PGO Tigra AF-125BAE Service Manual
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PGO Tigra AF-125BAE Service Manual

PGO Tigra AF-125BAE Service Manual

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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. The service manual
prepared from simple takedown to detailed disassembly and from performance
introduction to service preparation provides complete instructions for general
lubrication and routine check or adjustment. Explained with general views, exploded
views, or photos, all necessary items repeatedly cited should be referred to the
previous drawings and not further described in detail herein.
As a result of this service manual composed of directions for the following model,
please check the model of your motorcycle among different ones in the manual for
any contents available.
 AF-125BAE: Four-Stroke Cycle, 125CC Level, 4-valve, water cooling,
The high-performance electronic fuel-injected water-cooling engine provided in
this motorcycle is the up-to-date 125CC engine developed by Motive Power and being
excellent in the engine kept within the optimal operating temperatures for high
precision and the power output superior to that of a general air-cooling engine.
For any inadvertent mistakes attributed to preparation in a hurry, Motive Power
Industry sincerely wish any person skilled in the art offer any comments.
PREFACE
electronic injection engine
MOTIVE POWER INDUSTRY CO., LTD.
1

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  • Page 1 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. The service manual...
  • Page 2 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.
  • Page 3 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 Exhauster...
  • Page 4 Information Summary and Preparation 1 1-2 Positions of engine number / vehicle identification number: Vehicle identification number Engine number...

  • Page 5: Specifications

    Information Summary and Preparation 1 1-3 Specifications: (以下表格內容不需翻譯) 國 產 機 器 腳 踏 車 規 格 表 架 (身) 廠 牌 摩 特 動 力 車 鋼 管 AF-125BAE 型 式 懸 吊 前 伸 縮 式 1865 尺 全...
  • Page 6 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.
  • Page 7 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.
  • Page 8 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)
  • Page 9 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。 ...
  • Page 10 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.
  • Page 11 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.
  • Page 12 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 Operating Procedure Subsequent Steps Results Check the voltage between two battery terminals with a Next step...
  • Page 13 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 Operating Procedure Subsequent Steps Results Next step Connect a fuel pressure gauge before the fuel inlet of the nozzle; start the engine to check the fuel pressure at 300kPa or so.
  • Page 14 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 Operating Procedure...
  • Page 15 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.
  • Page 16 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 Operating Procedure...
  • Page 17 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 Operating Procedure...
  • Page 18 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 Operating Procedure...
  • Page 19 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 Operating Procedure Subsequent Steps Results Clean relevant parts. Remove the idle governor and check the air throttle, the idle governor, and the idle air bypass for any carbon deposition.
  • Page 20 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 Operating Procedure Subsequent Steps...
  • Page 21 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 Operating Procedure...
  • Page 22 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...
  • Page 23 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;...
  • Page 24 Information Summary and Preparation 1 PCODE List PCODE UAES Description Manifold Abs.Pressure or Bar.Pressure Low P0107 Inlet pressure sensor to GND short-circuited Input Inlet pressure sensor to power supply Manifold Abs.Pressure or Bar.Pressure High P0108 short-circuited Input Low voltage of the signal for the air inlet temperature P0112 Intake Air Temp.Circ.
  • Page 25 Installation or Removal of External Components Front & rear covers (handlebar) 1. Front cover → Front lamp assembly → Rear cover → Dashboard assembly → Left & right handlebar switch assembly Set screws Set screws ◙ Remove 4 set screws on the front cover. ◙...
  • Page 26 Installation or Removal of External Components 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 Set screws ◙...
  • Page 27 Installation or Removal of External Components 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 Set screws ◙ Remove 4 set screws on the rear lamp and left & right body cover assembly (A). ◙...
  • Page 28 Installation or Removal of External Components 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 ◙ Remove 4 set screws on the left & right air breathers (front inner panel) (A). ◙...
  • Page 29 Installation or Removal of External Components 4. Front inner panel cover → Front inner panel ◙ 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). ◙...
  • Page 30 Installation or Removal of External Components 6. Front inner fender 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. Set screw ◙...
  • Page 31 Check & Adjustment 1) Gear oil Volume Total oil volume: 110c.c. Filling orifice bolt Oil volume replaced: 90c.c. Service cycle: Every 3000km 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.
  • Page 32 Check & Adjustment 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;...
  • Page 33 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.
  • Page 34 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 0.6~0.7mm deposition. 3. Use carbon remover or a steel brush to clean any filth or deposited carbon.
  • Page 35 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.
  • Page 36 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.
  • Page 37 Check & Adjustment Change of a front brake pad Tool to change a brake pad: Allen wrench Pins fixing a 12” T-type wrench 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) Change a brake lining: Use an Allen wrench to loose two pins fixing a brake...
  • Page 38 Check & Adjustment Take out the brake shoe with pins removed. Pin fixing a brake shoe Left lining Right lining 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 Install all parts in a reverse order.
  • Page 39 Check & Adjustment Change the rear brake pad Brake pad ☉ Remove set screws fixing the rear brake shoe. ☉ Use the long nose pliers to remove the R-type snap ring. ☉ Remove the brake pad. ☉ Use the long nose pliers to remove the dowel pin. Install all parts in a reverse order.
  • Page 40 Check & Adjustment 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.
  • Page 41 Check & Adjustment 11) Check / adjust timing Align the flywheel mark to Check: the triangular sign on the timing window of the right crankcase for the piston at 1. Align the flywheel “T” mark to a triangular sign on the upper dead center.
  • Page 42 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.
  • Page 43  “○”: Required item  “*”: PGO distributor only  Maintenance cycle: Complete check every 6,000 km and minor maintenance every 3,000 km; follow the same frequency hereinabove for any motorcycle’s mileage greater than the number in the table.

  • Page 44: Lubrication System

    Lubrication System 4 Lubrication system diagram Oil lines inside a crankshaft designed to compulsively lubricate Cam shaft the connecting rod tip 曲軸箱 Crankcase Rocker arm Piston Oil filter element Crankshaft Oil pump Oil filter screen...
  • Page 45 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.
  • Page 46 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 Note: Check and replace the O-ring for proper installment simultaneously.
  • Page 47 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 Disconnect follows: nozzle, engine cables for the temperature sensor,...
  • Page 48 Disassembly of the Engine Assembly 5 4. Disassemble the engine’s throttle cable and vacuum tube Disconnect all vacuum Disassemble the hoses connected the throttle cable. engine manifolds and the air filter. 5. Disconnect high-pressure fuel hose connector Disconnect the Use a tool to remove 7.拆下下懸吊...
  • Page 49 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.

  • Page 50: Cylinder Head

    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 Remove 2 set screws of the chain adjuster and Set screws take out brackets and pads supporting the idle controller of the chain adjuster.
  • Page 51 Cylinder Head E. Remove the cylinder head, cylinder head gaskets Cylinder head and 2 dowel pins. 2 dowel pins Cylinder head gasket...
  • Page 52 Cylinder Head 2. Disassemble the cylinder head Rock arm (inlet valve) Rock arm A. Use a wrench to remove set screws on the camshaft (exhaust valve) mounting plate. B. Remove the camshaft mounting plate, the rock arm shafts (intake & exhaust valves) and the rock arms (intake &...
  • Page 53 Cylinder Head F. Loose bolts on the temperature controller; remove the Cylinder head body temperature controller cover and take out the temperature controller. Temperature Temperature controller controller cover G. Remove the engine temperature sensor. Engine Exhaust bolt temperature sensor...
  • Page 54 Cylinder Assembly Disassemble the cylinder Dowel pin Remove the cylinder head for the steps as follows: Cylinder gasket A. Sequentially take out parts such as chain guide, cylinder, cylinder gasket, and dowel pins. Cylinder Chain guide 鏈條導件 Check the angle to install an oil scraper ring of the piston ring and B.
  • Page 55 Cylinder Assembly Measurement and check Visually check the external of the piston or replace it with a new one in the event of the old one useless. 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.
  • Page 56 Cylinder Assembly 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.
  • Page 57 V Belt Driver Left cover / drive belt assembly A. Remove 3 set screws on the left cover cap and take out it. Set screws Remove 9 set screws on the left cover and take out Set screws 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.
  • Page 58 V Belt Driver 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. Balancing ball Size: 18.0mm Weight: 11g Size limit Inner diameter of the mobile drive flank hub: Standard Size limit size=24.0mm;...
  • Page 59 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 Dowel pins B.
  • Page 60 Crankcase & Crankshaft 9  Disassembly and installation of the engine oil pump sprocket: engine oil pump sprocket Disassembly of the 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. Remove the drive sprocket and the drive chain of the engine oil pump.

  • Page 61: Engine Oil Filter

    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.
  • Page 62 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.
  • Page 63 Crankcase & Crankshaft 9 Securely fix the right crankcase with the puller hammer installed for the bearing pulled out.  Evaluation and measurement of a removed crankshaft Check the connecting rod for any noise attributed to large radial and axial clearances of a running crankshaft.
  • Page 64 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. Horizontally place the case on the workbench.
  • Page 65 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.
  • Page 66 Final Speed Gear 10 Final drive gear Set screws Steps for removal: Remove the drain plug bolt and drain the gear oil. Remove 7 set screws on the gear box cover; take out the gear box cover. Remove the rear shaft. Final gear Idle gear and flat washer Rear shaft...

  • Page 67: Fuel Injection System

    Fuel Injection System 7 Configuration and performance of parts in the MSE3.0 gasoline engine’s electronic control unit 點火線圈/火花塞 節氣門體 Throttle Body Ignition Coil/Spark Plug 含氧感測器 節氣門位置感測器 Throttle 集成式節氣門體 Position Sensor Oxygen Sensor Integrated Module Small Engine 噴油器 催化轉化器 Injector Catalyst Converter 電子控制器...
  • Page 68 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.
  • Page 69 Fuel Injection System 7 ECU Pin Configuration ISA-TEV +canister purge(TEV) ECU Pin TEV (ISA)+Evaporative Emission Control Ignition1/CDI / 點火 GND (Ignition, power) / 點火接地 Vehicle speed sensor or else input / 車速感測器或其他輸入 MIL / 故障指示燈 KL15 / 點火開關 intake air temp.(ADC) / 進氣溫度感測器 Output / 輸出...
  • Page 70 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. Rang of pressures monitored: 10~115kPa Intake pressure sensor Principle: Due to any change in the intake manifold’s pressures causing deformation of a pressure sensor’s diaphragm, the piezo-resistance effect makes resistance changed and further developed to be signals (voltages) proportional to pressures under a processor chip’s functions.
  • Page 71 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.
  • Page 72 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.
  • Page 73 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.
  • Page 74 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.
  • Page 75 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.
  • Page 76 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.
  • Page 77 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...
  • Page 78 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.
  • Page 79 Cooling System 12 Cooling system diagram...

  • Page 80: Cooling System

    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).
  • Page 81 Cooling System 12 Change coolant  Steps to change water coolant (simplified): In order to avoid burn and make sure of safety during change of water coolant, please cool the engine temperature in advance. Loose the drain plug bolt on the water pump cover and evacuate water coolant.
  • Page 82 Cooling System 12 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.
  • Page 83 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...
  • Page 84 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.

  • Page 85: Water Pump

    Cooling System 12 Water pump  Steps to disassemble a water pump Take out the water pump cover. Loosen the vane first. (Note: Left-handed screw for the vane) Remove the water pump’s vane clockwise. 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).
  • Page 86 Cooling System 12 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.
  • Page 87 Cooling System 12  Sealing performance of the cooling system 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/cm ;...
  • Page 88 Charge, Ignition, and Start-up 13 Notices for operation: Sequentially disconnect cables on the battery’s Power supplied off and on  terminals “-” and “+”. Poor connection of battery cables  Keep watch for any spark plug’s model and torque Cable connector of the charging system loose for installation.
  • Page 89 Charge, Ignition, and Start-up 13 Check: Battery  Voltage check A. Use a multi-meter or a voltage meter to test a battery’s voltages. 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”...
  • Page 90 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. Night Voltage Current Voltage...
  • Page 91 Charge, Ignition, and Start-up 13 Ignition system Check the ignition system Measure the first circuit (Red) & (Black); resistance: 0.8~1.3Ω. Disconnect the high-tension wire; resistance: 9KΩ. Pickup coil (P/C)
  • Page 92 Chassis 14  Remove the rear wheel  Removal Remove the seat assembly; disconnect the Lambda sensor connector. Tool: 10” T-type wrench Remove the exhauster assembly; keep the Lambda sensor body not be collided during removal. Tool: 12” T-type wrench Remove the axle cover.

  • Page 93: Exhaust Emission Control System

    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.
  • Page 94 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.
  • Page 95 Remove deposited carbon on the cylinder head and the piston top or in system the exhaust system in the event of the engine’s power substantially dropped for the mileage between 5,000 and 10,000km. *: PGO dealer only...

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