PGO BR-150 Bug Rider Service Manual
  1. Manuals
  2. Brands
  3. PGO Manuals
  4. Offroad Vehicle
  5. BR-150 Bug Rider
  6. Service manual
PGO BR-150 Bug Rider Service Manual

PGO BR-150 Bug Rider Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

BR-150
SERVICE MANUAL
Manufactured by PGO
of Motive Power Industry Co., Ltd

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the BR-150 Bug Rider and is the answer not in the manual?

Questions and answers

John
March 12, 2025

Engine will only fire and keep running if you spray fuel straight into carburettor

User image 67d1e84343822
0
3 comments:
Mr. Anderson
March 12, 2025

The PGO BR-150 Bug Rider engine may only run when fuel is sprayed directly into the carburetor due to a fuel delivery issue. Possible causes include:

1. Clogged Fuel Line or Filter – A blockage in the fuel system may prevent fuel from reaching the carburetor.
2. Malfunctioning Fuel Pump – If the fuel pump is not operating properly, it may not deliver fuel to the carburetor.
3. Carburetor Issues – A clogged or faulty carburetor may not allow proper fuel flow.
4. Vacuum Leak – A vacuum leak may prevent fuel from being drawn into the carburetor.
5. Blocked Jets – If the carburetor jets are clogged, fuel may not mix properly with air.

These issues cause the engine to rely on direct fuel spraying into the carburetor for operation.

This answer is automatically generated

0
John
March 14, 2025

@Mr. Anderson

User image 67d465d11e122
0
John
March 14, 2025

Thanks for your info i will try What you mentioned i send you a picture Is this the starter relay i have to bridge the solenoid to turn over Thanks. John

User image 67d4676267289
0

Summary of Contents for PGO BR-150 Bug Rider

  • Page 1 BR-150 SERVICE MANUAL Manufactured by PGO of Motive Power Industry Co., Ltd...
  • Page 2 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 &...
  • Page 3 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.
  • Page 4 BUGXTER SPECIFICATION FRAME STEEL Name TYPE SUSPENSION SYSTEM DIMENSION FRONT SINGLE A ARM TOTAL LENGTH REAR SWING ARM TOTAL WIDTH TRANSM ISSION TOTAL HEIGHT RPIMARY RATIO SECONDARY RATIO 40/16*42/13 WHEELBASE DRY WEIGHT 263 KG CLUTCH C.V.T. FRONT TIRE REAR FRONT TOTAL REAR LOAD...
  • Page 5 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.
  • Page 6 1.2 TORQUE VALUE 1. Engine: Locking location Q’ TY Thread dia. (mm) Locking torque (kg-m) Remark 1 Cylinder head bolt A (intake ) 0.9~1.1 2 Cylinder head bolt B (Exhaust) 3 Cap, oil filter graze 1.5~2.0 4 Flange nut, cam shaft base 5 Fixing nut, air valve adjustment Greasing on thread 6 Guiding pin bolt, inner chain adjustment...
  • Page 7 3.Locking Torque Standard (Chassis) Locking location Thread dia Kg-m Remark (mm) Wheel nut Wheel axle nut Front absorber bolt Lower suspension arm bolt Ste ering handle bolt Seat belt fixture Upper suspension arm Tie rod nut Roll cage bar 10 Rear swing arm, lower 11 Engine hanger with frame 3.5~4.5 12 Engine hanger with engine...
  • Page 8 C: clean I: inspect, clean or replace if necessary L: lubricate R: replace 1. Items with “ *”mark indicate our recommendation to have it done by PGO dealer. 2. “ P ”denotes that function check or replace it when the engine performance reduces significantly.
  • Page 12 3.1 OPERATION 1.OPERATION LAYOUT...
  • Page 13 2.. Digital Speedometer • • 1.Symbol description •• s peed indication • • • • •• h igh beam indicator • •• s ign al lamp ind icator • •• r everse gear indicator • •• p arking indicator •• R ESET button ••...
  • Page 14 3.2 Steering Inspection & Adjustment Dismantle •Lock tight the bolts of steering handle. •Torque:0.5 kg-m...
  • Page 15 Steering Inspection •Inspect the coupling joint knuckle. Maintenance •Add grease into upper suspension arm per 10,000km from grease valve.
  • Page 16 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.
  • Page 17 Steering Inspection & Adjustment Steering Inspection & Adjustment •Lock tight the bolt •Add grease into lower suspension arm per 10,000km.
  • Page 18 Steering Inspection & Adjustment •When 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 •Rotating #4 to adjusting the toe-in...

  • Page 19: Brake Adjustment

    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) •Loosen nut#1 •Adjust bolt#2 out to increase park power. •Lock tight nut#1.

  • Page 20: Brake Inspection

    Brake adjustment •Hand Park (Caliper end) •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.
  • Page 21 Brake inspection and adjustment front brake rear brake •Adjusting braking power. •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.
  • Page 22 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.
  • Page 23 Wheel dismantle (1) •Withdraw the cap •Dismantle the 4 nuts Wheel dismantle (2) •You don’ t need to dismantle the wheel...
  • Page 24 Wheel dismantle (3) •Withdraw the wheel Wheel dismantle (4) •Withdraw the cotter •Dismantle the nut •Withdraw the hub...
  • Page 29 4. Electric inspection Parking button Headlamp switch • 1. Operation panel Main switch 12V power supply Horn button Signal lamp switch Panel terminal wiring • Panel back photo...
  • Page 30 Panel terminal wiring • Panel back 2. Parts location speedometer Signal lamp...
  • Page 31 2. Parts location Relay regulator resistor Ignition coil 2. Parts location Starting safety device battery...
  • Page 32 2. Parts location Head lamp Optional device Reverse shifting safety device Parking sensor...
  • Page 33 Electric inspection •Check the coupling, prevent losing connection of the terminals. •Spray some anti-dust wax if necessary. Electric inspection Flasher relay starting motor relay Head lamp & choke controller Fuse...
  • Page 34 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.
  • Page 35 3. Ignition •Ignition wiring •For CDI unit, you don’ t have to adjust the ignition timing...
  • Page 37 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 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 OP of Replacing Rear Engine Hanger Collar for BR150 1. Loosen lock nut. OP of Replacing Rear Engine Hanger Bush for BR150 2.Dismantle the bolt 3.Loosen the nut. Lock torque is: 11.0 kg-m...
  • Page 40 Muffler DISASSEMBLY •Loosen 2 bolts of muffler with cylinder head Muffler DISASSEMBLY •Loosen 1 hexagon bolt of muffler with LH cover •Remove muffler...
  • Page 41 Air cleaner removal •Loosen 9 hexagon flange screws of LH cover •Remove engine LH cover Air cleaner removal •Outside end is sponge, clean it if necessary •Inside end is paper element, replace it if necessary...
  • Page 42 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 •Remove cooling...
  • 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 lock...
  • Page 44 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)

  • Page 45: Cylinder And Head

    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.
  • Page 46 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. •Remove cylinder and piston rings...
  • Page 47 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...
  • Page 48 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 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 CRANKSHAFT DISASSEMBLY(2) •Pull out crankshaft from LH crankcase •Remove camshaft chain CRANKSHAFT INSTALLATION(1) •Put camshaft chain in LH crankcase...
  • Page 51 CRANKSHAFT INSTALLATION(2) •Assemble crankshaft in LH crankcase Crankshaft inspection data: ITEM Stand ard Limit of value(mm) use.(mm) Clearance of connecting rod big en d 0.10~0.35 0.55 axle direction Clearance of connecting rod big en d ------ 0.04 vertical direction Swingness of the crank shaft journal.
  • Page 52 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...
  • Page 53 inspection Engine •Engine layout • Cylinder head & cover “ “ “ 35TUBE C YL. C OMP.

  • Page 54: Cylinder Head Inspection

    inspection Engine • Cylinder head inspection • Different view of cylinder head Cylinder head data: Standa rd L im it use Description (mm) (mm) Valve Cl earance 0.08 (Before warm up ) 0.08 Compression pressu re 1 1 kg/700 rpm (B R 150) 26.625 26.23...
  • Page 55 Engine inspection •Valve train •Valve clearance •IN:0.08mm •EX:0.08mm CYLINDER & CYLINDER HEAD INSTALLATION •Installing camshaft, the valve timing shall be adjusted •Rotate the magneto MAGNETO “ T” “ T”make to RH crankcase allied position RH crankcase mark...
  • Page 56 CYLINDER & CYLINDER HEAD INSTALLATION •Ensure 2 line marks Hole in camshaft of camshaft parallel to cylinder head refer to photo •And the hole shall be in the top position refer to photo Line marks in camshaft CYLINDER & CYLINDER HEAD INSTALLATION •Installing camshaft holder “...
  • Page 57 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.
  • Page 58 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.
  • Page 59 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 Standard L im it ( mm ) ( mm ) Cy lin de rh ead...
  • Page 60 Engine inspection •Cylinder CYLINDER & CYLINDER HEAD INSTALLATION •Notice the marks To intake upon piston •“ IN” mark shall in t h e i n t a k e d i r e c t i o n ; To exhaust “...
  • Page 61 CYLINDER & CYLINDER HEAD INSTALLATION •Piston rings shall 1st ring “ 1R” be installed according to marks 2nd ring “ RN” •1st ring is marked “ 1R” ; 2 n d r i n g i s marked “ RN” •The marks shall face to piston head CYLINDER &...
  • Page 62 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 5.5 kg-m...
  • Page 63 CVT TRANSMISSION DISASSEMBLY(3) •Remove drive face, driving pulley assy., driven pulley assy., V-belt Ite m Standard val ue (mm ) Limit of use ( mm ) Th e in ne rdia . Of sl ide drivi ng 24.10 24.011~24 .052 pl ate inspection data Th e ou te rdia .
  • Page 64 inspection data Belt width Roller dia. Frt pulley dia Lining thickness Outer dia Spring length Engine inspection • Transmission System • Primary:CVT • Final:reduction gear • PV:CVT clutch-in • GV:CVT top speed...
  • Page 65 Engine inspection •Transmission System •Reverse gear is engaged Driving chain dismantle (1) 4.Dismantle 2 bolts 5.Push the reverse box to right hand approximately 10...
  • Page 66 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 (3) And make sure part #9 can rotate in pivot #17...
  • Page 67 Driving chain dismantle (4) 9.Adjust the chain slack by this nut. Driving chain dismantle (5) 10. Lock the lower nuts by : 5.0 to 6.0 kg-m...
  • Page 68 Driving chain dismantle (6) •When installing the lock pin of driving, keep the close end forward the Drive direction. Open end Close end...
  • Page 69 2.4 Carburetor dismantle & inspection: 1. dismantle Remove:-carburetor assembly, pipes, cables and wires Remove:- high-tension wire 2. adjustment there are two screws might be adjusted to tuning the engine intake mixture. is the stop screw: to adjust th e engine idle speed, recommended idle speed is 1600 to 1800 rpm.
  • Page 70 CARBURETOR PRINCIPLE Fuel lev el 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 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 u um p i st o n (JN) B ody Remarks: 1.No leakage of vacuum Throt tl e v al ve pis ton comp with body.
  • Page 72 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...

This manual is also suitable for:

Br-150 bugxter

Table of Contents

Save PDF