PGO PMX Sport 50 Service Manual
  1. Manuals
  2. Brands
  3. PGO Manuals
  4. Scooter
  5. PMX Sport 50
  6. Service manual

PGO PMX Sport 50 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

This manual offers all service specialist with professional technigues
techniguess of maintenance and repairing for PM50 &PM110. It provides a
Detailed guide for those whom may concern with how to maintain, repair,
Reassemble, and exchange parts of their scooters.
At every section, we illstrate each important point by assembling
Procedures, explosive diagrams and photographs.
Although we have tried our best to make this manual as perfect as
Possible, please kindly inform us if any fault needs to be corrected
in this manual.
Thank you for purchasing our POG scooters.
PREFACE
FACTORY：
Motive Power Industry Co.,Ltd.

Advertisement

Table of Contents
loading

Related Manuals for PGO PMX Sport 50

Summary of Contents for PGO PMX Sport 50

  • Page 1 PREFACE This manual offers all service specialist with professional technigues techniguess of maintenance and repairing for PM50 &PM110. It provides a Detailed guide for those whom may concern with how to maintain, repair, Reassemble, and exchange parts of their scooters. At every section, we illstrate each important point by assembling Procedures, explosive diagrams and photographs.
  • Page 2 CONTENTS： 1.The specifications 2.Service information (1)The operation notice (2)Torque value (3)Lubrication instruction (4)Wiring diagram (5)Troubleshooting 3.Checking and Adjustment (1)Regular checking table (2)Battery (3)Cleaning air cleaner (4)Final reduction mechanism oil (5)Spark plug (6)Compression pressure measurement (7)Ignition timing (8)Throttle cables adjustment (9)Idle adjustment (10)Front brake adjustment (11)Rear brake adjustment (12)Tire...
  • Page 3 (12)Fuel tank, oil tank 5.Electric equipment (1)Troubleshooting (2)Battery (3)Recharge system (4)Ignition system (5)Starting system...
  • Page 4 SCOOTER SPECIFICATION (1) Name PMX SPORT50 ERAME STEEL TYPE PM-50D SUSPENSION SYSTEM DIMENSION FRONT TELESCOPIC TOTAL LENGTH 1820 REAR UNIT-ABSORBER TOTAL WIDTH TRANSMISSION TOTAL HEIGHT 1090 RPIMARY RATIO WHEELBASE 1220 SECONDARY RATIO 52/13*44/13 DRY WEIGHT 94KG CLUTCH C.V.T. FRONT 37KG TIRE REAR 57KG...
  • Page 5 SCOOTER SPECIFICATION (2) Name PMX SPORT110 ERAME STEEL TYPE PM-110D SUSPENSION SYSTEM DIMENSION FRONT TELESCOPIC TOTAL LENGTH 1820 REAR UNIT-ABSORBER TOTAL WIDTH TRANSMISSION TOTAL HEIGHT 1090 RPIMARY RATIO WHEELBASE 1220 49*16*43/13 SECONDARY RATIO DRY WEIGHT 94KG CLUTCH C.V.T. FRONT 37KG TIRE REAR 57KG...
  • Page 6 2.Service information： (1)The operation notice (2)Locking torque value a.For engine b. For chassis c. Others (3) Lubrication instruction a.For engine b. For chassis c. Wheel bearing (4)Wiring diagram (5)Troubleshooting 1.Difficult starting or can’t 2.Weak acceleration 3.Engine running unsmoothly (low speed) 4.Engine running unsmoothly(high speed) 5.Clutch, drive, driven pulley 6.Handlebar steering astrayed when running...
  • Page 7 2.When trying to tighten screws or nuts, please lock tightly according to each recommended locking torque and in the sequence of the”X” pattern. 3.Please use PGO recommended parts. 4.After dismantling, please clean all parts involved or used for checking and grease all contact surfaces when reassembling.
  • Page 8 Locking Torque Value: 1.Engine No Locking location Thread dia Locking Remarks (mm) torque kg-m Cylinder head 1.0~1.4 When the engine is cold Flywheel plate 3.2~4.0 Rear brake lever 1.0~1.2 Driving pulley 3.2~4.0 Clutch outer 3.5~4.0 Right crankcase 1.0~1.2 Drive gear box cover 1.0~1.2 Left crankcase 1.0~1.2...
  • Page 9 3.Other parts: Please refer the following table: Standard torque values: Item Torque kg-m 1 5mm bolt and nut 0.45-0.6 2 6mm bolt and nut 0.8-1.2 3 8mm bolt and nut 1.8-2.5 4 10mm bolt and nut 3.4-4.0 5 12mm bolt and nut 5.0-6.0 6 5mm screw 0.35-0.5...
  • Page 10 B. Chassis parts...
  • Page 11 C. Wheel bearing part...
  • Page 13 (5)Trouble shooting: 1.difficult starting or can’t start: Check and adjust Trouble condition The reason Loose carburetor draining Screw, check if in side of Carburetor have fuel or not •check there is fuel or not ‚pipe between ful tank and carburetor is blocked The fuel supply in carburetors No fuel supply in ƒFloat is blocked...
  • Page 14 2.Weak acceleration: Trouble condition Check and Adjust The reason Start engine and open throttle Gradually, check and inspect •air cleaner blocked ‚fuel supply system abnormal ƒfuel tank cover blocked Engine can’t rotate Engine can rotate up „ muffler blocked Up completely …auto chock is malfunctioned †auto chock is malfunctioned Check ignition timing, (check...
  • Page 15 Check the oil level in gear box Is too much or dirty •oil level is too high ‚oil level is too low Oil level is ƒoil does not interchange Not normal Oil level is normal Check the combustion color of cylinder head •oil route is blocked ‚...
  • Page 16 3.Engine running unsmoothly (low speed and idling) Check and adjust Trouble condition The reason Check ignition timing •CDI faulty Correct Not correct ‚AC generator faulty Adjust carburetor air screw •mixture too rich Good Faulty (to loose the screw) adjustment adjustment ‚mixture too lean (to tight the screw) Check if there is air...
  • Page 17 4.Engine running unsmoothly (high speed) Check and adjust Trouble condition The reason Check ignition timing •CDI sets faulty correct Not correct ‚AC generator faulty Check auto cock, Fuel supply system •fuel level is too low ‚fuel pipe, fuel filter is blocked good unsmoothly ƒautocock faulty...
  • Page 18 5.Clutch, drive and driven pulley Trouble condition The reason •driving belt worn out, distortion ‚driven plate worn-out Engine can start but can’t ƒdriven plate spring distorted Move the vehicle „clutch lining worn-out …driving pulley shaft gear teeth cracked †final gear damage •clutch lining spring cracked or worn out Engine runs, but it stops...
  • Page 19 6.Handlebar steering astrayed when running. Trouble condition The reason (front and rear wheel pressure are normal) •steering column lock nut locked too tightly Handlebar operates heavily ‚steel ball cracked •rear, front wheel bearing swings Front and rear wheel swings ‚front, rear wheel rim distorted ƒfront axle nut is loose •front and rear wheel center not well- Handlebar astrayed to one direction...
  • Page 20 9.Oil indicator malfunction (a)The oil lamp doesn’t light up, (when the main switch is at “ON”position) Check and adjust Trouble condition The reason Turn the signal lamp On. Check wiring Of battey •fuse burn-out ‚battery has no power Normal Lamp dims, light does ƒmain switch abnormal Not flash, no light „circuit plug dropped off...
  • Page 21 10.Fuel indication malfunction (a)wrong fuel level indication(when the main switch is “ON”) Check and adjust Trouble condition The reason Turn the signal lamp On; check wiring of battery •fuse burn-out ‚battery has no power ƒmain switch abnormal normal Lamp dims, light „circuit plug dropped off Not flash, not light …main wiring disconnected...
  • Page 22 (b)Fuel gauge needle is not steady and sometimes moves up and down (when the main switch is “ON”) The reason Check and adjust Trouble condition Turn signal lamp on, Check wiring of •fuse burn-out battery ƒbattery has no power ƒmain switch abnormal normal No motion „circuit plug dropped off or...
  • Page 23 The starting motor abnormal (a)Starting motor can not rotate Check and adjust Trouble condition The reason Check brake switch •fuse burn-out ‚battery has no power Brake lamp Brake lamp ƒmain switch abnormal Lights up no light „circuit plug dropped off …main wiring disconnected Turn signal lamp No to check wiring...
  • Page 24 (b)Starting motor running slowly or no pick-up Check and adjust Trouble condition The reason Turn signal lamp On, to check wi- ring of battery normal Lamp dims, no •battery has no power Flashing, no light Connect starting Motor to Battery directly •electric plug is loose Running Runing slowly...
  • Page 25 12.No sparking Check and adjust Trouble condition The reason Replace new spark Plug, then check again Good sparking Weak sparking Spark plug faulty Or no sparking Check spark plug, cap And H.V. cable is Loose or not Spark plug cap is loose good loosen Check the CDI plug...
  • Page 26 13.Charging abnormal(battery over charging or over discharging) Check and adjust Trouble condition The reason Measure batter’s Voltage then start engine Voltage remain Voltage goes up The same To normal value, •battery is dead But after engine ‚battery malfunction Stop, the voltage Goes down again Check voltage rectifier Plug is loose or not...
  • Page 27 3.Checking and Adjustment: (1)Regular checking table (2)Battery (3)Cleaning air cleaner (4)The final reduction mechanism oil (5)Spark plug (6)Compression pressure measurement (7)Ignition timing (8)Throttle cables adjustment (9)Idle adjustment (10)Frt brake adjustment (11)Rr brake adjustment (12)Tire...
  • Page 28 (1)Regular checking table: 1.【O】mark indicates periodical checking 2.【※】indicates changing the parts Checking period first en-era home office Judgement month Item every6 every12 every1 every3 every12 Remark standard months months months months months che-cki Initial 500km 5000km 10000km 1000km 2500km 10000km ○...
  • Page 29 Checking period first en-era home office Judgement month Item every6 every12 every1 every3 every12 Remark standard months months months months months chec-ki Initial 500km 5000km 10000km 1000km 2500km 10000km Clearance on ○ ○ ○ ○ ○ ○ Front axle Bearing Clearance on ○...
  • Page 30 Checking period first en-era home office Judgement month Item every6 every12 every1 every3 every12 Remark standard months months months months months che-cki Initial 500km 5000km 10000km 1000km 2500km 10000km Performance, ○ ○ ○ ○ ○ Noise Low speed, dling:1900± ○ ○...
  • Page 31 Checking period en-era first home office Judgement month Item every6 every12 every1 every3 every12 Remark standard che-cki months months months months months Initial 500km 5000km 10000km 1000km 2500km 10000km ○ ○ ○ ○ ○ ○ Function Lamp system ○ ○ ○...
  • Page 32 (2)Battery: Recharge when power is out 1.Open the cover and remove the battery cover. àTake out the battery, 2.Remove the negative cable and then the positive Cable,àtake out the battery to recharge. 3.To re-assemble the battery, please follow the opposite Procedure of disassembling after recharging Note: A.
  • Page 33 (3)Cleaning air cleaner 1.Remove air cleaner cover 2.Take out the air cleaner filter 3.Clean the filter by the compressor air 4.Assemble the air cleaner by reversing above procedure Note: Do not start the engine When the air cleaner is Not installed (4)The final reduction mechanism oil 1.Change the oil in the gear box: a.
  • Page 34 (5)Spark plug 1.Remove spark plug 2.Check the spark plug electrode and check if it is Burnt out or not and carbonized or not 3.Clean the electrode, if it is dirty 4.Spark plug specification NGK:BY7HS or same spec. Gap of spark plug:0.6~0.7mm Electrode Burn out Carbon piled up...
  • Page 35 (6)Compression pressure measurement: 1.Measure it when the engine is warm. 2.Open the seat, remove the luggage. 3.Remove the cover. 4.Remove spark plug then place comp- Ression pressure gauge. 5.Fully open the throttle, kick on kickstarter 5 Times continuously, measure the compression Pressure.
  • Page 36 (8)Throttle cables adjustment: 1.check the clearance of throttle twist grip. 2.Normal clearance:1.5-3.5mm 3.Adjust it by : ①ｔａｋｅ　ａｗａｙ　ｔｈｅ　ｒｕｂｂｅｒ　 ②ｌｏｏｓｅｎ　ｔｈｅ　ｎｕｔ　 ③rotating the adjuster nut to adjust the clearance , change it if the throttle cables can’t be adjusted.
  • Page 37 (9) ldle adjustment: 1.remove left body cover 2.start the engine and connect the tachometer 3.adjust the throttle valve screw to the specified revolution 1900±100rpm 4.if the idling rpm is still unsteady or fuel up is not smooth, please adjust it by followings.
  • Page 38 (11)Rear brake adjustment 1.Check the clearance Of rear brake lever. Clearance: 10-20mm 2.If the clearance is Beyond the above standard, Adjust it by rotating the Adjuster nut. a. Lefthanded rotation enlarge the clearance. b. Righthanded rotation reduce the clearance. Note: When the arrow of rear brake indicator lay in The arrow of left crankcase, change the brake Lining.
  • Page 39 (12)Tire: 1.Check the tire air pressure Notice: Check the tire before running 2.Tire pressure: Front tire: 2.0 kg/c ㎡ Front tire: 2.0 kg/c ㎡ 3.Tire dimension: Front tire: 120/70-12 Rear tire: 130/70-12 4.Check is there any sharp Object pierce the tire. 5.Check the depth of tire Thread.
  • Page 40 4.Dismantling, maintaining, repairing and assembling operation: (1)Lubrication system (2)Plastic parts (3)Engine dismantling (4)Drive pulley, starter, clutch, driven pulley (5)Cylinder head, cylinder, piston (6)AC Generator flywheel magneto (7)Final transmission mechanism (8)Crankcase, crankshaft. (9)Carburetor, reed valve, auto cock (10)Steering column, front wheel, front damper, front fork (11)Rear wheel, rear brake, rear damper (12)Fuel tank, oil tank...
  • Page 41 (1)Lubrication system: 1.Lubrication system diagram. 2.Troubleshooting. A. If there is too much white fume from exhaust system, which means too much Carbon piled up on the spark plug or the oil quality is not good. B. Engine over heating: a. The adjustment of oil pump is not properly.(1ack of oil) b.
  • Page 42 3.Removing oil pump. Clean the oil pump and Crank case before operation a. Remove the luggage and rear bracket. b. Remove the input/output oil pipe. c. Take out the oil pump by removing The locking screw on oil pump and Oil gauge cable.
  • Page 43 5.Assemble the oil pump. a. Assemble the oil pump by reversing Above procedure. O-ring of oil pump sho uld be lubricated by Grease or oil, then place on cankcase. The contact surface of oil pump and crank Case should be assembled firmly. The gears of oil pump should be lubri- Cated by grease.
  • Page 44 (2)Dismantling & assembling of plastic parts 1.screwing out the screws of front windshield 2.Screwing out the screws of windshield & front inner cover. àtake off the windshield.
  • Page 45 3.Screwing out the screws of the rear carrier àtake off the rear carrier 4.Open the seat, screwing out the 9 screws of luggage compartment àtake off the luggage compartment. 5.Screwing out the screws of front body cover àtake off the front body cover.
  • Page 46 6.Screwing out the screws of left side cover àtake off the left side cover.
  • Page 47 7.Screwing out the screws of right side cover àtake off the right side cover. 8.Screwing out the screws of rear cover àtake off the rear cover.
  • Page 48 9.Take off the upper & lower handle cover firstly, then screwing off the screws of front fender. 10.screwing out the screws of front inner cover.
  • Page 49 11.screwing out the screws of front mudguard. 12.Before taking off the step floor, screwing out the screws of battery cover firstly àtake off the battery cover.
  • Page 50 13.Disconnect the negative cable firstly, then positive cable àtake out the battery. 14.Screwing out the four screws of the step plate àtake off the step plate. 15.Screwing out the screws of step floor & lo wer mudguard àtake off the step floor & lower mudguard. Locking torque: Note: Pay attention not to clamp or scraping the cables by M6:0.7-1.1kg- m...
  • Page 51 (3)Dismantling Engine A.Dismantling engine. 1.Take off the luggage compartment. 2.Remove vacuum pipe, fuel pipe, oil pipe. Cable of auto choke and carburetor.
  • Page 52 4.Remove the cap of spark plug. 5.Remove engine hanger shelf’s nut, rear damper blot and rear brake cable. 6.Remove the engine.
  • Page 53 B. installing engine. 1.Install engine please reserse above procedure. 2.Locking torque: M8:2.0~3.0kg- m M10:3.0~4.0kg- m M12:5.0~6.0kg- m 3.After installing, inspect and adjust the following: a. the wire connecting. b. throttle cable, oil control cable. c. fuel and oil route. d. rear brake adjustment.
  • Page 54 (4)Drive pulley, starter, clutch, driven pulley A. Troubleshooting: a. Engine starts, but vehicle does not move. 1.driving belt worn out 2.driven plate worn out 3.clutch lining worn out b. The vehicle stops or trembles when running, 1.clutch lining spring cracked or broken. c.
  • Page 55 C. Driving pulley. 1.Remove the 10 screws of left cover. 2.Take off the left cover.
  • Page 56 3.Remove the fixing nut of clutch. 4. Take off the ramp plate, belt & rear clutch, and the driving plate.
  • Page 57 7. Loosen 2 hexagon screws, and take off the driving gear starter fixing plate set. 8.Remove the start idle gear set.
  • Page 58 9.Assenbke driving pulley, please reverse above procedure. Locking torque: 1.M10 nut of driving pulley:3.5~4.0kg- m 2.M10 nut of clutch outer:3.5~4.0kg- m 10.Checking the driving belt (1)check whether it is cracked or its rubber and fiber are loose or not also check if they are extraordinarily worn out. (2)driving belt width: limit of use : change it when below 16.5mm.
  • Page 59 13.Assemble the slide driving plate. (1)Clean the inner surface of slide driving plate, then assemble the roller. (2)Assemble the ramp plate. (3)Please reverse the procedures of disassembling to finish assembling.
  • Page 60 D. Starter dismantling 1.Dismantle the left crankcase cover 2.Remove the hexagon nut, then remove the starter lever. 3.Remove five screws of partition plate. 4.Remove the stater spring from the start returning positioner. 5.Remove the driven gear comp of kick starter. 6.Remove the retaining c-type clip 7.Remove the spindle comp.
  • Page 61 E. Clutch driven pulley 1.Dismantle the clutch a. Remove left crankcase cover. b. Remove driving plate. c. Remove driving belt. d. Remove M10 locking nut, then the clutch. 2.Assembling the clutch:please follow the opposite procedure of dismantling. Locking torque: M10:3.5~4.0kg- m 3.Checking the clutch: Dismantling the clutch needs the special Tool, please contact your dealers.
  • Page 62 c. Check driven spring free length:standard:154.6mm Limit of use:change it as it Is below 149.3mm d. Check wearing condition of driving plate set. Outer diameter measurement: Limit of use:change it as it Is above 33.940mm e. Check wearing condition of slide driven plate.
  • Page 63 (5)Cylinder head, cylinder, piston: A. Troubleshooting. a. compression pressure is too low, difficult to start engine, low RPM running unsmoothly. 1. Cylinder washer cracked. 2. Spark plug not being locking well. 3. Piston ring worn out or cracked. 4. Cylinder, piston worn out or injured. 5.
  • Page 64 C-2. PISTON & CYLINDER DATAS for 50cc: Standard Value Limit of use Part name/description (mm) (mm) Cylinder head Flatness 0.100 cylinder Bore 39.995~40.015 40.050 Piston/ Clearance b/w Piston Lst ring 0.05~0.06 0.10 Piston ring ring piston and ring 0.05~0.06 0.10 Piston outer diameter 39.950~39.970 39.895...
  • Page 65 4.Remove the cooling cowl and fan cover. 5.Remove the spark plug.
  • Page 66 6.Screwing out the two M6-nut of muffler and cylinder, and the two M8-bolt of crankcase. 7.Remove muffler. 8.Remove the four M7-nut of cylinder head, then remove cylinder head and cylinder head gasket.
  • Page 67 9.Remove the C-type clip on the piston and piston pin by the nipper. Take off piston. 10.Dismantling of the piston ring Remove the lst ring, then 2 ring. 11.When assembling, please reverse the procedures of dismantling Locking torque: Opening end of piston ring M7:1.0-1.4kg- m M6:1.0-1.2kg- m...
  • Page 68 E. Check for the flatness of cylinder head. Check the flatness of contact surface of cylinder head. Limit of use:If it exceeds 0.1mm Change a new one. l cylinder l piston l piston pin snap l piston pin l needle bearing Head gasket head F.
  • Page 69 G. Check cylinder and piston: 1.Check the wearing and damage condition on the contact surface of cylinder and piston. 2.Clean out the carbon on the cylinder exhausting port. Be careful not to scratch the inner Surface of cylinder. 3.Cylinder bore measurement: (1)Measure each point : upper,middle,lower orderly, and in X.Y.
  • Page 70 4.Piston outer diameter measurement: (1)Measure at the skirt area where is 12 mm from the skirt lower end. (2)Limit of use: change if when below 51.905mm(110cc) (3)Calculate the clearance between cylinder and piston. Limit of use:change it when over 0.100mm 5.Inner diameter measurement of the piston pin hole Limit of use: change it when over 14.032mm(110cc)
  • Page 71 6.Outer diameter measurement of the piston pin limit of use: change it when under 13.074mm(110cc) 7.Check piston ring: Measure piston ring gap inside cylinder: Limit of use: change new ones when the first ring and second ring are over 0.4mm Push the piston ring into the cylinder By piston, then measure the gap...
  • Page 72 8.Check connecting rod small end (1)lnstall piston pin, bearing onto the connecting rod small end, then check the looseness of the piston pin. (2)Measure the inner diameter of the connecting rod small end. Limit of use: replace a new one when over 18.020mm. (110cc) H.
  • Page 73 (6)A.C. Generator, Flyweel Magneto A.Dismantling AC alternator flywheel magneto. 1.Remove fan cowl. 2.Screwing out the four M6-bolt of fan. 3.Screwing out the nut on flywheel. 4.Remove the AC flywheel magneto by special tool.
  • Page 74 5.Remove the flywheel. 6.Remove the electric plug of AC Flywheel magneto. Take out the magneto. B. Install AC generator To install, please reverse the dismantling procedures. Locking torgue: M6:1.0~1.2kg- m M10:3.2~4.0kg- m...
  • Page 75 (7)Final Transmission Mechanism A. Trouble shooting lEngine can be started, but vehicle doesn’t move. 1.Gear worn-out or cracked. 2.Gear burnt out. lNoise occurs when running. 1.Gear worn out, burnt or gear surface damaged. 2.Bearing worn out or loosen. lOil leakage 1.Too much oil.
  • Page 76 3.Remove the bolt in gear box cover, take off the gear box. 4.Remove final reduction gear and idle gear shaft. 5.Clean up the gear box...
  • Page 77 C. Check the final transmission mechanism 1.Check the wearing condition of the driving shaft and gears. 2.Check the wearing condition of the idle gear shaft and idle gears. 3.Check the wearing condition of the final reduction gear. 4.Check the wearing condition of the oil seal and bearing. D.
  • Page 78 (8)Crankcase, Crankshaft: A. Disassembling diagram...
  • Page 79 B. Troubleshooting. Engine noise: 1.The bearing of final transmission mechanism is loose. 2.Crank pin bearing is loose. 3.The bearing of gear box is loose. C. Data Item Stardard value Limit of use.(mm) Clearance of connecting rod big end 0.20-0.50 0.76 (Parallel direction to rod) Clearance of connecting rod big end 0.04...
  • Page 80 D. Dismantle the crankcase and crankshaft. 1.Remove the engine from the chassis. 2.Remove left E/G case, driving pulley (driving plate) clutch and belt. 3.Remove air cleaner.
  • Page 81 4.Remove carburetor. 5.Remove intake manifold and reed valve. 6.Remove oil pump, fan cowl and fan cover.
  • Page 82 7.Remove cylinder, AC flywheel magneto. 8.Remove the left and right crankcase with special puller. 9.Remove center stand, separate RH/LH crankcase, take out crankshaft.
  • Page 83 E. Check crankshaft: 1.measure the clearance between crank shaft and co-rod big end.(Parallel direction to rod) Limit of use: change it when above 0.76mm 2.check the looseness on X.Y. axis of the connecting rod big end(Perpendicular directions to rod) Limit of use: change it when above 0.04mm...
  • Page 84 3.measure the swingness of crank shaft neck. Limit of use Change it when Change it when Above 0.1mm Above 0.1mm 60mm 4.check the slackness of crankshaft bearing, if it is slack, change a new one. F. Assemble the crankcase. 1.To assemble the crankcase, please reverse the procedures of disaseembling. 2.The locking torque value for bolts and nuts are all described in the previous chapters Please refer.
  • Page 85 (9)Carburetor, Reed Valve and Auto cock A. Fuel system diagram Fuel tank fuel gauge autocock Fuel supplied to Carburetor...
  • Page 86 B: Carburetor dismantling diagram CARBURETOR ASSY. TOP SET SPG., COMP. PLATE SET TUBE SET JET NEEDLE THROTTLE VALVE SCREW SET SCREW SET（A.S） O RING NEEDLE JET SLOW JET HOLDER, NEEDLE JET MAIN JET FLOAT VALVE SET PIN, ARM FLOAT SET FLOAT CHAMBER SET 19 TUBE SET 20 "SCREW, WASHER"...
  • Page 87 C. Troubleshooting: a. Engine can not be started. 1.No fuel in the fuel tank. 2.Fuel pipe is blocked. 3.There is too much fue l in the cylinder. 4.Air cleaner is blocked. b. Engine idling(RPM)unsteady, running not smoothly 1.Improper adjustment of the carburetor idling. 2.Ignition disorder.
  • Page 88 D. Dismantling carburetor 1.Remove the luggage box. 2.Loose the hose clamp between the carburetor and the air cleaner. Then remove the air cleaner. 3.Unscrew the fuel draining screw of the carburetor. Drain off the fuel inside the carburetor. 4.Remove the fuel pipe and the vacuum pipe on the carburetor.
  • Page 89 F. Reed valve 1.Dismantling reed valve. (1)Take off the luggage box (2)Remove the air cleaner (3)Remove the carburetor. (4)Unscrew the locking screw of the manifold intake. (5)Remove the manifold intake. (6)Remove the reed valve. 2.checking for the reed valve. §chang a new one when the reed valve is worn out or distorted. §change a new one too when the base of the reed valve is cracked, injured or distorted.
  • Page 90 G. Check the auto cock 1.When the engine stop, remove the fuel pipe from carburetor and check if there is fuel flow Out or not. It means auto cock functions well if the residue fuel(for the amount of 5-10cc)flows out From the auto cock and fuel pipe.
  • Page 91 (10)Steering column, front wheel, frt disc brake comp, front fork: A. Troubleshooting 1.steering handlebar is abnormal, too tight. a.steering mechanism; washer of conical bush locked too tightly. b.steering mechanism; steel ball is cracked. c.steering mechanism; steel ball base and washer of conical base is injured. 2.steering handlebar is aslant.
  • Page 92 C. Change speedometer cable: 1.Remove the front handle cover. 2.Remove the nut of the speedometer cable. 3.Remove the fixed screw of the speedometer cable on the front wheel. 4.Pull out the damaged speedometer cable. 5.To assemble the new cable, please follow the opposite of dismantling procedures. Note: Put some grease onto the inner cable before assembling.
  • Page 93 D. Steering handlebar. 1.Remove the LH/RH back mirrors. 2.Remove the front handle cover. 3.Remove the rear handle cover, the speedometer and plugs of switch. 4.Remove the terminal of rear brake and the switch plug of the rear brake lamp. 5.Loose the throttle cable pulley’s cover. 6.Remove the throttle cable and RH grip assembly.
  • Page 94 8.Remvoe the bolts and nuts fixed the handlebar on the front damper. 9.Romove the steering handlebar. 10.To assemble the handlebar, please follow the opposite dismantling procedures. Locking torque: M6:1.0-2kg- m M10:3.0-4.0kg- m 11.Before assembling, please put the grease onto the cables.
  • Page 95 F. Front wheel: 1.Remove the locking nut of front wheel on the right side. 2.Pull out he axle of front wheel Remove the spacer ring and take off the gear sets of the speedometer. 3.Remove the front wheel assembly. 4.To assemble, please reverse the procedures of dismantling.
  • Page 96 5.Checking front axle a. Check the bending degree of the front axle. b. Limit of use:chang it when above 0.22mm 6.Check the front wheel bearing. Rotate the wheel. If any noise or slackness is found, Please change a new one. 7.Front wheel rim checking.
  • Page 97 F. Front Brake 1.Disassembling and assembling the front brake comp. a. Remove the two bolts fixed on the frt brake comp from the front fork. b. To assemble the frt. brake comp, please reverse the dismatling procedures. Locking torque: M8:2.0~3.0kg- m 2.The releasing of air from the frt brake comp.
  • Page 98 4.Disassembling and assembling the front brake disk. a. Remove the front wheel. b. Remove the three nuts on the disk. c. Remove the disk. d. To assemble the disk, please reverse the disassembling procedure. Locking torque M8:2.0~3.0kg-m 5.Checking for the front brake-disk. Standard thickness:3.6mm Limit of use: Replace a new one when below 3.1mm 6.Check the front brake lining.
  • Page 99 G. Front fork 1.Front fork system diagram. Tube fixing screw Spring fixing bolt 2.checking front fork: Please change a new one if it is distorted. 3.Checking front damper: Check the guiding rod of damper if it is bended. Also check if there is abnormal worn out or damage.
  • Page 100 (11)Rear wheel, rear brake, rear damper: A. Troubleshooting. 1.Rear wheel swings. a. Wheel rim is distorted. b. Tire worn out. c. The wheel axle is improperly assembled. 2.rear damper is too soft. a. Spring fatigue. 3.Bad braking a. The adjustment of brake is not proper. b.
  • Page 101 C. Disassembling and assembling the the rear wheel. 1.Remove the rear mudguard. 2.Remove the muffler. 3.Remove the nut on the rear wheel 4.Remove the rear wheel. 5.Assemble the rear wheel please reverse the dismantling procedure. Locking torque:M6:0.7-1.1kg- m M14:8.0-10.0kg- m D.
  • Page 102 E. Rear brake: 1.Rear brake disassembling diagram. (1)Checking rear brake hub: a. measure the inner diameter of rear brake hub. b.Limit of use:change it when above 111.0mm (2)Checking brake lining: a. measure the thickness of rear brake lining. b.linit of use:As the thickness is less than 2mm, change it.
  • Page 103 F. Rear damper 1.Rear damper disassembling diagram:...
  • Page 104 (12)Fuel tank, oil tank: A. Troubleshooting. 1.Engine can’t start: a. No fuel in fuel tank. b. Fuel pipe is blocked. c. Auto cock and fuel filter is blocked. d. The membrane of fuel cock over-extended. 2.The mixture is too lean. a.
  • Page 105 C. Fuel tank dismantling and assembling 1.Remove the rear carrier.(rear protector) 2.Remove luggage box. 3.Remo ve front body cover.
  • Page 106 4.Remove the side cover. 5.Remvoe the rear cover. 6.Remove the fuel tank cover. 7.Remove the vacuum pipe and fuel pipe from the fuel tank and carburetor to drain off the fuel. 8.Remove the fixing bolts from fuel tank. 9.Remove the fuel tank.
  • Page 107 D. Oil tank disassembling diagram: Dismantling and assembling oil tank: 1.Drain the oil off. 2.Disconnect plug of oil gauge. 3.Remove oil tank. 4.Clean the oil tank. 5.To assemble the oil tank, please reverse the procedures of dismantling.

  • Page 108: Electric Equipment

    5.Electric equipment: (1)Troubleshooting (2)Battery 1.recharge 2.check specific gravity of eletrolyte (3)Recharge system 1.the wiring diagram of recharge system 2.check A.C. flywheel magneto. 3.Check regulator/rectifier. (4)Ignition system 1.the wiring of ignition 2.check spark plug 3.check H.T. cable and H.V. coil 4.check C.D.I. set (5)Starting system 1.the wiring of starting 2.checking the starter...
  • Page 109 ŸCurrency is broken: (1)Troubleshooting: A. Recharge system: The wiring of batter connection is not good. ŸNo power: 2.Ignition system connection is not good. 1.Battery ove r discharging 3.Ignition system is short circuit. •No electrolyte in battery. 4.Lamp system connection is not good or ‚Battery is bleached short circuit.
  • Page 110 (2)Battery: Always remove the battery negative Cable(-)first, then remove positive Cable(+). But connect the positive Cable(+)first, then connect the Negative cable(-) when assembling. 1.Recharge ŸConnection procedure: connect the positive cable(+) of the recharger to the positive cable(+) of the battery, and the negative cable(-) of the recharge to the negative cable(-) of the battery.
  • Page 111 2.Testing the recharging performance ŸThis test needs to be done when the battery is fully recharged. ŸThis test needs to be done after engine is warm- up. a. Disconnect the orange cable of regulator. b. Open the fuse box, to remove the white cable. c.
  • Page 112 (3)Recharge system: 1.Recharge system diagram...
  • Page 113 2.Check A.C. Generator a. Open the seat and remove the luggage box. b. Measure the resistance value of terminals. Yellow/black 0.1-1.0 White/black 0.2-2.0 ACG inside 3.Check regulator Measure the resistance value between each terminal, It should be in the specified range, otherwise change a new one.
  • Page 114 (4)Ignition system: 1.the wiring or ignition 2.check spark plug. 3.Check H.V. cable and H.V. coil. Check with CDI tester, follow the instruction manual. 4.check CDI sets. Check with CDI tester and follow the instruction manual. If CDI test failed, please change a new one. Spark plug Ignition coil...
  • Page 115 (5)The starting system: 1.The wiring of starting Starting relay Starting motor 　 ①ｓｔａｒｔｉｎｇ　ｂｕｔｔｏｎ　 ②ｓａｆｅｔｙ　ｓｗｉｔｃｈ　 ③ｍａｉｎ　ｓｗｉｔｃｈ...
  • Page 116 2.check the starter ŸConnect green/white cable to positive pole of battery, connect black cable of negative pole of battery, It means starter is function well if above connection and both Red/Black cable of staring motor have currency passing through. 3.Dismantling the starting motor (a)Remove 2 screws on starting motor.

This manual is also suitable for:

Pmx sport 110

Table of Contents