Download
Share
Print this page
  1. Manuals
  2. Brands
  3. Motive Power Industry Manuals
  4. Motorized Toy Car
  5. Bugxter BR-150
  6. Service manual

Motive Power Industry Bugxter BR-150 Service Manual

Hide thumbs

Advertisement

Quick Links

Download this manual
SERVICE MANUAL
Manufactured by Motive Power Industry Co., Ltd

Advertisement

loading
Need help?

Need help?

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

Questions and answers

Related Manuals for Motive Power Industry Bugxter BR-150

Summary of Contents for Motive Power Industry Bugxter BR-150

  • Page 1 SERVICE MANUAL Manufactured by 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 SERVICE MANUAL Manufactured by Motive Power Industry Co., Ltd...

  • Page 4: Table Of Contents

    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 5 At every important section we illustrate by assembly, explosion diagrams and photographs, if necessary, please check the diagrams already shown. Though we have tried our best, please kindly instruct us any faults found in this manual. MOTIVE POWER INDUSTRY CO., LTD.
  • Page 6 BUGXTER SPECIFICATION BR-150 FRAME STEEL Name BR-150 TYPE SUSPENSION SYSTEM DIMENSION FRONT SINGLE A ARM TOTAL LENGTH REAR SWING ARM 2215 mm TOTAL WIDTH TRANSMISSION 1365 mm TOTAL HEIGHT RPIMARY RATIO 1480 mm WHEELBASE SECONDARY RATIO 40/16*42/13 1510 mm DRY WEIGHT 263KG CLUTCH C.V.T.
  • Page 7 1.1 The operation notice: 1. Always replace gasket, O ring, cotter, pins and clip whenever reassembled. 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.
  • Page 8 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 9 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 Steering 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 10 In order to achieve safe riding, good performance and reduce pollution, please execute the following recommended maintenance table base upon average driving condition. Driving in unusual dusty areas, require more frequent servicing. MONTHS/DISTANCE(IN KM)FOR CHECKING 1 or 3 or 6 or 9 or 12 or 15 or...
  • Page 11 LOCKING TORQUE...
  • Page 12 LOCKING TORQUE...
  • Page 13 LOCKING TORQUE...

  • Page 14: Engine Dismantle

    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. ENGINE DISMANTLE 1...
  • Page 15 Engine Dismantle • Loosen the bolt of upper swing arm with the lower swing arm rear. Engine Dismantle • Loosen 2 bolts of oil cooler ENGINE DISMANTLE 2...
  • Page 16 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 ENGINE DISMANTLE 3...
  • Page 17 Muffler DISASSEMBLY • Loosen 2 bolts of muffler with cylinder head Muffler DISASSEMBLY • Loosen 1 hexagon bolt of muffler with LH cover • Remove muffler ENGINE DISMANTLE 4...
  • Page 18 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 ENGINE DISMANTLE 5...
  • Page 19 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 ENGINE DISMANTLE 6...
  • Page 20 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 ENGINE DISMANTLE 7...
  • Page 21 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) ENGINE DISMANTLE 8...
  • Page 22 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 23 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 ENGINE DISMANTLE 10...
  • Page 24 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 •...
  • Page 25 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 ENGINE DISMANTLE 12...
  • Page 26 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 ENGINE DISMANTLE 13...
  • Page 27 CRANKSHAFT DISASSEMBLY(2) • Pull out crankshaft from LH crankcase • Remove camshaft chain CRANKSHAFT INSTALLATION(1) • Put camshaft chain in LH crankcase ENGINE DISMANTLE 14...
  • Page 28 CRANKSHAFT INSTALLATION(2) • Assemble crankshaft in LH crankcase Crankshaft inspection data: ITEM Standard Limit of value(mm) use.(mm) Clearance of connecting rod big end 0.10~0.35 0.55 axle direction Clearance of connecting rod big end ------ 0.04 vertical direction Swingness of the crank shaft journal.
  • Page 29 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 ENGINE DISMANTLE 16...

  • Page 30: Engine Inspection

    inspection Engine • Engine layout •Cylinder head & cover 1HEAD COMP. CYLINDER 13INSULATOR CARB 25LOCK PIN 2"GUIDE,EXH VALVE “ 14IGNITION PLUG (CR7HSA) 26CAMSHAFT HOLDER 3O-RING 15PLAIN WASHER 27PLAIN WASHER 4"GUIDE,IN VALVE “ 16"SPRING,VALVE “ 28HEXAGON FLANGE NUT 5VALVE EXHAUST 17RETAIER VALVE SPRING 29CYL.HEAD COVER COMP.
  • Page 31 inspection Engine •Cylinder head inspection •Different view of cylinder head Cylinder head data: Standard Limit use Description (mm) (mm) Valve Clearance － 0.08 (Before warm up) － 0.08 Compression pressure 11kg/700rpm (BR150) 26.625 26.23 Height of the cam ’s convex part 26.53 26.13 Inner diameter of rocker arm shaft...
  • Page 32 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 ENGINE INSPECTION 3...
  • Page 33 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 •...
  • Page 34 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 35 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 36 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 Limit ( mm ) ( mm ) Cylinder head flatness...
  • Page 37 Engine inspection • Cylinder CYLINDER & CYLINDER HEAD INSTALLATION • Notice the marks To intake upon piston • “IN” mark shall in To exhaust the intake direction ; “EX” mark shall in the exhaust direction ENGINE INSPECTION 8...
  • Page 38 CYLINDER & CYLINDER HEAD INSTALLATION • Piston rings shall 1st ring “1R” be installed according to marks 2nd ring “RN” • 1st ring is marked “1R” ; 2nd ring is marked “RN” • The marks shall face to piston head CYLINDER &...
  • Page 39 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 TRANSMISSION DISMANTLE & INSPECTIOM 1...
  • Page 40 CVT TRANSMISSION DISASSEMBLY(3) • Remove drive face, driving pulley assy., driven pulley assy., V-belt Item Standard value ( mm ) Limit of use ( mm ) The inner dia. Of slide driving 24.10 24.011~24.052 plate inspection data The outer dia. Of boss, movable 23.960.~23.974 23.940 Driving plate...
  • Page 41 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 TRANSMISSION DISMANTLE & INSPECTIOM 3...
  • Page 42 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 TRANSMISSION DISMANTLE & INSPECTIOM 4...
  • Page 43 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 TRANSMISSION DISMANTLE &...
  • Page 44 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 TRANSMISSION DISMANTLE & INSPECTIOM 6...
  • Page 45 Driving chain dismantle (6) • When installing the lock pin of driving, keep the close end forward the Drive direction. Open end Close end TRANSMISSION DISMANTLE & INSPECTIOM 7...
  • Page 46 2.4 Carburetor dismantle & inspection: 1. dismantle l Remove:-carburetor assembly, pipes, cables and wires l 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 the engine idle speed, recommended idle speed is 1600 to 1800 rpm.
  • Page 47 CARBURETOR PRINCIPLE Various Intake pressure a i r Fuel level Functions: 1.Fuel atomization 2.Air/Fuel Ratio 3.Engine Output Engine inspection • Carburetor Assembly • Idle adjustment(stop screw) 1700±100rpm • Pilot screw CARBURETOR DISMANTLE & INSPECTION...
  • Page 48 IDLE ADJUSTMENT 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. 怠速噴嘴 (PJ) fuel Pilot Screw (PS) 怠速空氣噴嘴 (SAJ) MAIN SYSTEM Vacuum 油針 piston (JN) Body Remarks: 1.No leakage of vacuum Throttle 主空氣噴嘴...
  • Page 49 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 CARBURETOR DISMANTLE & INSPECTION...

  • Page 50: Operation

    3.1 OPERATION 1.OPERATION LAYOUT...
  • Page 51 2.. Digital Speedometer 1.Symbol description １　 ①speed indication ８　 ２　 ②high beam indicator 　 ③signal lamp indicator ３ ④reverse gear indicator ３ ⑤parking indicator ⑥RESET button ⑦MODE button ⑧ｄｉｓｐｌａｙ　ａｒｅａ ６　　　　　　　４　５　　　　　　　７ 2.Setting: Press “MODE + RESET” 2 sec., then can get into the setting procedure. ①Unit: km/h or mile/h, switched by MODE, and RESET to confirm.

  • Page 52: Steering Inspection & Adjustment 1

    3.2 Steering Inspection & Adjustment Dismantle • Lock tight the bolts of steering handle. • Torque:0.5 kg-m STEERING INSPECTION & ADJUSTMENT 1...
  • Page 53 Steering Inspection • Inspect the coupling joint knuckle. Maintenance • Add grease into upper suspension arm per 10,000km from grease valve. STEERING INSPECTION & ADJUSTMENT 2...
  • Page 54 Inspection • Inspect the absorber, 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. STEERING INSPECTION & ADJUSTMENT 3...
  • Page 55 Steering Inspection & Adjustment • Lock tight the bolt • Add grease into lower suspension arm per 10,000km. Steering Inspection & Adjustment • Lock tight the bolt • Add grease into lower suspension arm per 10,000km. STEERING INSPECTION & ADJUSTMENT 4...
  • Page 56 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 •...

  • Page 57: Brake Inspection & Adjustment 1

    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. •...
  • Page 58 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. • Check the function of starting safety sensor SAFETY SENSOR BRAKE INSPECTION &...
  • Page 59 Brake inspection and adjustment • If there is air residual inside the brake hose, the brake power will decrease & the safety sensor will lose function. • Bleed the air from the screw of caliper. Brake inspection and adjustment front brake rear brake •...
  • Page 60 Brake inspection and adjustment • Make sure there is not any fluid leakage from the bolt. Brake inspection and adjustment • Specification of front brake caliper • Replace the pad of disk if necessary. BRAKE INSPECTION & ADJUSTMENT 4...
  • Page 61 Brake inspection and adjustment • Specification of rear brake caliper • Replace the pad of disk if necessary. Wheel dismantle (1) • Withdraw the cap • Dismantle the 4 nuts BRAKE INSPECTION & ADJUSTMENT 5...
  • Page 62 Wheel dismantle (2) • You don’t need to dismantle the wheel Wheel dismantle (3) • Withdraw the wheel BRAKE INSPECTION & ADJUSTMENT 6...
  • Page 63 Wheel dismantle (4) • Withdraw the cotter • Dismantle the nut • Withdraw the hub BRAKE INSPECTION & ADJUSTMENT 7...

  • Page 68: Chapter 4 : Electric

    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 ELECTRIC INSPECTION 1...

  • Page 69: Parts Location

    Panel terminal wiring • Panel back 2. Parts location speedometer Signal lamp ELECTRIC INSPECTION 2...
  • Page 70 2. Parts location Relay regulator resistor Ignition coil 2. Parts location Starting safety device battery ELECTRIC INSPECTION 3...
  • Page 71 2. Parts location Head lamp Optional device Reverse shifting safety device Parking sensor ELECTRIC INSPECTION 4...
  • Page 72 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 ELECTRIC INSPECTION 5...
  • Page 73 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). •...
  • Page 74 3. Ignition • Ignition wiring • For CDI unit, you don’t have to adjust the ignition timing ELECTRIC INSPECTION 7...