Motive Power PGO Manuel d'utilisateur

PGO All Terrain Vehicle Service Manual INDEX Chapter 1 Model introduction Chapter 2 Operation indicator Chapter 3 Important operating to

3. Chassis: NO Locking location Q’TYThread dia. (mm) Locking torque (kg-m) Remark 1 Locking nut, steering stem 1 14 4.0 ~ 5.0 2 Handle bar w

Carburetor dismantle & inspection: 2 stroke engine carburetor 1. dismantle  Remove:-carburetor assembly, pipes, cables and wires  Remove:-high-

CARBURETOR 01 CARBURETOR ASSY. 02 TOP SET 03 SPG., COMP. 04 PLATE SET 05 TUBE SET 06 JET NEEDLE 07 THROTTLE VALVE 08 SCREW SET 09 SCREW SET（

Chap 7.3 - 1 Wiring diagram

Main switch (off-on-light) Battery & fuse horn Signal flasher relay Starting relay Reg

Starting relay inspection 1.System diagram battery relay Starting motor1.Start button 2.Safety switch3.Main switch 2.Check the resistance with pocket

OP of replacing Brake Lever for ATV1501.Dismantle the clip of park stopper.2.Loosen the bolt of brake lever.

OP of replacing Brake Lever for ATV1503. Replace the brake lever & park stopper.4. Lock torque : 1.0 kg-m.

OP OF REPLACING INTAKE PIPE FOR ATV501. Take off the cover

Steering stem nut Handle bar nut Steering holder Wheel hub Rear axle nut & disc screw

OP OF REPLACING INTAKE PIPE FOR ATV502. Loosen the 2 screws

OP OF REPLACING INTAKE PIPE FOR ATV503. Take off the intake pipe by a thin tool.

OP OF REPLACING INTAKE PIPE FOR ATV504.Replace the intake pipe

OP of Replacing the Reverse-Gearbox• Step 1:• Dismantle the chain coupling set with pivor.

OP of Replacing the Reverse-Gearbox•Step 2• Dismantle the foot protector• Loosen bolt (M8) of brake kick

OP of Replacing the Reverse-Gearbox• Step 3 :• Loosen 3 bolts (M10)

OP of Replacing the Reverse-Gearbox• Step 4 :• Dismantle cable of reverse-gearbox

OP of Replacing the Reverse-Gearbox• Step 5 :• Remove rubber cap & Loosen bolt (M10)

OP of Replacing the Reverse-Gearbox•Step 6 :• Replace the gearbox set

OP of Replacing the Reverse-Gearbox•Step 7 :• Lock the reverse-gearbox (M10)• Lock torque: ① 4 kg-m• ②8~9 kg-m12

4.Other parts please refer the following table: Standard torque values: NO Item Torque (kgf-m) 1 5mm bolt and nut 0.45-0.6 2 6mm bolt and nut 0

OP of Replacing the Reverse-Gearbox• Step 8 :• Fix the cable

OP of Replacing the Reverse-Gearbox• Step 9 :• Lock the nut

OP of Replacing the Reverse-Gearbox• 步驟十 :• Lock the RH stepplate(M10)• Lock torque: 4.5~5 kg-m

OP of Replacing the Reverse-Gearbox• Step 11 :• Lock bolt of brake kick(M8)• Lock torque: 3 kg-m

OP of Replacing the Reverse-Gearbox• Step 12 :• Assemble the driving chain

(2)Lubrication instruction: A. Engine NO Lubrication location Oil type Remarks Oil type Remarks MODEL2 STROKE ENGINE 4 STROKE ENGINE 1 crank

(1) Periodical checking table: 1.[○] mark indicates periodical checking 2.[＊] indicates changing the parts Checking period Check item Gen-eral che- c

Checking period Check item Gen- eral che- cking First MonthOr Initial 500kmHome Per6 per12 Months monthsOr or 5000km 1000kmOffice Per1

Checking period Check item Gen- eral che- cking First MonthOr Initial 500kmHome Per6 per12 Months monthsOr or 5000km 1000kmOffice Per1

Checking period Check item Gen- eral che- cking First Month Or Initial 500km Home Per6 per12 Months monthsOr or 5000km 1000kmOffice Per

FRONT BRAKE INSPECTION AND ADJUSTMENT  Proper brake lever free play can avoid brake dragging. 1. Front brake inspection Apply the front brake le

brake inspection: Chap 5 - 2

SPECIFICATIONS Model XR50 XR110 XR150ENGINE Displacement 49 / 82 cc 106.2 cc 150.1 CC Cooling Force air cooled Force air cooled Force a

01 FRT BRAKE CABLE COMP. 02 OUTER SPACER 03 PLAIN WASHER 04 HEX SLOTTED & CASTLE NUTS05 COTTER PIN 06 RUBBER CAP 07 FRONT BRAKE DRUM 08 OIL

Rear brake inspection: 1. Remove the rear brake system  Remove the left rear wheel  Remove the axle collar  Remove the rear brake caliper  Remov

Chap 5 - 5 01REAR AXLE02 WHEEL RIM 03 TIRE 04 PLAIN WASHER 05 HEXAGON SLOTTED&CASTLE NUTS 06 COTTER PIN 07 RUBBER CAP 08 HEX WASHER FACE

Foot brake inspection: (Option)  Adjust the front & rear brake screws to make the foot brake balance, avoiding brake unevenly.  Make sure there

3. FRONT & REAR SHOCK ABSORBERS INSPECTION AND ADJUSTMENT 1. Check the front shock absorbers Movement Raise and drop the handlebar up and down

Steering Tie inspection & adjustment 1. Keep the vehicle in flat surface, turn the front 2. Wheel to forward parallel. 3. Make sure length C

1RIGHT STEP FLOOR ASSY.2 KICK BRAKE 3 "LEVER, REAR BRAKE PUMP" 4 "LEVER, KICK BRAKE" 5 KICK BRAKE SPRING 6 KICK BRAKE BUSH

ENGINE DISASSEMBLY(1)• Loosen engine from• frame.

ENGINE DISASSEMBLY(2)• Loosen nut• Remove throttle cable

TRANSMISSION DISASSEMBLY(1)• Loosen 10 hexagonflange screws

MODEL INTRODUCTION: PART 1 RESISTORREGULATOR SAFETY COVERHANDLEBAR CLAMP SHIELD DRIVE CHAINREAR SHOCK Fuel tank cap Chap 1 - 3

TRANSMISSION DISASSEMBLY(1)• Dismantle engine LH cover• Loosen 2 nuts of driving face & clutch outer

TRANSMISSION DISASSEMBLY(3)• Remove driving face, driving pulley, v-belt, clutch outer, driven pulley • Loosen 2 hexagon screws of starting idle gear

MAGNETO DISASSEMBLY(1)• Loosen 3 screws• Remove cooling fan cover

MAGNETO DISASSEMBLY(2)• Loosen 4 hexagon screws• Remove cooling fan

MAGNETO DISASSEMBLY(3)• Loosen nut of magneto

MAGNETO DISASSEMBLY(4)• Pull out magneto with tool (no:S620270G014)• ☆Tighten tool to prevent magneto thread worse

MAGNETO DISASSEMBLY(5)• Loosen 4 hexagon screws of stator

MAGNETO DISASSEMBLY(6)• Loosen 1 wire fixing plate screw• Remove wire fixing plate and stator

CYLINDER HEAD & CYLINDER DISASSEMBLY(1)• Loosen 2 hexagon screws• Remove cooling cover

CYLINDER HEAD & CYLINDER DISASSEMBLY(2)• Loosen 4 nuts of cylinder• Remove cylinder head

MODEL INTRODUCTION: PART 2 32REAR BRAKE CABLEREAR BRAKE LEVERNUTChap 1 - 4

CYLINDER HEAD & CYLINDER DISASSEMBLY(3)　• Remove cylinder

CYLINDER HEAD & CYLINDER DISASSEMBLY(4)• Remove piston pin clip• Remove piston pin/piston/bearing☆ The piston pin clip shall not overlap the openi

CYLINDER HEAD & CYLINDER DISASSEMBLY(5)• Assemble the cylinder head & cylinder from LH to RH☆ The opening end of piston ring shall be mounted

CYLINDER HEAD & CYLINDER DISASSEMBLY(6)• The arrow mark upon piston shall face to exhaust port

CYLINDER HEAD & CYLINDER DISASSEMBLY(7)• The ”EX” mark upon cylinder head shall face to exhaust (down)☆ Tighten nuts crossly and lock torque:1.2kg

CRANKSHAFT DISASSEMBLY(1)• Loosen 3 hexagon of intake manifold• Dismantle oil pipe• Remove intake manifold

CRANKSHAFT DISASSEMBLY(2)• Remove reed valve comp.

CRANKSHAFT DISASSEMBLY(3)• Loosen the screw of cable-fixing plate, remove fixing plate• Loosen 2 C-R recess pan hd. screws• Remove oil pump

CRANKSHAFT DISASSEMBLY(4)Don’t missing☆Do not miss plain washer when installing oil pump• The oil inlet & outlet pipe shall be full of oil(no resi

CRANKSHAFT DISASSEMBLY(5)• Loosen 2 C-R recess pan hd. screws• Remove starting motor

Chap 1 - 5 Body Cover Explosive Parts: 01 FRONT FENDER 02 REAR FENDER 03 SEAT ASSEMBLY 04 FOOTBOARD (R) 05 FOOTBOARD (L) 06 WITH W

CRANKSHAFT DISASSEMBLY(6)• Pull out R-clip of central stand axle• Remove central stand spring• Remove central stand axle• Remove central stand

CRANKSHAFT DISASSEMBLY(7)• Loosen 7 hexagon screws of RH crankcase

CRANKSHAFT DISASSEMBLY(8)• Pull out RH crankcase from crankshaft with tool

CRANKSHAFT DISASSEMBLY(9)• Remove crankshaft assy.

CRANKSHAFT INSTALLATION(1)• Pull crankshaft into LH crankcase with tool

CRANKSHAFT INSTALLATION(2)• Assemble engine hanger axle & RH crankcase• Tighten hexagon screws of RH crankcase crossly step by step☆ Replace oil s

GEAR BOX DISASSEMBLY(1)• Loosen nut of rear wheel• Remove rear wheel

GEAR BOX DISASSEMBLY(2)• Loosen 6 hexagon screws• Remove transmission cover

GEAR BOX DISASSEMBLY(3)• Remove idle gear comp & final gear

GEAR BOX DISASSEMBLY(4)• Mount the idle gear comp. first, then the final fear• The cone washer is inside, and plain washer outside when assembling id

Operating indicator Chap 2 - 1

ENGINE DISMANTLE• Loosen screws of engine hanger from frame

TRANSMISSION DISASSEMBLY(1)• Loosen 8 hexagon flange screws of LH cover• Remove engine LH cover

TRANSMISSION DISASSEMBLY(2)• Loosen nuts of driving pulley and clutch outer• When installing nuts, tighten torque is 5.5 kg-m

TRANSMISSION DISASSEMBLY(3)• Remove drive face, driving pulley assy., driven pulley assy., V-belt

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

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 lock

MAGNETO DISASSEMBLY(5)• Loosen 4 hexagon screws of stator• Remove stator

CYLINDER AND HEAD DISASSEMBLY(1)• Loosen 1 hexagon screw and 2 tapping screws of cooling cowl(2)• Remove cooling cowl(2)

Speedometer Counter(Optional) 1. Names of the parts 1. Speed display 2. Function indication 3. Mode button 4. Start/stop button 5. Unit of speed 6. B

CYLINDER AND HEAD DISASSEMBLY(2)• Loosen 1 hexagon screw of cooling cowl(1)• Remove cooling cowl(1)

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 cylin

CYLINDER AND HEAD DISASSEMBLY(6)• Remove cam chain guide comp.• Remove cylinder and piston rings

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 g

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

OIL PUMP DISASSEMBLY(3)• Loosen 2 hexagon screws of oil pump• Remove oil pump

(1) TORQUE VALUE 1. 2 stroke engine: NO Locking location Q’TYThread dia. (mm)Locking torque (kg-m) Remark 1 Cylinder head 4 7 1.0~1.42

CRANKSHAFT DISASSEMBLY(1)• Loosen 2 hexagon screws of RH crankcase• Remove RH crankcase with plastic hammer

CRANKSHAFT DISASSEMBLY(2)• Pull out crankshaft from LH crankcase• Remove camshaft chain

CRANKSHAFT INSTALLATION(1)• Put camshaft chain in LH crankcase

CRANKSHAFT INSTALLATION(2)• Assemble crankshaft in LH crankcase

CRANKSHAFT INSTALLATION(3)• Assemble RH crankcase into crankshaft• Tight 2 hexagon screws• (torque is1.0kg-m)• Replace the oil seal and packing.

CRANKSHAFT INSTALLATION(4)• To avoid the oil seal detected, shall assemble the oil seal after crankshaft is fixed in crankcase

CYLINDER & CYLINDER HEAD INSTALLATION• Notice the marks upon piston• “IN” mark shall in the intake direction ; “EX” mark shall in the exhaust dire

CYLINDER & CYLINDER HEAD INSTALLATION• Piston rings shall be installed according to marks• 1st ring is marked “1R” ; 2nd ring is marked “RN”• The

CYLINDER & CYLINDER HEAD INSTALLATION• The opening end of piston rings shall face to intake valve and allied to 120 degree• And shall not allied t

CYLINDER & CYLINDER HEAD INSTALLATIONRH crankcase markMAGNETO “T”• Installing camshaft, the valve timing shall be adjusted• Rotate the magneto “T

2. 4 stroke Engine: (XR150) NOLocking location Q’TYThread dia. (mm)Locking torque (kg-m)Remark 1 Cylinder head bolt A (intake) 2 6 0.9~1.1 2

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

CYLINDER & CYLINDER HEAD INSTALLATION• Installing camshaft holder，“EX”mark shall face to exhaust valve• Tighten 4 nuts crossly, lock torque is 2.0