PGO BR-150 Bug Rider Service Manual Download

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BR-150
SERVICE MANUAL

Manufactured by PGO

of Motive Power Industry Co., Ltd

Summary of Contents for BR-150 Bug Rider

Page 1: ...BR 150 SERVICE MANUAL Manufactured by PGO of Motive Power Industry Co Ltd...

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

Page 3: ...oncern how to maintain in detail repair change parts troubleshoot and reassemble etc At every important section we illustrate by assembly explosion diagrams and photographs if necessary please check t...

Page 4: ...CE FRONT DISC BRAKE TOP SPEED 70KM H REAR DRUM BRAKE FUEL CONSUMPTION 25KM L LIGHT CLIMBING ABILITY 25 HEAD LIGHT H L 12V 35W 35W 2 TAIL LIGHT 12V 5W CYCLE 4 BRAKING LIGHT 12V 21W FUEL UNLEADED TURN L...

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

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

Page 7: ...suspension arm 2 8 3 0 8 Tie rod nut 4 10 5 0 9 Roll cage bar 6 8 4 0 10 Rear swing arm lower 2 12 6 0 11 Engine hanger with frame 2 10 3 5 4 5 12 Engine hanger with engine 1 10 3 5 4 5 13 Rear absorb...

Page 8: ...L I C A L I C A L Steering joint rod Check looseness Adjust it if required I I I Absorber Leakingand function check I I I I Parking Function check or replace it if required I I I I I I I Nuts bolts fa...

Page 9: ...1 1 2 3 4 5 6 7 8...

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

Page 11: ...3 16 17 18 19 20 21...

Page 12: ...3 1 OPERATION 1 OPERATION LAYOUT...

Page 13: ...hout pressing any button during20 sec it will escape to main menu automatically Button operation Situation Button Setting Main menu MODE to next parameter 2 escape switch display RESET digital 1 2 no...

Page 14: ...1 3 2 Steering Inspection Adjustment Dismantle Lock tight the bolts of steering handle Torque 0 5 kg m...

Page 15: ...2 Steering Inspection Inspect the coupling joint knuckle Maintenance Add grease into upper suspension arm per 10 000km from grease valve...

Page 16: ...spection Inspect the absorber function check and oil leakage check Inspection Lock tight the nut of tie rod with steering spindle support Inspect the clearance of tie rod with the steering spindle sup...

Page 17: ...4 Steering Inspection Adjustment Steering Inspection Adjustment Lock tight the bolt Add grease into lower suspension arm per 10 000km...

Page 18: ...en checking the alignment of front wheel Keep the vehicle at flat surface From the top view wake sure C D and A B 1 8 1 4 Front Steering Inspection Adjustment Adjusting the toe in Loosen unit 2 and 3...

Page 19: ...ion and adjustment Brake system Brake cylinder Adjust the hand brake to rear brake disk cable if necessary Hand Park Front end Loosen nut 1 Adjust bolt 2 out to increase park power Lock tight nut 1 Br...

Page 20: ...rake adjustment Hand Park Caliper end Loosen nut 1 Adjust the cable to front to increase hand brake power Lock tight nut 2 1 2 Brake inspection Check the brake fluid level add it when below MIN level...

Page 21: ...tment Adjusting braking power Loosen nut Adjust the length of bolt screw it in can get bigger brake power Lock the nut front brake rear brake Brake inspection and adjustment Make sure there is not any...

Page 22: ...e inspection and adjustment Specification of front brake caliper Replace the pad of disk if necessary Brake inspection and adjustment Specification of rear brake caliper Replace the pad of disk if nec...

Page 23: ...5 Withdraw the cap Dismantle the 4 nuts Wheel dismantle 1 You don t need to dismantle the wheel nut Wheel dismantle 2...

Page 24: ...6 Withdraw the wheel Wheel dismantle 3 Withdraw the cotter pin Dismantle the nut Withdraw the hub Wheel dismantle 4...

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Page 29: ...1 4 Electric inspection Main switch Headlamp switch Parking button 12V power supply Horn button Signal lamp switch 1 Operation panel Panel terminal wiring Panel back photo...

Page 30: ...2 Panel terminal wiring Panel back 2 Parts location speedometer Signal lamp...

Page 31: ...3 2 Parts location Relay regulator resistor Ignition coil 2 Parts location battery Starting safety device...

Page 32: ...4 2 Parts location Head lamp CDI Optional device Reverse shifting safety device Parking sensor...

Page 33: ...ectric inspection Check the coupling prevent losing connection of the terminals Spray some anti dust wax if necessary Electric inspection Head lamp choke controller Flasher relay starting motor relay...

Page 34: ...le speed turn on the headlamp Disconnect the red white wire Use the pocket tester to measure the charging current as photo shown 1 Black to battery 2 Red to wire harness Adjust the idle speed to 1600...

Page 35: ...7 3 Ignition Ignition wiring For CDI unit you don t have to adjust the ignition timing...

Page 36: ......

Page 37: ...1 Engine Dismantle Loosen the bolt of connecting rod with upper swing arm Engine Dismantle Dismantle the nut Withdraw the engine from the upper swing arm...

Page 38: ...2 Engine Dismantle Loosen the bolt of upper swing arm with the lower swing arm rear Engine Dismantle Loosen 2 bolts of oil cooler...

Page 39: ...3 OP of Replacing Rear Engine Hanger Collar for BR150 1 Loosen the lock nut 1 OP of Replacing Rear Engine Hanger Bush for BR150 2 3 2 Dismantle the bolt 3 Loosen the nut Lock torque is 11 0 kg m...

Page 40: ...4 Muffler DISASSEMBLY 1 Loosen 2 bolts of muffler with cylinder head Muffler DISASSEMBLY 2 Loosen 1 hexagon bolt of muffler with LH cover Remove muffler...

Page 41: ...r cleaner removal 1 Loosen 9 hexagon flange screws of LH cover Remove engine LH cover Air cleaner removal 2 Outside end is sponge clean it if necessary Inside end is paper element replace it if necess...

Page 42: ...6 MAGNETO DISASSEMBLY 1 Loosen 2 hexagon screws and 2 C R recess pan hd tapping screws Remove fan cover MAGNETO DISASSEMBLY 2 Loosen 4 hexagon screws of cooling fan Remove cooling fan...

Page 43: ...MAGNETO DISASSEMBLY 3 Loosen nut of magneto When installing tighten lock torque is 5 5 kg m MAGNETO DISASSEMBLY 4 Pull out the magneto with special tool part no S620402G01A tool should be tighten loc...

Page 44: ...O DISASSEMBLY 5 Loosen 3 hexagon screws of stator Remove stator Stator flywheel cooling fan CYLINDER AND HEAD DISASSEMBLY 1 Loosen 1 hexagon screw and 2 tapping screws of cooling cowl 2 Remove cooling...

Page 45: ...MBLY 3 Loosen 4 hexagon screws of cylinder head cover Remove cylinder head cover assy CYLINDER AND HEAD DISASSEMBLY 4 Loosen 1 hexagon screw of chain adjuster Loosen 2 hexagon screws fixed in cylinder...

Page 46: ...SSEMBLY 5 Loosen 4 nuts of camshaft holder Loosen 2 hexagon screw of cylinder head Remove camshaft holder camshaft and cylinder head CYLINDER AND HEAD DISASSEMBLY 6 Remove cam chain guide comp Remove...

Page 47: ...n 8 hexagon screws of RH crankcase cover Remove RH crankcase cover CYLINDER AND HEAD DISASSEMBLY 2 Loosen nut of one way clutch with special tool part no S620401G015 Remove one way clutch comp and sta...

Page 48: ...12 OIL PUMP DISASSEMBLY 1 Loosen 2 C R recess screws of oil separator Remove oil separator OIL PUMP DISASSEMBLY 2 Loosen nut of oil pump driving gear Remove oil pump driving gear and chain...

Page 49: ...13 OIL PUMP DISASSEMBLY 3 Loosen 2 hexagon screws of oil pump Remove oil pump CRANKSHAFT DISASSEMBLY 1 Loosen 2 hexagon screws of RH crankcase Remove RH crankcase with plastic hammer...

Page 50: ...14 CRANKSHAFT DISASSEMBLY 2 Pull out crankshaft from LH crankcase Remove camshaft chain CRANKSHAFT INSTALLATION 1 Put camshaft chain in LH crankcase...

Page 51: ...LH crankcase 0 10 0 03 Swingness of the crank shaft journal 0 04 Clearance of connecting rod big end vertical direction 0 55 0 10 0 35 Clearance of connecting rod big end axle direction Limit of use m...

Page 52: ...emble RH crankcase into crankshaft Tight 2 hexagon screws torque is1 0kg m Replace the oil seal and packing CRANKSHAFT INSTALLATION 4 To avoid the oil seal detected shall assemble the oil seal after c...

Page 53: ...1 Engine inspection Engine layout 35TUBE CYL COMP Cylinder head cover...

Page 54: ...26 625 26 23 EX 26 53 26 13 Inner dia me ter of roc ker arm shaft IN 10 00 10 015 10 10 EX 10 00 10 015 10 10 Oute rdiameter of rocker armshaft IN 9 972 9 987 9 91 EX 9 972 9 987 9 91 Va lve base angl...

Page 55: ...lve train Valve clearance IN 0 08mm EX 0 08mm CYLINDER CYLINDER HEAD INSTALLATION Installing camshaft the valve timing shall be adjusted Rotate the magneto T make to RH crankcase allied position RH cr...

Page 56: ...l to cylinder head refer to photo And the hole shall be in the top position refer to photo Line marks in camshaft Hole in camshaft CYLINDER CYLINDER HEAD INSTALLATION Installing camshaft holder EX mar...

Page 57: ...ed System by pump splash Make sure the oil path is through clean Engine inspection Intake Exhaust system Inspect element per 1 000km replace it if necessary If the vehicle is often used in dusty area...

Page 58: ...locked with the cylinder head to avoid leakage Lock muffler at 4 with engine LH cover Engine inspection Engine oil cooler Always clean the cooling fin to increase the cooling efficiency Replace the o...

Page 59: ...iston ring lst r in g 0 10 2 nd ring 0 10 Cle ar ance o f cutting section lst r in g 0 50 2 nd ring 0 50 Piston outer diameter 57 475 57 490 57 400 Mea suring location of pistonouter dia 5mm from the...

Page 60: ...ne inspection Cylinder CYLINDER CYLINDER HEAD INSTALLATION Notice the marks upon piston IN mark shall in t h e i n t a k e d i r e c t i o n EX mark shall in the exhaust direction IN To intake EX To e...

Page 61: ...ks 1st ring is marked 1R 2 n d r i n g i s marked RN The marks shall face to piston head 1st ring 1R 2nd ring RN CYLINDER CYLINDER HEAD INSTALLATION The opening end of piston rings shall face to intak...

Page 62: ...ISSION DISASSEMBLY 1 Loosen 9 hexagon flange screws of LH cover Remove engine LH cover Loosen nuts of driving pulley and clutch outer When installing nuts tighten torque is 5 5 kg m CVT TRANSMISSION D...

Page 63: ...4 052 24 10 The oute rdia Of boss movable Driving plate 23 960 23 974 23 940 Beltwidth 20 0 21 0 19 0 Clutch lining thickness 3 1 5 Clutc houter inner diamete r 125 0 125 2 125 5 Driven pla te spring...

Page 64: ...CVT inspection data Belt width Roller dia Lining thickness Outer dia Frt pulley dia Spring length Engine inspection Transmission System Primary CVT Final reduction gear PV CVT clutch in GV CVT top spe...

Page 65: ...4 Engine inspection Transmission System Reverse gear is engaged 4 5 4 Dismantle 2 bolts 5 Push the reverse box to right hand approximately 10 mm Driving chain dismantle 1...

Page 66: ...ue is 2 5 to 3 0 kg m And make sure part 9 can rotate in pivot 17 7 Replace the collar 17 8 Assemble the engine mount link by reverse step 1 to 6 Driving chain dismantle 2 And make sure part 9 can rot...

Page 67: ...6 9 Adjust the chain slack by this nut Driving chain dismantle 4 10 Lock the lower nuts by 5 0 to 6 0 kg m 10 Driving chain dismantle 5...

Page 68: ...7 When installing the lock pin of driving keep the close end forward the Drive direction Close end Open end Driving chain dismantle 6...

Page 69: ...r screw to adjust the air fuel ratio 3 Auto by start function check the carburetor is equipped with auto by start to improve the engine cold start it shall be warm after the engine has been starting f...

Page 70: ...1 CARBURETOR PRINCIPLE Fuel level Functions 1 Fuel atomization 2 Air Fuel Ratio 3 Engine Output Engine inspection Carburetor Assembly Idle adjustment stop screw 1700 100rpm Pilot screw...

Page 71: ...opening turns of PS A F ratio is richer 2 Clean the jets and body with compressed air MJ NJ JN Body MAJ Throttle valve Vac uum piston Remarks 1 No leakage of vacuum piston comp with body 2 Keep jets...

Page 72: ...3 3 pilot screw assy 4 vacuum piston assy 5 jet needle 8 cover 13 main jet 14 pilot jet 15 float 19 by start cap 20 auto by start...

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PGO BR-150 Bug Rider, Service Manual

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