Page 28: ...shaft in LH crankcase 0 10 0 03 Swingness of the crank shaft journal 0 04 Clearance of connecting rod big end vertical direction 0 55 0 10 0 35 Clearance of connecting rod big end axle direction Limit...

Page 29: ...ION 3 Assemble RH crankcase into crankshaft Tight 2 hexagon screws torque is1 0kg m Replace the oil seal and packing CRANKSHAFT INSTALLATION 4 To avoid the oil seal detected shall assemble the oil sea...

Page 30: ...ANGE NUT 5VALVE EXHAUST 17RETAIER VALVE SPRING 29CYL HEAD COVER COMP 6VALVE INLET 18COTTER VALVE 30CYL HEAD COVER 7GASKET HEAD CYL 19 CAM SHAFT ASSY 31 PACKING CYL HEAD COVER 8LOCK PIN D10 14L 20 SHAF...

Page 31: ...vex part IN 26 625 26 23 EX 26 53 26 13 Inner diameter of rocker arm shaft IN 10 00 10 015 10 10 EX 10 00 10 015 10 10 Outer diameter of rocker arm shaft IN 9 972 9 987 9 91 EX 9 972 9 987 9 91 Valve...

Page 32: ...ection Valve train Valve clearance IN 0 08mm EX 0 08mm CYLINDER CYLINDER HEAD INSTALLATION Installing camshaft the valve timing shall be adjusted Rotate the magneto T make to RH crankcase allied posit...

Page 33: ...t parallel to cylinder head refer to photo And the hole shall be in the top position refer to photo Line marks in camshaft Hole in camshaft CYLINDER CYLINDER HEAD INSTALLATION Installing camshaft hold...

Page 34: ...lubricated System by pump splash Make sure the oil path is through clean Engine inspection Intake Exhaust system Inspect element per 1 000km replace it if necessary If the vehicle is often used in du...

Page 35: ...1 is well locked with the cylinder head to avoid leakage Lock muffler at 4 with engine LH cover Engine inspection Engine oil cooler Always clean the cooling fin to increase the cooling efficiency Repl...

Page 36: ...iston and Piston ring lst ring 0 10 2nd ring 0 10 Clearance of cutting section lst ring 0 50 2nd ring 0 50 Piston outer diameter 57 475 57 490 57 400 Measuring location of piston outer dia 5 mm from t...

Page 37: ...NSPECTION 8 Engine inspection Cylinder CYLINDER CYLINDER HEAD INSTALLATION Notice the marks upon piston IN mark shall in the intake direction EX mark shall in the exhaust direction IN To intake EX To...

Page 38: ...rding to marks 1st ring is marked 1R 2nd ring is marked RN The marks shall face to piston head 1st ring 1R 2nd ring RN CYLINDER CYLINDER HEAD INSTALLATION The opening end of piston rings shall face to...

Page 39: ...TIOM 1 CVT TRANSMISSION DISASSEMBLY 1 Loosen 9 hexagon flange screws of LH cover Remove engine LH cover Loosen nuts of driving pulley and clutch outer When installing nuts tighten torque is 5 5 kg m C...

Page 40: ...ing plate 24 011 24 052 24 10 The outer dia Of boss movable Driving plate 23 960 23 974 23 940 Belt width 20 0 21 0 19 0 Clutch lining thickness 3 1 5 Clutch outer inner diameter 125 0 125 2 125 5 Dri...

Page 41: ...TLE INSPECTIOM 3 CVT inspection data Belt width Roller dia Lining thickness Outer dia Frt pulley dia Spring length Engine inspection Transmission System Primary CVT Final reduction gear PV CVT clutch...

Page 42: ...ANSMISSION DISMANTLE INSPECTIOM 4 Engine inspection Transmission System Reverse gear is engaged 4 5 4 Dismantle 2 bolts 5 Push the reverse box to right hand approximately 10 mm Driving chain dismantle...

Page 43: ...nut 10 Lock torque is 2 5 to 3 0 kg m And make sure part 9 can rotate in pivot 17 7 Replace the collar 17 8 Assemble the engine mount link by reverse step 1 to 6 Driving chain dismantle 2 And make su...

Page 44: ...TRANSMISSION DISMANTLE INSPECTIOM 6 9 Adjust the chain slack by this nut Driving chain dismantle 4 10 Lock the lower nuts by 5 0 to 6 0 kg m 10 Driving chain dismantle 5...

Page 45: ...TRANSMISSION DISMANTLE INSPECTIOM 7 When installing the lock pin of driving keep the close end forward the Drive direction Close end Open end Driving chain dismantle 6...

Page 46: ...e air screw to adjust the air fuel ratio 3 Auto by start function check the carburetor is equipped with auto by start to improve the engine cold start it shall be warm after the engine has been starti...

Page 47: ...TION CARBURETOR PRINCIPLE To Manifold Fuel level Intake air Various pressure Functions 1 Fuel atomization 2 Air Fuel Ratio 3 Engine Output Engine inspection Carburetor Assembly Idle adjustment stop sc...

Page 48: ...troke engine more opening turns of PS A F ratio is richer 2 Clean the jets and body with compressed air MAIN SYSTEM MJ NJ JN Body MAJ Throttle valve Vacuum piston Remarks 1 No leakage of vacuum piston...

Page 49: ...CARBURETOR DISMANTLE INSPECTION 3 pilot screw assy 4 vacuum piston assy 5 jet needle 8 cover 13 main jet 14 pilot jet 15 float 19 by start cap 20 auto by start...

Page 50: ...3 1 OPERATION 1 OPERATION LAYOUT...

Page 51: ...ing any button during 20 sec it will escape to main menu automatically Button operation Situation Button Setting Main menu MODE to next parameter 2 escape switch display RESET digital 1 2 no function...

Page 52: ...STEERING INSPECTION ADJUSTMENT 1 3 2 Steering Inspection Adjustment Dismantle Lock tight the bolts of steering handle Torque 0 5 kg m...

Page 53: ...STEERING INSPECTION ADJUSTMENT 2 Steering Inspection Inspect the coupling joint knuckle Maintenance Add grease into upper suspension arm per 10 000km from grease valve...

Page 54: ...ADJUSTMENT 3 Inspection Inspect the absorber function check and oil leakage check Inspection Lock tight the nut of tie rod with steering spindle support Inspect the clearance of tie rod with the steer...

Page 55: ...ON ADJUSTMENT 4 Steering Inspection Adjustment Lock tight the bolt Add grease into lower suspension arm per 10 000km Steering Inspection Adjustment Lock tight the bolt Add grease into lower suspension...

Page 56: ...on Adjustment When checking the alignment of front wheel Keep the vehicle at flat surface From the top view wake sure C D and A B 1 8 1 4 Front Steering Inspection Adjustment Adjusting the toe in Loos...

Page 57: ...Brake inspection and adjustment Brake system Brake cylinder Adjust the hand brake to rear brake disk cable if necessary Hand Park Front end Loosen nut 1 Adjust bolt 2 out to increase park power Lock...

Page 58: ...Hand Park Caliper end Loosen nut 1 Adjust the cable to front to increase hand brake power Lock tight nut 2 1 2 Brake inspection Check the brake fluid level add it when below MIN level Check the functi...

Page 59: ...e the brake hose the brake power will decrease the safety sensor will lose function Bleed the air from the screw of caliper Brake inspection and adjustment Adjusting braking power Loosen nut Adjust th...

Page 60: ...CTION ADJUSTMENT 4 Brake inspection and adjustment Make sure there is not any fluid leakage from the bolt Brake inspection and adjustment Specification of front brake caliper Replace the pad of disk i...

Page 61: ...BRAKE INSPECTION ADJUSTMENT 5 Brake inspection and adjustment Specification of rear brake caliper Replace the pad of disk if necessary Withdraw the cap Dismantle the 4 nuts Wheel dismantle 1...

Page 62: ...BRAKE INSPECTION ADJUSTMENT 6 You don t need to dismantle the wheel nut Wheel dismantle 2 Withdraw the wheel Wheel dismantle 3...

Page 63: ...BRAKE INSPECTION ADJUSTMENT 7 Withdraw the cotter pin Dismantle the nut Withdraw the hub Wheel dismantle 4...

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Page 68: ...ELECTRIC INSPECTION 1 4 Electric inspection Main switch Headlamp switch Parking button 12V power supply Horn button Signal lamp switch 1 Operation panel Panel terminal wiring Panel back photo...

Page 69: ...ELECTRIC INSPECTION 2 Panel terminal wiring Panel back 2 Parts location speedometer Signal lamp...

Page 70: ...ELECTRIC INSPECTION 3 2 Parts location Relay regulator resistor Ignition coil 2 Parts location battery Starting safety device...

Page 71: ...ELECTRIC INSPECTION 4 2 Parts location Head lamp CDI Optional device Reverse shifting safety device Parking sensor...

Page 72: ...CTION 5 Electric inspection Check the coupling prevent losing connection of the terminals Spray some anti dust wax if necessary Electric inspection Head lamp choke controller Flasher relay starting mo...

Page 73: ...keep in idle speed turn on the headlamp Disconnect the red white wire Use the pocket tester to measure the charging current as photo shown 1 Black to battery 2 Red to wire harness Adjust the idle spee...

Page 74: ...ELECTRIC INSPECTION 7 3 Ignition Ignition wiring For CDI unit you don t have to adjust the ignition timing...

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