PGO BR-500 Service Manual Download Page 224

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Replace or fix the wiring.

Check the valve position and the fluid temp. lines.

YES

go to 13

- Connect the specific tool dwg. 020481Y to the controller.

Set the switch to "ON" with switch to "RUN" and side stand raised.

YES

go to 16

- Measure voltage at

terminals 18 and 22.

18-22 = V as per table.

TEMPERATURE VOLTAGE

XXX V -10degree C

XXX V 0

XXX V +10degree C

XXX V +20degree C

XXX V +30degree C

YES

go to 21

go to 17

Measured value

5 ?0,2V

Repeat the wiring and sensor continuity checks.

YES

go to 18

Measured value = 0 V

Repeat the sensor circuit earth insulation check.

YES

go to 19

go to 20

Check the controller connection connector.

Check the controller power supply.

Replace the controller, if necessary.

Replace or fix the wiring.

Start the engine and check that voltage decreases gradually according to the air filter

box temperature increase.

NOTE: With mild weather, 30

degree

C can be easily reached after a few

minutes

of stop with idle engine.

PGO BR-500 ENGINE

P.9-77

Sucked air temperature sensor

Summary of Contents for BR-500

Page 1: ......

Page 2: ...INDEX OF TOPICS TIME CHART 12 ...

Page 3: ...confirming of the repairing The unit is hour 4 When repairing more than 2 parts if they belong to same repairing system then the longest time will represent the whole repairing time 5 When repairing more than 2 parts if they belong to different repairing system then the summation of every time will represent the whole repairing time 6 If the parts repaired are not in the table please find the near...

Page 4: ...PER FILTER 空氣濾清器紙蕊 0 25 0416 AIR CLEANER ASSY FOR TK 空氣濾清器組合 0 5 0417 CARBURETTOR ASSY 化油器總成 NA 0418 MOTOR COMP STARTER 起動馬達組合 0 5 0419 INTAKE MANIFOLD 進氣歧管 0 6 0420 COVER SECOND AIR 空氣進氣蓋 NA 0421 SECOND AIR PIPE COMP 進氣導管組合 NA 0422 AIAC COMP 空氣導入控制閥組合 NA 0423 INJECTOR 噴油嘴 0 3 0424 THROTTLE BODY 節流閥體 0 7 UNIT 單位 HOUR 小時 MOTIVE POWER INDUSTRY CO LTD KART STANDARD OPERATING TIME SCALE ENGINE KART 車輛...

Page 5: ... ASSY 單向離合器總成 2 0608 CAP TAPPET ADJUSTING HOLE 濾油網蓋 0 25 0609 GROOVE BALL BEARING 曲軸滾珠軸承 6 5 0610 CRANKCASE ASSY LH RH 左右曲軸箱組合 7 0611 CYLINDER HEAD COVER 汽缸頭蓋 1 0612 CYLINDER HEAD 汽缸頭 4 5 0613 CHAIN ADJUSTER COMP 鏈條調整器組合 0 7 0614 CAM ASSY 凸輪軸總成 1 2 0615 OIL FILTER 機油濾清器 0 25 0616 CYLINDER ASSY 汽缸組合 4 5 0617 PISTON ASSY 活塞組合 4 5 0618 CRANKSHAFT COMP 曲柄軸總成 6 0619 ENGINE OIL 引擎機油 0 3 0620 OIL SEAL LH...

Page 6: ...動踏桿組合 NA 1210 DRIVE FACE 驅動面 0 3 1211 DRIVING FACE COMP MOVABLE 活動驅動面組合 0 4 1212 SIDE PIECE 滑塊 0 4 1213 BELT V型皮帶 0 4 1214 DEEP GROOVE BALL BEARING 被驅動面軸承 0 6 1215 WEIGHT SET CLUTCH 離合器比重組 0 6 1216 OUTER BODY COMP CLUTCH 離合器外套本體組合 0 4 1217 BODY COMP DRIVE PLATE 驅動板組合 0 6 1218 BELT PULLEY COMP DRIVEN FACE 被驅動面皮帶輪組合 0 4 1219 TRANSMISSION COVER CASE 傳動箱蓋 1 5 1220 DRIVE SHAFT 驅動軸 1 3 1221 FINAL GEAR A...

Page 7: ...WATER PIPECOOLER PRESSURE VALVE AD TANK 水管水箱洩壓閥副水箱 0 5 2006 WATER TANK FOR FAN 水箱風扇 0 3 2007 SENSOR SWITCH 溫度感測開關 0 4 2008 IMPELLER WATER PUMP 水泵葉輪 1 2009 SEAL MECHANICAL 機械油封 1 2010 COVER WATER PUMP 水泵蓋 0 8 2011 GASKET WATER PUMP 水泵墊片 0 8 2012 SHAFT WATER PUMP 水泵樞軸 0 8 2013 HOSE A B WATER 冷卻水管 A B 0 3 2014 THERMOSTAT ASSY 恆溫器 0 4 2015 COVER THERMOSTAT 恆溫器蓋 0 4 2016 EARTH TERMINAL THERMO 恆溫器座 0...

Page 8: ...REVERSE PARKING LEVER ASSY 倒檔手煞車拉桿組合 0 2 B0111 DRIVING CHAIN 驅動鏈條 NA B0112 ENGINE MOUNT LINK 引擎連接座 0 3 B0113 BEARING ENGINE MOUNT LINK 引擎連接座軸承 0 2 B0114 REVERSE GEAR FIXING PLATE 倒檔固定板 0 1 B0115 REVERSE GEAR BOX COMP 倒檔齒輪箱總成 3 B0116 BEARING REVERSE GEAR BOX 倒檔齒輪箱軸承 3 5 B0117 REVERSE CABLE 倒檔導線 1 B0118 HAND PARKING CABLE 手煞車導線 0 5 B0119 DRIVING SHAFT CV JOINT 傳動軸 0 8 B0120 DIFFERENTIAL CABLE 差速導線...

Page 9: ... FRONT BRAKE DRUM 前剎車盤本體 0 3 B0208 REAR BRAKE DRUM 後剎車盤本體 0 3 B0209 REAR AXLE FIX SEAT 後輪軸固定座組合 NA B0210 FINAL DRIVE SPROCKET 後鏈輪 NA B0211 FINAL DRIVE SPROCKET HOLDER 後鏈輪固定座 NA B0212 BRAKE CYLINDER ASSY 煞車總泵組合 0 3 B0213 CALIPER COMP FRONT OR REAR 煞車夾總成前或後 0 4 B0214 BRAKE PAD SET FRONT OR REAR 煞車片組合前或後 0 5 B0215 HOSE HYDRAULIC BRAKE FRONT OR REAR 油壓剎車管前或後 0 3 B0216 PROTECTIVE COVER DRIVING CHAIN...

Page 10: ...306 COVER SPEEDOMETER 碼錶飾蓋 0 05 B0307 FUEL TANK COMPLETE 汽油箱 0 4 B0308 FUEL TUBE TUBE A OR B 汽油管 A OR B 0 2 B0309 AUTOCOCK 自動油杯 NA B0310 FUEL FILTER ASSEMBLY 汽油過濾器 0 1 B0311 OIL TANK ASSEMBLY 機油箱 NA B0312 OIL TUBE 機油管 NA B0313 THROTTLE CABLE 加油導線總成 0 3 B0314 INDUCT MAGNETO 感應磁鐵 0 1 B0315 REAR MIRROR ASSY 後視鏡總成 0 05 B0316 BRACKET 2 COUNTER INDUCT 計數器感應固定板2 0 2 B0317 BRACKET 1 COUNTER INDUCT 計數器感應固定...

Page 11: ...ING TIE ROD ASSEMBLY LH OR RH 轉向拉桿左或右 0 2 B0408 KNUCKLE LH OR RH 轉向軸左或右 0 3 B0409 FRONT SUSPENSION 前避震器 0 2 B0410 REAR SUSPENSION 後避震器 0 2 B0411 UPPER SUSPENSION ARM LH OR RH 上懸吊總成左或右 0 3 B0412 LOWER SUSPENSION ARM LH OR RH 下懸吊總成左或右 0 3 B0413 UPPER SUSPENSION ARM BUSH 上懸吊避震襯套 0 4 B0414 LOWER SUSPENSION ARM BUSH 下懸吊避震襯套 0 4 B0415 SWING ARM ASSEMBLY UPPER 上搖臂 NA B0416 SWING ARM ASSEMBLY LOWER 下搖...

Page 12: ...DIRECTION LIGHT CONTROLLER 方向燈繼電器 0 05 B0511 MAIN SWITCH ASSEMBLY 主電源開關 0 1 B0512 STEERING LOCK 防盜瑣 0 1 B0513 BATTERY LINE 電極正線 0 1 B0514 C D I UNIT ASSEMBLY C D I 電子元件組合 0 2 B0515 REAR RACK 置物架 0 2 B0516 REFLECTOR FRONT OR REAR 反光片前或後 0 05 B0517 HEAD LAMP BULB 頭燈泡 0 1 B0518 HEAD LAMP ASSY 頭燈組合 0 2 B0519 RUBBER MOUNT HEADLAMP 頭燈橡膠底座 0 1 B0520 BACK LAMP COMP 後燈總成 0 1 B0521 BACK LAMP COVER 後燈蓋 0 05...

Page 13: ......

Page 14: ...INDEX OF TOPICS PRIOR TO DELIVERY 11 ...

Page 15: ......

Page 16: ......

Page 17: ......

Page 18: ...tric System Main switch Headlights upper beams dipped beams tail lights and relevant light indicators Headlight position adjustment Direction indicators and relevant lights Instrument panel lights Instruments fuel and cooling water temperature indicator Instruments unit indicator lights Horn Elecrric starter up Parking button function Caution charge the battery before use to ensure optimum perform...

Page 19: ... clothes should be avoided Caution never use fuses having a higher capacity than the recommended value Using fuses with inadequate capacity may cause damages to the kart or even cause fire hazards Level Check Hydraulic braking system fluid level Rear hub oil level Engine coolant level Engine oil level P 11 6 PGO BR 500 ENGINE ...

Page 20: ...TOPICS ENGINE 10 Automatic transmission 10 2 Final reduction 1 0 22 Flywheel cover 1 0 31 Flywheel and start up 10 52 Thermal unit and timing system 1 0 64 Crankcase and driving shaft 10 100 Lubrication 1 0 122 ...

Page 21: ...omatic Transmission PGO BR 500 ENGINE Remove the External Air Conveyor Unscrew the 2 fastening screws shown in the figure to remove the conveyor filter Remove the Outside transmission cover Unscrew the 4 fastening screws shown in the figure to remove the external air conveyor P 10 2 ...

Page 22: ...exagon bush Remove the nut and the two washers Note due to the high tightening torque using different wrenches such as a conventional polygonal bush may damage the hexagon obtained on the shaft or break the bush itself Remove the six M6 screws Remove the four M8 screws Remove the transmission cover Check that the bearing rotates freely otherwise replace it PGO BR 500 ENGINE P 10 3 Automatic Transm...

Page 23: ...ightening torque Air conveyor screws 11 12 Nm PGO BR 500 ENGINE Check that the roller is free from wear and that it rotates freely Remove the fastening screw by a 13 mm wrench Remove the roller and the bearing N B If the roller does not rotate freely it requires replacement P 10 4 Automatic Transmission ...

Page 24: ...so as to insert the stud bolts on the band into the holes obtained onto the tool itself Tighten the two tool fastening nuts by hand Loosen the central nut Remove the spring washer and the flat washer Remove the fixed driving half pulley Remove the bushing connection washer Move the belt downwards Suitable support the roller contrast and extract the mobile driving half pulley with the relevant bush...

Page 25: ...ell is not worn or damaged Measure the clutch bell inside diameter Standard value 160 2 mm Max value 160 5 mm N B Check the eccentricity measured 0 2 mm max PGO BR 500 ENGINE Extract the driven pulley unit with the belt P 10 6 Automatic Transmission ...

Page 26: ...pring compressor 020444Y 55 mmwrench 020444Y009 Ring 020444Y010 To remove the clutch with the driven pulley it is necessary to use the specific tool dwg Arrange the tool with the mean pins screwed in position E on the inside Install the driven pulley unit onto the tool inserting the pins into the ventilation holes Move the rear stop screw in abutment against the fixed driven pulley as shown in the...

Page 27: ...specific tool inserted through the roller bearing pull out the ball bearing N B Properly support the pulley to prevent damaging the threading Specific equipment and tools Handle 020376Y 24 mm adapter 020456Y 20 mm guide 020363Y Remove the roller bearing by the specific tool supporting the fixed half pulley with the bell Specific equipment and tools Handle 020376Y Adapter 28x30 mm 020375Y 25 mm gui...

Page 28: ...ller casing 020478Y Bell001467Y002 Install a new roller bearing by the specific tool N B Place the bearing with the writings and the embedded oil guard facing outwards Properly support the half pulley to prevent damaging the threading If you are working on the driven pulley unit fully assembled use tool 001467Y002 Install a new ball bearing by the specific tool Specific equipment and tools Handle ...

Page 29: ...o damage the top sealing ring during the introduction Check that the pins and the collar are free from wear install pins and collar PGO BR 500 ENGINE Measure the free length of the mobile driven half pulley spring Standard length 125 5 mm Admissible limit after use 120 mm Check the thickness of the clutch mass friction material Minimum admissible thickness 1 mm The masses must exhibit no traces of...

Page 30: ... Check that the driving belt is not damaged Check the belt width Minimum width 25 mm Standard width 26 2 mm PGO BR 500 ENGINE P 10 11 Automatic Transmission ...

Page 31: ...ding bushing outside diameter shown in the figure Minimum admissible diameter 29 95 mm Standard diameter 29 959 mm Check that the rollers are not damaged or worn Minimum admissible diameter 24 5 mm Standard diameter 24 9 mm Check that the roller contrast plate slide blocks are not damaged Check the wear of the roller housings and of the belt contact surfaces on both half pulleys PGO BR 500 ENGINE ...

Page 32: ...lf pulley as shown in the figure The covered side must rest onto the inside thrust side of the roller container Assemble the half pulley with the roller contrast and the sliding blocks Insert the half pulley on the driving shaft Insert the spacer bushing PGO BR 500 ENGINE P 10 13 Automatic Transmission ...

Page 33: ...PGO BR 500 ENGINE P 10 14 Automatic Transmission ...

Page 34: ...edge on the engine crankcase side Tighten the central screw at the prescribed torque N B Turn the driven and or driving pulley to properly tension the belt Tightening torque Anti flapping roller screw 16 7 19 6 Nm PGO BR 500 ENGINE P 10 15 Automatic Transmission ...

Page 35: ...g and insert the clutch on the driven pulley bushing N B Be careful not to damage the sheath or the bushing threaded end Tighten the ring nut by hand and complete the tightening by the specific wrench at the prescribed torque Tightening torque Clutch ring nut 65 75 Nm Specific equipment and tools 55 mm wrench 020444Y009 To facilitate reassembly on the engine turn the mobile driven pulley and inser...

Page 36: ... in contact with the spacer and with the mobile driving pulley sliding bushing Remove the flat washer and the spring washer as shown in the figure Insert the nut in the original position nut side in contact with the spring washer PGO BR 500 ENGINE P 10 17 Automatic Transmission ...

Page 37: ... and tools Driving pulley stop wrench 020474Y004 Insert the retain band on the rear side so that the groove is fully abutted Finally install the tool by siding the nuts by hand and ensuring the tool is resting flatly Tighten the driving pulley fastening nut at the prescribed torque Remove the specific tool Tightening torque Driven pulley shaft nut 160 175 Nm PGO BR 500 ENGINE P 10 18 Automatic Tra...

Page 38: ...spacer PGO BR 500 ENGINE Note due to the high tightening torque using different wrenches such as a conventional polygonal bush may damage the hexagon obtained on the shaft or break the bush itself P 10 19 Automatic Transmission ...

Page 39: ...s 23 26 Nm Lock the M6 screws Tightening torque M6 screws 11 13 Nm Insert the washers on the driven pulley shaft N B Insert the larger washer first Insert the flanged nut Prepare the dynamometric wrench for LH locking using a machine hexagon wrench Tighten the driven pulley shaft fastening nut using a misaligned wrench Tightening torque Driven pulley nut 92 100 Nm PGO BR 500 ENGINE P 10 20 Automat...

Page 40: ...n the transmission cover N B Check that the air inlet and the air outlets are totally free Insert the outside plastic transmission cover Tighten the 4 fastening screws at the prescribed torque Tightening torque Outside transmission cover screws 7 9 Nm PGO BR 500 ENGINE P 10 21 Automatic Transmission ...

Page 41: ...LUBRICATE WITH OIL CLEAN CAREFULLY LUBRICATE WITH GREASE CAUTION HANDLE WITH CARE APPLY PRODUCT ALWAYS REPLACE REFERENCE A B QUANTITY 6 1 TORQUE Nm 24 27 15 17 PGO BR 500 ENGINE P 10 22 Final Reduction ...

Page 42: ... shaft Remove the wheel axle with gear Check all bearings wear clearance and noise In case of anomalies proceed as follows To remove the wheel axle bearing on the engine crankcase use the following parts Specific equipment and tools 15 mm pliers 001467Y34 or 001467Y014 Bell 001467Y031 To remove the lay shaft bearing on the engine crankcase use the special removing tool Specific equipment and tools...

Page 43: ...he hub cover using the column kit Pull out the bearing by the specific tool Specific equipment and tools Column kit 020476Y Handle 020376Y Adapter 37 mm 020477Y 30 mm guide 020483Y Remove the oil guard by a screwdriver PGO BR 500 ENGINE P 10 24 Final Reduction ...

Page 44: ...ard remove the transmission cover and the clutch unit as described in Chapter 3 Automatic transmission Extract the driven pulley shaft from the bearing Remove the oil guard by a screwdriver into the hub gear box Remove the snap ring shown in the figure Pull out the driven pulley shaft bearing from the engine crankcase using the specific tool Specific equipment and tools Handle for punches 020376Y ...

Page 45: ...n in the figure Heat the wheel axle bearing seat on the crankcase Insert the wheel axle bearing in the upper crankcase seat by the specific tool N B Place it with the balls facing the hub this applies to bearings with plastic cage Specific equipment and tools Handle 020376Y Adapter 42x47 mm 020359Y 15 mm guide 020412Y PGO BR 500 ENGINE P 10 26 Final Reduction ...

Page 46: ...haft bearing until it abuts against the bottom of the seat using the specific tool N B Place it with the balls facing the hub this applies to bearings with plastic cage Specific equipment and tools Handle 020376Y Adapter 52x55 mm 020360Y 25 mm guide 020364Y Heat the crankcase by the thermal gun Specific equipment and tools Heater 020151Y PGO BR 500 ENGINE Check that the matching surface exhibits n...

Page 47: ...χε Τιµεσ Νεω Ροµαν Place the oil guard flush with the crankcase Specific equipment and tools Handle 020376Y Adapter 52x55 020360Y Column kit 020476Y Replace the snap ring Heat the wheel axle bearing seat from the cover outside Insert the wheel axle bearing on the cover by the specific punch until abutment Specific equipment and tools Handle 020376Y Adapter 52x55 mm PGO BR 500 ENGINE P 10 28 Final ...

Page 48: ...hub this applies to bearings with plastic cage Specific equipment and tools Handle 020376Y Adapter 52x55 mm 020360Y 20 mm guide 020363Y Heat the bearing seats on the cover using the thermal gun Support the hub cover using the column kit Specific equipment and tools Heater 020151Y Column kit 020476Y PGO BR 500 ENGINE P 10 29 Final Reduction ...

Page 49: ...f faults replace the damaged parts PGO BR 500 ENGINE Place the 3 shafts as shown in the figure Place the 7 fastening screws tighten them atthe prescribed torque checking the position of the vent pipe sealing bands andof the 3 shorter screws as shown in the figure Refill with the prescribed oil to the maximumlevel Tighteningtorque Hubcover screws 24 27 Nm Prescribed oil TUTELA ZC90 Quantity 250 cc ...

Page 50: ...EAN CAREFULLY LUBRICATE WITH GREASE CAUTION HANDLE WITH CARE APPLY PRODUCT ALWAYS REPLACE REFERENCE B C D E F G H I L M QUANTITY 14 1 1 6 3 1 1 2 2 1 TORQUe 12 4 24 3 8 2 14 1 5 3 4 PGO BR 500 ENGINE P 10 31 Flywheel Cover ...

Page 51: ...0 ENGINE Remove the three bands shown in the figure for an easier removal of the flywheel cover remove the cylinder delivery sleeve and disconnect the recirculation sleeve from the pump cover N B The bands must be replaced To remove them open with a screwdriver or cut them Be careful not to damage the plastic unions P 10 32 Flywheel Cover ...

Page 52: ...oil Remove the pre filter Remove the oil filter using a filter tape or shaped cup wrench Loosen the 14 fastening screws Remove the flywheel cover with the relevant gasket and the cooling system sleeve support N B The screws are of 4 different lengths Note PGO BR 500 ENGINE P 10 33 Flywheel Cover ...

Page 53: ...rferences between stator androtor Caution Be careful to prevent slippage of the by pass valve and of the relevantspring the relevant positions PGO BR 500 ENGINE Remove the by pass and the relevant spring Remove the sealing gasket P 10 34 Flywheel Cover ...

Page 54: ...e bracket Unscrew the 3 fastening screws and remove stator and its wiring Unscrew the 2 fastening screws and remove the reed valve support with head Remove the blow by reed valve with the relevant sealing gasket PGO BR 500 ENGINE P 10 35 Flywheel Cover ...

Page 55: ...g Remove the water pump impeller by unscrewing it from the relevant shaft N B The threading is clockwise It is advisable to prevent the shaft rotation by inserting a 12 mm wrench into the drive Extract the shaft with the relevant abutment washer PGO BR 500 ENGINE P 10 36 Flywheel Cover ...

Page 56: ... Remove the sealing ring Remove the ceramic ring and the relevant gasket Remove the sealing ring for the pump shaft lubrication using a suitably shaped tool PGO BR 500 ENGINE P 10 37 Flywheel Cover ...

Page 57: ... Remove the engine oil filling cap bar and the reference oil cap for the timing Remove the minimum oil pressure sensor PGO BR 500 ENGINE P 10 38 Flywheel Cover ...

Page 58: ...erature gives higher values Approximate resistance of each phase 0 2 1 Ω Check the earth insulation of each phase In case of irregularities carefully check the wiring as this consists of 2 cables stiff cables close to the stator and soft cables to the connector Check that the winding is placed so as to not interfere with the fastening screw heads PGO BR 500 ENGINE P 10 39 Flywheel Cover ...

Page 59: ...PGO BR 500 ENGINE P 10 40 Flywheel Cover ...

Page 60: ... no wear on the connection in contact with the case in the oil guard working zone and on the drive Check that the ceramic seal working surfaces are not scratched or worn Check that the impeller is free from deformation or cracks Check that the plastic impeller is perfectly integral with the metal part Check that the water pump cover is free from deformation or cracks Check that the sealing O rings...

Page 61: ... Check that the blow by circuit reed closes properly PGO BR 500 ENGINE P 10 42 Flywheel Cover ...

Page 62: ...of all components For the cover case carefully check all lubrication paths in particular the 3 by pass ducts Oil feeding duct at the water pump shaft connection Pump drainage duct Oil pressure sensor feeding duct PGO BR 500 ENGINE P 10 43 Flywheel Cover ...

Page 63: ...th head tightening the screws at the prescribed torque Tightening torque Support screws with head 0 3 0 4 Nm Install a new pump shaft sealing using the specific tool Install the minimum oil pressure sensor and tighten at the prescribed torque Tightening torque Minimum oil pressure PGO BR 500 ENGINE P 10 44 Flywheel Cover ...

Page 64: ...eal Insert the ceramic seal on the flywheel cover N B Assemble by hand to prevent damages to the ceramic seal Insert the water pump shaft after lubricating the flywheel cover seat Insert the mechanical seal on the shaft up to the impeller abutment surface N B The final introduction depth will be determined by the impeller Screw the impeller and tighten at the prescribed torque Tightening torque Wa...

Page 65: ...PGO BR 500 ENGINE P 10 46 Flywheel Cover ...

Page 66: ...ews at the prescribed torque Tightening torque Wiring guide bracket fastening screws 3 4 N m Temporarily install the timing check hole cap and the engine oil filling cap bar Insert the blow by recovery duct using a new O ring Tighten the screw at the prescribed torque Tightening torque Blow by recovery duct fastening screws 3 4 N m Insert the spring and the by pass piston on the flywheel cover N B...

Page 67: ...PGO BR 500 ENGINE P 10 48 Flywheel Cover ...

Page 68: ...ver already assembled Install the flywheel cover on the engine being careful to prevent any possible interferences between stator and rotor Caution Failure to observe this rule can cause the breakage of the ceramic magnets Tighten the 14 cover fastening screws at the prescribed torque N B The screws are of 4 different lengths the 3 shorter ones are in the position shown in the figure the longer on...

Page 69: ...m PGO BR 500 ENGINE Tighteningtorque Flywheelcover fastening screws 3 4 Nm Carefully place a new O ring avoiding contacts with grease or oil Caution Failure to observe this regulation can cause irreversible deformation to the O ring Install the water pump cover and tighten the 6 fastening screws at the prescribed torque P 10 50 Flywheel Cover ...

Page 70: ...cover using 3 new bands N B Lock the bands with the special pliers being careful not to cut deeply into the sleeve and preventing insufficient tightening Install the pre filter and the engine oil drainage cap and tighten at the prescribed torque Refill the engine with the prescribed oil type Tightening torques Oil drainage cap 24 30 Nm Recommended oil Selenia HI Scooter 4 Tech 5W 40 PGO BR 500 ENG...

Page 71: ...E WITH OIL CLEAN CAREFULLY LUBRICATE WITH GREASE CAUTION HANDLE WITH CARE APPLY PRODUCT ALWAYS REPLACE REFERENCE A B C D QUANTITY 6 3 2 1 TORQUE Nm 14 3 5 12 120 PGO BR 500 ENGINE P 10 52 Flywheel and Start up ...

Page 72: ...culation sleeve from the pump cover N B The bands must be replaced To remove them open with a screwdriver or cut them Be careful not to damage the plastic unions PGO BR 500 ENGINE N B This operation may also be carried out with flywheel cover assembled Loosen the two fastening screws Extract the complete starter motor P 10 53 Flywheel and Start up ...

Page 73: ...he introduction of the specific tool Tighten the bushing of the flywheel lock tool on the removing tool threading Insert the specific tool as shown in the figure making sure that the pins are perfectly inserted into the previously aligned holes and that it is perfectly abutted and almost flush with the flywheel Specific equipment and tools Flywheel lock tool 020472Y Loosen the magneto flywheel fas...

Page 74: ...may therefore cause the rotor slippage with the consequent breakage of the magnets Insert the specific removing tool Using a 27 mm wrench and a 19 mm bushing release the magneto flywheel Specific equipment and tools Flywheel removing tool 020467Y Remove the removing tool Remove the nut and extract the magneto flywheel with the start up rim Remove the driving shaft key PGO BR 500 ENGINE P 10 55 Fly...

Page 75: ...astening screws N B Since the free wheel must be removed it is advisable to loosen the 6 fastening screws in advance with the flywheel still installed on the driving shaft The free wheel is coupled to the flywheel with high precision if removal is difficult use 2 screws as gripping points and as removing tools if required PGO BR 500 ENGINE P 10 56 Flywheel and Start up ...

Page 76: ...rovided with torque limiter PGO BR 500 ENGINE Check the integrity of the magnets Check that the magnet support cage is free from deformation or cracks Check that the flywheel nailing exhibits no loosening P 10 57 Flywheel and Start up ...

Page 77: ...rn Brass inside diameter d 27 0 020 0 041 mm N B In the event of failures concerning the hub it is advisable to replace the start up rim and the free wheel If only the brass is worn it is possible to replace only the complete start up rim In that case check also the diameter and the surface of the connection on the driving shaft In case or irregularities replace the driving shaft PGO BR 500 ENGINE...

Page 78: ...ameter d 12 0 034 0 016 mm Engine crankcase connectiondiameter d 12 0 034 0 016 mm N B The torque limiter is provided with 4 gears that have the function of clutch driving plates Driven plates consist of 4 Belleville washers provided with grooved profiles this assembly allows transmitting torques lower than 10 kgm In case of incorrect start up manoeuvres the limiter prevents any kicks with consequ...

Page 79: ...n the magneto flywheel with the rectified part in contact with the flywheel that is with visible wheel snap ring Tighten the 6 fastening screws in a crossed sequence at the prescribed torque Tightening torque Free wheel fastening screws 13 15 Nm Lubricate the free wheel rollers PGO BR 500 ENGINE Lubricate the inside brass and the start up rim hub surface Install the start up rim on the flywheel tu...

Page 80: ... Lubricate the gear housing on the engine crankcase Insert the intermediate gear with torque limiter PGO BR 500 ENGINE P 10 61 Flywheel and Start up ...

Page 81: ... tool and loosen by 1 4 turn N B Failure to observe this rule causes the locking of the guide on the flywheel Specific equipment and tools Flywheel lock tool 020472Y Align the 2 holes of the magneto flywheel with the case housing to allow the introduction of the specific tool Insert the specific tool checking that the pins are perfectly introduced into the seat Specific equipment and tools Flywhee...

Page 82: ...plate tightening the 3 screws at the prescribed torque N B Before tightening the screws move the start up rim in contact with the crankcase and check that it is free to rotate in counter clockwise direction Tightening torque Chain guide sliding block retain plate fastening screws 3 4 Nm PGO BR 500 ENGINE P 10 63 Flywheel and Start up ...

Page 83: ...limiter on the flywheel cover Align the water pump drive with a reference and install the flywheel cover as described in the Engine Flywheel Cover Assembly chapter Check that the O ring is in good working order and lubricate it Insert the starter motor Tighten the 2 fastening screws at the prescribed torque Tightening torque Starter motor fastening screws 11 13 Nm P 10 64 Thermal Unit timing syste...

Page 84: ... the injectionsystem matches that actually started on the engine Proceed as follows Remove the external transmission cover as described in the Automatic transmission chapter Remove the TDC reference inspection cap between flywheel and cover housing See the Flywheel cover chapter By the driving pulley nut turn the engine to find the alignment of the references to identify the TDC Repeat the referen...

Page 85: ...e Select the menu on the parameters function Select the stroboscopic lamp control in the conventional 4 stroke engine position 1 spark 2 revolutions Check that the real values of rpm and ignition advance match those measured by the diagnostic tester PGO BR 500 ENGINE P 10 66 Thermal Unit timing system ...

Page 86: ...stening screws Remove the intake manifold unit PGO BR 500 ENGINE Loosen the 6 special screws with abutment and the relevant rubber gaskets Remove the tappet cover with relevant gasket P 10 67 Thermal Unit timing system ...

Page 87: ...tools Adjustable wrench 020565Y Remove the return spring and the valve lifting mass with relevant travel end washer N B Be careful not to make washer and spring fall into the engine through the chain compartment Align the references located on the wheel speed sensor and on the head Loosen the tightener central screw Unscrew the 2 fastening screws and remove the tightener with relevant gasket PGO B...

Page 88: ...he timing belt rim Remove the wheel speed sensor Remove the engine stroke revolution sensor and relevant O ring by loosening the fastening screw and removing the fixing band from the special hole obtained on the head gasket N B To check this component see the 9 Injection chapter PGO BR 500 ENGINE P 10 69 Thermal Unit timing system ...

Page 89: ...t retain bracket N B Removing the fastening screws may be difficult Be careful not to damage the inside hexagon In case of need separate the threads in advance Remove the camshaft Remove pins and rockers by the transmission side holes P 10 70 Thermal Unit timing system ...

Page 90: ...e head on the exhaust and on the intake side Remove the two M6 screws into the distribution channel and the M6 screw on the spark plug side with the thermostat support N B In case of need the head may be removed with the camshaft pins rockers and fixing bracket Loosen the 4 head cylinder fastening nuts in 2 or 3 times and in a crossed sequence Remove the head the 2 centering dowels the gasket and ...

Page 91: ...springs and valves Specific equipment and tools Valve removing tool 020382Y Adapter 020382Y012 Caution Arrange the valves so as to recognise the original position on the head flywheel side and transmission side Remove the oil guards by the specific tool Specific equipment and tools Removing tool for oil guards 020431Y Remove the spring supports N B Blow the seats with compressed air to facilitate ...

Page 92: ...prevent damages to the piston support it while removing the cylinder Remove the 2 piston pin locking rings by the specific housings Extract the pin and remove the piston N B Close the cylinder housing mouth on the crankcase with paper or with a cloth to prevent slippage of one of the pin locking rings into the case Remove the piston sealing rings and the scraper ring Caution Note the assembly posi...

Page 93: ... rod small end diameter Standard diameter 22 0 025 0 015 mm N B If the connecting rod small end diameter exceeds the standard diameter exhibits wear or overheating proceed to replace the driving shaft as described in Chapter Driving shaft oil sump P 10 74 Thermal Unit timing system ...

Page 94: ...001 0 010 mm N B The pin housings are provided with 2 lubrication channels For this reason measurement must be made according to the piston axis Measure the piston outside diameter according to a direction orthogonal to the pin axis Take the measurement in the position shown in the figure A 43 2 mm Piston diameter 92 mm Using a bore gauge measure the cylinder inside diameter according to the direc...

Page 95: ...the coupling clearance between sealing rings and piston housings as shown in the figure If higher clearance values than those reported in the table are measured replace the piston N B Measure the clearance by inserting the thickness gauge on the second sealing ring side Standard coupling clearance Admissible clearance after use First compression lining A 0 9 0 005 0 030mm B 1 5 0 005 0 03 mm C 0 9...

Page 96: ...as the original diameter Insert the rings in orthogonal position into the cylinder axle using the piston Measure the opening see figure of the sealing rings by a thickness gauge If higher values than those prescribed are measured replace the linings Standard opening Max value Compression lining 0 15 0 35 mm 0 5 mm Scraper ring lining 0 25 0 50 mm 0 65 mm Scraper ring lining 0 25 0 50 mm 0 65 mm PG...

Page 97: ...ing into the specific tool with the opening in the position indicated on the tool S left D right Move the locking ring into position by the punch Install the pin lock using the pin shown in the figure Specific equipment and tools Pin lock installation tool 020470Y PGO BR 500 ENGINE P 10 78 Thermal Unit timing system ...

Page 98: ...ing shaft to the TDC point of reversal of the comparator rotation Measure the deviation from the reset value Identify the thickness of the cylinder base gasket to be used for re assembly by the table below The proper identification of the cylinder base gasket thickness allows maintaining the correct compression ratio Remove the specific tool and the cylinder N B If deviations or recesses or projec...

Page 99: ... any case the step must be facing opposite the piston top Install the first compression lining in the direction imposed by the housing It is advisable to use a fitter to facilitate the installation of the linings N B The 2 sealing linings have a conical surface of contact with the cylinder This is to ensure a better adaptation Misalign the lining openings at 120 as shown in the figure Lubricate th...

Page 100: ...of irregularities replace the headand check also the corresponding component Using a rectified bar and a thickness gauge check that the head surface exhibits no deformations or wear Maximum admissible out of plane 0 1 mm In case of irregularities replace the head Check the sealing surfaces for the intake and exhaust manifold Check that the camshaft and the rocker pin capacities exhibit no wear Che...

Page 101: ...ng the Prussian blue check the width of the impression on the valve seat V Measure the inside diameter of each valve guide Measure according to the rocker thrust direction at three different heights Standard value 1 1 3 mm Admissible limit 1 6 mm If the impression width on the valve seat is larger than the prescribed limits true the seats with a 45degree mill and then grind In case of excessive we...

Page 102: ...ce between valve and valve guide Check the deviation of the valve stem by resting it on a V shaped abutment and measuring the extent of the deformation by a comparator Admissible limit 0 01 mm Check the concentricity of the valve head by arranging a comparator at right angle relative to the valve head and rotate it on a V shaped abutment Admissible limit 0 03 mm PGO BR 500 ENGINE P 10 83 Thermal U...

Page 103: ...es you can use the same valves To obtain better sealing performance grind the valve seats Perform this operation carefully using fine grain emery paste While grinding keep the head with the valve axes in horizontal position to prevent the emery paste residues from penetrating into the valve guide stem coupling see figure Warning To prevent scratching the contact surface do not force the valve rota...

Page 104: ...ith fuel and checking that the head does not bleed from the valves when pressed by your fingers only PGO BR 500 ENGINE Check that the spring upper support plates and half cones are free from irregular wear Measure the free length of the spring Standard length 44 4 mm Admissible limit after use 42 4 mm P 10 85 Thermal Unit timing system ...

Page 105: ...pecific tool Lubricate the oil guards and the valve guides Specific equipment and tools Punch for installing oil guards 020306Y Insert valves springs and plates Using the specific tool provided with the special adapter compress the springs and insert the half cones into the relevant seats Specific equipment and tools Valve installation tool 020382Y Adapter 020382Y012 PGO BR 500 ENGINE P 10 86 Ther...

Page 106: ...Maximum admissible axial clearance 0 3 mm If different values or wear than those prescribed are found replace the faulty parts Check that the retain plate seat shown in the figure exhibit no wear Check that the automatic valve lifting device cam the travel end roller and the rubber abutment on the containment bell are free from wear Check that the valve lifting spring has not yielded In case of we...

Page 107: ...rol timing rim unit exhibit no wear In case of wear of the sliding blocks replace them In case of wear of the chain or rim replace the entire unit N B If the chain has damaged the pinion replace the driving shaft as described in Chapter Driving shaft oil sump Remove the central screw with the washer and the tightener spring Check that the unidirectional gear is not worn Check the integrity of the ...

Page 108: ...nd has a standard thickness Check that the head lubrication channel is perfectly clean Clean with compressed air jets if required Insert the head Lubricate the stud bolts and the 4 fastening columns Tighten the 4 fastening columns in a crossed sequence as shown in the figure at a torque of 7 Nm Tighten the 4 screws by 90 degree in the sequence shown in the figure Further tighten by 90 in the seque...

Page 109: ...3 side screws at the prescribed torque Tightening torque Head fastening screws 10 12 Nm Install the cooling fluid temperature sensor with the washer and tighten at the prescribed torque Caution Failure to observe the tightening torque can damage the sensor Tightening torque Cooling fluid temperature sensor 10 12 Nm PGO BR 500 ENGINE P 10 90 Thermal Unit timing system ...

Page 110: ...g sliding block fastening screw 10 14 Nm Insert pins and rockers on the flywheel side Lubricate the 2 rockers through the top holes Clean the camshaft by blowing with little compressed air jets especially the retaining plate housing Lubricate the 2 ends Insert the camshaft into the head with the cams opposite the rockers Remove any residues of LOCTITE from the camshaft retain bracket fastening scr...

Page 111: ...d sensor timing peg are free from deformations or dents Insert the wheel speed sensor on the camshaft keeping the stroke reference visible Install the engine stroke revolution sensor using a new O Ring orientating it as shown in the figure Tighten the 2 fastening screws at the prescribed torque N B To check this component see Chapter 9 Injection Tightening torques Stroke revolution sensor fastenin...

Page 112: ... wrench remove the timing check cap Align the wheel speed sensor references with the head as shown in the figure Keeping the belt slightly pulled turn the driving shaft by the driving pulley to make the reference located on the magnet support collimate with that on the flywheel cover Insert the belt on the camshaft control timing rim Insert the timing rim on the camshaft checking that the referenc...

Page 113: ...d torque using LOCTITE 242 Tightening torque Balance weight mass fastening screw 7 8 5 Nm Remove the central screw Install the valve lifting mass being careful to the proper positioning of the travel end ring Lubricate the mass and de compressor control pin Install the return spring and load it by about 3 4 turn Turn the engine to move the references to the top as PGO BR 500 ENGINE P 10 94 Thermal...

Page 114: ... Tightening torque Valve lifting device mass stop bell fastening screws 30 35 Nm Place the engine with the valve clearance adjustment timing references aligned with the head Check the clearance between valve and rocker using a thickness gauge Prescribed clearance intake 0 15 mm with cold engine exhaust 0 15 mm with cold engine In case of different values adjust by loosening the lock nut and using ...

Page 115: ...st position keeping the retain tab pressed Install a new tightener on the cylinder using a new gasket Tighten the two fastening screws at the prescribed torque Tightening torque Tightener fastening screws 11 13 Nm Insert the spring with the central screw and the washer Tighten the central screw at the prescribed torque Tightening torque Tightener screw 5 6 N m PGO BR 500 ENGINE P 10 96 Thermal Uni...

Page 116: ... a crossed sequence 3 4 5 6 N B Check the proper position of the gasket Tightening torque Tappet cover fastening screws 7 9 Nm Install the transmission cover and the relevant net filter and the outside transmission cover as described in the Automatic transmission chapter Install the cooling system sleeves using new bands as described in the Flywheel cover chapter PGO BR 500 ENGINE P 10 97 Thermal ...

Page 117: ... on the matching surfaces between throttle body and manifold and head and manifold are in good working order Caution Air leaks may affect the injection system performance especially with idling engine Carefully check that the gas valve and relevant duct are clean Check that the additional air channel managed by the stepper motor is clean N B If the throttle body is replaced reset the T D C and the...

Page 118: ...orque Throttle body fastening screws 11 13 Nm PGO BR 500 ENGINE Install the intake manifold on the engine Insert the 3 fastening screws one of which with a support band for the cooling system sleeve and tighten at the prescribed torque Tightening torque Intake manifold fastening screws 11 13 Nm P 10 99 Thermal Unit timing system ...

Page 119: ...OIL CLEAN CAREFULLY LUBRICATE WITH GREASE CAUTION HANDLE WITH CARE APPLY PRODUCT ALWAYS REPLACE REFERENCE A B C D E F G H I L M N O QUANTITY 1 2 2 14 4 TORQUE N m 25 9 5 8 0 10 2 10 2 P 10 100 Crankcase Driving shaft ...

Page 120: ...eel cover with the cooling system sleeves as described in the Flywheel cover chapter Remove the magneto flywheel with start up control as described in the Flywheel and start up chapter Remove the thermal unit cylinder head piston as described in the Thermal unit and timing system chapter PGO BR 500 ENGINE P 10 101 Crankcase Driving shaft ...

Page 121: ...denotes wear of the crankcasedriving shaft rest surfaces For a correct measurement fully recover theclearance in both directions by operating between crankcase and engine Before opening the engine crankcase check the driving shaft axial clearance To this purpose use a plate e g the specific tool and a support with specific tool comparator PGO BR 500 ENGINE P 10 102 Crankcase Driving shaft ...

Page 122: ...he fastening screws are of 3 different lengths Note their correct position Split the crankcases while keeping the driving shaft inserted on the flywheel side half crankcase Remove the coupling gasket N B The bushing support can be left in the flywheel side half crankcase PGO BR 500 ENGINE P 10 103 Crankcase Driving shaft ...

Page 123: ... crankcase and removing the driving shaft check that the shaft threaded ends do not interfere with the bench brasses Failure to observe this precaution can damage the bench brass Removal of the oil pump and counter shaft control gear To remove the control gear loosen the 4 fastening screws N B The screws have a countersunk head and their threading is locked by LOCTITE Be careful not to damage the ...

Page 124: ...figure Specific equipment and tools Counter shaft lock wrench 020479Y Remove the fastening nut with relevant washer Remove the specific tool and extract the counter shaft with the control gear PGO BR 500 ENGINE P 10 105 Crankcase Driving shaft ...

Page 125: ...plate by loosening the 2 fastening screws with the relevant washers Remove the oil pump with the gear loosening the 2 fastening screws through the slits obtained on the gear Remove the gasket PGO BR 500 ENGINE P 10 106 Crankcase Driving shaft ...

Page 126: ...ecific equipment and tools Handle for punches 020376Y Adapter 37x40 mm 020358Y 17 mm guide 020439Y Remove the bearing from the transmission side half crankcase by the specific tool Specific equipment and tools Pliers 001467Y008 Bell 001467Y007 Before installing a new bearing heat the flywheel side half crankcase by the specific tool Place the half crankcase on a wooden base Specific equipment and ...

Page 127: ...ter 42x47 mm 020359Y 17 mm guide 020439Y Install the snap ring Before installing the new bearing on the transmission side crankcase heat the seat by the specific tool Specific equipment and tools Heater 020151Y Insert a new bearing on the specific tool after greasing the guide seat Install the new bearing on the engine crankcase by the specific tool N B If a bearing with plastic cage is used keep ...

Page 128: ...Specificequipment and tools Handlefor punches 020376Y Adapter42x47 mm 020359Y 17 mmguide 020439Y PGO BR 500 ENGINE P 10 109 Crankcase Driving shaft ...

Page 129: ...are free from scratches Shim adjustment to a given clearance Check the overall height of the driving shaft shoulders gear assembly Standard thickness 71 804 72 000 mm Check that shim adjustment is free from scratches N B In case of reuse keep the initial assembly position Specific equipment and tools Driving shaft check support 020074Y If the driving shaft crankcase axial clearance is higher than ...

Page 130: ... good working order In case of failures replace the driving shaft N B Bench ends are not rectifiable The connecting rod cannot be replaced To check the connecting rod small end diameter see chapter Thermal unit and timing system When cleaning the driving shaft be careful to prevent any impurity from entering into the shaft lubrication hole CAUTION In case of replacement of a driving shaft consisti...

Page 131: ... jet is fed through the bench brasses Proper operation of this component improves the piston top cooling Clogging has effects that are difficult to detect piston temperature increase Failure or leak can considerably decrease the bench brass and connecting rod lubrication pressure For the flywheel side half crankcase special attention should be given to the lubrication channels for the bench brasse...

Page 132: ... the measurements for the other half of the brass See figure N B Do not take the measure on the half bearing matching surface since the ends are released to allow deformation upon insertion The standard brass diameter after driving is variable on the basis of a coupling selection The brass seats into the crankcases are classified into 2 categories as for the driving shaft Cat 1 and Cat 2 Brasses a...

Page 133: ...brication chapter PGO BR 500 ENGINE Using a micrometer measure the 2 capacities of the counter shaft as shown in the figure Standard diameter 17 0 01 0 02 mm Check that the water pump drive is not worn P 10 114 Crankcase Driving shaft ...

Page 134: ...riation of the rotor and water pump coupling clearance Tightening torque Oil pump fastening screws 5 6 Nm Insert the counter shaft with the gear on the flywheel side half crankcase Install the specific tool in the position shown in the figure Specific equipment and tools Counter shaft lock wrench 020479Y Keep the counter shaft into position and insert the washer with the nut Tighten the nut at the...

Page 135: ...gear as well Before installing the gear on the driving shaft carefully clean the two matching surfaces removing any residues of LOCTITE from the holes by a brush Lubricate the bench brass on the flywheel side half crankcase Lubricate the shim adjustment washer Insert the shim adjustment washer on the driving shaft in its original position Insert the specific timing tool in the hole on the counter ...

Page 136: ...plate Tighten the 2 flanged fastening screws at the prescribed torque Tightening torque Closing plate fastening screws 8 10 Nm PGO BR 500 ENGINE P 10 117 Crankcase Driving shaft ...

Page 137: ...n oil circulation Specific equipment and tools Adapter 52x55 mm 020360Y Handle for punches 020376Y Insert the gasket on the flywheel side half crankcase Lubricate the bench brass on the transmission side half crankcase Couple the 2 half crankcases being careful not to damage the brass on the transmission side half crankcase with the threaded tang of the driving shaft Insert the engine support reta...

Page 138: ...ithout tightening Insert the 14 fastening screws by arranging the single shorter screw A and the single longer screw B as shown in the figure Install the thermal unit cylinder head piston as described in the Thermal unit and timing system chapter Install the magneto flywheel with start up control as described in the Flywheel and start up chapter Install the flywheel cover with the cooling system s...

Page 139: ...e complete driving pulley the transmission cover and the relevant net filter and the outside transmission cover as described in the Automatic transmission chapter PGO BR 500 ENGINE P 10 120 Crankcase Driving shaft ...

Page 140: ...pe piston Piston diameter d13 9 039 mm 0 057 Spring free length 62 5 mm Calibration pressure 4 bar Pre filter Type net plastic Oil filter Type paper with overpressure and anti emptying by pass Oil minimum pressure indicator light switch Calibration 0 3 0 6 bar Head lubrication control jet Diameter d 1 0 05 0 057 mm Tightening torque 5 7 Nm Piston cooling nozzle Diameter d 0 8 0 05 0 057 mm Base ve...

Page 141: ...C Cylinder crankcase plane D Water pump impeller E Minimum oil pressure sensor F Oil filter cartridge G To the oil sump H By pass valve L Oil pump M Net pre filter N Driving shaft O Connecting rod PGO BR 500 ENGINE P 10 122 Lubrication ...

Page 142: ...iming feeding duct is found at the flywheelside connection delivery to the head is controlled by the specific jet startedin the engine crankcase The timing components work with low pressurelubrication The camshaft ends are directly obtained in thehead aluminium the camshaft axial clearance is partly recovered by the oilsent to the connection with smaller diameter The camshaft lubricates the rocker...

Page 143: ... go to 12 6 nbsp Let the engine warm up and repeat the check with hot engine Standard values 80degree Temperature 1 5 bar 1400 rpm YESgo to 7 NOgo to 8 7 Replace the oil minimum pressure switch 8 If pressure lower than 1 3 1 5 bar is measured GOto 9 9 Replace the oil filter and repeat the pressure check with oil at 80degree YESgo to 10 NO go to 13 10 _The failure was fixed It is recommended to res...

Page 144: ...ystem chapter YES o to 16NO o to 17 15_Replace the faulty components Flywheel cover chapter 16_Overhaul the engine Crankcase and driving shaft chapter 17 _Open the engine crankcase and remove the oil pump as described in the Crankcase and driving shaft chapter Check the oil pump as described in the following pages Check that the cooling nozzle and the timing feeding jet are properly installed Visu...

Page 145: ...and compressed air Extract the shaft with its gear and check that it is in good working order and free from wear Reassemble the rotors with the pump body keeping the 2 references visible Insert the shaft with the gear and install the lock ring then turn it with the opening opposed to the shaft face Check any irregular clearance between shaft and pump body PGO BR 500 ENGINE P 10 126 Lubrication ...

Page 146: ...rectified bar as reference plane as shown in the figure Admissible limit value 0 1 mm PGO BR 500 ENGINE Tightening torque Oilpump coupling screws 0 7 0 9 Nm Lubricate the inside rotors Check that the pump cover exhibits no wear or scratching If non conforming values are measured replace it Install the pump cover so as to allow the alignment of the holes for the crankcase fixing screws Tighten the ...

Page 147: ...bar YESgo to 4 NOgo to 5 4 Replace the damaged components 5 Check the adjustment by pass efficiency see Flywheel cover chapter and restore the proper sliding 1 If oil consumption is higher than 250 gr 1000 km on run in engine proceed as follows GOto 2 2 Check the presence of oil at the recovery duct on the filter box YES go to 3 NO go to 4 3 Check the unidirectional reed valve and the decantation ...

Page 148: ... power supply circuit 9 29 Diagnostic tester connection circuit 9 33 Injection indicator circuit 9 34 Auto diagnostic system 9 37 Fuel feeding system 9 38 Revolution sensor 9 62 H V coil 9 65 Ignition timing 9 68 Cooling fluid temperature sensor 9 71 Sucked air temperature sensor 9 75 Pressure sensor 9 78 Gas valve position sensor TPS 9 79 Gas valve position signal reset TPS reset 9 82 Stepper mot...

Page 149: ...the vehicle do not insist on electric wiring and components 8 If ignitionfaults are detected start the checks from the injection system and batteryconnections 9 Beforedisconnecting the EMS controller connector perform the following operations inthe order shown Set the switch to OFF Disconnect the battery Failureto observe this rule can damage the controller 10 Whenreplacing the battery be careful ...

Page 150: ...ingle support The injector is connected by two pipes providedwith quick couplings This allows obtaining a continuous circulation therebyavoiding the risk of fuel boiling The pressure regulator is located at the endof the circuit The fuel pump is controlled by the EMScontroller this ensures the vehicle s safety The ignitioncircuit consists of H V coil H V cable Screened cap EMS controller Spark plu...

Page 151: ...ailures are detected and restored by the diagnostic tester dwg 020460Y In any case when the fault has been fixed the stored value is automatically deleted after 16 usage cycles cold start running in temperature stop The diagnostic tester is also P 9 4 Introduction ...

Page 152: ...d by replacing the EMScontroller install the original controller again and check whether the faultoccurs again 4 For troubleshooting use a multimeter with aninternal resistance of more than 10K ohm V Improper instruments may damage the EMScontroller The instruments to be preferred have adefinition of more than 0 1V and 0 5Ω and an accuracy of more than 2 1 Power supply Battery voltage Burnt fuse R...

Page 153: ...NTROL SWITCH 18 AIR TEMPERATURE SENSOR 6 STEPPER MOTOR 19 85 REMOTE CONTROL SWITCH PUMP INJECTOR H V COIL 7 ENGINE RPM SENSOR 20 H V COIL NEGATIVE CONTROL 8 21 STEPPER MOTOR 9 EMS DIAGNOSTIC CONNECTOR 22 SENSOR POWER SUPPLY 10 EMS DIAGNOSTIC CONNECTOR 23 CONTROLLER NEGATIVE 11 THROTTLE POTENTIOMETER SIGNAL 24 STEPPER MOTOR 12 ENGINE RPM SENSOR 25 13 INJECTOR CONTROL NEGATIVE 26 UNDER PANEL POWER S...

Page 154: ... POSITIVE 4 NEGATIVE 5 6 EMS CONTROLLER SERIAL 7 8 UNDER PANEL POWER SUPPLY POSITIVE IMMOBILIZER ANTENNA IMMOBILIZER ANTENNA PGO BR 500 ENGINE P 9 7 Immobilizer and EMS Controller ...

Page 155: ...rottle potentiometer 11 Stepper motor 12 EMS controller 13 Immobilizer antenna 14 Decoder 15 EMS diagnostic socket 16 Stroke revolution sensor 17 Stand switch 18 Emergency switch 19 Diode 2A 20 Fuse 3A 21 Engine stop remote control switch 22 Master remote control switch 23 Key switch 24 Rectifier regulator 25 Fuse 10A 26 Fuse 30A 27 Fuse 5A 28 Utilities PGO BR 500 ENGINE P 9 8 EMS system layout ...

Page 156: ...jection circuit check H V coil Injector Stroke revolution sensor Fuel feeding Fuel in the tank Activation of the fuel pump Fuel pressure low Injector capacity low Spark plug power supply H V coil screened cap spark plug secondary insulation Compression end pressure Parameter reliability Cooling fluid temperature Injection ignition timing Sucked air temperature PGO BR 500 ENGINE P 9 9 Troubleshooti...

Page 157: ...switch Battery Earth connections Compression end pressure Spark plug power supply Spark plug Screened cap H V coil Stroke revolution sensor Ignition advance Fuel feeding Fuel pressure low Injector capacity low Injector seal poor Parameter correctness Cooling fluid temperature Sucked air temperature Gas valve position Stepper effective steps and opening Cleaning of the auxiliary air duct and of the...

Page 158: ...Gas valve position sensor Stepper Cooling fluid temperature sensor Sucked air temperature sensor Intake system cleaning Air filter Gas valve and choke Stepper and additional air duct Intake system seal infiltrations Intake manifold head Throttle body manifold Intake manifold Filter box Fuel feeding low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust gas analysis before ...

Page 159: ...Ignition timing Parameter correctness Gas valve position sensor Stepper Cooling fluid temperature sensor Sucked air temperature sensor Intake system seal infiltrations Intake manifold head Throttle body manifold Intake manifold Filter box Fuel feeding low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust gas analysis before catalytic converter Trimmer value adjustment CO ...

Page 160: ...per Cooling fluid temperature sensor Sucked air temperature sensor Intake system seal infiltrations Intake manifold head Throttle body manifold Intake manifold Filter box Fuel feeding low pressure Fuel pump Pressure regulator Fuel filter Injector capacity Exhaust system seal infiltrations Manifold head Manifold silencer Analyzer socket Silencer welding Exhaust gas analysis before catalytic convert...

Page 161: ...Air filter Gas valve and choke Stepper and additional air duct Intake system cleaning Intake manifold Filter box Ignition system Spark plug wear check Parameter reliability Gas valve position signal Cooling fluid temperature signal Sucked air temperature signal Ignition advance TPS reset performed successfully Exhaust gas analysis collected before the catalytic converter Trimmer value adjustment C...

Page 162: ...ature Atmospheric pressure Spark plug power supply Spark plug Screened cap H V cable H V coil Intake system Air filter Filter box seal Intake manifold seal Parameter reliability Gas valve position signal Cooling fluid temperature signal Sucked air temperature signal Ignition advance Fuel feeding Fuel level in the tank Fuel pressure Fuel filter Injector capacity PGO BR 500 ENGINE P 9 15 Immobilizer...

Page 163: ...heric pressure Ignition efficiency Spark plug Parameter reliability Gas valve position signal Cooling fluid temperature signal Sucked air temperature signal Ignition advance Intake system cleaning Intake manifold Filter box TPS reset performed successfully Fuel feeding Fuel pressure Fuel filter Injector capacity Fuel quality Selection of the cylinder base gasket thickness PGO BR 500 ENGINE P 9 16 ...

Page 164: ...The EMS system is integrated with the immobilizer anti theft device Its functions are Start up enabled by key recognition Deterrent flashing PGO BR 500 ENGINE P 9 17 Immobilizer system ...

Page 165: ...AL FUSE 30A 10 DIODE 2 span 2 FUSE 7 5A 11 VEHICLE SYSTEM CONNECTOR INJECTION SYSTEM 3 FUSE 3A 12 INSTRUMENT UNIT 4 FUSE 5A 13 IMMOBILIZER LED 5 STAND SWITCH 14 DECODER 6 EMERGENCY SWITCH 15 IMMOBILIZER ANTENNA 7 KEY SWITCH 16 ECU CONTROLLER 8 ENGINE STOP REMOTE CONTROL SWITCH 9 MAIN REMOTE CONTROL SWITCH PGO BR 500 ENGINE P 9 18 Immobilizer system ...

Page 166: ... turned on by the decoder The controller data can be checked by the diagnostic tester dwg 020460Y To connect the diagnostic tester open the spark plug inspection port and pull out the EMS diagnostic socket Remove the protection cap and connect the tester terminal Power the diagnostic tester by connecting the terminals to the battery poles or the specific connector to the socket inside the gloves c...

Page 167: ...grammed within the same storage operation Times and procedure must be strictly observed or it will be necessary to repeat from the beginning Once the system has been programmed master keytransponder decoder and controller are strictly matched This matching allows performing further servicekey programming in case of loss replacement etc Every programming deletes the previous one toadd or delete a k...

Page 168: ...ent discharging the battery A new48 h cycle starts by switching from OFF to ON and OFF again Switching from ON to OFF with programmed system causes the intermittent switching on of the led with an anti theft effect This occurs with any key used for programming The information will be as follows Blank controller OFF Start up disabled OFF Number of keys 2 The number denotes how many keys have been u...

Page 169: ...ced to enable the engine start up In this case it is sufficient to switch to ON using the master key NOTE The service key black coloured is not usedfor programming When not programmed the controller allows nofunctional diagnosis on the engine 4Replacing or duplicating service keys Keys can be duplicated using the preforms andthe original master key A copy may also be requested using the vehicle sC...

Page 170: ...nents see the components layout chapter Code 1 indicates a non programmed system If the code is still displayed after having carried out the programming procedure repeat the procedure carefully observing the ON times of each key 1 Using a multimeter check the continuity between pin 16 of the controller and pin 6 of the decoder connector YES go to 3 NO go to 2 2 Replace or fix the wiring 3 Check th...

Page 171: ...eplace the transponder using one from the new cylinder kit Replace decoder and controller Program again 3 Check the proper connection of the antenna connector YES go to 5 span NO go to 4 4 Restore the connection and check the presence of the code 5 Disconnect the antenna connector and check continuity 8 2 Ω YES go to 7 span NO go to 6 6 Replace the antenna 7 Check the proper position of the antenn...

Page 172: ...1 Check whether the code is still displayed using the master key YESgo to 3 font NOgo to 2 2 Program again using all service keys 3 Check that all components keys decoder controller are properly matched YESgo to 5 font NOgo to 4 4 Restore 5 Replace decoders and controller Program the components again PGO BR 500 ENGINE P 9 25 Immobilizer system ...

Page 173: ...e using the original MASTER key Code no 4 denotes a system where the decoder is blank and the controller is programmed The key is recognised by the controller Start up disabled Indicator light PGO BR 500 ENGINE P 9 26 Immobilizer system ...

Page 174: ...e led turns on YESgo to 6 NOgo to 7 5 Restore YESgo to 2 6 Replace the decoder and program again 7 Check the continuity of the yellow grey wire by measuring between the decoder connector and the 8 pin connector to the instrument unit YESgo to 8 NOgo to 10 8 Check the presence of battery positive voltage at the red black wire of the 8 way connector of the instrument unit YESgo to 9 NOgo to 10 9 Fau...

Page 175: ...This section describes the operations to be carried out to check the power supplycircuit PGO BR 500 ENGINE P 9 28 Immobilizer system ...

Page 176: ...roperly programmed YES go to 3 3 Switch set to ON with side stand raised and emergency switch set to OFF The injection indicator turns on for about 3 seconds YES go to 5 NO go to 4 4 Check the instrument unit and its power supply YES go to 3 5 Set the emergency switch to RUN The injection indicator turns on for about 5 seconds YES go to 6 NO go to 7 6 The injection controller is certainly powered ...

Page 177: ...cific tool to check the controller power supply Pin 17 battery positive Pin 23 battery negative YES go to 12 NO go to 13 12 Controller with proper base power supply 13 If the battery negative is not present check continuity between Pin 23 of the specific tool and earth Detect the presence of the battery positive on Pin 17 of the specific tool and on pin 3 of the decoder connector YES go to 12 NO g...

Page 178: ...the fuse holder under the right side YES go to 5 font NOgo to 6 5 Place the specific tool dwg No 020480Y between controller and injection system YES go to 7 6 Fix any short circuits and replace the fuse Check decoder and controller if necessary YESgo to 1 7 Disconnect the main decoder connector and check the following conditions switch set to ON switch to RUN and side stand raised Terminal no 8 ba...

Page 179: ...ontinuity Pin 26 controller Pin 87 engine stop remote control switch continuity Pin 8 decoder Pin 87 engine stop remote control switch continuity YES go to 12 NOgo to 11 11 ix the wiring or the connection YESgo to 10 12 roper under panel power supply YESgo to 13 13 Check the connector and the continuity of the key switch set to ON Pin 1 2 continuity YESgo to 14 PGO BR 500 ENGINE P 9 32 Decoder and...

Page 180: ...nd switch and connector YES go to 16 16 Check the wiring continuity Check the utility control main remote control switch Disconnect the master remote control switch Check the diode installed on the earth connection of the main remote control switch pickup 86 earth continuity with high resistance connect the tester positive with 86 negative with earth When the polarity is inverted there should be n...

Page 181: ...erated by the digital instrument This step is normallyinterrupted by the injection controller control The timing lasts 5 seconds The diagnostic tester dwg 020460Y is notprogrammed to check this circuit Proceed as follows TERMINAL CONDITIONS STANDARD VALUES 15 23 switch set to ON side stand raised switch to RUN during the check O V after the check battery voltage P 9 34 Injection indicator circuit ...

Page 182: ... ON Set the emergency switch to RUN Keep the side stand raised Check whether the indicator turns on for 5 seconds YES go to 2 NO go to 3 2 The system is in good working order 3 Place the specific tool dwg 020481Y between controller and system YES go to 4 4 Switch set to ON Emergency switch set to RUN Side stand raised Wait more than 5 seconds 15 23 battery voltage YES go to 5 NO go to 6 5 Check th...

Page 183: ...e signal cooling fluid temperature signal sucked air temperature signal wrong battery voltage Injector and relevant circuit HV coil and relevant circuit Stepper and relevant circuit Pump relay circuit Electric fan relay circuit RAM memory ROM memory EEPROM Microprocessor Signals panel stroke revolution signal unsteady cycle Underlined failures cause the engine to stop In the other cases the engine...

Page 184: ... the relevant sections of the chapter dwg 020460Y Select the menu on the errors deleting function Press OK and follow the instructions Perform a trial cycle and check whether the failure occurs again PGO BR 500 ENGINE P 9 37 Injection indicator circuit ...

Page 185: ...half the level Failureto observe these rule can damage the pump Fuel is fed to the injector by a pump a filter and a pressure regulator integrated with the fuel level indicator inside the tank The pump unit is connected to the injector by 2 semi flexible pipes 4 quick unions 1 T union with O ring and retain bracket for the injector The pipes are crossed and fixed to the intake manifold to prevent ...

Page 186: ... starts the pump in the followingconditions by setting the switch to ON withemergency switch to RUN and side stand raised No pump feeding when the stroke revolution signal is onContinuous feeding The initial timing is useful to bleed the systemespecially after a stop with engine in temperature In these conditions thefuel altered by boiling will be mixed with that in the tank During use the pump op...

Page 187: ...S go to 8 NOgo to 28 7 Pump control relay circuit failure YESgo to 9 8 Failure of injector H V coil signals panel YESgo to 18 9 The controller has detected a failure on the line of pin 19 YESgo to 10 YES go to 11 10 Line to earth In this case the pump is always in rotation when the under panel voltage is on YESgo to 12 11 Interrupted line The relay cannot control the pump feeding YESgo to 13 12 Ch...

Page 188: ...the controller Fix the wiring if required Check the relay coil continuity 85 86 100 50Ω 18 Check the efficiency of the 10 A fuse no 2 YES go to 20 NO go to 19 19 Disconnect the following connectors fuel pump H V coil injector YESgo to 22 20 Check the efficiency of the pump remote control switch Check the wiring continuity between remote control switch and pump 87 remote control switch green black ...

Page 189: ...ation of the injector coil and of the HV coil primary YES go to 25 25 Check the pump winding resistance 1 5Ω YESgo to 26 NO go to 27 26 Replace the fuse and check the pump 27 Check the absorbed current 28 Select the diagnostic tester menu dwg 020460Y on the ACTIVE DIAGNOSIS function Select the fuel pump simulation function Enable the function with under panel power supply on and engine off YES go ...

Page 190: ...ct female terminals injector side press the two tails and extract Caution If you cannot pull out the terminal do not force it but try turning The system is designed to further lock the terminal when the traction is increased To disconnect male terminals pump side press the pipe coaxial rings towards the pump support and extract the terminals Caution If you cannot pull out the terminal do not force...

Page 191: ...gher than 12 V Regulation pressure 300 320KPa 3 3 2 BAR YESgo to 4 NOgo to 5 4 The pressure regulator is efficient 5 Pressure too high Check that the return duct is not clogged or squashed YESgo to 6 NOgo to 7 6 Replace the pressure regulator 7 Pressure regulation too low Start the pump rotation again Using pliers with flat and long tips temporarily clamp the return duct by the extension of the sp...

Page 192: ... pressure 600 KPa 6 BAR YES go to 3 NO go to 4 3 Check the system seal Start the pump for 30 seconds by the diagnostic tester dwg 020460Y When the pump stops wait 3 minutes Check the system pressure Fuel pressure over 200 KPa 2 BAR YES go to 5 NO go to 6 4 If pressure is lower carefully check the voltage with pump under stress If voltage is higher than 12 V replace the pump 5 The system seal is ef...

Page 193: ...c tool dwg 020480Y in the portion between the branch and the pump Check whether pressure decreases much more slowly YES go to 14 NO go to 15 14 The pump unidirectional valve is faulty Replace the pump see pump support overhaul 15 Check the pipe and the injector union seals more carefully Check the component seals again if needed NOTE a poor system seal only affects the start up velocity 16 Disconn...

Page 194: ...to 18 NO go to 19 18 The fuel filter is not clogged The vehicle can be used respecting the limit of 48000 Km 19 The flow rate is less than 250 cc The fuel filter is dirty Replace the pump support PGO BR 500 ENGINE P 9 47 Fuel feeding system ...

Page 195: ...eck Disconnect the connector from the pump support Using a tester measure the pump winding resistance Connect the tester prods to the pump support pins as shown in the figure Resistance 1 5 Ω In case of infinite resistance replace the pump PGO BR 500 ENGINE This section describes the operations to be carried out to perform electric checkson the pump P 9 48 Fuel feeding system ...

Page 196: ... tester prods on amperometer function see figure check the pump rotation and absorption Absorbed current 3 5 4 2 A NOTE this absorption refers to power supply voltage 12 V pump run in system pressure 300 KPa 3 bar fuel filter clean The a dirty filter causes an increase of the absorption If the overpressure valve opens the pump absorbs 6 A In case of excessive absorption 5A replace the filter See p...

Page 197: ... flow Current absorbed by the pump A clogged filter causes Poor performance especially Pump absorption increase NOTE Do not blow the filter with compressed air A damaged filter may cause theinjector clogging PGO BR 500 ENGINE P 9 50 Fuel feeding system ...

Page 198: ... by the quick unions Warning Prevent any fuel spraying Loosen the pump support fixing ring nut RH threading Remove the pump support and the sealing gasket NOTE when extracting be careful not to deform the float arm To replace the components proceed as follows 1 Level indicators Note the assembly position and the path of the two connecting wires pos 2 wire connected to the circuit pos 3 wire connec...

Page 199: ...orrect orientation may impair the level indicator performance Screw the fixing ring nut and tighten thoroughly Tightening torque Motor pump locking ring nut 20 Nm Connect the feeding circuit pipes again and check the proper introduction by pulling and turning upwards Reconnect the electric connector Recharge the system with at least 4 5 timings key switch OFF ON NOTE do not start the pump before r...

Page 200: ...e between the two level indicator wires Moving the float arm check that the resistance is subject to gradual variations according to the arm motion Limit values empty tank position 95 105 Ω full tank position 0 9 Ω Repeat the operations in the reverse order for re assembly 2 Pressure regulator Remove the locking spring Extract the pressure regulator with sealing rings NOTE to overcome the resistan...

Page 201: ...mp Note the position of the power supply wires on the support pos 1 positive red pos 4 negative black NOTE the pump connections are not interchangeable Disconnect the power supply cables Cut the delivery pipe fixing band on the support Remove the pump fixing washer PGO BR 500 ENGINE P 9 54 Fuel feeding system ...

Page 202: ...t remove the pre filter and the annular support For re assembly perform the removal operations in the reverse order using a new band for the delivery pipe and a new pump fixing washer NOTE To clean the pre filter use gasoline and compressed air Orientate the pump properly PGO BR 500 ENGINE P 9 55 Fuel feeding system ...

Page 203: ... assembled with the pump support To replace the support move the level indicator the pressure regulator and the pump from the old to the new support For these operations follows the instructions given above PGO BR 500 ENGINE P 9 56 Fuel feeding system ...

Page 204: ...opening The injector openings are repeated for a few seconds YESgo to 3 3 Acoustically check the injector openings and wait for the tester results YESgo to 4 NO go to 5 4 5 injector openings detected The injection tester displays test successful YES go to 7 5 No injector openings detected The injection tester displays test failed YESgo to 9 font NOgo to 6 6 No injector openings detected The inject...

Page 205: ...m YESgo to 15 15 Arrange a multimeter with positive prod on pin 13 and negative prod on pin 23 Set the switch to ON with switch to RUN and side stand raised Check the presence of battery voltage during the fuel pump timing 13 23 battery voltage for 2 seconds YES go to 16 NOgo to 17 16 The injector electric circuit is steady Repeat the checks If the fault continues check the controller connector Re...

Page 206: ...arth insulation of the injector negative line Disconnected controller and injector connectors 13 23 Ωinfinity NOgo to 20 20 Fix or replace the wiring 21 Check the continuity between the injector power supply connector red yellow and pin 13 Restore the continuity if required or replace the wiring 22 Replace the injector PGO BR 500 ENGINE P 9 59 Fuel feeding system ...

Page 207: ... seconds of pump diagnosis power the injector by the wire and the auxiliary battery for 15 seconds Collect the fuel delivered by the injector into the graduated container Power supply pressure 300 KPa 3 BAR Quantity delivered approx 40 cm3 YES go to 3 NO go to 4 3 Perform the injector sealing test Dry up the injector outlet by a compressed air jet Start the fuel pump Wait a minute check that there...

Page 208: ...g and the start up features after a short stop with hot engine In case of clogging of the injector it is necessary to replace it along with the fuel filter contained in the tank Carefully clean the system and the tank PGO BR 500 ENGINE P 9 61 Fuel feeding system ...

Page 209: ...en circuit occursduring use on the road the indicator light indicate the start of a failure bya flash as follows To check the sensor and the relevant circuit proceed as follows TERMINAL CONDITIONS STANDARD 7 12 Start up 0 8 4 5 V 1 CONTROLLER 2 ENGINE RPM SENSOR A Indicator light on B Indicator light off 1 Connect the diagnostic tester dwg 020460Y Start the engine The engine starts regularly YES g...

Page 210: ...ion between one pole and the shielding S infinity 1MΩ YESgo to 13 NOgo to 12 12 Replace the revolution sensor 13 Reconnect the stroke revolution sensor connector Repeat the resistance check through the injection wiring pin 7 pin 12 7 12 680 15 The value should be very close to that detected directly by the sensor YESgo to 17 NOgo to 14 14 Higher or infinite resistance YES go to 15 NO go to 16 15 C...

Page 211: ... the sensor and controller connectors Replace or fix the injection wiring 19 Measure the alternated voltage between pins 7 and 12 with engine at start up speed 7 12 0 8 5 V eff Revolution speed 300 00 G 1 YESgo to 20 NOgo to 21 20 The sensor circuit is conforming If the start up failure continues replace the controller 21 Check the sensor air gap and magnetic activity See 1007 Thermal unit and tim...

Page 212: ...UN and side stand raised Wait for the tester to display TEST SUCCESSFUL YESgo to 3 NO go to 2 2 The tester displays TEST FAILED Repeat the test and wait for the tester to display TEST SUCCESSFUL YESgo to 3 font NOgo to 4 3 Select the menu on the ERRORS function Check the presence of current or stored errors relating to the H V coil YESgo to 6 NOgo to 5 4 Test failed YESgo to 6 5 The coil control c...

Page 213: ...2 NOgo to 11 11 Check the continuity of the punk black wire in the two systems Pink black coil connector 20 Continuity YESgo to 12 NOgo to 13 12 Check the earth insulation of the negative line 20 23 Ω infinity 1MΩ YESgo to 15 NOgo to 14 13 Replace or fix the faulty system Repeat the check with the menu on ACTIVE DIAGNOSIS 14 Repeat the earth insulation check in the two sections Replace or fix the ...

Page 214: ...rimary earth Ω infinity 1MΩ YESgo to 17 NO go to 19 17 Check the secondary resistance Measure the resistance between one of the primary terminals and the spark plug cable output Primary HV cable output 3 1K 9 YESgo to 18 NOgo to 19 18 The coil is conforming 19 Replace the coil PGO BR 500 ENGINE P 9 67 H V coil ...

Page 215: ... If different values are measured 1 20KΩ replace the screened cap NOTE An unscreened cap or spark plug can affect the injection system For further information on the spark plug see 01 Characteristics and 03 Maintenance PGO BR 500 ENGINE P 9 68 H V coil ...

Page 216: ...tion advance determined by the injectionsystem matches that actually started on the engine Proceed as follows Remove the transmission compartment cover as described in the Automatic transmission Remove the TDC reference inspection cap between flywheel and cover housing See the 1005 Flywheel cover By the driving pulley turn the engine to find the alignment of the references to identify the TDC Repe...

Page 217: ...diagnostic tester dwg 020460Y Start the engine Select the menu on the parameters function Select the stroboscopic lamp control in the conventional 4 stroke engine position 1 spark 2 revolutions Check that the real values of rpm and ignition advance match those measured by the diagnostic tester PGO BR 500 ENGINE P 9 70 Ignition timing ...

Page 218: ...2 VALVE POSIT SENSOR 4 FLUID TEMPERATURE SENSOR 1 Connect the injection diagnostic tester dwg 020460Y and select the menu on the errors function Check whether there are any indications regarding the cooling fluid temperature sensor YESgo to 3 NOgo to 2 2 The EMS system has received no indications of temperatures out of the range of possible temperatures If you suspect a wrong temperature indicatio...

Page 219: ...ls 4 and 22 4 22 Resistance equal to the value directly detected at the sensor YESgo to 13 NOgo to 11 11 If slightly higher values are detected check the connectors If infinite resistance is detected 1MW check the continuity between the two lines with disconnected connectors Blue white 4 0W continuity Light blue green 22 0W continuity YESgo to 12 12 Replace or fix the wiring YESgo to 10 13 Check t...

Page 220: ...VOLTAGE X V 10degree C X V 0 X V 10degree C X V 20degree C X V 30degree C X V 80degree C YESgo to 21 NOgo to 17 17 Measured value 5 0 2 V Repeat the wiring and sensor continuity checks YESgo to 18 18 Measured value 0 V Repeat the sensor and circuit earth insulation check SIgo to 19 NOgo to 20 19 Check the controller connection connector Check the controller power supply Replace the controller if n...

Page 221: ...Replace the temperature sensor NOTE For a more accurate check of the sensor remove it from the engine and check its resistance at controlled temperature Using a suitable container immerse the metal portion of the sensor in water heat gradually and read the temperature and resistance values Check the matching as per table PGO BR 500 ENGINE P 9 74 Cooling Fluid temperature sensor ...

Page 222: ...o to 3 NOgo to 2 2 The EMS system has received no indications of temperatures out of the range of possible values If you suspect a wrong temperature indication check as follows 3 Before checking the sensor and the relevant circuit wait until the engine has cooled down and the vehicle has set to the working area temperature YESgo to 4 4 Set the switch to ON with switch to RUN and side stand raised ...

Page 223: ...ensor YESgo to 13 NOgo to 11 11 If slightly higher values are detected check the connectors If infinite resistance is detected 1MW check the continuity between the two lines with disconnected connectors Grey white 18 0 W continuity Light blue green 22 0 W continuity YESgo to 12 12 Replace or fix the wiring YESgo to 10 13 Check that the sensor circuit is earth insulated 18 23 W infinity 1MW 22 23 W...

Page 224: ... to 17 17 Measured value 5 0 2V Repeat the wiring and sensor continuity checks YESgo to 18 18 Measured value 0 V Repeat the sensor circuit earth insulation check YESgo to 19 NOgo to 20 19 Check the controller connection connector Check the controller power supply Replace the controller if necessary 20 Replace or fix the wiring 21 Start the engine and check that voltage decreases gradually accordin...

Page 225: ...the menu on the ERRORS function Check whether there are any indications regarding the pressure sensor YES go to 2 NO go to 3 2 Replace the injection controller 3 Select the menu on the parameters function Check that the pressure value in mm Hg matches that of another vehicle or of an external barometer Max error 20 mmHg YES go to 4 NO go to 5 4 The ambient pressure signal is correct 5 Replace the ...

Page 226: ...ATURE SENSOR 2 VALVE POSIT SENSOR 4 FLUID TEMPERATURE SENSOR 1 Connect the diagnostic tester dwg 020460Y Set the switch to ON with switch to RUN and side stand raised Select the tester menu on the ERRORS function Check whether the controller has detected any failures relating to the gas valve position signal YESgo to 6 NOgo to 2 2 Select the diagnostic tester menu on the parameters function Check ...

Page 227: ... to 12 NO go to 11 11 Check the controller connection connector Replace the controller if necessary YESgo to 10 12 Connect the gas valve position sensor connector Repeat the voltage measurement between terminals 1 and 22 of the specific tool 1 22 5 0 2 V YESgo to 13 NOgo to 14 13 Measure voltage between terminals 11 and 22 Gradually open the throttle valve and check that the voltage value increase...

Page 228: ...r YESgo to 12 15 Check that the voltage measured at pins 11 and 22 matches that indicated by the diagnostic tester set to parameters YES go to 16 NOgo to 17 16 The gas valve position sensor and relevant circuit are conforming 17 Replace the controller PGO BR 500 ENGINE P 9 81 T P S ...

Page 229: ...sensor withvalve at minimum value may vary for different throttle bodies For optimum carburetion especially with smallopenings of the gas valve it is necessary to match the throttle body with thecontroller according to the procedure called TPS This operation allows setting the mV value inthe controller as starting point corresponding to the pre calibration position The controller will recognise su...

Page 230: ...cement of the throttle body in case of replacement of injectioncontroller NOTE TheTPS reset procedure must not be carried out with old throttle bodies since thepossible valve and abutment wear make the air flow rate different from that ofpre calibration PGO BR 500 ENGINE P 9 83 T P S Reset ...

Page 231: ...t closing of the stepper to stabilise the speed In case of irregular speed before carrying outelectric checks inspect the gas valve and the auxiliary air circuit cleaning To check the stepper and the relevant circuit proceed as follows 1 Controller 2 Stepper 1 Connect the diagnostic tester dwg 020460Y Set the switch to ON with switch to RUN and side stand raised Lift the vehicle on the central sta...

Page 232: ...throttle body Check the auxiliary air circuit cleaning Switch from ON to OFF and again to ON and check whether the piston valve moves If the valve does not move replace the throttle body 10 Replace the throttle body 11 Connect the specific tool dwg 020481Y For these checks do not connect the specific tool to the controller Check the continuity of the 4 power supply lines of the stepper A Light blu...

Page 233: ...ised Repeat the ON OFF ON switching Check the presence of voltage pulses on the stepper command lines Setup for direct voltage measurements 14 24 V pulses for a few seconds 6 21 V pulses for a few seconds NOTE pulses are used to change the stepper position After reaching the optimum position the power supply voltage becomes null YESgo to 17 NOgo to 18 17 The stepper circuit is efficient 18 Check t...

Page 234: ...r pipe YESgo to 3 3 Connect the diagnostic tester dwg 020460Y Set the switch to ON with switch to RUN and side stand raised YESgo to 4 4 Select the menu on the ERRORS function Check whether there are any failures YESgo to 6 NOgo to 5 5 Select the menu on the PARAMETERS function YESgo to 7 6 Fix the wiring according to the instructions provided YESgo to 4 7 Start the engine and let it warm up to ob...

Page 235: ...o decrease the CO it is necessary to decrease the injection time Adjust the trimmer value according to the information provided in the table YESgo to 14 TRIMMER VALUE 100 50 10 0 10 50 100 INJECTION TIME HIGH LOW MEDIUM C O INCREASES DECREASES 14 After changing the trimmer wait for the CO value to adjust When adjustment is correct press OK to store the value in the controller YESgo to 15 15 Select...

Page 236: ...e of the original controller if available In any case check the CO value again NOTE When the CO percentage is correct and the CO2 percentage does not fall within the prescribed values the LAMBDA value is not correct In this case carefully check the exhaust system seal When the CO percentage is correct and the HC value PPM is higher than the maximum admissible value check spark plug valve clearance...

Page 237: ...TRIC FAN REMOTE CONTROL SWITCH 3 FUSE 30A 1 Connect the diagnostic tester dwg 020480 Set the switch to ON with switch to RUN and side stand raised Select the ERRORS function Check whether the controller has detected any failures relating to the electric fan control circuit YESgo to 8 NOgo to 2 2 Select the menu on the ACTIVE DIAGNOSIS function Start the electric fan diagnosis function Acoustically...

Page 238: ...tery positive voltage at pin 85 of the remote control switch connector 85 blue grey 23 battery voltage with switch set to ON YESgo to 13 NOgo to 12 12 Replace or fix the wiring 13 Keeping the remote control switch disconnected and check the continuity between pin 86 of the remote control switch connector and pin 5 of the controller 86 green white 5 0W continuity YESgo to 14 NO go to 15 14 Check th...

Page 239: ...between terminals 5 and 23 with key switch set to ON 5 23 battery voltage with panel set to ON YESgo to 17 17 Repeat the check with connected controller and cold engine 5 23 battery voltage with panel set to ON If the fault continues replace the controller PGO BR 500 ENGINE P 9 92 Electric Fan control circuit ...

Page 240: ...INDEX OF TOPICS BRAKING SYSTEM 8 ...

Page 241: ...uid tank fill it with brake fluid and bleed air at front and rear calipers 4 Push the pedal and continue to bleed air until there is no air inside the brake tube 5 There is about 500 c c of brake fluid inside the whole brake circuit Brake hose When install the brake hose take care there are 1 washer in each side of the hose joint Lock torque of the bolt 2 0 3 0 kg m P 8 2 PGO BR 500 ENGINE ...

Page 242: ...cket bolts of caliper s pads 4 Fix the bracket and body with pliers 5 Withdraw the pads and yoke as figure shown Inspect If the pads almost reach the grove bottom or less than 1 5mm you have to replace a new pairs Install 1 Be careful the big pad shall locate outside the lock pin of the yoke 2 Reverse the dismantle procedure to install the pads P 8 3 PGO BR 500 ENGINE ...

Page 243: ...oosen the 2 bolts of caliper bracket with the rear brake hub 4 Loosen the 2 socket bolts of caliper s pads 5 Press the bracket of caliper to the cylinder side 6 Withdraw the brake pads Inspect If the pads almost reach the grove bottom or less than 1 5mm you have to replace a new pairs Install 1 Reverse the dismantle procedure to install the pads P 8 4 PGO BR 500 ENGINE ...

Page 244: ... bolts with the rear swing arm withdraw the hand park caliper 4 Punch the 2 lock pin 6mm diameter according to the figure shown direction 5 Withdraw the pads Inspect If the pads almost reach the bottom or less than 1 5mm you have to replace a new pairs Install 1 Reverse the dismantle procedure to install the pads P 8 5 PGO BR 500 ENGINE ...

Page 245: ...INDEX OF TOPICS STEERING WHEEL AND SUSPENSIONS 7 ...

Page 246: ...is only necessary to remove the 4 lug nuts to remove the wheel See Figure Tighten the nuts after replacing the wheels B Rear Wheel Replacement Do not disassemble the castle nuts when you replace the rear wheels It is only necessary to remove the 4 lug nuts to remove the wheel P 7 2 PGO BR 500 ENGINE ...

Page 247: ...1 8 1 4 greater than dimension B 2 To adjust the alignments loosen the lock nuts on both sides of Front Tie Rods To make dimension B smaller turn the rod to the left Adjust the rod to right direction to make dimension B larger After adjusting to the desired length tighten the lock nut against the rod end 3 Recheck the dimensions for proper alignment B A Right tie rod Left tie rod P 7 3 PGO BR 500 ...

Page 248: ...eplace the bush 3 Install the bush to the swing arm apply some grease on the inner diameter of the bush before inserting the spacer tube E Front A arms 1 before install A arms to chassis you have to lock the bolts of front absorber first Lock torque 4 0 5 0 kg m 2 Then lock the bolts of A arms with Lock torque 4 0 4 5 kg m 3 Check the bush make sure there is no any crack occurs 4 Check the clip of...

Page 249: ...tion and turn counterclockwise to left direction 2 Check the rubber of turn mechanism assembly if worn out or grease leaking out that will make you harder to operate turning 3 Check the tie rod of turn mechanism assembly lock tight the cotter hexagon nut with Locking torque 3 5 4 0 kg m P 7 5 PGO BR 500 ENGINE ...

Page 250: ...INDEX OF TOPICS VEHICLE ENGINE 6 ...

Page 251: ...om the intake manifold and cooling system piping outlet from the head and the inlet to the thermostat Disconnect the spark plug H V cable and the generator cables from the vehicle electric system Take off the CV joints Loosen the bolts of rear muffler section and dismantle muffler Loosen the bolts of engine with the engine hanger loosen the bolts of reverse gear box with the bracket Loosen the nut...

Page 252: ... torques indicated in chapter Characteristics Check the engine oil level and top up using the recommended brand if required Fill the cooling circuit Check that accelerator and electric devices are in good working order Caution Be very careful to ensure that the fuel control layout is in proper position P 6 3 ...

Page 253: ...INDEX OF TOPICS VEHICLE ENGINE 6 ...

Page 254: ...om the intake manifold and cooling system piping outlet from the head and the inlet to the thermostat Disconnect the spark plug H V cable and the generator cables from the vehicle electric system Take off the CV joints Loosen the bolts of rear muffler section and dismantle muffler Loosen the bolts of engine with the engine hanger loosen the bolts of reverse gear box with the bracket Loosen the nut...

Page 255: ... torques indicated in chapter Characteristics Check the engine oil level and top up using the recommended brand if required Fill the cooling circuit Check that accelerator and electric devices are in good working order Caution Be very careful to ensure that the fuel control layout is in proper position P 6 3 ...

Page 256: ...assis loosen the bolts of reverse gear box bracket with the engine Loosen the socket nut of transmission with engine assembly take off the complete transmission away from engine Attention when lock this socket nut back to engine apply anti loosen glue loctite 243 to the inner thread and lock torque is 100 120N m 100 120 N m apply loctite 243 Damper bolt P 6 4 ...

Page 257: ...Transmission Gear box explosive diagram P 6 5 ...

Page 258: ...P 6 6 ...

Page 259: ...INDEX OF TOPICS ELECTRIC SYSTEM 5 ...

Page 260: ...ure the fuel gauge can move freely up and down The full capacity of fuel tank is about 20 liters whenever the fuel indicator twinkling only about 5 liters left in fuel tank you have to fill the fuel as soon as possible Otherwise it might damage the fuel pump for long time lacking fuel Fuel pump gauge outlet return ECU REGULATOR Fuel gauge Fuel pump Fuel filter P 5 2 PGO BR 500 ENGINE ...

Page 261: ...3 Ignition coil 4 Neutral sensor 5 Oil pressure sensor Ignition coil Neutral sensor Oil pressure sensor P 5 3 PGO BR 500 ENGINE ...

Page 262: ...ed is the related circuit EMS diagonist Gear shift controller Signal flasher Solenoid valve shift gear Only when engine speed between 1000 3000 rpm push the brake pedal that controller permit the solenoid valve act Gear shift controller 12V Rpm sensor ground Relay gear shift Solenoid valve 12V ground Brake sensor To gear shift indicator P 5 4 PGO BR 500 ENGINE ...

Page 263: ...e pole of battery connect black cable of negative pole of battery It means starter is function well if above connection and both Red Black cable of staring motor have currency passing through Red main relay Blue high beam relay White low beam relay Black cooling fan relay White fuel pump relay P 5 5 PGO BR 500 ENGINE ...

Page 264: ... 1 3A 2 10A 2 15A 3 25A 1 NOTE when replacing the fuses always use the specification as original manufactured right is the individual fuse and related parts indication Low lamp High beam Position lamp When switch to low beam only low lamp is ON When switch to high beam both high lamp position lamp are ON fuses Starting circuit relay P 5 6 PGO BR 500 ENGINE ...

Page 265: ... injector Air temperature sensor Throttle position sensor Coolant sensor Fuel pump injector Coolant sensor Engine speed sensor Ignition coil Throttle position sensor Air temperature sensor Generator coupling Engine speed pick up coupling P 5 7 PGO BR 500 ENGINE ...

Page 266: ...sure is enough Thermal sensor Throttle cable Cooling fan coupling Cooling fan coupling locates above the radiator Cooling fan is controlled by ECU 100 ON 95 OFF Relay of control circuit Ignition switch 12V Brake sensor Starting relay pole of battery To starting motor 12V P 5 8 PGO BR 500 ENGINE ...

Page 267: ... and the negative cable of the recharge to the negative cable of the battery Recharging currency Please recharge 12V according to the following current and time Standard 1 4A 5 10Hr or Rapid 14A 30min Attention disconnect the battery wires when storage period is longer than 1 month NOTICE This battery is totally sealed Do not remove seal bolt when recharging Notice Keep away from fire when recharg...

Page 268: ... switch at OFF engine revolution is at 2000 rpm while testing Then increase the rpm slowly Assume the battery is fully charged situation Head Lamp Switch 1 500rpm 3 000prm OFF DAY 0 8A MIN 1 0A MIN ON NIGHT 0 4A MIN 0 7A MIN d System layout While testing the red wire cable must not touch the frame This test needs to be done when the battery is fully recharged This test needs to be done after engin...

Page 269: ...uced 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 ELECTROLYTE Take most care so as not to cause battery acid to contact a person and the vehicle If battery acid has contacted the skin clothes or vehicle immediately flush with plenty of water If battery...

Page 270: ...olyte 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 thereafter press the cap little by little into each filler hole evenly and horizontally Inserting the cap at once in one cell and then in the next Cell will cause the cap to deform resulting in poor sealing CAUTION ...

Page 271: ...ry 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 charging unless otherwise necessary After recharging wait for more than 30 minutes and check the battery voltage with a pocket tester If the battery voltage is less than the 12 5V recharge the battery again in ...

Page 272: ...PGO BR 500 ENGINE P 5 14 ...

Page 273: ...INDEX OF TOPICS COOLING SYSTEM 4 ...

Page 274: ...hermostat output to the radiator is closed even thoughthere is still a little flow for de aeration obtained by a hole into theclosing plate In thiscase the circulation into the thermal unit is active to ensure an evenheating Once theworking temperature has been reached the main circulation on radiator andexpansion tank starts With thesmall openings in the thermostat there is a flow overlapping rec...

Page 275: ...AX levels indicated in the expansion tank filler Do not close the expansion tank with the cap Use a transparent hose to connect the venting union with the expansion tank filler Loosen the vent and start the engine Keep it open until the air has been fully vented Close the venting screw Stop the engine Restore the level into the expansion tank and tighten the cap Start the engine and let it warm up...

Page 276: ...ype wax with deviator Starts opening 82 2蚓 ELECTRIC VENTILATION Type Piston Electric ventilation start 107蚓 Electric ventilation end 103蚓 WATER PUMP Type Centrifugal Control Coaxial at the countershaft RADIATOR Type Aluminium with horizontal circulation EXPANSION TANK Calibration Automatic venting in parallel with the radiator P 4 4 PGO BR 500 ENGINE Cooling System ...

Page 277: ...flywheel cover paragraph Visually check that the thermostat exhibits no mechanical faults Prepare a metal container with 1 litre of water Immerse the thermostat keeping it in the middle of the container Immerse the multimeter thermometer probe close to the thermostat Heat the container by the thermal gun Heat the water and periodically pull the thermostat out until its opening becomes visible Inse...

Page 278: ... full opening N B Heating should be gradual Caution Avoid contact between thermostat and container for a correct test performance If incorrect values are detected replace the thermostat Repeat the filling and venting procedure P 4 6 PGO BR 500 ENGINE Cooling System ...

Page 279: ...tion controller see Injection chapter If the analogue instrument temperature is close to the red zone but the degrees indicated by the diagnostic tester is below the electric ventilation temperature check the temperature sensor on the head and the relevant injection circuit see 11 Injection chapter N B The electric ventilation temperature at 107 C can only be managed with a system supplied with a ...

Page 280: ...005 Flywheel cover span hapter 1 Check the system outside seals as described above YESgo to 2NOgo to 3 2 Check the head gasket seal see Thermal unit and timing system chapter If water leaks are detected in the engine oil inspect the pad on the head cooling circuit 3 Fix any damaged seals 1 Oil into the cooling fluid YES go to 2 2 Check the head gasket seal see Thermal unit and timing system chapte...

Page 281: ...INDEX OF TOPICS MAINTENANCE 3 ...

Page 282: ... I Cooling water radiator hose Leaking check and clean the radiator if necessary I I I I I I I Clutch linings Check or replace it if necessary I I I I I I Tires Worn out check or replace it if necessary I I I I I I Wheel bearing Fasten tightly if loosen I I I I I I Driving CV joint Lubricate check the slack I I C A L I C A L I C A L Chassis suspension arm spindle Check looseness Add grease if requ...

Page 283: ... 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 Change the oil seal of main cylinder and caliper every two years 4 Change the brake fluid hose every four years NOTE 3 water cooled engine 1 Clean the filter of cooling fan per 3 000 kms 2 Check the clamping and...

Page 284: ...ses Chip type 1A 1 3A 2 10A 2 15A 3 25A 1 17 Lubrication By trochoidal pump inside the crankcase pressure adjustment by pass and oil filter 18 Lubrication pressure 4 bar 19 Minimum allowed at 100 degree C 0 8 bar 20 Engine oil Synthetic SAE 5W 40 of higher quality than API SJ specification 21 Engine reduction Gear oil TUTELA ZC 90 250 cc replacement 22 Transmission gear oil TUTELA ZC 90 750 cc rep...

Page 285: ...er 50 coolant distilled water Coolant replacement at least every 2 years 1 Coolant draining a Remove the engine drain bolt b Remove the inlet hose of front radiator right lower or the drain cap of radiator left lower c Reinstall the drain bolt and inlet hose of front radiator ATTENTION Service the cooling system ONLY when the engine is COLD DRAINING Engine coolant drain bolt inlet hose of radiator...

Page 286: ...fied ratio coolant from the radiator cap when the engine is stopped 5 when the coolant flow out from the ventilation screw start the engine and keep in idle speed refill the coolant until the flow is steady and without any bubbles Lock the ventilation screw 6 The total coolant capacity step 2 3 is about 3 500 C C Fill in coolant from radiator cap FILLING P 3 6 PGO BR 500 ENGINE Maintenance ...

Page 287: ... if full 3 Cleaning The element of BR 500 is sponge type that means you can maintain it to multiple usage a Wash the sponge with water and shampoo b Dry up by small compressed air jets and a clean cloth c Soak with 50 fuel and oil SELENIA AIR FILTER OIL mixture d Let the filtering element drip and press it with your hands without squeezing e Replace the filtering element Caution Never let the engi...

Page 288: ...ine oil when without replacing the oil filter 5 Repeat step 1 2 check the oil gauge make sure the oil level is between the MAX and MIN 6 Check oil level before each use of kart or after each 1 000 kilometers of operation Add oil to bring up to proper level Do not mix various grades of oil Replace engine oil filter 1 Use a filter tape wrench to remove the oil filter 2 Make sure that the O rings of ...

Page 289: ... E SERVICE AIR CLEANER ASSEMBLY On the occasion to replace the air cleaner assembly 1 dismantle the rear rack first to make the air cleaner body could be removed or installed easily 2 Pay attention to the front housing of air cleaner assy it shall be engaged to the engine case bracket properly then lock the screw Fill in Cap Oil draining bolt P 3 9 PGO BR 500 ENGINE Maintenance ...

Page 290: ...fter draining the oil be sure install the plug and clip back well G SERVICE CLEANING THE AIR INLET of CVT TRANSMISSION 1 Continuous Variable Transmission CVT sucks fresh air to reduce the high temperature inside 2 To have longer life for the CVT parts such as V belt you have to maintain the air inlet So we recommended you to clean the inlet about per 1 000 kilometers 3 Even clean it every time aft...

Page 291: ...wder etc inside the CVT periodically about 2000 3000 kilometers Check the V belt if there is any crack occurs replace it Check the o ring as right figure shown lubricate it or replace it when it worn out I SERVICE THE GASKET of MUFFLER 1 There are 2 sections of the muffler and they are coupled by a clamp as shown 2 There is a gasket inside the clamp to avoid leakage be sure to replace it when leak...

Page 292: ...re easy starting and good engine performance J Idle Adjustment Never make unnecessary adjustments The factory recommended settings are correct for most Applications Meanwhile this kart s idle is controlled by EMS Electric Management System you don t have to adjust the idle speed But however you still have to make sure the throttle cable clearance as follows 1 Make sure the front section is well nu...

Page 293: ...ee of debris for proper cooling L Kart Lubrication Lubricate vehicle every 90 days of use M Driving shaft Lubrication 1 To increase driving shaft life it should be lubricated with grease inside the rubber 2 Check the rubber make sure there is no any grease comes out from it If the rubber is wear defect contact your dealer to replace a new one Wheel side of CV joint engine side of CV joint P 3 1 3 ...

Page 294: ...e event your kart is not to be operated for a period in excess of 30 days or at the end of each driving season prepare of storage as Follows 1 Drain fuel tank and fuel pipes by allowing engine to run out of fuel and use a fuel stabilizer 2 Lubricate engine cylinder by removing the air cleaner then spray engine fogging oil though the carburetor until motor dies 3 Do not save or store gasoline over ...

Page 295: ...plug H V cable cap Unscrew the spark plug using the spanners supplied Inspect the spark plug the insulator s integrity too worn or sooty electrodes sealing washer state and measure the distance between the electrodes using the special thickness gauge Distance between the electrodes 0 7 0 8 mm Adjust the distance if required by bending the side electrode carefully In case of irregularity replace th...

Page 296: ...eezing Replace the filtering element N B Failure to observe the rules regarding the filtering element cleaning could cause an improper lubrication of the same A poor lubrication affects the filtering capacity An excessive lubrication causes a concentration of the carburetion Caution If the vehicle has ridden on dusty roads the air filter must be cleaned more frequently than what indicated in the s...

Page 297: ... the check is carried out after the vehiclehas been used and therefore with a hot engine the level line will be lower in order to carry out a correct check it is necessary to wait at least 10minutes after the engine has been stopped so as to get the correct level Oiltop up The oil should be topped up after having checkedthe level and in any case by adding oil withoutever exceeding the MAX level Re...

Page 298: ...filter and drainage cap are not worn Lubricate the O rings and replace net filter and oil drainage cap tighten at the prescribed torque Replace a new cartridge filter after lubricating the O ring then screw it up to touching the gasket and tighten further to the prescribed torque Replace the silencer Fill in approx 1700 cc of engine oil span Start the engine let it run for a few minutes and stop i...

Page 299: ...re if the level is below the MIN value restore the proper amount of oil in the hub Screw the oil bar back on checking that it is tightly in place PGO BR 500 ENGINE Prepare a suitable container Remove the oil loading cap A Remove the oil drainage cap B and let the oil drain out completely Tighten the drainage cap again and fill the hub with oil Remove the oil loading cap Recommended oil TUTELA ZC 9...

Page 300: ...into the filler indicates the MIN and MAX level The cooling fluid consists of a mixture of 50 demineralised water and ethylene glycol and corrosion inhibitors based anti freeze solution Caution To prevent leaks of the cooling fluid from the expansion tank during the use of the vehicle never exceed the MAX level upon filling N B The cooling fluid consists of a mixture of demineralised water and flu...

Page 301: ...n positionas long as the gauge value is steady If pressure is correct 11 bar remove the tool and reinstall the spark plug the cap and the stroke revolutionconnector Ifthe pressure is less than what indicated check the rpm at which the test iscarried out ifit is less than 450 rpm check the start up system if not check thefollowing Timing Valveclearance Valveseal Liningseal Propercompression ratio s...

Page 302: ...mp cover and theloading cap located on the expansion tank Caution This operation should be carried out on coldengine Open thewater pump cover shown in the figure by loosening the 6 fixing screws Cooling systemcapacity 1 7 lt Follow theinstructions provided in the Engine chapter to partly discharge thesystem and to inspect the pump Once thefault has been fixed and all components have been replaced ...

Page 303: ...INDEX OF TOPICS OPERATION 2 ...

Page 304: ...mbly to ensure that when the pedal is pushed all the way forward the assembly is working smoothly and returns to idle If unable to correct the problem through lubrication linkage fail to return to idle If unable to correct the problem through lubrication adjustment or replacement of worn parts contact your dealer for assistance b Brake The brake is located on the left side of the buggy See Fig 1 A...

Page 305: ...g this vehicle test the Parking Button to assure that it is operating properly With the key on push and hold the Parking Button for two seconds for the signal lamps to twinkle For your safety please usually choose a flat area to park the vehicle Before leave the vehicle besides shifting the gear to P position remember to pull the Parking lever up e Control panel of BR 500 Parking switch LCD dashbo...

Page 306: ...f Fuel cap The fuel cap is located at the rear right side of the buggy insert the main key turn it clockwise to open the cap fill with unleaded fuel only P 2 4 PGO BR 500 ENGINE ...

Page 307: ...w this lamp warns you to inspect the engine oil level Parking indicator lamp EMS check indicator lamp when this lamp is ON during driving you have to inspect the EMS as soon as possible Excludes the initial self test after the main key is ON High beam indicator lamp Neutral gear indicator lamp only at this position that you can start the engine You can t shift the gear until this bulb lights ON Th...

Page 308: ...elect 12 then it will show AM or PM rpm Engine high speed warning limit accelerating the engine to shifting warning speed and press RESET to input this parameter hereafter when the engine reaches this speed the display rpm will twinkling to warn you reducing the engine speed SPC Engine ignition parameter 0 5 1 0 1 5 2 0 the default value is 2 0 3 Display description switched by MODE in main menu S...

Page 309: ...water warning When the indicator reaches RED area that warns you the temperature of cooling water is too high you have to stop the engine and cold down the temperature immediately RED area P 2 7 PGO BR 500 ENGINE ...

Page 310: ...heels to see that all axle nuts and lug nuts are tightened properly Check and tighten as necessary all other fasteners to specified condition i Check Roll Cage Bar Ensure all protective roll cage bars are in place before operating the Kart j Check Brake Light Check for proper operation k Check Wheels Check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins l ...

Page 311: ...asic Component locations Rear Signal Lamp Rear absorber Muffler Driving Shaft Fuel Tank Rear Brake Lamp Interior Mirror Back Mirror Head Lamp Seat Belt Steering Wheel Front Absorber P 2 9 PGO BR 500 ENGINE ...

Page 312: ...nd that seat is locked into position Before attempting to adjust the seat ensure that engine of the buggy is stopped Never operate this buggy when the provided seat is not securely fastened to do so could result in strong Possibility of severe personal injury or loss of life Before attempting to adjust the seat ensure that engine of buggy is stopped F Driving control When shifting the lever to R y...

Page 313: ...P Parking Attention Shift the gear Only when the buggy is stationary for the machine s good Keep in N or P position when you stop the buggy for your safety refer to the gear shift box as right photo practice making gear lever slide into correct position Be more familiar with the gear lever shift route and it will get easier to enjoy driving H Differential control lever LOCK means the differential ...

Page 314: ...wly until you are familiar with it d The turning radius of this buggy is small and agile so the centrifugal force is very high whenturning at high speed Slow down to a more controllable speed when turning to prevent the buggy from rolling over e To prevent vehicle from rolling over be sure to only turn the vehicle at a slow more controllable speed Heel on the ramp of the main board when turning Ke...

Page 315: ...ark adjusting nut Hand park cable adjusting nut Clearance adjusting nut for throttle Stop bolt for GO pedal Lock nut for throttle cable Adjusting nut for shifting cable Lock nut for differential control cable P 2 1 3 PGO BR 500 ENGINE ...

Page 316: ...whom may concern 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 the diagrams already shown Though we have tried our best please kindly instruct us any faults found in this manual MOTIVE POWER INDUSTRY CO LTD ...

Page 317: ... TOPICS CHARACTERISTICS 1 OPERATION 2 MAINTENANCE 3 COOLING SYSTEM 4 ELECTRIC SYSTEM 5 VEHICLE ENGINE 6 STEERING WHEEL AND SUSPENSIONS 7 BRAKING SYSTEM 8 INJECTION 9 ENGINE 10 PRIOR TO DELIVERY 11 TIME CHART 12 ...

Page 318: ...INDEX OF TOPICS CHARACTERISTICS 1 ...

Page 319: ... 8 12 TOP SPEED 80 KM H REAR 27 10 12 FUEL CONSUMPTION 20 km l BRAKE SYSTEM CLIMBING ABILITY 25 FRONT DISC BRAKE ENGINE TYPE M343M REAR DISC BRAKE CYCLE 4 LIGHT FUEL UNLEADED 95 HEAD LIGHT H L 12V 35W 35W 2 CYLINDER NUMBER 1 TAIL LIGHT 12V 5W ARRANGEMENT HORIZONTAL BRAKING LIGHT 12V 21W DISPLACEMENT 460 cc TURN LIGHT 12V 10W 2 12V 21W 2 BORE φ92 mm STROKE 69 mm COMPRESSION RATIO 10 5 1 MAX POWER R...

Page 320: ...connect positive pole first 7 Before installing a new fuse confirm the specification is correct or not Do not use a higher ampere than the original specification 8 After reassembling please re check that all connecting point locking parts circuits polar characteristics are good before selling out 9 Fuel is highly flammable and in some conditions it can be explosive Do not smoke in the working area...

Page 321: ...10 14 10 Phase evolution sensor fastening screw 1 3 4 11 Injector fastening screw 1 3 4 12 Valve lifting device mass stop bell fastening screw 1 30 35 13 Intake manifold fastening screws 3 11 13 14 Tappet cover fastening screws 6 7 9 15 Throttle body fastening screws 3 11 13 16 Camshaft retaining bracket fastening screws 3 4 6 17 Tightener fastening screws 2 11 13 18 Head fastening screws 3 10 12 ...

Page 322: ...INAL REDUCTION 31 Hub cover screws 24 27 TRANSMISSION COVER 32 Driven pulley nut 1 92 100 33 Driving pulley nut 1 160 175 34 Transmission cover M8 fastening screws 4 23 26 35 M6 fastening screws 7 11 13 36 Anti flapping roller fastening screw 1 17 19 37 Clutch ring nut 1 65 75 38 Internal air conveyor screws 2 7 9 39 Water pump cover screws 6 3 4 40 Outside transmission cover screws 4 7 9 41 Flywh...

Page 323: ...rvice Engine parts Engine oil drain bolt 2nd Oil filter Hub gear oil drain bolt Engine coolant water drain bolt Bolts for cylinder head cover Reverse gear oil drain bolt P 1 6 Locking Torques PGO BR 500 ENGINE ...

Page 324: ...ie rod nuts 4 10 3 5 4 0 10 Roll cage bar 6 8 4 0 11 Rear swing arms with frame 2 16 10 0 11 0 12 Rear swing arms with rear hub 8 10 3 5 4 0 13 Engine hanger with frame 2 8 2 0 3 0 14 Engine hanger with engine 1 12 4 0 5 0 15 Connecting rod nuts 2 10 3 5 4 0 16 Brake caliper fixture 8 8 2 0 3 0 17 Park Brake fixture 4 8 2 0 3 0 18 Brake hose bolt 6 8 2 0 3 0 19 Braking sensor 1 8 2 5 3 0 20 Neutra...

Page 325: ...Chassis parts nut for tie rod V S A arm adjusting nut for tie rod Nuts for wheel rim Bolt for balance bracket Bolts for A arm Bolts for cushion lower upper P 1 8 Locking Torques PGO BR 500 ENGINE ...

Page 326: ...ear swing arm V S brake hub Bolt for rear swing arm Nut for engine hanger V S engine Bolts for Reverse gear V S bracket Bolts for fixing muffler Bolts for engine V S engine upper bracket P 1 9 Locking Torques PGO BR 500 ENGINE ...

Page 327: ...ter 4 Tech Brake fluid Synthetic fluid SAE J1703 NHTSA 116 DOT 4 ISO 4925 TUTELA TOP 4 Coolant Anti freezing fluid based on monoethylene glycol CUNA NC 956 16 PARAFLU FE Grease for driven pulley shaft compensating ring and mobile driven pulley sliding seat Molybdenum bisulphide grease MONTBLANC MOLYBDENUM GREASE Dwg 498345 Grease for steering wheel bearings pin seats and oscillating arm Lithium so...

Page 328: ...arance upon assembly Abbrev Cylinder Piston A 91 990 91 997 91 947 91 954 0 036 0 050 B 91 997 92 004 91 954 91 961 C 92 004 92 011 91 961 91 968 D 92 011 92 018 91 968 91 975 Fit linings 2 and 3 with TOP upwards Arrange the strip opening as shown Value A of the sealing ring into the cylinder Ring opening NAME DIMENSION CLEARANCE NAME CLEARANCE WHEN SEATED MAX CLEARANCE AFTER USE First compression...

Page 329: ...he plane formed by thecylinder top the thicker the base gasket On the other hand the more thepiston top is recessed into the cylinder top plane the smaller the gasketthickness The values indicated with refer to recesses MEASURE TAKEN A BASE GASKET THICKNESS 0 185 0 10 0 4 0 05 0 10 0 10 0 6 0 05 0 10 0 185 0 8 0 05 PGO BR 500 ENGINE Driving shaft crankcase axial clearance 0 1 0 5 mm when cold P 1 ...

Page 330: ...Flywheel side shoulder F 13 0 025 Complete driving shaft G 63 5 0 1 0 05 PGO BR 500 ENGINE Drivingshaft alignment Specificequipment and tools Driving shaft support 020074Y Comparator 020335Y Measure the capacity on both axes x y Driving shaft Standard diameter Cat 1 40 010 40 016 Cat 2 40 016 40 022 Max admissible displacement A 0 15 mm B 0 010 mm C 0 010 mm D 0 10 mm P 1 13 Vehicle Overhaul Data ...

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