PREFACE This service manual contains chief instructions in connection with service and maintenance of PGO TIGRA motorcycle and is also one technical manual and one best guideline illustrating details for service workers who are engaged in maintenance, reparation, replacement of parts, troubleshooting, and reassembly.
Contents This manual is a service manual for PGO Tigra Series with details specifying skills to disassemble or install various mechanisms, basic maintenance (check and adjustment) of components, notices for operation, and configuration of colored electrical wires in connection with the motorcycle in which there are 5 chapters and 10 sections as references of users or mechanics during service.
1-1 Configuration Warning lamp switch High / low beam switch Start button Over-speed lamp switch Front lamp switch Signal lamp switch (L & R) Horn button Shutter magnetic lock Filler hole (auxiliary water tank) Seat / Oil tank switch Oil tank cover Start / ECU relay Variable voltage rectifier Air filter Oil meter Exhauster Water pump Rear brake caliper Rear brake disk Battery / fuse Water tank / fan Diagnosis connector Auxiliary water tank Gear oil Front brake disk Filling orifice bolt F
Information Summary and Preparation 1 1-2 Positions of engine number / vehicle identification number: Vehicle identification number Engine number 4
Information Summary and Preparation 1 1-3 Specifications: (以下表格內容不需翻譯) 國 產 機 廠 牌 摩 特 動 力 型 式 AF-125BAE 尺 度 全 長 全 寬 全 高 軸 距 空 重 重 器 腳 1865 710 1140 mm 1300 mm 車 規 格 架 (身) 車 mm mm 踏 表 鋼 管 懸 吊 前 伸 縮 式 裝 後 整體搖擺式 置 傳 一次減速裝置 0.8~2.34 動 二次減速裝置 43/15*42/13=9.262 裝 離 合 器 乾式離心重錘式 置 變 速 器 V 皮帶式 C.V.T 前 48 ㎏ 後 74 ㎏ 輪胎尺寸及 前 110/70-12 128 ㎏ 層數(p.r) 後 130/70-12 合 計 乘坐人數或載重 2 人 (150 ㎏) 煞 前 碟 式 車 後 碟 式 量 性 燈 後燈/牌照燈 12V-0.
Information Summary and Preparation 1 1-4 Code of practice: 1. Any clamp or cotter pin removed shall be replaced with a new one. 2. Any part to be replaced shall be manufactured by Motive Power. 3. Make sure of any assembled component securely fastened and formally activated. 4. Any bolts or nuts with large external diameters rather than small ones shall be screwed first and diagonally according to rated torque values as follows. 5.
Information Summary and Preparation 1 prior to a connector removed or connected. 3. During any operation to simulate the thermal state of one defective unit or increase temperatures, the temperature of the electronic control unit shall be less than 80 degrees Celsius. 4. All fuel hoses shall be high pressure-tolerant pipes in virtue of the high fuel pressure in the Electronic Management System (300kPa or so) or even at the engine stopped.
Information Summary and Preparation 1 Body / Engine Type Torque (kg-m) Type Torque (kg-m) Type Torque (kg-m) Disk 2.0-2.5 Flywheel 5.0-6.0 Handlebar 4.5-6.0 Front axle 5.0-6.0 Cylinder head - nut 2.0-2.4 Engine hanger 2.4-3.0 Brake caliper 2.0-3.0 Cylinder head - screw 0.9-1.1 Front shock absorber Joint bolt (brake hose) 3.5±0.2 Crank case cover (right) 0.9-1.1 Rear shock absorber 3.5-4.5 Brake pump assembly 0.8-1.2 Gear box nut 5.0-6.0 Exhauster (Front) 1.5-1.
Information Summary and Preparation 1 1-6 Service tools Summary of service tools Tool name: Electronic Management System diagnosis tester (EMS diagnosis system) Functions: Read / delete PCODE of EMS; check data & process, and test parts’ functions. 測試等。 Tool name: Fuel pressure gauge Functions: Check pressures of the fuel system; determine status of the fuel pump and the fuel pressure governor in the fuel system.
Information Summary and Preparation 1 Tool name: Water pump shaft SC seal kit Functions: Install SC seals on the water pump shaft Tool name: Mechanical seal kit Functions: Install the mechanical seal. Tool name: Crank bearing withdrawal kit Functions: Disassemble and separate the crank bearing. Tool name: Snap-fit kit Functions: Remove or install a snap-fit of the cooling water hose or high-pressure fuel hose Tool name: Crank extraction kit Functions: Extract the crank from the case.
Information Summary and Preparation 1 1-7 Procedure to maintain the Electronic Management System (EMS) Systematic procedure to diagnose any troubles for reparation Items to be checked first prior to any diagnoses for engine troubles: 1. Make sure of the engine trouble indicator normally running; 2. Check with a trouble diagnosis meter to ensure no trouble information recorded; 3. Check any trouble phenomenon hinted by the vehicle owner and trouble-related conditions.
Information Summary and Preparation 1 (1) Engine not running or slowly running during start-up General trouble location: 1. Battery; 2. Start motor; 3. Main wiring or power switch; 4. Engine mechanism. Procedure for general diagnoses: Detection No. Operating Procedure Subsequent Steps Results 1 Check the voltage between two battery terminals with a multi-meter to ensure the voltage between 11 and 12V during start-up of the engine.
Information Summary and Preparation 1 (3) Trouble of hot start General trouble location: 1. Water in fuel; 2. Fuel pump; 3. Engine temperature sensor; 4. Ignition coils Procedure for general diagnoses: Detection Results No. Operating Procedure 1 Connect a fuel pressure gauge before the fuel inlet of the nozzle; start the engine to check the fuel pressure at 300kPa or so. 2 3 Disconnect the ignition cable and connect a spark tester; start the engine and check any high-voltage flash (blue/white).
Information Summary and Preparation 1 (4) Trouble of cold start General trouble location: 1. Water in fuel; 2. Fuel pump; 3. Engine temperature sensor; 4. Nozzle; 5. Ignition coils; 6. Air throttle and & idle air bypass; 7. Engine mechanism. Procedure for general diagnoses: Detection No. Operating Procedure Subsequent Steps Results 1 2 3 Connect a fuel pressure gauge before the fuel inlet of the nozzle; start the engine to check the fuel pressure at 300kPa or so.
Information Summary and Preparation 1 (5) Trouble of start-up anytime despite RPM normal General trouble location: 1. Water in fuel; 2. Fuel pump; 3. Engine temperature sensor; 4. Nozzle; 5. Ignition coils; 6. Air throttle and & idle air bypass; 7. Air intake; 8. Ignition timing; 9. Spark plug; 10. Engine mechanism. Procedure for general diagnoses: Detection No. Operating Procedure Subsequent Steps Results 1 2 3 Check any jam of the air filter and leakage of the air intake.
Information Summary and Preparation 1 (6) Start-up normal but idle speed unstable anytime General trouble location: 1. Water in fuel; 2. Nozzle; 3. Spark plug; 4. Air throttle and idle air bypass; 5.Air intake; 6. Idle governor; 7. Ignition timing; 8. Spark plug; 9. Engine mechanism. Procedure for general diagnoses: Detection No. Operating Procedure Subsequent Steps Results 1 2 3 4 5 Check any jam of the air filter and leakage of the air intake. Check the Idle governor for the control valve jammed.
Information Summary and Preparation 1 (7) Start-up normal but idle speed unstable during warm-up General trouble location: 1. Water in fuel; 2. Engine temperature sensor; 3. Spark plug; 4. Air throttle and idle air bypass; 5. Air intake; 6. Idle governor; 7. Engine mechanism. Procedure for general diagnoses: Detection Subsequent Steps No. Operating Procedure Results 1 2 3 4 5 6 7 8 Check any jam of the air filter and leakage of the air intake.
Information Summary and Preparation 1 (8) Start-up normal but idle speed unstable with warm-up finished General trouble location: 1. Water in fuel; 2. Engine temperature sensor; 3. Spark plug; 4. Air throttle and idle air bypass; 5. Air intake; 6. Idle governor; 7. Engine mechanism. Procedure for general diagnoses: Detection No. Operating Procedure Subsequent Steps Results 1 2 3 4 5 Check any jam of the air filter and leakage of the air intake.
Information Summary and Preparation 1 (9) Start-up normal but idle speed unstable or stall with load such as front lamp applied General trouble location: 1. Idle governor; 2. Nozzle. Procedure for general diagnoses: Detection No. Operating Procedure Subsequent Steps Results 1 Remove the idle governor and check the air throttle, the idle governor, and the idle air bypass for any carbon deposition.
Information Summary and Preparation 1 (10) Start-up normal but idle speed too high General trouble location: 1. Air throttle and idle air bypass; 2. Vacuum tube; 3, Idle governor; 4. Engine temperature sensor; 5. Ignition timing. Procedure for general diagnoses: Detection Subsequent Steps No. Operating Procedure Results 1 Check the throttle cable for jammed or too tight. 2 Check the air intake system and the connected vacuum tube for any leakage.
Information Summary and Preparation 1 (11) RPM low or stall during acceleration General trouble location: 1. Water in fuel; 2. Inlet pressure sensor & air throttle sensor; 3, Spark plug; 4. Air throttle & idle air bypass; 5. Air intake; 6. Idle governor; 7. Nozzle; 8. Ignition timing; 9. Exhauster. Procedure for general diagnoses: Detection No. Operating Procedure Subsequent Steps Results 1 2 Check the air filter for any jam.
Information Summary and Preparation 1 (12) Acceleration slow General trouble location: 1. Water in fuel; 2. Inlet pressure sensor and air throttle sensor; 3. Spark plug; 4. Air throttle and idle air bypass; 5. Air intake; 6. Idle governor; 7. Nozzle; 8. Ignition timing; 9. Exhauster. Procedure for general diagnoses: Detection Subsequent No. Operating Procedure Results Steps 1 2 Check the air filter for any jam.
Information Summary and Preparation 1 (13) Acceleration powerless; performance bad General trouble location: 1. Water in fuel; 2. Inlet pressure sensor and air throttle sensor; 3. Spark plug; 4. Ignition coils; 5. Air throttle and idle air bypass; 6. Air intake; 7. Idle governor; 8. Nozzle; 9. Ignition timing; 10. Exhauster. Procedure for general diagnoses: No. Operating Procedure Detection Results 1 Check any troubles such as clutch slip, low tire pressure, brake drag, wrong tire size.
Information Summary and Preparation 1 1) PCODE List No. PCODE UAES Description 1 P0107 2 P0108 3 P0112 4 P0113 5 P0117 Low voltage of the engine temperature sensor Engine Coolant Temp.Circ. Low Input 6 P0118 High voltage of the engine temperature sensor Engine Coolant Temp.Circ. High Input 7 P0122 8 P0123 9 P0130 Signal of the oxygen sensor irrational O2 Sensor Circ. Malfunction 10 P0131 Low voltage of the signal for the oxygen sensor O2 Sensor Circ.
Installation or Removal of External Components 2 Front & rear covers (handlebar) 1. Front cover → Front lamp assembly → Rear cover → Dashboard assembly → Left & right handlebar switch assembly 1 Set screws Set screws 2 ◙ Remove 4 set screws on the front cover. ◙ Remove 6 set screws on the front lamp. 3 Set screws Set screws 4 ◙ Remove 4 set screws on the dashboard. ◙ Remove 2 set screws on the front cover. Set screws ◙ Remove 2 set screws on the left & right handlebar switches.
Installation or Removal of External Components 2 Removal and installation of body cover & lower cover 2. Storage compartment → Luggage carrier → Front body cover → body cover assembly (left / right-hand side of the license plate) → Front lower cover → Lower cover Set screws 1 Set screws ◙ Remove 4 set screws on the storage compartment. ◙ Remove 3 set screws on the rear luggage carrier. 2 Set screws B A Set screw 3 ◙ Remove 3 set screws on the front body cover (A).
Installation or Removal of External Components 2 Removal of body cover and license plate 2-1 License plate and left & right body cover assembly → Left & right body covers → License plate → Lower sector → Reflector A 1 B Set screws ◙ Remove 4 set screws on the rear lamp and left & right body cover assembly (A). ◙ Remove 2 set screws on the left & right body covers. ◙ Remove 4 set screws on the rear lamp & license plate assembly (B).
Installation or Removal of External Components 2 3. Left & right air breathers (front inner panel) → Windshield → Front air deflector cover (water tank) → Air deflector cover (Windshield) → Left & right signal lamp covers → Floor panel B B 1 A ◙ Remove 4 set screws on the left & right air breathers (front inner panel) (A). ◙ Remove 6 set screws on the windshield (B). 2 A B Set screws 5 3 ◙ Remove 7 set screws on the front air deflector cover (water tank) (A).
Installation or Removal of External Components 2 4. Front inner panel cover → Front inner panel B A 1 C A B ◙ Remove 4 speed rivets on the front inner panel (A). ◙ Remove 1 set screw on the front hook (A). ◙ Remove 1 set screw on the secondary security lock (B). ◙ Remove 1 set screw on the fuel hose bundle (B). ◙ Remove the fuel tank cover counterclockwise (C). 5. Front mud fender / Lower body cover Set screws Set screws ◙ Remove 4 set screws on the front mud fender.
Installation or Removal of External Components 2 6. Front inner fender 1 Set screw ◙ Remove the set screw / nut on the handlebar. ◙ 1. Remove the self-lock nut and the upper ring-shaped nut. 2. Remove the cage ball bearings (upper & lower) and the front fork. 2 Set screw ◙ Remove 1 set screw on the front inner panel.
Check & Adjustment 3 1) Gear oil Volume Total oil volume: 110c.c. Oil volume replaced: 90c.c. Service cycle: Every 3000km Filling orifice bolt Check the oil level Park the motorcycle on a horizontal surface for check. Drain plug bolt 1. Place a graduated cup under the drain plug bolt prior to removal of the bolt. 2. Check the oil volume after the gear oil is evacuated. Oil replaced 1. Place a vessel under the drain plug bolt; remove and clean the bolt. 2.
Check & Adjustment 3 3) Engine oil Volume Total oil volume: 1000c.c. Oil volume replaced: 800c.c. Service cycle: 1000km Check the oil level Park the motorcycle on a horizontal surface for check. Start the engine for 3-minute running and stop it for another 3-minute; make a measurement. 1. Remove the oil meter counterclockwise and clean it. 2. Screw the oil meter into the filling orifice to measure the oil level. 3. The oil level should be higher than the lower limit but lower than the upper limit.
Check & Adjustment 3) Air filter Recommended service cycle: Check: Every 1000 km Change: Every 6000 km or less than 6000 km in the event of filth. Check / Change 1. Remove 8 set screws on the air filter cover. 2. Check packing for filth or damage; clean packing with high-pressure air gun. 3. Replace the air filter with a new one in the event of the old one too filthy. Set screws △Note: Do not rinse packing with water or organic solvent.
Check & Adjustment 6) Spark plug Check 1. Use a spark plug socket to remove the spark plug. 2. Check the spark plug for damage, filth, or carbon deposition. 3. Use carbon remover or a steel brush to clean any filth or deposited carbon. 0.6~0.7mm Specific model: CR7E NGK or similar substitute Spark plug gap: 0.6~0.7mm 0.6~0.
Check & Adjustment 8) Back-play of throttle cable Check Turn the right grip and check movement of the throttle. If unsmooth, check the throttle cable, throttle, throttle spring or replace any of them. Back-play: 2-6mm ☉ Adjustment of the back-play should be completed at the throttle by loosing the nut attached to the set screw for back-play properly adjusted.
Check & Adjustment 9) Brake system Brake lever Check the back-play by pressing the brake lever for any inconformity. Back-play: 10-20mm Brake disk Check the brake disk for any surface uneven. Check the brake disk’s runout within the spec. Rated value: ±0.1mm Runout limit: ±0.3mm Brake oil Check if the oil level is less than the lower limit. If any, please add brake oil to the upper limit. ☉ Check the thicknesses of any brake lining prior to adding any brake oil.
Check & Adjustment 3 Change of a front brake pad Tool to change a brake pad: 1. Allen wrench 2. 12” T-type wrench Pins fixing a brake shoe Set screws fixing calipers Check a brake pad’s thickness: Lowest acceptable thickness of a front brake pad >4.0mm (with the base’s thickness) 1 Change a brake lining: 1. Use an Allen wrench to loose two pins fixing a brake shoe. Pin fixing a brake shoe 2. Use a 12” T-type wrench to remove two set screws and then the brake calipers. 3.
Check & Adjustment 3 4. Take out the brake shoe with pins removed. Pin fixing a brake shoe 5. Check if the thickness of each of two brake linings is within the limit again with the brake shoe removed. Lowest limit of a brake lining >4.0mm 6. Install all parts in a reverse order.
Check & Adjustment 3 Change the rear brake pad Brake pad 1 ☉ Remove set screws fixing the rear brake shoe. ☉ Use the long nose pliers to remove the R-type snap ring. 2 3 ☉ Remove the brake pad. ☉ Use the long nose pliers to remove the dowel pin. Install all parts in a reverse order. Check the rear brake pad Check the brake pad for any excessive wear or break. Lowest acceptable thickness of a rear brake pad >3.9mm Lowest limit > 3.
Check & Adjustment 3 Change brake oil Steps: 1. Loose the drain plug bolt. 2. Use an oil pump to draw used oil. 3. Add new oil. 4. Use an oil pump to evacuate air in the oil hose; keep the oil cup not empty during evacuation. 5. Tighten the drain plug bolt. 6. Check back-play of the brake. If unconformable, repeat the previous steps to evacuate air. 10) Valve clearance Check valve clearance.
Check & Adjustment 3 11) Check / adjust timing Check: 1. Align the flywheel “T” mark to a triangular sign on the timing window of the right crankcase. △Note: Torque, T=0.9~1.1kg-m Align the flywheel mark to the triangular sign on the timing window of the right crankcase for the piston at the upper dead center. Timing window Chain adjuster Mark of the upper dead center 2. Check if the mark for the upper dead center of the camshaft sprocket is aligned to the mark “→” on the cylinder head. Adjust 1.
Check & Adjustment 12) Driving belt / clutch lining 1. Check the driving belt for any chaps or wear; replace it if necessary. 2. Gradually increase RPM and check articulation of the clutch lining. Please check the clutch lining or replace it, if necessary, for any situation such as vehicle starting unsmooth, no movement, stall, etc. 1 2 13) Tire & wheel Check the tread / wall for any wear, break, or nail. ▽: Tread wear indicator ▽ Check tire pressure: 1 Person 2 Persons Front Wheel Rear Wheel 2.
Check & Adjustment 3 15) Steering lever system Use the center stand to support the motorcycle and make the front wheel leave the ground; turn the steering lever to check any non-smoothness. In the event of tension incorrect, adjust the steering arm nut and control the triple trees in place. First 300km or 1 month 16) Items and cycle for periodical maintenance Every ____ km or ______ months Change (Refer to Note 1 on the previous page.
Lubrication System 4 Lubrication system diagram Oil lines inside a crankshaft designed to compulsively lubricate the connecting rod tip Cam shaft Crankcase 曲軸箱 Rocker arm Piston Oil filter element Crankshaft Oil pump Oil filter screen 44
Lubrication System 4 1) Cleaning of filter screen A. Remove the oil filter screen cover B. Remove the oil filter screen and the spring. C. Clean the oil filter screen. D. Make sure of the O-ring and the oil filter screen, or replace any of broken part, if any. Note: Clean the oil filter screen with the engine disassembled to avoid the oil hose blocked by any impurity and the engine damaged. Oil pump Removal: Refer to disassembly of the engine.
Lubrication System 4 3) Oil filter Change A. Remove 3 set screws on the oil filter cover and take out the cover. B. Take out the oil filter element and replace it with a new one. Mileage for replacement of an oil filter element: 5000 km Note: Check and replace the O-ring for proper installment simultaneously.
Disassembly of the Engine Assembly 5 1) Separate the engine from the vehicle body Procedure: 1. Remove the luggage compartment 2. Disconnect the engine wiring harness; remove the spark plug cap Disconnect the sensor cable Remove parts as follows: nozzle, engine temperature sensor, throttle valve sensor, idle controller, and oxygen sensor. Disconnect Disconnect the Disconnect the engine ground power line cable on the linked to the right crankcase. start motor.
Disassembly of the Engine Assembly 5 4. Disassemble the engine’s throttle cable and vacuum tube Disassemble the Disconnect all vacuum throttle cable. hoses connected the engine manifolds and the air filter. 5. Disconnect high-pressure fuel hose connector 7.拆下下懸吊 Use a tool to remove Disconnect the the clamp. high-pressure fuel hose. Note: Release the pressure first prior to disconnection of the high-pressure fuel hose. 6. Drain cooling water Drain cooling water by removing the drain plug bolt. 7.
Disassembly of the Engine Assembly 5 8. Remove calipers and fuel hose clips Remove the Disconnect fuel hose calipers. clips to remove the calipers and the fuel hose. 9. Remove set bolts for shock absorbers 10. Remove bolts for the engine hanger 11. Separate the engine from the vehicle body Remove the vehicle body with the engine separated from the vehicle body; disassemble the engine.
Cylinder Head Removal and disassembly 1. Remove the cylinder head Procedure: A. Remove 4 set screws on the cylinder head to take out the cylinder head cap. Set screws B. Remove 2 set screws of the chain adjuster and take out brackets and pads supporting the idle controller of the chain adjuster. Set screws Bracket Chain adjuster C. Remove 1 set screw of the camshaft sprocket and take out the camshaft sprocket and the turning disk. Set screws D.
Cylinder Head E. Remove the cylinder head, cylinder head gaskets and 2 dowel pins.
Cylinder Head 2. Disassemble the cylinder head A. Use a wrench to remove set screws on the camshaft mounting plate. 6 Rock arm (inlet valve) Rock arm (exhaust valve) B. Remove the camshaft mounting plate, the rock arm shafts (intake & exhaust valves) and the rock arms (intake & exhaust valves). Rock arm shaft Camshaft mounting plate C. Remove the camshaft. Set screw Camshaft D. Remove the camshaft and the rock arm to remain the main body and the intake & exhaust valves. E.
Cylinder Head F. Loose bolts on the temperature controller; remove the temperature controller cover and take out the temperature controller. G. Remove the engine temperature sensor.
Cylinder Assembly 7 Disassemble the cylinder Dowel pin Remove the cylinder head for the steps as follows: A. Sequentially take out parts such as chain guide, cylinder, cylinder gasket, and dowel pins. Cylinder gasket Cylinder Chain guide 鏈條導件 B. Use the long nose pliers to take out parts such as C-ring, piston pin, and piston.
Cylinder Assembly 7 Measurement and check 1. Visually check the external of the piston or replace it with a new one in the event of the old one useless. 2. Check the inner diameter of the piston pin (standard size: 15mm; size limit: 15.040mm) or replace the old one in the event of the bore out of the size limit. 3. 4. Check the outer diameter of the piston pin (standard size: 15mm; size limit: 14.960mm) or replace the old one in the event of the bore out of the size limit.
Cylinder Assembly 7 2. Installation of the cylinder 1. Install dowel pins and cylinder gaskets on the crankcase. 2. Install the piston and apply engine oil at the contacting surface between any piston pin and the connecting rod. 3. Apply engine oil on the cylinder’s inner surface, the piston, and the piston rings during assembly of the cylinder. Cautiously install the piston along with piston rings into the cylinder. Apply engine oil. Apply engine oil. 3. Installation of the cylinder head 1.
V Belt Driver 8 Left cover / drive belt assembly A. Remove 3 set screws on the left cover cap and take out it. Set screws B. Remove 9 set screws on the left cover and take out it. Set screws C. Remove 1 set nut on the front drive unit and take out parts such as drive flank, mobile drive flank, mobile drive flank hub, and sleeve. Remove 1 set nut on the rear drive unit and take out parts such as bearing sleeve, clutch housing, driven belt pulley, and belt.
V Belt Driver 8 Limit sizes of parts A. Balancing ball: Standard outer diameter=18.0mm; limit size>17.40mm. Replace any part with the measured size unconformable to spec. Size: 18.0mm Weight: 11g B. Balancing ball Size limit Inner diameter of the mobile drive flank hub: Standard size=24.0mm; limit size=24.06mm. Replace any part with the measured size unconformable to spec. Size limit Flank check: Replace any flank with the level not good (any groove developed) which makes the speed change unsmooth.
Crankcase & Crankshaft 9 Right crankcase cover A. Remove 3 set screws on the water pump cover and take out parts such as water pump cover, gasket, and dowel pin. Torque=0.9~1.1kg-m Set screws Water pump cover gasket B. Remove 7 set screws on the right crankcase cover and take out the right crankcase cover, gaskets and dowel pins. Magnetic motor assembly and starting clutch assembly Dowel pins Set screws Flywheel A. Remove the starting reduction gear and the starting reduction gear shaft. B.
Crankcase & Crankshaft 9 Disassembly and installation of the engine oil pump sprocket: Disassembly of the engine oil pump sprocket 1. 2. Remove 2 set screws on the engine oil separator and take out the engine oil separator. Use the long nose pliers to remove the E-ring and the flat washer. 3. Remove the drive sprocket and the drive chain of the engine oil pump. 4. Remove 2 set screws on the engine oil pump and take out the engine oil pump.
Crankcase & Crankshaft 9 Engine oil filter A. Remove 3 set screws on the engine oil filter cover and take out the engine oil filter. B. Install the cover with the filter element replaced and installed. Keep watch for the washer correctly installed. (Replace the filter element and the washer simultaneously.) C. Tighten set screws with the cover and the washer correctly installed. O-ring Note: Replace the filter element (engine oil) every 5000km.
Crankcase & Crankshaft 9 Crankcase Left crankcase Remove 11 set screws on the crankcase; place the inner chain horizontally and inward; take out the left crankcase. Left crankcase Inner chain Right crankcase / crankshaft As a result of tight fit between the right bearing of the A1 engine crank and the right crankcase, the specific tool for removing the crankshaft should be used to separate the crankshaft and the case during disassembly. Do not use a hammer to strike any part. 1.
Crankcase & Crankshaft 9 3. Securely fix the right crankcase with the puller hammer installed for the bearing pulled out. Evaluation and measurement of a removed crankshaft 1. Check the connecting rod for any noise attributed to large radial and axial clearances of a running crankshaft. Replace the useless crankshaft assembly with a new one if necessary. 2. Check the bearing for any noise attributed to large radial and axial clearances of a running bearing.
Crankcase & Crankshaft 9 Installation of the crankcase Method (1) Install the bearing and the engine oil pump sprocket on the crankshaft first. Clean the washer first and the crankcase; install all parts into the crankcase in a reverse order. 1. Horizontally place the case on the workbench. 2. Install the inner chain. 3. Cautiously place the crankshaft into the case. 4. Install the washer and then the right crankcase cover. 5.
Crankcase & Crankshaft 9 Method (2) Separate the bearing and the engine oil sprocket 1. Use the fixture to install the bearing onto the bearing housing of the right crankcase. 2. Install the crankshaft in place. 3. Install the fixture for the crankshaft. 4. Draw the crankshaft to the bottom. 5. Install the engine oil pump sprocket; use the fixture to press the sprocket.
Final Speed Gear 10 Final drive gear Set screws Steps for removal: 1. Remove the drain plug bolt and drain the gear oil. 2. Remove 7 set screws on the gear box cover; take out the gear box cover. 3. Remove the rear shaft. 4. Final gear 5. Idle gear and flat washer 6. Drive shaft Rear shaft Idle gear Flat washer Final gear Please always renew any washer during assembly. Drive shaft Dowel pin Gear box cover Steps for removal: 1. Check each bearing which is removed from the final drive system. 2.
Fuel Injection System 7 Configuration and performance of parts in the MSE3.
Fuel Injection System 7 11-1 ECU Principle: Electronic Control Unit (ECU) is the brain of the whole electronic system. ECU is effective in analyzing and processing information supplied by sensors and issuing conclusion-induced commands to any actuator for optimization of the running engine. ECU's appearance Function: 1. 2. 3. 4. 5. 6. 7. 8. 9. Receive signals from the engine’s RMP sensor. Receive signals for the engine’s load. Control injection of fuel. Control ignition. Control the idle speed.
Fuel Injection System 7 ECU Pin Configuration ISA-TEV +canister purge(TEV) ECU Pin TEV (ISA)+Evaporative Emission Control 1 Ignition1/CDI / 點火 2 GND (Ignition, power) / 點火接地 3 Vehicle speed sensor or else input / 車速感測器或其他輸入 4 MIL / 故障指示燈 5 KL15 / 點火開關 6 intake air temp.(ADC) 7 Output / 輸出 8 A/D input / A/D 輸入 9 Input / 輸入 10 5V ex.
Fuel Injection System 7 11-2 Intake manifold pressure sensor Function: Monitor absolute pressures (kPa) in the intake manifolds; provide information about the engine load.
Fuel Injection System 7 11-3 Temperature sensor Function: The sensor is used to provide information about water coolant, cylinder temperature, or intake temperature. Temperature sensor Principle: As one NTC (Negative Temperature Coefficient) thermistor, the temperature sensor has its resistance descending with the water coolant’s ascendant temperatures in which there is no linear relationship. Sectional view of a temperature sensor: 1. Electric connector; 2. Bushing; 3. NTC thermistor.
Fuel Injection System 7 11-4 LSF Lambda sensor Function: Test the oxygen content in exhaust to make sure of the mixture of gasoline and air completely burned and promote the Air/Fuel Ratio precisely controlled by ECU. Theoretical Air/Fuel Ratio: 14.7:1 Fig. 11-4.
Fuel Injection System 7 Fault diagnosis A variety of signals from different sensors, actuators, power amplifiers and detection circuits are monitored by ECU. In the event of each of the following situations detected by ECU, the corresponding PCODE for a Lambda sensor might be indicated on the dashboard. (Refer to “Conditions of error information & records”.) 1. Error of a Lambda sensor’s signals 2. Error of a battery’s voltages 3. Error of signals of an intake manifold’s absolute pressures 4.
Fuel Injection System 7 11-5 Electromagnetic fuel nozzle Function: Subject to ECU, the fuel nozzle injects atomized fuel into the engine in the specific timing. Constitution: EV-Cup; clamp; EV Principle: Developed by the fuel nozzle coils with electrical pulse supplied from ECU, the magnetic force will increases to overcome a resultant force composed of the return spring’s pressure, the needle valve’s gravity, and friction and makes the needle valve lifted and fuel injected.
Fuel Injection System 7 11-6 DKG (Throttle sensor) Function: The sensor can provide information about a throttle’s opening to ECU. According to the information thereof, ECU has necessary data for engine load, operating status (start-up, idle speed, partial load, and full load), acceleration, deceleration, etc. Principle: As one angle sensor for linear output, this sensor is composed of two curved slide resistors and two contact sliders.
Fuel Injection System 7 Principle: The idle sped actuator is composed of electromagnetic coils, armature iron, and valve. The airflow passing the idle speed actuator is relevant to both the duty factor of pulse exported to the idle speed actuator by ECU and the pressure difference between the inlet and the outlet of the idle speed actuator. The idle speed actuator is disabled during no supply of electrical pulse.
Fuel Injection System 7 ① Airflow direction conformable to spec. during installation; ② Check and replace the idle speed controller in case of failure of the controller due to some black particles inside the valve; ③ No liquid such as water and oil entering into the valve during maintenance; ③ In order to avoid any solid-borne noise, connect the idle speed controller to a hose without the controller contacting any other supports.
Fuel Injection System 7 Fig. 2-34, Electric circuits of an intake temperature sensor ③ To inspect the absolute pressures (KPa) of intake air, the intake pressure sensor connects the throttle body’s main duct via a pressure duct of the throttle body. The sensor is divided into the two parts: sensing element and detection circuits as shown in Fig. 2-35. Fig.
Cooling System 12 Cooling system diagram 79
Cooling System 12 System maintenance Regular maintenance Every 1000km: Check if the coolant level in the auxiliary water tank is within the standard range, or add new coolant up to the standard, if necessary. Check the cooling tube for any leakage in the event of coolant unusually consumed (the level below the lower limit). Add the diluted coolant (30%~50%) with distilled water or soft water mixed.
Cooling System 12 Change coolant Steps to change water coolant (simplified): 1. In order to avoid burn and make sure of safety during change of water coolant, please cool the engine temperature in advance. 2. Loose the drain plug bolt on the water pump cover and evacuate water coolant. Reinstall the drain plug bolt with water having been evacuated. 3. Add new coolant from the inlet; start the engine with the full level reached. 4.
Cooling System 12 7. 8. 9. During the coolant temperature gradually increased to the circulating temperature, some bubbles from coolant will be observed at the inlet (residual air evacuated by the system). Stop the engine and check coolant for addition in the event of no bubble observed at the inlet and the coolant level stable. Keep watch for the coolant level of the auxiliary water tank at the first three drives with the water coolant having been changed.
Cooling System 12 Water tank / fan Check 1. Check the water tank and the fan for any damaged or deformed surface. 2. Check heat sinks for any deformation or filth; rinse heat sinks with the low-pressure water column. Cautiously restore any heat sink deformed. Heat sink Auxiliary water tank Total volume: 485c.c Upper limit: 335c.c Lower limit: 180c.
Cooling System 12 Thermostat Function: Control temperature of water coolant for the engine running at the best temperature. Trouble: Jam: Thermostat “ON”: Warm-up too long; engine temperature unstable during a drive. Thermostat “OFF”: Water coolant too hot during a drive; temperature displayed on the thermometer high. Note: Check the thermostat by immersing it into hot water. Disassembly: Remove 2 set screws on the thermostat cover and take out the thermostat.
Cooling System 12 Water pump Steps to disassemble a water pump 1. Take out the water pump cover. 2. Loosen the vane first. (Note: Left-handed screw for the vane) 3. Remove the water pump’s vane clockwise. 4. Remove the crankcase cover (right). In order to remove the vane easily, please loosen the impeller first prior to removal of the crankcase cover (right). 5. Take out the water pump shaft and the washer. 6. Take out the mechanical seal and the SC seal. Installation 1.
Cooling System 12 3. Screw the water pump impeller in place with the water pump shaft and the washer installed. Put the crankcase cover (right) on the engine. ∆ Note: No collision between the axle and the sliding surface for any damage generated during installation. 4. Screw the water pump’s vane with a torque wrench. Torque: 1.0~1.4kg-m Post-installation check 1. Check of an installed mechanical seal: A. Make sure of the mechanical seal installed in place. B.
Cooling System 12 Sealing performance of the cooling system 1. 2. 3. 4. Change the water tank cover with a specific water tank cover for leakage tests. Connect a specific air pump with a pressure gauge attached. Pump air into the tank until the pressure reaches 1.1 kg/cm2; repeatedly pump air up to 1.1 kg/cm2 after reducing the pressure for several seconds. No pressure drop is indicated on the gauge within one minute; if any, check each connector of the cooling hoses for any leakage.
Charge, Ignition, and Start-up 13 Notices for operation: 1. 2. 3. 4. 5. Sequentially disconnect cables on the battery’s terminals “-” and “+”. Keep watch for any spark plug’s model and torque for installation. Do not try fast charge except for any emergency case. Use a multi-meter to test any wiring. Use a spark tester to check a spark plug. 5. Power supplied off and on Poor connection of battery cables Cable connector of the charging system loose 6.
Charge, Ignition, and Start-up 13 Check: 1. Battery Voltage check A. Use a multi-meter or a voltage meter to test a battery’s voltages. B. Voltage: Full charge: >12.8V Under charge: <12.0V Use a clamp meter to measure charging current by turning the rotary switch to the “current” function and hooking the fuse’s “+” terminal for measurement of charging current. Charge A. Connect a charger’s “+” to the battery’s “+” terminal B.
Charge, Ignition, and Start-up 13 ACG charge performance Use a clamp meter to test charge performance by turning the rotary switch to the “current” (and “voltage”) function; connect the fuse’s “+” to measure current (and voltage) at charging. Day RPM 1600 3000 4000 5000 6000 7000 3. Voltage 14.45 14.47 14.48 14.48 14.48 14.49 Current 0.94 0.95 0.86 0.87 0.86 0.85 Night Voltage Current 13.23 0.5 14.16 1.45 14.18 1.35 14.18 1.27 14.20 1.14 14.20 1.
Charge, Ignition, and Start-up 13 4. Ignition system Check the ignition system 1. 2. 3. Measure the first circuit (Red) & (Black); resistance: 0.8~1.3Ω. Disconnect the high-tension wire; resistance: 9KΩ.
Chassis 14 92 Remove the rear wheel Removal A. Remove the seat assembly; disconnect the Lambda sensor connector. Tool: 10” T-type wrench B. Remove the exhauster assembly; keep the Lambda sensor body not be collided during removal. Tool: 12” T-type wrench C. Remove the axle cover. Tool: Slotted screwdriver D. Cautiously remove and lay the brake caliper and clips on the brake oil hose. Do not press the brake lever with the caliper separated from the brake disk. Tool: 12” & 10” T-type wrenches E.
Exhaust Emission Control System 9 Letter of guarantee for the exhaust emission control system Motive Power, Inc. warranties the exhaust emission control system conformable to standards of the Environmental Protection Administration, Executive Yuan, and effective under a user’s correct use and maintenance. Warranty period: Motorcycle in conformity with standards of the exhaust test, regular or occasional, demanded by the government during the first three years or 15,000km.
Exhaust Emission Control System 9 1. Evaporative Emission Controller (EEC) Principle: Make any HC inside the gasoline tank evaporated and absorbed by active carbon for pulse generated by the control valve during starting the engine and gasoline directed into the air filter and then the engine room for combustion.
Exhaust Emission Control System 9 2. Regular maintenance table for the exhaust emission control system Mileage or Months First Item Content 300km (1 month) Valve clearance* Check and adjust the valve clearance for the engine being cooled down. Spark plug Check the spark plug. Adjust the clearance and clean the spark plug. Change the spark plug, if necessary. 2,500km 6,000km (3 months) (6 months) ○ 9,000km ○ ○ ○ 12,000km ○ ○ ○ Positive crankcase Check the vent pipe for chaps or jam.
