Download
Share
Print this page
Genuine Scooter Company Buddy 170 Service Manual
  1. Manuals
  2. Brands
  3. Genuine Scooter Company Manuals
  4. Scooter
  5. Buddy 170
  6. Service manual

Genuine Scooter Company Buddy 170 Service Manual

Hide thumbs

Advertisement

Quick Links

Advertisement

loading
Need help?

Need help?

Do you have a question about the Buddy 170 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Genuine Scooter Company Buddy 170

Summary of Contents for Genuine Scooter Company Buddy 170

  • Page 2 PREFACE This manual offers all service specialists with the technological procedures of maintenance, repairing for Buddy170 detailedly show those whom may concern how to maintain, repair, change parts,troubleshoot and reassemble, etc. At every important section we illustrate by assembly, explosiondiagrams and photographs, if necessary, please check the diagrams already shown.

  • Page 3: Table Of Contents

    CONTENTS The specification Service information (1)The operation notice (2)Looking torque value (3)Lubrication instruction (4)Periodical maintenance table (5)Wiring diagram (6)Troubleshooting Checking and adjustment (1)Checking table (2)Battery (3)Clean the air cleaner (4)Oil screen (5)The final reduction mechanism oil (6)Spark plug (7)Compression pressure measurement (8)Valve clearance (9)Ignition timing Front brake adjustment...
  • Page 4 (2)Battery (3)Recharge system (4)Starting system (5)Starting clutch (6)Handle bar switch...

  • Page 5: The Specification

    Specification Chassis steel pipe Suspension Name PA-170DAAE front: telescopic Model PA-170 rear: 4-bar linkage, Dimension uni-absorber Overall length: 1710mm Transmission Overall width: 645mm primary reduction :direct drive Overall height: 1090mm second reduction:40/16*43/13 Overall base: 1210mm clutch type: centrifugal dry type V belt ,C.V.T.

  • Page 6: Service Information

    2. Service information: (1) The notice for operation3 (2) Locking torque value a. For engine b. For chassis c. Others (3) Lubrication instruction6 a. For engine b. For chassis c. Wheel bearing (4) Periodical maintenance table (5) Wiring diagram (6) Troubleshooting Engine not running or slowly running during start-up Engine running but start-up failing during start-up Trouble of hot start...

  • Page 7: The Operation Notice

    (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: Looking Torque Value

    (2) Torque value: a. Engine: Thread dia. Locking location Q’TY Locking torque (kg-m) Remark (mm) 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: Standard Torque Values

    c. Other parts please refer the following table: Standard torque values: Item Torque (kgf-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: Lubrication Instruction

    (3)Lubrication instruction: Engine NO Lubrication location Oil type Remarks 1 crankcase:rotating part, Auto-separated sliding part premium 4 stroke Lubrication 2 cylinder:rotating part, motorcycle oil Total: 1000 c.c. sliding part. or SAE15W40 Replacement 800c.c 3 drive gear box SAE85-140 Total 110 c.c. Replacement 90c.c 4 gasket of starter shaft clean grease...
  • Page 11 B. Chassis Steel ball, steering item Front brake fluid Front brake cam...
  • Page 12 C. Wheel bearing Motor oil Final transmission mechanism gear oil Speedometer gear-clean grease Front wheel bearing-clean grease...

  • Page 13: Periodical Maintenance Table

    (4) PERIODICAL MAINTENANCE TABLE MONTHS/DISTANCE(IN MILE)FOR CHECKING Model 1 or 3 or 6 or 9 or 12 or 15 or 18 or Item Checking Content 200 mile 1800 3600 5400 7200 9000 10800 mile mile mile mile mile mile Replace 800cc total 1000cc Engine oil* Replace it initially 200 mile, and then replace it per 1800mile...
  • Page 14 NOTE 2： The exchange of brake fluid 1. After disassembling of brake main cylinder or caliper, do change the new fluid. 2. Check the fluid level often, Refill if necessary. 3. Change the oil seal of main cylinder and caliper every two years. 4.

  • Page 15: Wiring Diagram

    (5) Wiring diagram.

  • Page 16: Troubleshooting

    (6) Trouble shooting: 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 17: Engine Not Running Or Slowly Running During Start-Up

    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 multi-meter to ensure the voltage between 11 and 12V Replace the battery.

  • Page 18: Trouble Of Hot Start

    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 19: Trouble Of Cold Start

    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 Subsequent Steps Results...

  • Page 20: Trouble Of Start-Up Anytime Despite Rpm Normal

    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 21: Start-Up Normal But Idle Speed Unstable Anytime

    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. ISC; 7. Ignition timing; 8. Spark plug; 9. Engine mechanism. Procedure for general diagnoses: Detection Operating Procedure...

  • Page 22: Start-Up Normal But Idle Speed Unstable During Warm-Up

    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 Subsequent Steps...

  • Page 23: Start-Up Normal But Idle Speed Unstable With Warm-Up Finished

    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. ISC; 7. Engine mechanism. Procedure for general diagnoses: Detection Operating Procedure Subsequent Steps...

  • Page 24: Start-Up Normal But Idle Speed Unstable Or Stall With Load Such As Front Lamp Applied

    9. Start-up normal but idle speed unstable or stall with load such as front lamp applied General trouble location: 1. ISC 2. Nozzle. Procedure for general diagnoses: Detection Operating Procedure Subsequent Steps Results Remove the ISC and check the air throttle, the ISCand the idle Clean relevant parts.

  • Page 25: Start-Up Normal But Idle Speed Too High

    10. Start-up normal but idle speed too high General trouble location: 1. Air throttle and idle air bypass; 2. Vacuum tube; 3, ISC ; 4. Engine temperature sensor; 5. Ignition timing. Procedure for general diagnoses: Detection Operating Procedure Subsequent Steps Results Adjustment Check the throttle cable for jammed or too tight.

  • Page 26: Rpm Low Or Stall During Acceleration

    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.ISC ; 7. Nozzle; 8. Ignition timing; 9.

  • Page 27: Acceleration Slow

    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. ISC ; 7. Nozzle; 8. Ignition timing; 9. Exhauster. Procedure for general diagnoses: Detection Subsequent...

  • Page 28: Acceleration Powerless; Performance Bad

    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. ISC ; 8. Nozzle; 9. Ignition timing; 10. Exhauster.

  • Page 29: Checking And Adjustment

    3.Checking and Adjustment: (1)Periodical checking table (2)Battery (3)Clean air cleaner (4)Oil screen (5)The final reduction mechanism oil (6)Spark plug (7)Cylinder pressure (8)Valve clearance (9)Ignition timing Front brake adjustment (10) Rear brake adjustment (11) Tire (12) Throttle cable adjustment (13)

  • Page 30: Checking Table

    (1) Periodical checking table: 1.[○] mark indicates periodical checking 2.[＊] indicates changing the parts Checking period Gen- First Home Office eral Month Per6 per12 Per1 per3 per12 Judgement Check item Remark che- Months months Months months months standard cking Initial 200mile 3000mile 6000mile mile...
  • Page 31 Checking period Gen- First Home Office eral Month Per6 per12 Per1 per3 per12 Judgement Check item Remark che- Months months Months months months standard cking Initial 200mile 3000mile 6000mile mile 1500mile 6000mile Wheel Front Bearing of axle, ○ ○ ○ ○...
  • Page 32 Checking period Gen- First Home Office eral Month Per6 per12 Per1 per3 per12 Judgement Check item Remark che- Months months Months months months standard cking Initial 200mile 3000mile 6000mile mile 1500mile 6000mile Engine Engine Performance, ○ ○ ○ ○ ○ parts noise Low speed,...
  • Page 33 Checking period Gen- First Home Office eral Month Per6 per12 Per1 per3 per12 Judgement Check item Remark che- Months months Months months months standard cking Initial 200mile 3000mile 6000mile mile 1500mile 6000mile Performance ○ ○ ○ ○ ○ ○ Lamp system Dirty, cracked ○...

  • Page 34: Battery

    Battery: Recharge when run out of it 1.Remove the floor mat. 2.Screwing out the two screws on the battery cover; remove the battery cover. 3.Remove the negative cable and then the positive cable, take out the battery to recharge. 4.Re-assembling the battery as the opposite procedure of disassembling after recharging. Note: Do not take out the sealed bolt when recharging.

  • Page 35: Clean The Air Cleaner

    (3) Clean air cleaner 1.Remove air cleaner cover. 2.Take out the air cleaner filter. 3.Clean the filter by compressed air. 4.Assemble the air cleaner by the opposite procedure. MOTOR OIL Attn: Do not start engine when air cleaner is not installed. Oil volume Note: The vehicle must park on the flat ground...

  • Page 36: Oil Screen

    Oil screen Cleaning for the oil screen Drain the Oil in the engine, remove the Oil draining bolt the spring and the Screen. If any adherent material is found, please use detergent to clean the screen. Check the 0-ring. If it is damaged, change a new one.

  • Page 37: Spark Plug

    (6)Spark plug 1.Remove spark plug. 2.Check the spark plug electrode and see whether it is burnt out/ carbonized or not. 3.Clean the electrode, if it is dirty. Spark plug specification NGK: CR6HSA Gap of spark plug:0.6~0.7mm spark plug Electrode burnt out Carbon piled up or not Washer is distorted or not Porcelain is cracked or not...

  • Page 38: Valve Clearance

    (8)Valve Clearance Note: Checking and adjustment of valve clearance only can be done under 35 C of engine temperature. 1.Remove cylinder head cover. 2.Remove intake pipe from the cover of cylinder head. 3.Screw out the cap nut. 4.Remove cylinder head. 5.Rotate cooling fan, the mark on cam shaft gear must reach The upper dead position, the “T”...

  • Page 39: Front Brake Adjustment

    (10) Front Brake Adjustment 1.Check the clearance of front brake lever Clearance: 10~20mm. 2.If the clearance is beyond standard, check whether: a. The air mix into the pipe/caliper. b. The oil brake system is leaking. Note: Try brake lever to see if it’s loose. Check the brake oil.once air mixed in the oil pipe, which will reduce or damage the brake efficiency or even its function.

  • Page 40: Rear Brake Adjustment

    (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 rotation the screw. a. Left-handed rotation-Enlarge the clearance. b. Right-handed rotation-Reduce the clearance. Note: When the arrow of rear brake indicator align with the arrow of left crankcase, change the brake lining.

  • Page 41: Throttle Cables Adjustment

    3.Check if there is any sharp object piece the tire. 4.Check the depth of wheel stripe. Depth (front and rear): According to the mark of tire”▲” indicating the necessity to change a new tire. (13) Throttle cables Adjustment 1.Check the clearance of throttle 2.Normal clearance: 1.5~3.5mm Adjust it by rotating the adjust nut.

  • Page 42: Dismantling, Maintaining, Repairing And Assembling Operation

    4. Dismantling, Maintaining, Repairing and assembling operation (1) Lubrication system (2) Plastic parts of Chassis (3) Engine dismantling (4) Drive pulley, starter, clutch, driven pulley (5) Cylinder head and valve (6) Cylinder and piston (7) AC generator (8) Final transmission mechanism (9) Crankcase, crank shaft (10) Carburetor (11) Steering stem, front wheel, frt brake comp., frt fork...

  • Page 43: Lubrication System

    (1) Lubrication System Lubrication System Diagram (PA150)

  • Page 44: Oil Pump

    Oil Pump Dismantling 1.Remove the muffler. 2.Remove the AC flywheel magneto. 3.Remove the AC generator coil. 4.Tale off the locking bolts of the right crankcase cover. 5.Remove the crankcase cover 6.Remove the washer, lock pin 7.Remove starter reduction gear and the starting clutch.
  • Page 45 8.Remove oil pump separate plate by taking off the 2 bolts. 9.Remove the bolts from oil pump driving gear 10.Take off the driving gear and chain. 11.Remove the oil pump by taking off the locking bolt of the oil pump. Assembly 1.Install the inner and outer of the oil pump.
  • Page 46 Measurement data Standard Value Limit of use item ( mm ) ( mm ) Clearance between the inner gear 0.12 And outer gear Clearance between the outer gear 0.045-0.10 0.12 And oil pump body pump Clearance between gear end and 0.045-0.10 0.12 Oil pump body...

  • Page 47: Plastic Parts Of Chassis

    (2)Plastic parts of Chassis A.Dismantling the plastic parts 1.Removal of luggage compartment Open the seat, take off the screws of the luggage compartment. 2.Removal of fuel tank Open the lock cover of the fuel tank. Take off the fuel tank cover. Take off both the right and left handles by removing the screws off.
  • Page 48 3.Removal of left and right hand Side covers. Take off the screws of left and right side covers. Remove the left and right hand side cover. Removal of front mudguard Remove the screws of front fender. Take off the front mudguard.
  • Page 49 B.Dismantling the Fender 1.Take off the screws of front inner cover And fender. 2.Take off the screws between the front Fender and chassis. 3.Separate the head light and signal lamp Cable. 4.Take off the fender.
  • Page 50 C.Dismantling the upper handle cover. 1.Remove the left and right Back mirror. 2.Remove the screws of upper And lower handle cover. 3.Unplug the speedometer cable. 4.Unplug each switch cables. 5.Remove the upper handle cover.
  • Page 51 D.Dismantling the step plates and lower D.Dismantling the step plates and lower Mudguard: 1.Take off the screws of the four step plates and take off the four step plates. 2.Screwing out the screws of lower mudguard. E.Dismantling the step floor and front inner cover: 1.screwing out the screws of battery cover.

  • Page 52: Engine Dismantling

    Engine dismantling: A.Dismantling engine B.lnstalling engine...
  • Page 53 A.Dismantling engine 1.Take off the luggage compartment. 2.Take off the left and right body covers. 3.Take off the lower mudguard fender. 4.Remove vacuum pipe, fuel pipe ,auto choke, cap of spark plug, rear brake cable carburetor pipe, engine suspension nut, starter motor cable, flywheel plate and rear damper bolt.

  • Page 54: Drive Pulley, Starter, Clutch,Driven Pulley

    Drive pulley, starter clutch. driven pulley A.troubleshooting B.Measurement data C.Driving pulley D.Starter E.Clutch driven pulley...
  • Page 55 A.Troubleshooting: a.Engine starts, but vehicle don’t move. 1.driving belt worn out 2.driving plate worn out 3.clutch lining worn out 4.driving plate’s spring broken b.the vehicle stops or tremble when running. 1.clutch lining spring cracked or broken. c.Can’t reach high speed, no pick-up 1.driving belt worn out.
  • Page 56 (C)Driving Pulley 1.Take off the screws of Left cover, Remove the left cover. 2.Remove the lock nuts of driving Plate and the nuts of Starter gear And clutch. 3.Take off the ramp plate, Belt and clutch. 4.Take off the boss and driving plate.
  • Page 57 4.Continuous Various Transmission engagement speed inspection Connect an electric tachometer. Seated on the motorcycle with on level ground, increase the engine’s speed slowly and notice the RPM at which the motorcycle begins to move forward. Specified Engagement RPM : 3800 ± 300 rpm 5.Clutch “LOCK-UP”...
  • Page 58 5.To assemble the driving pulley, reverse the whole procdeure. Locking torque: 1.Nut of driving pulley M10:4.0-5.5kg/m. 2.Locking nut of clutch M10:4.0-5.5kg/m 6.Checking driving belt (1)check driving belt is cracked or not rubber and fiber is loosened or not also check if they are extraordinary worn out.
  • Page 59 (2)Check gasket inner dia of slide driving plate: limit of use : change it over 24.1mm. (3)Check the driving pulley surface wearing condition. (4)Check the outer diameter of the contact surface of the movable driving plate. limit of use : change it below 23.94mm.
  • Page 60 D.Starter dismantle 1.Dismantle left crankcase cover 2.Remove hexagon nut, then remove the starter lever. 3.Remove five screw of separated plate. 4.Remove start spring from start returning positioner. 5.Remove driven gear comp. of kick starter. 6.Remove the retaining C-type Ring. 7.Remove spindle comp. of kick starter.
  • Page 61 E. Clutch driven pulley 1.Dismantling the clutch a.Remove left crankcase cover. b.Remove driving plate. c.Remove driving belt. d.Remove locking nut, then remove clutch. 2.Assemble the clutch : follows the opposite procedure of dismantling. Locking torque: M10:4.0~5.5kg.m 3.Checking clutch: dismantling tool a.Check clutch driving face.
  • Page 62 c.Check driving spring free length. Standard: 151mm Limit of usage: Change it below 127 mm Check wearing condition of driving plate sets. And measure outer diameter. limit of use: change it above 33.95mm. e.Check wearing condition of slide driven plate. And measure its Inner diameter.

  • Page 63: Cylinder Head And Valve

    (5)Cylinder head and valve A.Trouble shooting B.The operation data information C.Dismantling and installing...
  • Page 64 A.Troubleshooting. If the cylinder head is malfunctioned, usually it can tell from the measurement of the Compression pressure or from the noise that comes from the upper part of the engine. 1.Unsmooth idle speed Compression pressure is too low. 2.Insufficient compression pressure. 5.Abnormal noise -Poor adjustment of valve clearance -Poor adjustment of valve clearance...
  • Page 65 C.Dismantling and installing the Cam shaft 1.Take off the left cover. 2.Remove the intake pipe from the Cylinder head cover. 3.Take off the 4 bolts of the cylinder head cover and take off the cylinder head cover. 4.Turn the flywheel counterclockwise and let the ”T”...
  • Page 66 Check cam shaft Check the convex surface and the height and see whether it has Been damaged. Limit of Use: IN :replace it below 26.23mm(150CC) EX :replace it below 26.13mm(150CC) Check camshaft. If the bearing is loosen or worn out, change the whole set if necessary. Check cam shaft holder 1.Check the cam shaft holder, cam rocker arm, and cam Rocker arm shaft and see whether it is loosen or worn...
  • Page 67 Dismantling the cylinder head: 1.Remove the carburetor. 2.Remove the muffler. 3.Remove the fan cover. 4.Remove the bolts on the engine cover. 5.Remove the camshaft. 6.Remove the cylinder head 7.Remove the lock pin, cylinder head gasket. 8.Remove cam chain guide Notice: Not to injure the contact Surface of the cylinder.

  • Page 68: Cylinder And Piston

    (6)Cylinder and piston A.Trouble shooting B.The Operation notice C.Data D.Dismaniling cylinder, piston E.Installing cylinder, piston C.Data () Part name /description Standard value Limit of use ( mm ) ( mm ) Bore 61.000~61.010 61.10 Curve 0.05 Cylinder Cylindrility 0.05 Roundness 0.05 lst ring 0.02~0.06...
  • Page 69 A.Troubleshooting. a.Compression pressure is too low, difficult to start engine and engine running unsmoothly. 1.Cylinder head gasket cracked 2.Spark plug is not well locked 3.Piston ring worn out or cracked 4.Cylinder, piston worn out. 5.Reed valve is out of order. b.Compression pressure is too high;...
  • Page 70 D.Dismantling a.Dismantling Cylinder 1.Remove the cylinder head. 2.Remove 2 bolts, then the camshaft chain adjuster 3.Remove CAM chain guide. 4.Remove cylinder. 5.Remove the cylinder gasket, lock pin and clean the gasket on the cylinder. b.Dismantling piston 1.Remove the piston pin clip. NOTICE: Dot’...
  • Page 71 5.The difference between the X and y is the roundness. 6.The cylindrility is the max value of the difference between the upper, Middlle and lower position of the inner dia in X or Y direction. Limit of use : Roundness:change it when above 0.05mm.
  • Page 72 E.Installing Cylinder and piston a.Installing piston and piston rings 1.Lubricate the piston rings by motor oil. NOTICE: a.Be careful not to scratch the piston and not to break the piston ring. b.The mark (on the ring) should be upward when installing. c.after installing, the ring should be smoothly rotated.

  • Page 73: Ac Generator Flywheel

    (7)A.C. Generator A.Dismantling AC generator B.Installing AC generator...
  • Page 74 Dismantling AC generator 1.Rimove fan cowl. 2.Remove the M6 screws 3.Remove screws of flywheel magneto. 4.Remove the AC flywheel magneto by special tool. 5.Remove the flywheel. 6.Remove the electric plug of AC flywheel magneto.
  • Page 75 B.Installing AC generator To install, please reverse the dismantling procedure. Locking torque: 1.0~1.2kg/m M10: 3.2~4.0kg/m...

  • Page 76: Final Transmission Mechanism

    (8)Final transmission mechanism A. Troubleshooting. B. Dismantle the final transmission mechanism. C. Check the final transmission mechanism. D. Assemble the final transmission mechanism. A. Troubleshooting Engine can be started, but the vehicle doesn’t move. 1.Gear worn-out or cracked. 2.Gear burnt out. Noise occur when running.
  • Page 77 3.B. Disassemble the final transmission mechanism: 1.Remove the rear wheel. 2.Drain the oil in the gear box. 3.Remove the bolt in the gear box cover. Take off the gear box.
  • Page 78 4.Remove the final reduction gear And idle gear. 5.Clean up the gear box. C. Check the final transmission mechanism 1.Check the wearing condition of driving shaft and gears. Gear teeth number: 16 T (buddy170)
  • Page 79 2.Check the wearing condition of idle gear shaft and idle gears. Gear teeth number 40/13T (buddy170) 3.Check the wearing condition of the final reduction gear. 4.Check the wearing condition of the oil seal and bearing. D. Assemble the final transmission mechanism, please follow the opposite procedure Of disassembling.

  • Page 80: Crankcase, Crankshaft

    (9)Crankcase, Crankshaft: A. Disassembling diagram. B. Troubleshooting. C. Data D. Remove crankcase and crankshaft. E. Check crankshaft. F. Assemble the crankcase.
  • Page 81 A. Disassembling diagram Torque: 1.0~1.2kg-m B. Troubleshooting Engine noise: 1.The bearing of final transmission mechanism is loosen. 2.Crank pin of bearing is slack. 3.The bearing of gear box is loosen.
  • Page 82 C.Data Item Standard value(mm) Limit of use.(mm) Clearance of connecting rod big end 0.15~0.35 0.55 axle direction Clearance of connecting rod big end 0.006~0.014 0.05 vertical direction. Swingness of the crank shaft journal. 0~0.015 0.05 D. Remove the crankcase and crankshaft by the following procedures: 1.Remove the engine.
  • Page 83 E.Check crankshaft 1.Measure the difference of the connecting rod big end between the X and Y Limit of use : replace it when above 0.05mm. 2.Measure the swing ness of the crankshaft journal. Limit of use Change it when above Change it when above 0..05mm 0.05mm...
  • Page 84 Troubleshooting Difficult to start 1.No sparking in spark plug. 2.Compression pressure too low. 3.No fuel in the carburetor -air cleaner blocked -oil pipe blocked -bad adjustment of the fuel level float valve is jell Mixed air too dilute 1.Main jet blocked 2.Float valve blocked 3.Fuel level too low 4.Fuel system blocked...
  • Page 85 Too much fuel in the engine 1.Air cleaner blocked 2.Mixed air is too dilute in the idle system Sparking unsteady while increasing speed 1.Ignition system malfunction. 2.Air mixture is too dilute Difficult to start, Ignition off, Unstable idling 1.Fuel system blocked 2.Ignition system malfunction 3.Air mixture is too dilute or too thick 4.Fuel deterioration...

  • Page 86: Steering Stem, Front Wheel, Front Brake Comp., Front Fork

    (10)Steering stem, front wheel, frt brake comp and front fork. A. Troubleshooting B. Data C. Steering handlebar E. Front wheel F. Front brake G. Front fork...
  • Page 87 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 damaged. d. wheel pressure is too low. 2.steering handlebar is aslant.
  • Page 88 C.Changing the speedometer cable 1.Remove the fixed screws of the front cover. 2.Remove the nut of speedometer cable. 3.Remove the front handle cover. 4.Remove the fixed screws of speedometer cable on the right of front wheel. 5.Draw out the damage speedometer cable.
  • Page 89 (B)Steering handlebar 1.Remove the LH/RH back mirrors. 2.Remove the upper handle cover. 3.Remove the nuts on front fork and handlebar. 4.Take off the fixing bolt. 5.Remove the nut and bolt of the front fork fixed on The handlebar. 6.Take off the handle bar. 7.When assembling, please follow the opposite procedures.
  • Page 90 (E)Front wheel 1.Remove the locking nut of the front wheel on the right side. 2.Draw out the axle of front wheel, remove the ring and take off the gear sets of speedometer. 3.Remove the front wheel assy. 4.Assemble the front wheel follows the opposite procedure of dismantling.
  • Page 91 6.Front wheel bearing checking Turn the tire. If the bearing is Loosen or any occurrence for noise, Please change a new one. 7.Front wheel rim checking (1)Check the swing of the front wheel rim. (2)Limit of use: Horizontal direction: Change a new one when above 2.0mm. Vertical direction: Change a new one when above2.0mm.
  • Page 92 (F)Front brake 1.Disassembling and assembling of the front brake comp. a.Remove two bolts fixed on the front brake comp and the front fork. b.Remove the front brake comp. c.Assemble the front brake comp. Follows the opposite procedure of dismantling. Locking Torque: M8: 2.0~3.0kg-m 2.Air releasing of the front brake comp The procedure of air releasing...
  • Page 93 3.Front fork checking: If it is bent or cracked, please replace with a new one. 4.Front shock absorber checking Check is there any unusual damage or worn-out condition, and whether the guide rod of the Front fork is crooked or not. Front fork oil type: SAE 10W20 Capacity (each side): 80 CC...
  • Page 94 5.Disassembling and assembling the front brake-disk. a.Remove the front wheel. b.Remove three nuts on the disk. c.Remove the disk. d.Assemble the disk follows the disassembling procedure. Locking torque M8: 2.0~3.0kgm 6.Checking the front brake-disk. Standard thickness of disk: 3.6mm Limit of usage: change it when below 3.1mm 7.Checking the front brake-lining.

  • Page 95: Rear Wheel, Rear Brake, Rear Damper

    (11)Rear wheel, rear brake, rear damper: A.Troubleshooting. B.Data. C.Dismantling the rear wheel. D.Checking the rear wheel. E.Rear brake. F.Rear damper.
  • Page 96 A.Troubleshooting. 1.Rear wheel swings. a.wheel rim is distorted. b.wheel is abnormal. c.improperly assemble the wheel axle. 2.Rear damper is too soft a.rear damper spring fatigue. 3.Bad braking a.the adjustment of brake is not good. b.the brake lining is dirty. c.the brake lining is worn out. d.the cam of brake lining is worn out e.the brake cam lever is worn out.
  • Page 97 C.Dismantling and assembling The rear wheel. 1.Remove the fixed screws and bolts of the exhaust pipe. 2.Remove the fixed screws of the rear wheel drum. 3.Remove the bolts. 4.Remove the rear wheel. 5.To assemble the rear wheel, please reverse the dismantling procedures.
  • Page 98 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 as the diameter is above 131.0mm (2)Checking brake lining: a.measure the thickness of rear brake lining. b.Limit of use:As the thickness is less than 2mm, change it.
  • Page 99 F.Rear damper 1. Rear damper disassembling diagram...

  • Page 100: Engine Management System(Pgo 2Nd-Stage Ems)

    5. Engine Management System(PGO 2nd-stage EMS) (1)PGO 2nd-stage EMS structure (2)EMS units (3)EMS diagnostic...

  • Page 101: Pgo 2Nd-Stage Ems Structure

    (1)PGO 2nd-stage EMS structure ＊feature 1.small, light 2.integrity 3.accuracy 4.simple EMS structure (A) Fuel supply 4 sensors ignition injector Crank speed sensor coil Engine temperature sensor Throttle position sensor Idle speed control Intake pressure sensor EMS structure (B) (ISC) Electric control unit Spark coil plug...

  • Page 102: Ems Units

    (2)EMS units 1.ECU (electric control unit) ＊dismantle 1.luggage comp. 2.body cover ＊within the left body cover 2.Important PIN no.# of ECU ＊ECU (PIN) 1 PIN 18 PIN 19 PIN 36 PIN PIN NO. function Control pole of fuel pump Control pole of headlamp relay supply(5V) voltage to sensors Control pole of injector Control pole of coil...

  • Page 103: Ems Diagnostic

    (3)EMS diagnostic 3.Crank speed sensor ＊dismantle 1.cover of fan 2.fan ＊at the right of engine Function of Crank speed sensor ＊function：induct the engine speed, tell ECU to control inject fuel & ignition ＊theory：calculate the interval time of each flange on the outer...
  • Page 104 4. Engine temperature sensor ＊dismantle 1.engine LH cover 2.middle cover ＊below the cylinder head cover ＊function：induct engine oil temperature, then ECU knows engine is cold or hot ＊theory：different temperature vary resistence T(℃) resistance(KΩ) -20℃ 18.800 KΩ 40℃ 1.136 KΩ 100℃ 0.155 KΩ...
  • Page 105 5. Throttle position sensor (TPS) ＊dismantle 1.luggage comp. ＊above the engine ＊function：induct throttle angle, provides the road load condition to ECU ＊theory：angle changes, resistance changes! Lb(+) / Gr(-) throttle output(V) 0.6 ±0.02V close 3.8 ±0.10V ＊Lb <output> ＊Pu <power(5V)> ＊Gr <ground>...
  • Page 106 6. Intake pressure sensor ＊dismantle 1.luggage comp. ＊above the engine ＊function： induct intake air pressure, ECU judge intake or compress stroke to decide injection & ignition ＊theory：different pressure outputs diferent resistance...
  • Page 107 ＊Pu ＊Pu G/B(+) / Gr(-) <output(5V)> <output(5V)> press(KPa) output(V) ＊G/B ＊G/B 13.3KPa 0.5V <output> <output> ＊Gr ＊Gr <ground> <ground> 120 KPa 3.4V 壓力特性 絕對壓力 (kPa) ＊Pu ＊Pu <output(5V)> <output(5V)> ＊G/B ＊G/B ＊average resistance in ambient ＊average resistance in ambient <output> <output>...
  • Page 108 7. Injector ＊dismantle 1.luggage comp ＊above the intake manifold ＊function：inject the gas, mixed with air＊theory：control the opening time interval to decide the gas amount...
  • Page 109 ＊R/B(+) <output(12V)> ＊Br/W(+) <output(12V)> ＊each terminal virus ground is 12V time(msec) time(msec) injecting feeding...
  • Page 110 8. Transistor ignition ＊dismantle 1.middle cover ＊at the right, inside the side cover 9.FUEL PUMP ＊dismantle 1luggage comp. 2.rear rack 3.body cover 4.bracket of tank ＊below the rear rack...
  • Page 111 ＊function：pumping the gas to injector, and keep the constant pressure as 3kgf/cm ＊theory：the regulator keeps constant pressure regulator pump filter ＊R/B(+) R/B(+)+B(-) <output(12V)> voltage ~12V ＊B(-) resistance <1KΩ <ground>...
  • Page 112 10.Fall down sensor ＊function：when vehicle fall down more than 65degree, then EMS cut off the power and cease the engine ＊theory：there is ball mechanism inside the sensor, act by gravity and conduct the wiring. ＊O power degree output(+) <input(12V)> +ground(-) ＊Bl/W <output>...
  • Page 113 11. ISC(Idle Speed Control) ＊dismantle 1.luggage comp. ＊above the engine ＊what is ISC ? ( IDLE SPEED CONTROL) ＊control method of ISC when engine is at idle, ECU refer the sensors and decide how much air is required, then tell the ISC to act forward or backward.
  • Page 114 Throttle body By-pass air Step motor Air flow engine Throttle valve ISC initialization timing ＊timing when used scooter occur: 1. Hard to start the engine 2. Engine Idle speed is unstable 3. Other unstable situation To initialize the ISC, then the ISC reset to control zero point. Procedure of ISC initialization 1.don’t plug quick- diagnostic...
  • Page 115 13. Draining cap of injector ＊bleed the air Used when replace the fuel pump, pipe…etc. ＊drain the gas The gas inside the pipe may become poor quality after...
  • Page 116 14.EMS diagnostic . a. quick diagnostic part no.：S320840G01 name：quick diagnostic How to use quick diagnostic 4.turn on the key 1. Prepare quick diagnostic 5.wait for about 8 seconds 2. Open the rubber cover inside 6.observe the EMS led on dash the luggage comp.
  • Page 117 b.PC diagnostic PC diagnostic assy.： S320891G01 + S320838G01 (software & adapter + connect cable) KEIHIN RS232 or USB adapter software PGO vehicle connect cable part number：S320891G01 name： (software & adapter ) ＊software ＊adapter part number：S320838G01 name：connect cable...
  • Page 118 Clear the defect code memory 1.plug quick diagnostic into vehicle seat 2.wide open the throttle, turn on the key 3.after the EMS led off, release the throttle 4.don’t turn off the key until EMS led on again. 5.turn on the key to confirm again. throttle EMS led on EMS led off...
  • Page 119 15.EMS system Repairing tool a. pocket tester wiring ＊pocket tester wiring part no.：S905310005 b.Ignition gauge ＊connect ＊minimum distance 6mm Plug cap. ground...
  • Page 120 c. Fuel pressure gauge ＊fuel pressure gauge part no.：S905330008 Connect to the vehicle ＊measure the fuel pressure standard 3kgf/cm ＊usage 1.dismantle the hose to injector 2.connect the gauge assembly to the pipe 3.turn on the key 4.read the pressure...
  • Page 121 d. EMS fuses EMS fuses ＊ECU(1A) <Yellow+Green/Black> ＊fuel pump(5A) <Red/White+Green/Black> ＊EMS system(10A) <Orange+Deep-Green> ＊ignition coil(7.5A) <Orange+Green/Black> Main purpose of EMS fuses ＊ (FUSE) 1A / 5A / 7.5A / 10A / 15A protect the units when extra-current occurs ： protect the (ECU) ：...
  • Page 122 e. EMS relays ＊dismantle 1.luggage comp. 2. Rear rack 3.body cover ＊inside the RH body cover ＊A.EMS system Gr/B Bl/W ＊B.fuel pump/injector ＊C.headlamp...
  • Page 123 Control of relays Big current ＊ (Relay) 15A ＊theory： use small current to control big current ＊Usage： fuel pump & injector EMS whole system headlamp Small current(ECU) Measure the relays ＊use the pocket tester 2.fit 12V to the control coil 3.the relay sounds “ka”...
  • Page 124 f.General Electric units Horn ＊inside the windshield ＊dismantle 1.windshield Flasher relay ＊inside the windshield ＊dismantle 1.windshield...
  • Page 125 Fuel gauge ＊dismantle 1.luggage comp. 2.rear rack 3.body cover ＊below the rear rack ＊make sure the arrow direction! Measure the fuel gauge ＊gray(+) gray(+)+black(-) <output> ＊black(-) 4~10Ω <ground> 80~90Ω...

  • Page 126: Electric Equipment

    6.Electric equipment: (1)Troubleshooting (2)Battery 1.check specific gravity of eletrolyte 2.recharge (3)Recharge system 1.the wiring diagram of recharge system 2.check A.C. flywheel magneto 3.check regulator/ rectifier. (4)Starting system 1.the wiring of starting 2.checking the starter 3.dismantling the starting motor 4.checking the starting motor (5)Starting clutch (6)Handle bar switch...

  • Page 127: Troubleshooting

    Currency is unstable. (1) Troubleshooting: A.Recharge system: 1.The wiring of battery connects No power: improperly. 1.battery over charge 2.Ignition system connects abnormally. No electrolyte in battery. 3.Ignition system is short circuit. Battery becomes white. 4.Lamp system connects abnormally or Short circuit in battery. Short circuit.

  • Page 128: Battery

    (2) Battery: Always, remove the battery negative Cable(-), then remove positive cable (+). But connect the positive cable (+)first, then connect the negative cable(-) when assembling. 1.Recharging Connection method: Connect the positive cable(+)of the recharger to the positive cable(+)of the battery; and The negative cable(-)of the recharger to the negative cable(-)of the battery.
  • Page 129 2.Testing the recharging performance This test needs to be done under the Battery has been recharged completely a. This test needs to be done after engine is warm-up. And take off the luggage case Firstly. b. Disconnect the orange cable of regulator.

  • Page 130: Recharge System

    (3)Recharge system 1.Recharge system diagram (a) Use Multimeter check resistance of 2 different yellow wires at a time from 3 different phases. (test value: Ω), these 3 resistances need to be the same, if there is resistance shows different value, it means the generator is NG, the charging is not enough. ＞ Resistance: about 0.8Ω (20°c) (b) There are 2 R/W wire on the VOL REGULATOR, 1 is for charging, the other is acting like a “standard voltage”...
  • Page 131 2. Check A.C. flywheel magneto. a. Remove the LH side strip and LH body cover. b. Measure the resistance value of terminals. 3.Check regulator measure the resistance value between each terminal, it should be in specified range, otherwise change a new one. Pocket tester range: * 1k range...

  • Page 132: Starting System

    (4)Starting system 1.Starting wiring...
  • Page 133 2.Checking Other spare parts comp. Checking. Change a new one when there is any scratch, damage or burnt on the surface. Any adherent metal powder in-between the layers of the direction exchanger should be cleaned. The conductivity check among each contact surfaces to other parts.

  • Page 134: Starting Clutch

    (5)Starting clutch Explosive diagram...
  • Page 135 Dismantling 1.Remove the right crankcase Cover. 2.Remove the starting idle gear axle and take off the gear. 3.Remove the left crankcase cover. 4.Use screwing tool to fix the driving plate. 5.Remove the lock nut of the starting clutch. NOTE: Lock nut is left thread. 6.Remove the starting clutch.

  • Page 136: Handle Bar Switch

    (6)Handle bar switch The colors for each switch cables: Head Light Switch Operation Dark green Yellow Yellow/black Blue Starting Button /Color Operation Green/White Black ● ● /Color FREE ● ● ● PUSH ● ● HI/LO bean Horn Switch Operation Blue Brown/White Purple/White Operation...
Save PDF