BR-150 SERVICE MANUAL Manufactured by PGO of Motive Power Industry Co.
Content Chapter 1 : ¢ ¢ Service notation Specification Locking torque Chapter 2: Engine dismantle & inspection ¢ ¢ ¢ ¢ Engine dismantle Engine inspection Transmission dismantle & inspection Carburetor adjustment Chapter 3 : Chassis inspection ¢ ¢ ¢ ¢ Operation Steering inspection & adjustment Brake inspection & adjustment Installation Chapter 4 : Electric ¢ ¢ ¢ ¢ Parts location Charging inspection & adjustment Ignition inspection Wiring diagram
PREFACE This manual offers all service specialists with the technological procedures of maintenance, repairing for BR-150 show those 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.
Name BUGXTER SPECIFICATION FRAME TYPE STEEL SUSPENSION SYSTEM FRONT SINGLE A ARM REAR SWING ARM DIMENSION TOTAL LENGTH TOTAL WIDTH TOTAL HEIGHT TRANSM ISSION RPIMARY RATIO 1 WHEELBASE SECONDARY RATIO DRY WEIGHT FRONT 263 KG CLUTCH 40/16*42/13 C.V.T.
1.1 The operation notice: 1. Always replace gasket, O ring, cotter, pins and clip whenever reassembled. 2. When tighten screws or nuts, lock tightly as per specified locking torque, and in the sequence of cross direction. 3. Use PGO, or PGO Recommended parts. 4. After dismantling please wash all parts necessary for checking and grease all contact surface when reassembling. 5. Use grease recommended by P.G.O. 6.
1.2 TORQUE VALUE 1. Engine: NO Locking location Q’TY Thread dia. (mm) Locking torque (kg-m) 1 Cylinder head bolt A (intake ) 2 6 0.9~1.1 2 Cylinder head bolt B (Exhaust) 2 8 2.2 3 Cap, oil filter graze 1 30 1.5~2.0 4 Flange nut, cam shaft base 4 8 2.2 5 Fixing nut, air valve adjustment 2 5 0.7 6 Guiding pin bolt, inner chain adjustment 1 6 0.9~1.1 7 Oil bolt 1 8 1.7~2.0 8 Fixing nut, clutch outer 1 12 5.0~6.0 9 Nut, driven plate 1 12 5.0~6.
3.Locking Torque Standard (Chassis) No Locking location Qty Thread dia (mm) Kg-m 1 Wheel nut 16 10 6.0 2 Wheel axle nut 1 16 8.0 3 Front absorber bolt 4 10 6.0 4 Lower suspension arm bolt 2 10 6.0 5 Ste ering handle bolt 6 3 0.5 6 Seat belt fixture 5 8 3.0 7 Upper 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.
1.3 In order to achieve safe riding, good performance and reduce pollution, please execute the following recommended maintenance table base upon average driving condition. Driving in unusual dusty areas, require more frequent servicing.
1 3 2 4 5 7 6 8 1
9 10 11 13 12 14 15 2
16 17 19 18 20 21 3
3.1 OPERATION 1.
2.. Digital Speedometer •• 1.Symbol description •• speed indication •• •• •• high beam indicator • •• sign al lamp ind icator • •• r everse gear indicator • •• parking indicator •• RESET button •• MODE button •• •••••••••••• ••• •• ••• ••• •• •• •• •• 2.Set t i n g:Pr e s s“MODE + RESET”2 sec., then can get into the setting procedure. •• Unit: km/h or mile/h, switched by MODE, and RESET to confirm.
3.2 Steering Inspection & Adjustment Dismantle •Lock tight the bolts of steering handle. •Torque:0.
Steering Inspection •Inspect the coupling joint knuckle. Maintenance •Add grease into upper suspension arm per 10,000km from grease valve.
Inspection •Inspect the absorbe r, 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 support.
Steering Inspection & Adjustment Steering Inspection & Adjustment •Lock tight the bolt •Add grease into lower suspension arm per 10,000km.
Steering Inspection & Adjustment •When checking the alignment of front wheel.
3.3 Brake inspection and adjustment •Brake system •Brake cylinder •Adjust the hand brake (to rear brake disk) cable if necessary Brake adjustment •Hand Park (Front end) 2 1 •Loosen nut#1 •Adjust bolt#2 out to increase park power. •Lock tight nut#1.
Brake adjustment •Hand Park (Caliper end) 1 2 •Loosen nut#1 •Adjust the cable to front to increase hand brake power. •Lock tight nut#2. Brake inspection •Check the brake fluid level, add it when below “MIN”level.
Brake inspection and adjustment •Adjusting braking power. front brake rear brake •Loosen nut •Adjust the length of bolt, screw it in can get bigger brake power. •Lock the nut. Brake inspection and adjustment •Make sure there is not any fluid leakage from the bolt.
Brake inspection and adjustment •Specification of front brake caliper •Replace the pad of disk if necessary. Brake inspection and adjustment •Specification of rear brake caliper •Replace the pad of disk if necessary.
Wheel dismantle (1) •Withdraw the cap •Dismantle the 4 nuts Wheel dismantle (2) •You don’ t need to dismantle the wheel nut 5
Wheel dismantle (3) •Withdraw the wheel Wheel dismantle (4) •Withdraw the cotter pin •Dismantle the nut •Withdraw the hub 6
4. Electric inspection • 1.
Panel terminal wiring •Panel back 2.
2. Parts location Relay regulator resistor Ignition coil 2.
2.
Electric inspection •Check the coupling, prevent losing connection of the terminals. •Spray some anti-dust wax if necessary.
2. Charging Adjustment of BR150 •Start the engine, keep in idle speed, turn on the headlamp. •Disconnect the red/white wire . •Use the pocket tester to measure the charging current as photo shown: 1.Black (to battery). 2.Red (to wire harness). •Adjust the idle speed to 1600 to 1800 rpm, then the charging current shall be positive.
3.
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.
Engine Dismantle •Loosen the bolt of upper swing arm with the lower swing arm rear.
OP of Replacing Rear Engine Hanger Collar for BR150 1 1. Loosen the lock nut. OP of Replacing Rear Engine Hanger Bush for BR150 2 2.Dismantle the bolt 3.Loosen the nut. Lock torque is: 11.
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 4
Air cleaner removal (1) •Loosen 9 hexagon flange screws of LH cover •Remove engine LH cover Air cleaner removal (2) •Outside end is sponge, clean it if necessary •Inside end is paper element, replace it if necessary 5
MAGNETO DISASSEMBLY(1) •Loosen 2 hexagon screws and 2 C-R recess pan hd.
MAGNETO DISASSEMBLY(3) •Loosen nut of magneto •When installing, tighten lock torque is 5.
MAGNETO DISASSEMBLY(5) •Loosen 3 hexagon screws of stator •Remove stator Stator flywheel cooling fan CYLINDER AND HEAD DISASSEMBLY(1) •Loosen 1 hexagon screw and 2 tapping screws of cooling cowl(2) •Remove cooling cowl(2) 8
CYLINDER AND HEAD DISASSEMBLY(3) •Loosen 4 hexagon screws of cylinder head cover •Remove cylinder head cover assy. CYLINDER AND HEAD DISASSEMBLY(4) •Loosen 1 hexagon screw of chain adjuster •Loosen 2 hexagon screws fixed in cylinder •Remove chain adjuster comp.
CYLINDER AND HEAD DISASSEMBLY(5) •Loosen 4 nuts of camshaft holder •Loosen 2 hexagon screw of cylinder head •Remove camshaft holder camshaft and cylinder head CYLINDER AND HEAD DISASSEMBLY(6) •Remove cam chain guide comp.
ONE WAY CLUTCH DISASSEMBLY(1) •Loosen 8 hexagon screws of RH crankcase cover •Remove RH crankcase cover CYLINDER AND HEAD DISASSEMBLY(2) •Loosen nut of one way clutch with special tool (part no: S620401G015) •Remove one way clutch comp and starting idle gear •The nut is LH thread 11
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 12
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 13
CRANKSHAFT DISASSEMBLY(2) •Pull out crankshaft from LH crankcase •Remove camshaft chain CRANKSHAFT INSTALLATION(1) •Put camshaft chain in LH crankcase 14
CRANKSHAFT INSTALLATION(2) •Assemble crankshaft in LH crankcase Crankshaft inspection data: ITEM Stand ard value(mm) Limit of use.(mm) Clearance of connecting rod big en d axle direction 0.10~0.35 0.55 Clearance of connecting rod big en d vertical direction ------ 0.04 0.03 0.10 Swingness of the crank shaft journal.
CRANKSHAFT INSTALLATION(3) •Assemble RH crankcase into crankshaft •Tight 2 hexagon screws •(torque is1.0kg -m) •Replace the oil seal and packing.
Engine inspection •Engine layout • Cylinder head & cover “ “ “ 35TUBE C YL. C OMP.
Engine inspection • Cylinder head inspection • Different view of cylinder head Cylinder head data: Description Valve Cl earance (Before warm up) IN/ EX IN EX Standard (mm) L im it use (mm) 0.08 0.08 Compression pressure Height of t he cam’s convexpart IN 11kg/700rpm (B R 150) 26.625 26.
Engine inspection •Valve train •Valve clearance •IN:0.08mm •EX:0.
CYLINDER & CYLINDER HEAD INSTALLATION •Ensure 2 line marks of camshaft parallel to cylinder head refer to photo •And the hole shall be in the top position refer to photo Hole in camshaft Line marks in camshaft CYLINDER & CYLINDER HEAD INSTALLATION •Installing camshaft holder “EX” mark shall face to exhaust valve •Tighten 4 nuts crossly, lock torque is 2.
Engine inspection •Oil lubricated System (by pump & splash) •Make sure the oil path is through & clean. Engine inspection •Intake & Exhaust system •Inspect element per 1,000km, replace it if necessary. •If the vehicle is often used in dusty area, decrease the inspection interval.
Engine inspection •Exhaust muffler •Make sure the flange #1 is well locked with the cylinder head to avoid leakage. •Lock muffler at #4 with engine LH cover. Engine inspection •Engine oil cooler •Always clean the cooling fin to increase the cooling efficiency. •Replace the oil filter per 5,000 kms. •Lock torque:10 N-m •Inspect the oil leakage.
Engine inspection •Pulse air system •Keep the air-in path clean. •Keep the vacuum pipe well connected to intake manifold, •Never jam the vacuum pipe. Cylinder & piston inspection data: Part name /description Cylinde rhead Cylinder Standard ( mm ) L im it ( mm ) Bore 57.490~57.510 57.600 Cur ve - 0.05 Cylindrili ty - 0.05 Roundness Cl earance b/w Piston and - 0.05 flatness Pis ton ring Cle ar an ce o f cu ttin g sect ion lst r ing 0.10 2 nd rin g 0.10 lst r ing 0.
Engine inspection •Cylinder CYLINDER & CYLINDER HEAD INSTALLATION •Notice the marks upon piston •“IN”mark shall in t h ei nt a kedi r e c t i on; “EX”mark shall in the exhaust direction To intake IN To exhaust EX 8
CYLINDER & CYLINDER HEAD INSTALLATION •Piston rings shall be installed according to marks •1st ring is marked “ 1R”;2 ndr i n gi 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 intake valve and allied to 120 degree •And shall not allied to the piston pin Allied to 120 9
CVT TRANSMISSION DISASSEMBLY(1) •Loosen 9 hexagon flange screws of LH cover •Remove engine LH cover CVT TRANSMISSION DISASSEMBLY(2) •Loosen nuts of driving pulley and clutch outer •When installing nuts, tighten torque is 5.
CVT TRANSMISSION DISASSEMBLY(3) •Remove drive face, driving pulley assy., driven pulley assy., V-belt Ite m CVT inspection data Standard val ue (mm ) Limit of use ( mm ) The inne rdia . Of sl ide drivi ng pl ate 24.011~24.052 24.10 The oute rdia . Of boss, movable Driving pl ate 23.960.~23.974 23.940 Bel t width Cl utch li ni ng thi ckness 20.0~21.0 19.0 3 1. 5 125.0~125.2 125.5 151 127 The outer di ameter of drive n Plate sets 33.965~34.025 33.
CVT inspection data Belt width Roller dia.
Engine inspection •Transmission System •Reverse gear is engaged Driving chain dismantle (1) 5 4.Dismantle 2 bolts 5.Push the reverse box to right hand approximately 10 mm.
Driving chain dismantle (2) 6.Dismantle the bolt(#16) & nut.(#10) Lock torque is: 2.5 to 3.0 kg-m And make sure part #9 can rotate in pivot #17 7.Replace the collar (#17) 8.Assemble the engine mount link by reverse step 1 to 6.
Driving chain dismantle (4) 9.Adjust the chain slack by this nut. Driving chain dismantle (5) 10 10. Lock the lower nuts by : 5.0 to 6.
Driving chain dismantle (6) •When installing the lock pin of driving, keep the close end forward the Drive direction.
2.4 Carburetor dismantle & inspection: 1. dismantle ò Remove:-carburetor assembly, pipes, cables and wires ò Remove:- high-tension wire 2. adjustment there are two screws might be adjusted to tuning the engine intake mixture. ò 1st is the stop screw: to adjust the engine idle speed, recommended idle speed is 1600 to 1800 rpm. ò 2nd is the air screw to adjust the air/fuel ratio. 3.
CARBURETOR PRINCIPLE Fuel lev el Functions: 1.Fuel atomization 2.Air/Fuel Ratio 3.
Remarks: 1.For 4 stroke engine,more opening turns of PS, A/F ratio is richer. 2.Clean the jets and body with compressed air. (PJ) fuel Pilot Screw (PS) (SAJ) Vac uum pi st on (JN) B ody Throt tl e val ve (M AJ) (NJ) Remarks: 1.No leakage of vacuum pis ton comp with body. 2.Keep jets and paths clean. 3.Don’t miss small parts like O-ring, spacer …etc.
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.
