Table Of Contents - PGO PMX Sport 50 Service Manual

Table of Contents

Table Of Contents2
Scooter Specification4
Service Information6
The Operation Notice6
Lubrication Instruction6
Wiring Diagram6
Troubleshooting6
Locking Torque Value8
Engine8
Chassis8
Other Parts9
Chassis Parts10
Wheel Bearing Part11
Trouble Shooting13
Difficult Starting or Can't Start13
Weak Acceleration14
Engine Running Unsmoothly (Low Speed And Idling)16
Engine Running Unsmoothly (High Speed)17
Clutch, Drive And Driven Pulley18
Handlebar Steering Astrayed When Running19
Front, Rear Damper Not In Balanced19
Brake Disorder19
Oil Indicator Malfunction20
The Oil Lamp Doesn't Light Up, (When the Main Switch Is at "On" Position)20
Oil Is Enough but the Indicator Turns on All the Time (When the Main Switch Is "On")20
Fuel Indication Malfunction21
Wrong Fuel Level Indication (When the Main Switch Is "On")21
Fuel Gauge Needle Is Not Steady and Sometimes Moves up and down (When the Main Switch Is "On")22
The Starting Motor Abnormal23
Starting Motor Can Not Rotate23
Starting Motor Running Slowly Or No Pick-Up24
Starting Motor Can Not Stop After Starting24
No Sparking25
Charging Abnormal (Battery Over Charging Or Over Discharging)26
Checking And Adjustment27
Regular Checking Table28
Battery29
Battery: Recharge When Power Is Out32
Cleaning Air Cleaner33
The Final Reduction Mechanism Oil33
Spark Plug34
Compression Pressure Measurement35
Checking Ignition Timing35
Throttle Cables Adjustment36
Idle Adjustment37
Front Brake Adjustment37
Rear Brake Adjustment38
Tire39
Dismantling, Maintaining, Repairing And Assembling Operation40
Lubrication System Diagram41
Removing Oil Pump42
Check Oil Pump42
Assemble The Oil Pump43
Releasing Air In The Oil Pump43
Dismantling & Assembling Of Plastic Parts44
Screwing Out The Screws Of Front Windshield44
Screwing Out The Screws Of Windshield & Front Inner Cover.44
Screwing Out The Screws Of The Rear Carrier45
Screwing Out The Screws Of Front Body Cover45
Screwing Out The Screws Of Left Side Cover46
Screwing Out The Screws Of Right Side Cover47
Screwing Out The Screws Of Rear Cover47
Take Off The Upper & Lower Handle Cover Firstly, Then Screwing Off The Screws Of Front Fender48
Screwing Out The Screws Of Front Inner Cover48
Screwing Out The Screws Of Front Mudguard49
Before Taking Off The Step Floor, Screwing Out The Screws Of Battery Cover Firstly49
Disconnect The Negative Cable Firstly, Then Positive Cable50
Screwing Out The Four Screws Of The Step Plate50
Screwing Out The Screws Of Step Floor & Lo Wer Mudguard50
Dismantling Engine51
Take Off The Luggage Compartment51
Remove Vacuum Pipe, Fuel Pipe, Oil Pipe. Cable Of Auto Choke And Carburetor51
Remove The Cap Of Spark Plug52
Remove Engine Hanger Shelf's Nut, Rear Damper Blot and Rear Brake Cable52
Remove The Engine52
Installing Engine53
Drive Pulley, Starter, Clutch, Driven Pulley54
Measurement Data54
Driving Pulley55
Remove The 10 Screws Of Left Cover55
Take Off The Left Cover55
Remove The Fixing Nut Of Clutch56
Take Off The Ramp Plate, Belt & Rear Clutch, And The Driving Plate56
Loosen 2 Hexagon Screws, And Take Off The Driving Gear Starter Fixing Plate Set57
Remove The Start Idle Gear Set57
Assemble Driving Pulley, Please Reverse Above Procedure58
Checking The Driving Belt58
Disassemble Slide Driving Plate Set58
Checking List58
Assemble The Slide Driving Plate59
Starter Dismantling60
Clutch Driven Pulley61
Cylinder Head, Cylinder, Piston63
The Operation Data Information For 110Cc63
Piston & Cylinder Datas For 50Cc64
Dismantle Cylinder Head, Cylinder, Piston64
Remove The Spark Plug65
Remove The Cooling Cowl And Fan Cover65
Screwing Out The Two M6-Nut Of Muffler And Cylinder, And The Two M8-Bolt Of Crankcase66
Remove Muffler66
Remove The Four M7-Nut Of Cylinder Head, Then Remove Cylinder Head And Cylinder Head Gasket66
Remove The C-Type Clip On The Piston And Piston Pin By The Nipper67
Dismantling Of The Piston Ring67
When Assembling, Please Reverse The Procedures Of Dismantling67
Check For The Flatness Of Cylinder Head68
Combustion Chamber Cleaning68
Check Cylinder And Piston69
Check The Wearing And Damage Condition On The Contact Surface Of Cylinder And Piston69
Clean Out The Carbon On The Cylinder Exhausting Port69
Cylinder Bore Measurement69
Piston Outer Diameter Measurement70
Inner Diameter Measurement Of The Piston Pin Hole70
Outer Diameter Measurement Of The Piston Pin71
Check Piston Ring71
Check Connecting Rod Small End72
Installing Cylinder And Piston72
A.c. Generator, Flyweel Magneto73
Dismantling Ac Alternator Flywheel Magneto73
Install Ac Generator74
Final Transmission Mechanism75
Check The Final Transmission Mechanism77
Assemble The Final Transmission Mechanism77
Crankcase, Crankshaft78
Disassembling Diagram78
Engine Noise79
Data79
Dismantle The Crankcase And Crankshaft80
Remove The Engine From The Chassis80
Remove Left E/G Case, Driving Pulley (Driving Plate) Clutch And Belt80
Remove Air Cleaner80
Remove Carburetor81
Remove Intake Manifold And Reed Valve81
Remove Oil Pump, Fan Cowl And Fan Cover81
Remove Cylinder, Ac Flywheel Magneto82
Remove The Left And Right Crankcase With Special Puller82
Remove Center Stand, Separate Rh/Lh Crankcase, Take Out Crankshaft82
Check Crankshaft83
Assemble The Crankcase84
Carburetor, Reed Valve And Auto Cock85
Fuel System Diagram85
Carburetor Dismantling Diagram86
Dismantling Carburetor88
Dismantling Float, Nozzle88
Dismantling Reed Valve89
Checking For The Reed Valve89
Check The Auto Cock90
Steering Column, Front Wheel, Frt Disc Brake Comp, Front Fork91
Change Speedometer Cable92
Steering Handlebar93
Front Wheel95
Front Brake97
Front Fork System Diagram99
Checking Front Fork99
Checking Front Damper99
Rear Wheel, Rear Brake, Rear Damper100
Disassembling And Assembling The The Rear Wheel101
Checking The Rear Wheel101
Rear Brake Disassembling Diagram102
Checking Rear Brake Hub102
Checking Brake Lining102
Rear Damper Disassembling Diagram103
Fuel Tank, Oil Tank104
Fuel Tank Disassembling Diagram104
Fuel Tank Dismantling And Assembling105
Dismantling And Assembling Oil Tank107
Electric Equipment108
Recharge System109
Starting System109
Recharge110
Testing The Recharging Performance111
Recharge System Diagram112
Check A.c. Generator113
Check Regulator113
Ignition System114
The Starting System115
The Wiring Of Starting115
Check The Starter116
Dismantling The Starting Motor116
Checking The Starting Motor116