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Motive Power Industry BLUR 150 Service Manual

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Summary of Contents for Motive Power Industry BLUR 150

  • Page 2 This manual includes 2 kinds of engine displacement: BLUR 150 : abbreviated as “BLUR-150” is 4 stroke engine (4T), 150cc displacement. BLUR SS220i: abbreviated as “BLUR SS220” is 4 stroke engine (4T), 220cc displacement.

  • Page 3: Table Of Contents

    ……………………………………………….49 (10)Front/Rear brake adjustment ………………………………………………49 (11) Tire ………………………………………………50 4.Dismantling, maintaining, repairing and assembling operation … ………………………51 (A). Plastic parts ……………………..………………………51 (B). BLUR 150 Engine dismantling ……………………………………………...58 (1) Lubrication system ……………………………………………..59 (2) Engine dismantling ……………………………………………..63 (3) Install Engine ……………….…………………………….63 (4) Drive pulley, starter, clutch, driven pulley …………………………………………….64 (5) Cylinder head and valve .
  • Page 4 (E)Fuel supply ……………………………………………..119 (F).Electric equipment ……………………………………………...121 (1)Troubleshooting ……...………………………………………122 (2)Battery ………………………………………………123 (3)Recharge system ………………..……………………………..129 (4)Ignition system ……………………………………………….131 (5)Starting system ……………………………………………….132 5. BLUR-220 characteristics , dismantle & inspection …………………………...………134 (1) Engine dismantling ……………………………………………….134 (2) engine inspection …………………….………………………….144 (3) Electric system ………………………………………………..146 (4) Maintenance ……………………………..…………………153 (5)Engine Management System(EMS) ………………………………………………..168...

  • Page 5: The Specification Of Blur (Alloro)

    1、 The specification of BLUR (ALLORO) 1.1 BLUR 150 SPECIFICATION Genuine BRAND FRAME STEEL PIPE MODEL BLUR-150 FRONT TELESCOPE LENGTH 1885 mm REAR SWING WIDTH 730 mm PRIMARY DIRECT HEIGHT 1170 mm 42/15*42/13 AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT...
  • Page 6 1.2 BLUR220 SCOOTER SPECIFICATION BRAND Genuine FRAME STEEL TUBE BLUR-SS220I MODEL FRONT TELESCOPE SUSPENSION LENGTH 1885 mm REAR UNI-ABSORBER WIDTH 730 mm REDUCTION 0.81~2.43 HEIGHT 1170 mm REDUCTION 8.077 WHEEL BASE 1365 mm CLUTCH CENTRIFUGAL FRONT 57 KG GEARBOX C.V.T. REAR 87 KG FRONT...

  • Page 7: Service Information

    2.Service information： (1)The operation notice (2)Locking torque value 1.For engine 2. For chassis 3. Others (3) Lubrication instruction a.For engine b. For chassis c. Wheel bearing (4)Periodical Maintenance Table (5)Troubleshooting 1.Difficult starting or starting 2.Weak acceleration 3.Engine running not smoothly (low speed) 4.Engine running not smoothly(high speed) 5.Clutch, drive &...

  • Page 8: The Operation Notice

    The operation notice： 1.For parts like the gasket, o-ring, clips and circlets, please change a new part whenever re-assembled. 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 or PGO recommended parts.

  • Page 9: Locking Torque Value

    Locking Torque Value: 1. 4T Engine (150/220CC) Thread dia. Locking torque Locking location Q’ty (mm) (kg-m) 1 Fixing nut (Tappet screw nut) 0.7~0.8 2 Nut of oil pump sprocket 0.7~1.0 3 Cylinder head bolt A (intake) 0.9~1.1 4 Guiding pin bolt, chain extensioner 0.4~0.6 5 Screw, chain extensioner 0.9~1.1...
  • Page 10 2. Chassis Thread dia. Locking torque Locking location Q’TY (mm) (kg-m) Air bleed bolt of caliper Brake arm bolt, front drum 0.8~1.0 Brake arm bolt , rear drum 0.8~1.0 Nut of starter relay 0.5~0.6 Front brake caliper bolt 2.0 ~ 3.0 Bolt of disk 2.5~3.0 Locking nut, steering stem...

  • Page 11: Lubrication Instruction

    (3) Lubrication instruction 4T Engine (150 /220cc) NO Lubrication location Oil type Remarks Crankcase: rotating part, Auto-Separated Sliding part Lubrication premium 4 stroke BLUR-150 Cylinder: rotating part, Total 1000 c.c. Sliding part. motorcycle oil Replacement 800c.c BLUR220 or SAE15W40 Total 1400 c.c. Replacement 1000c.c 3-1 Drive gear box(BLUR-150) SAE85-140...
  • Page 12 C. Chassis appearance 1. Apply oil : #1, #2 2. Apply grease (#3, #4, #5. #6 ,#7, #8)
  • Page 13 D.Wheel bearing Final transmission mechanism gear oil Speedometer gear: clean grease...

  • Page 14: Periodical Maintenance Table

    Engine oil* BLUR 150:800cc total 1000cc Replace it initially 200 mile, BLUR 220:1000cc total 1400cc and then replace it per 1800mile Oil Filter BLUE-150 Replace replace it per 3600mile Coarse oil filter* (on oil...
  • Page 15 Check the fluid level often, Refill if necessary. Change the oil seal of main cylinder and caliper every two years. Change the brake fluid hose every four years.

  • Page 16: Troubleshooting

    (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 Float is blocked...
  • Page 17 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 fuel tank cover blocked Engine can’t rotate Engine can rotate up muffler blocked Up completely fuel pump is malfunctioned auto chock is malfunctioned Check ignition timing, check...
  • Page 18 For 4T engine only: Check the oil level in crankcase Is too much or dirty oil level is too high oil level is too low Oil level is oil does not interchange Not normal Oil level is normal Check the lubrication of cylinder head oil route is blocked insufficient oil pumping from...
  • Page 19 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 thick Good Faulty ( loose the screw) adjustment Not correct mixture too lean ( tight the screw) Check if there is air...
  • Page 20 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 fuel pump, Fuel supply system fuel level is too low fuel pipe, fuel filter is blocked good unsmoothly fuel pump faulty...
  • Page 21 5.Clutch, drive and driven pulley Trouble condition The reason driving belt worn out, distortion Engine can start but can’t driven plate worn-out driven plate spring distorted Move the vehicle driven lining worn-out driving pulley shaft gear teeth cracked final gear damage driven lining spring cracked or Engine runs, but it stops worn out...
  • Page 22 6.Handlebar steering astrayed when running. Trouble condition The reason (front and rear wheel pressure are normal) steering column lock screw locked too tightly Handlebar operates heavily steel ball cracked rear, front wheel bearing swings Front and rear wheel swings front, rear wheel rim distorted loosen front axle nut front and rear wheel center not well- Handlebar astrayed to one direction...
  • Page 23 9.Oil indicator malfunction (Only available for 2T engine) (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 Normal battery has no power Lamp dims, light does main switch abnormal...
  • Page 24 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 normal main switch abnormal Lamp dims, light circuit plug dropped off Not flash, not light main wiring disconnected...
  • Page 25 (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 battery has no power main switch abnormal normal No motion circuit plug dropped off or...
  • Page 26 11.The starting motor abnormal (a)Starting motor can not rotate Check and adjust Trouble condition The reason Check brake switch fuse burn-out Brake lamp Brake lamp battery has no power Lights up no light main switch abnormal circuit plug dropped off main wiring disconnected Turn signal lamp No to check wiring...
  • Page 27 (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 Starting Connect motor to the starting motor to Battery directly electric;...
  • Page 28 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 29 13.Charging abnormal(battery over charging or over discharging) Check and adjust Trouble condition The reason Measure battery’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 30 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. Check with a trouble diagnosis meter to ensure no trouble information recorded; 3.
  • Page 31 (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 32 (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 33 (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 34 (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 35 (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 36 (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 37 (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 38 (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 39 (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 40 (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 41 (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 42 (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 43: Checking And Adjustment

    3. Checking and Adjustment: (1)Regular checking table (2)Battery (3)Clean 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)Front brake adjustment /Rear (11) Tire...
  • Page 44 (1)Regular checking table: 1.【O】mark indicates periodical checking 2.【※】indicates changing the parts Checking period general first home office checking month every6 every12 every1 every3 every12 Judgement Item Remark months months months months months standard Initial 3000 6000 1800 6000 mile mile mile mile mile...

  • Page 45: Battery

    Clutch and Shift mec- LH crank Gear oil ○ ○ ○ ○ ○ hanism leakage case BLUR 220: BLUR 150: ○ ○ ○ ○ ○ Gear oil 110C.C. / replace 90C.C. / replace Change gear oil 130C.C/ total 110C.C/ total Clearance: BLUR-150 ○...
  • Page 46 Performance, ○ ○ ○ ○ ○ Noise Low speed, ○ ○ ○ ○ ○ BLUR 150 dling: 1600±100rpm Acceleration BLUR 220 Check the ○ ○ ○ ○ ○ ○ Exhaustion color of exhausting-air ○ ○ ○...
  • Page 47 Checking period general first home office checking month Judgement every6 every12 every1 every3 every12 Item Remark months months months months months standard Initial 3000 6000 1800 6000 mile mile mile mile mile mile ○ ○ ○ ○ ○ ○ Function Lamp system ○...
  • Page 48 A. The battery is totally sealed, do not remove seal bolts when recharging B. It’s no need to add any electrolyte for this re-filling free battery Please recharging (12V) by the following currency BLUR 150: Standard recharging:0.7A* 5-10 hr or rapid recharging:3A* 60min. BLUR 220: Standard recharging:0.9A* 5-10 hr or rapid recharging:3A*60min.
  • Page 49 BLUR 150 (3) Air clearance 1.Remove air cleaner cover 2.Take out the air cleance filter 3.Clean the filter by the compressor air. BLUR 220 4.Assemble the air cleance by the opposite procedure. Note: Do not start the engine when the air...

  • Page 50: The Final Reduction Mechanism Oil

    2.Check the spark plug electrode and check if it is Burnt out or not and carbonized or not 3.Clean the electrode, whether it is dirty 4.Spark plug specification BLUR 150/220: CR7E (NGK) or equivalent spec. Gap of spark plug :0.6~0.7mm(general) Electrode burn out/ Carbon piled up...

  • Page 51: Compression Pressure Measurement

    (6)Compression pressure measurement: 1.Measure it when the engine is warm. 2.Remove the cover. 3.Remove spark plug then place compression pressure gauge. 4.Fully open the throttle, and using starting motor 5 seconds continuously, measure the compression pressure. 5.Compression pressure: 150/220 cc: 11 kg/c ㎡ @650rpm 6.when the compression pressure is too low, check the following: a.

  • Page 52: Ignition Timing

    (7) Ignition timing:(BLUR150) This scooter is using CDI set, it is no need to adjust ignition timing. If ignition timing is not correct, check the CDI sets and AC magneto, change it if it is checking ignition timing: 1.remove seat the luggage compartment 2.Remove right body cover 3.Remove the fan case.

  • Page 53: Idle Adjustment

    (9) Idle adjustment: Note: adjust it when the engine is warm. 1.remove left body cover 2.start the engine and connect the tachometer 3.adjust the throttle valve screw to the specified revolution 1600±100rpm. (BLUE150&220) if the idling rpm is still unsteady or fuel up is not smooth, please adjust it by followings.

  • Page 54: Tire

    1.Check the tire air pressure(when it’s cold) 2.Tire pressure: Front tire: 2.0 kg/c ㎡ Rear tire: 2.0 kg/c ㎡ 3.Tire dimension: BLUR 150/220: Front tire: 120/60-13 Rear tire: 130/60-13 Note: a. Check and adjust the tire pressure when it is too low.

  • Page 55: Dismantling, Maintaining, Repairing And Assembling Operation

    Dismantling, maintaining, repairing and assembling operation Plastic part dismantle Overview Dismantle the plastic parts according to above figure sequence by sub-assembly, especially pay attention to followings: Before dismantle front fender, dismantle the front wheel assy. First. (BLUR150 /SS220I) Windshield & frt signal lamp cover shall be dismantled together. LH &...
  • Page 56 Actual dismantle procedure: Dismantle the upper cover & windshield. Loosen 2 tapping screws at the upper with the inner cover. Withdraw the windshield decorated cover. Dismantle the handle upper cover. Loosen 5 tapping screw under the handle. Dismantle windshield & turn signal front cover.
  • Page 57 Loosen 3(LH) & 3(RH) tapping screws of front inner cover. Loosen 3(LH) & 3(RH) tapping screws of front inner cover. Loosen 1 machine screw in the middle of windshield. Dismantle windshield & front turn signal cover together.
  • Page 58 Dismantle the front fender. Only for G-MAX125/150: Loosen nut of front wheel, dismantle the front wheel & brake disc together. Loosen screws at LH & RH of front fender, dismantle front fender Open the seat. Loosen 3 bolts of rear luggage bracket, dismantle it.
  • Page 59 Loosen 2 bolts of rear luggage compartment Lift the cover with finger, withdraw the cover of rear luggage compartment. Withdraw the rear luggage compartment. Turn the tank inner cover counterclockwise a little bit, dismantle it. Dismantle the tank upper cover by releasing coupling ribs Withdraw fuel tank decorated cover.
  • Page 60 Dismantle the keel cover. Loosen 2(LH) & 2(RH) screws at the front upper section. Loosen 2(LH) & 2(RH) inner socket screws, dismantle the keel cover. Dismantle the LH & RH lower cover Loosen 4 tapping screws on the top of LH & RH lower cover Dismantle quick plastic screw(2 EA in each side)
  • Page 61 Dismantle 1 tapping screw in the front side. Withdraw LH & RH lower cver. Dismantle other PP covers. Dismantle the license plate Push the middle of quick plastic screw. Loosen 2 screws at the rear of vehicle. Withdraw the license plate.

  • Page 62: (B). Blur 150 Engine Dismantling

    (B) BLUR 150 engine Dismantling, Maintaining, Repairing and assembling operation (1) Lubrication system (2) Engine dismantling (3) Install Engine (4) Drive pulley, starter, clutch, driven pulley (5) Cylinder head and valve (6) Cylinder and piston (7) AC generator (8) Final transmission mechanism...
  • Page 63 (1) Lubrication System...
  • Page 64 Oil Pump Dismantling 1.Remove the rear section of 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 65 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. Oil pump Assembly 1.Install the inner and outer of the oil pump.
  • Page 66 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 67 (2) Engine dismantling 1.Take off the luggage compartment. 2.Take off the left and right body covers. 3.Take off the air cleaner fixing screws. 4.Loosen 2 nuts of intake manifold, withdraw intake system assembly. 5.Remove vacuum pipe, fuel pipe ,auto choke, cap of spark plug, rear brake cable carburetor pipe, starter motor cable.
  • Page 68 Drive pulley, starter clutch. driven pulley A. Troubleshooting B. Measurement data C. Driving pulley D .Starter E. Clutch driven pulley...
  • Page 69 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 70 (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.
  • Page 71 4.Take off the boss and driving plate. 5.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.
  • Page 72 5.To assemble the driving pulley, reverse the whole procdeure. Locking torque: 1.Nut of driving pulley M12: 4.0-5.5kg/m. 2.Locking nut of clutch M12: 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 73 (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 74 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 position. 5.Remove driven gear comp. of kick starter. 6.Remove the retaining C-type Ring. 7.Remove spindle comp. of kick starter.
  • Page 75 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: M12: 4.0~5.5kg.m 3.Checking clutch: dismantling tool a.Check clutch driving face.
  • Page 76 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 77: Cylinder Head And Valve

    (5)Cylinder head and valve A.Trouble shooting B.The operation data information C.Dismantling and installing HEAD COMP. CYLINDER 19 "CAM,SHAFT ASSY." "GUIDE,EXH VALVE " 20 "SHAFT,EX.ROCKER ARM" O-RING 21 VALVE RXKER ARM "GUIDE,IN VALVE " 22 SCREW TOPPED ADJUSTER VALVE EXHAUST 23 HEXAGON NUT VALVE INLET 24 "SHAFT,EX.ROCKER ARM "...
  • Page 78 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 79 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 80 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 81 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 82: 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 (150CC) Part name /description Standard value Limit of use ( mm ) ( mm ) Bore 57.490~57.510 57.600 Curve 0.005 Cylinder Cylindrility 0.005 Roundness 0.005 Clearance b/w Piston lst ring...
  • Page 83 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 84 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 85 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 0.005mm.
  • Page 86 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 87: Ac Generator

    (7)A.C. Generator A.Dismantling AC generator B.Installing AC generator...
  • Page 88 Dismantling AC generator 1. Dismantle the rear section of muffler. 2. Remove fan cowl. 3. Remove the M6 screws 4. Remove screws of flywheel magneto. 5. Remove the AC flywheel magneto by special tool. 6. Remove the flywheel. 7. Remove the electric plug of AC flywheel magneto.
  • Page 89 B.Installing AC generator To install, please reverse the dismantling procedure. Locking torque: 1.0~1.2kg/m M12: 3.2~4.0kg/m...

  • Page 90: 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 91 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 92 3.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: 14 T (125CC) ; 15 T (150CC)
  • Page 93 2.Check the wearing condition of idle gear shaft and idle gears. Gear teeth number 42 T (150CC) 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 94: 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 95 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 96 C.Data Item Standard value(mm) Limit of 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. 0.03 0.10 D. Remove the crankcase and crankshaft by the following procedures: 1.Remove the engine.
  • Page 97 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 0.04mm. Measure the swing ness of the crankshaft journal. Limit of use Change it when above Change it when above 0.1mm 0.1mm...

  • Page 98: Carburetor

    (10)Carburetor: A.General theory B.Troubleshooting. C.Dismantling the carburetor. D.Dismantling the float and nozzle. CARBURETOR SPECIFICATIONS: ITEM SPECIFICATION Model M2-150 Carburetor type KEIHIN CVK24 Bore size 24 mm I.D. NO 1700 ± 100 Idle r/min 18.0 ± 0.5 mm Float height Main jet #102 Jet needle 4HLGL...
  • Page 99 General theory DIAPHRAGM AND PISTON OPERATION The carburetor is a variable-venturi type, whose venturi cross sectional area is increased or decreased automatically by the piston valve . The piston valve moves according to the negative pressure present on the downstream side of the venturi A. Negative pressure is admitted into the diaphragm chamber through an orifice provided in the piston valve .
  • Page 100 SLOW SYSTEM This system supplies fuel during engine operation when the throttle valve is closed or slightly opened. The fuel from the float chamber is metered by the pilot jet where it mixes with air coming in through the pilot air jet .
  • Page 102 MAIN SYSTEM As the throttle valve is opened, engine speed rises and negative pressure in the venturi A increases. This causes the piston valve to move upward. The fuel in the float chamber is metered by the main jet . The metered fuel enters the needle , mixes with the air admitted through the main air jet and forms an emulsion.
  • Page 103 AUTO-ENRICHENER (AUTO-CHOKE) SYSTEM The automatic enrichener (automatic choke) device consists of the PTC heater A, the thermo-wax B and the plunger/needle . When the thermo-wax B is cold, the plunger/needle moves upward, Fuel is drawn into the enrichener circuit from the float chamber Enrichener jet meters this fuel, which then flows into fuel pipe and mixes with the air...
  • Page 104 FLOAT SYSTEM The float and needle valve work in conjunction with one another. As the float chamber the float rises and the needle valve pushes up against the valve seat. When this occurs, no fuel enters the float chamber . As the fuel level falls, the float lowers and the needle valve unseats itself;...
  • Page 105 ACCELERATOR PUMP SYSTEM This system works only when the rider opens throttle grip quickly as pump send the necessary amount of fuel to the carburetor bore for correcting fuel/air mixture ratio. When the rider open the throttle grip quickly, the intaken air volume becomes large and air velocity at the bottom of the throttle valve (piston valve)is slow and sucking volume of fuel is less.

  • Page 106: Carburetor Cleaning

    INSPECTION Check the following parts for damage and clogging. * Pilot jet * Piston valve * Main jet * Starter jet * Main air jet * Gaskets and O-rings * Pilot air jet No.1 & No.2 * Pilot outlet and bypass * Needle jet holder * Coasting enrichement valve * Float...

  • Page 107: Float Height Adjustment

    AUTO-ENRICHENER INSPECTION Disconnect the lead wire coupler . Remove the cover . Connect the positive ♁ terminal of a 12V battery to Yellow/white lead and the negative Θ terminal to Black/ White. Check that the auto-enrichener section (PTC heater built-in area)is heated in 5 minutes after the battery has been connected.
  • Page 108 (B) 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 109 (C)Dismantling the carburetor 1.Remove the auto starter connector. 2.Remove the throttle cable, then the fuel pipe from the carburetor. 3.Remove the screws on the intake manifold. 4.Unscrew the fixing belt on the connecting pipe. 5.Remove the carburetor. Assembling the carburetor To assemble the carburetor, please follow the reversed procedures of the dismantling and do the following adjustment after installation is finished: -Adjust the throttle cable...
  • Page 110 (D)The float nozzle 1.Dismantling Remove the screws to take off the float chamber. Remove the float, the float pin, and float valve. 2.Checking Check the float valve, valve base to see whether it is blocked or damaged. Check the float valve, valve base surface if sectional worn out or dirty.
  • Page 111 (C)Handle bar, front wheel, front brake and 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 damaged. d.
  • Page 112 C. Change the 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 113 D.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 114 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 115 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 above 2.0mm.
  • Page 116 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.
  • Page 117 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. Fork oil type: SAE 10W20 Capacity (each side): 95 CC (BLUR-150/220) NOTE:...
  • Page 118 5.Disassembling and assembling the front brake-disk. Remove the front wheel. Remove bolts on the disk. Remove the disk. Assemble the disk follows the disassembling procedure. Locking torque M8: 2.0~3.0kgm 6.Checking the front brake-disk. ;4.0 mm (BLUR-150/220) 3.5 mm (BLUR-150/220) 7.Checking the front brake-PAD. a.

  • Page 119: (D)Rear Wheel, Rear Brake, Rear Damper

    (D)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 120 C. Disassembling and assembling the rear wheel. 1.Remove the rear mudguard and the exhaust pipe. 2.Remove the locking nut of the rear wheel 3.Remove the rear wheel 4.To assemble the rear wheel please reverse the dismantling procedure. D. Checking the rear wheel a.
  • Page 121 1. Brake pad inspection for BLUR -150...
  • Page 122 F. Rear absorber 1. Check the locking torque of rear absorber at lower & upper. 2. Both locking torque is 3.5~4.5 kg-m. 3. Oil leakage check is always necessary. BLUR -150/220...

  • Page 123: (E)Fuel Supply

    (E)Fuel supply A. Troubleshooting. 1.Engine can’t start: a. No fuel in fuel tank. b. Fuel pipe is blocked. c. Auto cock and filter is blocked. d. The membrane of fuel pump is over swell. 2.The membrance of auto cock is over-extended. a.
  • Page 124 C. Dismantling and assembling Fuel Tank 1.Remove the front luggage box. Open the fuel tank cover cap 2.Remove the fuel tank cover.. 3.Remove the fuel pipe. 4.Remove the connecting terminal of the fuel gauge. 5.Remove the fuel gauge. 6.Remove the fixing blot of the fuel tank. 7.Take off the fuel tank.

  • Page 125: Battery

    F. Electric equipment: (1)Troubleshooting (2)Battery 1.Check the cells of battery 2. recharging 3.Test the recharging performance (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.

  • Page 126: Ignition System

    (1)Troubleshooting: Currency is unstable. A. Recharge system: The wiring of batter connection is not good. No power: 2.Ignition system connection is not good. 1.Battery over 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 127 (2)Battery: 1.Check the cells of battery. Always remove the battery negative Cable(-)first, then positive cable (+). But connect the positive cable (+)first, then connect the Negative cable(-) when assembling. BLUR-150/220...
  • Page 128 2.Recharge Connection procedure: connect the positive cable(+) of the negative cable(+) of the battery, and the negative cable(-) of the recharge to the negative cable(-) of the battery. Recharging currency: Please recharge (12V) according to the following current and time. Standard: 0.9A * 5~10Hr or Rapid:3A * 60min(150/220cc) NOTICE: This battery is totally sealed.
  • Page 129 3.Testing the recharging performance This test needs to be done when the battery is fully recharged. This 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 130 BATTERY CONSTRUCTION PGO sscooters uses an MF (Maintenance Free) battery. As shown in the right illustration, the battery consists of electrodes, separators, safety valve, filter, etc. Fine glass fiber is used for constructing the separator which holds electrolyte inside. When a discharged conventional open type battery is re- charged fully, lead sulfate turns to lead dioxide and sponge- like lead.
  • Page 131 Insert the nozzles of the electrolyte container into the battery’s electrolyte filler holes, holding the container securely. ! CAUTION Take precaution not to allow any of the fluid to spill. Insert the nozzles squarely to the battery. Check that air bubbles are coming up from each electrolyte container and leave in this position for more than 20 minutes.
  • Page 132 PRECAUTION FOR HANDLING BATTERY The battery produces combustible gasses and therefore can explode if handled improperly. Use Caution for the following in addition to general service precautions. Never allow the battery to short-circuit. Keep away from sparks and fire. Charging of the battery must be operated in an open and well ventilated area and never operate in an closed indoor.
  • Page 133 (3)Recharge system: A. Recharge system diagram for BLUR-150...
  • Page 134 2.Check A.C. Generator a. Open the seat cover and remove the luggage box. b. Measure the resistance value of terminals. Yellow V.S. black 0.1-1.0 White V.S. black 0.2-2.0 3.Check regulator Measure the resistance value between each terminal, It should be in the specified range, otherwise change a new one. BLUR-150/220 M2-50...
  • Page 135 (4)Ignition system: 1.the wiring or ignition 2.Check spark plug. 3.Check the H.V. cable and H.V. coil by using the CDI tester. 4.CDI sets checking. Check with the CDI tester and please follow the instruction manual. If the CDI test failed, please change a new one.
  • Page 136 (5)The starting system: 1.The wiring of starting 2.Make sure the Engine RUN/OFF switch is in “Run” position. 3.Check the safety switch by operating the brake lever, and the brake lamps shall light on.
  • Page 137 4.check the starting relay a. Find the control coil by measuring the resistance. b. Connect 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.

  • Page 138: Blur-220 Characteristics,Dismantle&Inspection

    5.BLUR-220 characteristics,dismantle&inspection (1)Engine dismantling Engine assembly 1.dismantle the chassis parts connected to engine 2.take off engine assembly Front section muffler 1.dismantle 2 castle nuts 2.take off front section oil cooler 1.loosen 2 bolts remark：there are 2 washers 2.dismantle the oil cooler Second Air Injection (SAI) 1.dismantle 1 bolt 2.take off the SAI...
  • Page 139 Cooling cowl 1.dismantle 3 tapping screws 2.dismantle 1 upper hexagon bolt 3.take off upper cooling cowl 4.dismantle 1 lower hexagon bolt 5.take off lower cooling cowl...

  • Page 140: Cylinder Head Cover

    Cylinder head cover 1.loosen 4 hexagon bolts 2.dismantle cylinder head cover Chain tensioner 1.loosen the middle bolt 2.dismantle the spring 3.loosen 2 bolts of the body 4.dismantle the chain tensioner body 5.take off the packing --------------------------- Recover the chain tensioner 1.dismantle the bolt &...

  • Page 141: Cylinder Head

    Camshaft holder 1.loosen 4 nuts & washers 2.dismantle the holder 3.dismantle 2 lock pins 4.dismantle the camshaft Cylinder head 1.loosen 2 hexagon bolts 2.dismantle cylinder head 3.dismantle 2 lock pins 4.take off the gasket...
  • Page 142 Cylinder 1.dismantle the lower chain tensioner 2.take off the cylinder 3.dismantle 2 lock pins 4.take off the packing Piston 1.dismantle 2 clips 2.dismantle piston pin 3.take off the piston Attention! To prevent clip falling down the crankcase, use clothes to cover the crankcase.
  • Page 143 2.loosen right 2 hexagon bolts 3.dismantle the engine lower hanger Cooling fan 1.loosen 4 bolts 2.dismantle the fan Generator outer 1.Loosen 1 nut & washer 2.use special tool: turn the outer counterclockwise， lock the inner bolt clockwise 3. dismantle the outer S620505G01 ACG special tool:...
  • Page 144 Generator stator 1.loosen 2 bolts & washers of pulser 2.dismantle the bracket of pulser 3.loosen 3 socket bolt 3.dismantle the stator Starting motor 1.loosen 2 hexagon bolts 2.dismantle starting motor...
  • Page 145 Right crankcase cover 1.loosen 9 bolts 2.dismantle the right crankcase cover 3.dismantle 2 lock pins 4.dismantle the packing Attention! Be careful of the surface, don＇t defect it to avoid oil leaking. Starting idle gear 1.dismantle the shaft 2.dismantle the body One way Clutch 1.loosen the nut &...

  • Page 146: Oil Pump

    Sprocket of oil pump 1.dismantle E clip & washer 2.dismantle the sprocket & chain 3. dismantle the sprocket of crankshaft Oil pump 1.loosen 2 bolts 2.dismantle oil pump body Attention! There is a lock pin in the shaft of oil pump, don＇t miss it.

  • Page 147: Right Crankcase

    定位銷 Right crankcase 1.loosen 2 bolts 2.dismantle the right crankcase 3.dismantle 2 lock pins 4.take off the packing Attention! Be careful of the surface, don ＇ t defect it to avoid oil leaking. Crankshaft 1.dismantle the crankshaft assembly (including a ball bearing in the left side) 2.take off the timing chain Attention!

  • Page 148: Engine Inspection

    (2) Engine inspection data CVT parts I n sp ectio n d ata standard( m m ) using limit( m m ) Item 27.011~27.021 27.10 The inner dia. Of slide drivingplat The outer dia. Of boss, 26.970~26.990 26.95 movable Driving 17.70 Belt width 18.7~19.3...
  • Page 149 Piston & Cylinder inspection (220CC) Part name /description Standard value Limit of use ( mm ) ( mm ) Bore 67.485~67.505 67.595 Curve 0.005 Cylinder Cylindrility 0.005 Roundness 0.005 lst ring 0.04~0.08 0.15 Clearance b/w Piston and Piston ring ring 0.02~0.06 0.15 lst ring...

  • Page 150: Electric System

    (3)Electric system What is transistor ignition? Transistor Ignition System Transistor: a kind of semi-conductor that can control electric current, has the switch function Apply transistor to engine ignition control, called transistor ignition...
  • Page 151 Major components of Transistor ignition Digital ignition controller Ignition coil DC-generator, with longer pulse flange TPS: Throttle Position Sensor (optional part of Carburetor) Ignition coil Digital ignition controller...
  • Page 152 Comparision of Transistor V.S. CDI ignition item parts Traditional CDI BLUR 220 transistor Digital controller ACG flange shorter longer Ignition coil Less coils More coils More coils longer Digital controller Traditional C.D.I Transistor ignition...
  • Page 153 BLUR 220 Electric system Headlamp & choke (carburetor) diagram When engine speed > 1000rpm,the digital controller permits the relay to conduct the circuit 12V from battery fuse Green/ Headlamp Digital black switch controller relay 1000 Control timing To headlamp & choke...
  • Page 154 Charging system diagram Charging to battery yellow ＋ － 3-phase yellow Regula- generator battery yellow Battery feedback voltage ground ground...
  • Page 155 Fuse wire: Main fuse layout relay fuse layout reserved fuse layout Red/white white Red/black Red/white white...
  • Page 156 BLUR 220 Electric parts relay fuse(15A-) Digital controller Seat lamp controller battery diode Remarks: If dismantle the battery, engine will cease fire!

  • Page 157: Maintenance

    (4) General maintenance BLUR 220 BLUR 150 Replace 1000cc Replace 800cc Engine oil Total 1400cc Total 1000cc Replace 110cc Replace 90cc Gear oil Total 130cc Total 110cc Oil filter filter filter Air element Wet paper(bigger) Wet paper CVT sponge Circle shape...
  • Page 158 BLUR 220 Specified engine oil (synthetic 1000ml)
  • Page 159 Engine oil、gear oil: Gear oil filling Replace 110cc total 130cc Drain of engine oil drain of gear oil...
  • Page 160 Engine oil、gear oil: Engine oil filling & gauge replacement 1000cc total 1400cc Check the oil level: 1.park in flat area 2.keep in idle for 3 minutes 3.cold down 3 minutes 4.take off the gauge upper lowest 5.when lower the lowest limit, add oil to upper limit...
  • Page 161 Replace the 2 oil filter 1.dismantle the right lower cover 2.replace the filter ＊keep the surface clean 　apply grease to the O-ring before installing!
  • Page 162 Air element 1.loosen 8 screws Don’t forget to install the 2.dismantle the cover, black-rubber packing Take off the element back to the element...
  • Page 163 CVT sponge 1.loosen 3 bolts Clean with compressed air, or replace a new one 2.take off the sponge...
  • Page 164 CVT dismantle 1.loosen the outer bolts Don’t miss the lock pin 2.dismantle the cover falling into the 3.loosen 2 hexagon nuts crankcase...
  • Page 165 CVT install notes: 1.keep the words of belt facing to operator 2.push the belt to bottom 3.lock the nuts Rotation direction...
  • Page 166 Spark plug Dismantle the right lower cover Loosen with the special tool Spark plug: C7E(carburetor) or CR7E(EMS model)

  • Page 167: Ignition Coil

    Ignition coil: Dismantle the right lower cover You can see the ignition coil clearly...
  • Page 168 Front brake system: Service data: ◎tire pressure:2.0 kg/cm ◎using limit of Disk thickness: 3.5mm ◎ using limit of pad thickness: to groove bottom...
  • Page 169 Replace the front pads ●dismantle 1.dismantle clip 2.take off the pin 3.take off the yoke 4.dismantle the pads ●install reverse procedure of dismantle...
  • Page 170 Front brake system: Service data: ◎ tire pressure:2.0 kg/cm ◎ using limit of Disk thickness: 3.5mm ◎ using limit of pad thickness: to groove bottom...
  • Page 171 Replace the rear pads ●dismantle 1.dismantle clip 2.take off the pin 3.take off the yoke 4.dismantle the pads ●install reverse procedure of dismantle...

  • Page 172: Engine Management System(Ems)

    (5)Engine Management System (EMS)
  • Page 173 EMS index ◇EMS units ◇EMS diagnostic...
  • Page 174 Feature of PGO 2 -stage EMS ＊feature 1.small, light 2.integrity 3.accuracy 4.simple...
  • Page 175 EMS structure (A) Fuel supply 5 sensors ignition injector Crank speed sensor coil Engine temperature air control sensor Throttle position sensor Idle speed control Intake pressure sensor Oxygen sensor...
  • Page 176 EMS structure (B) (ISC) Electric control unit Spark coil plug injector Intake pressure sensor Throttle position sensor Engine temperature sensor Oxygen sensor Crank speed sensor...

  • Page 177: Ems Units

    EMS units...
  • Page 178 Intake pressure sensor ※ Idle Speed Controller ※噴油嘴 injector Throttle position ※ sensor...
  • Page 179 ※FUEL PUMP COMP ※COIL COMP IGNITION ※O2 SENSOR ※TE SENSOR ※ crankshaft ANGLE SENSOR...
  • Page 180 ※ AIAC ASSY SOLENOID ※ECU ※SAFETY SENSOR，SIDE STAND...
  • Page 181 Important PIN no.# of ECU ＊ECU (PIN) 1 PIN 18 PIN 19 PIN 36 PIN...
  • Page 182 Important PIN no.# of ECU ＊ Important PIN no.# of ECU 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 Input voltage from battery...
  • Page 183 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 184 Engine temperature sensor ＊function：induct engine oil temperature, then ECU knows engine is cold or hot ＊theory：different temperature vary resistance...
  • Page 185 Measure engine temperature sensor T(℃) resistance(KΩ) -20℃ 18.800 KΩ 40℃ 1.136 KΩ 100℃ 0.155 KΩ usually 1.5~5.5 KΩ...
  • Page 186 Throttle position sensor (TPS) ＊function：induct throttle angle, provides the road load condition to ECU ＊theory：angle changes, resistance changes!
  • Page 187 Throttle position sensor (TPS) Lb(+) / Gr(-) throttle output(V) 0.6 ±0.02V close 3.8 ±0.10V ＊Lb <output> ＊Pu <power(5V)> ＊Gr <ground>...
  • Page 188 Intake pressure sensor ＊function： induct intake air pressure, ECU judge intake or compress stroke to decide injection & ignition ＊theory：different pressure outputs different resistance...
  • Page 189 Intake pressure sensor ＊Pu G/B(+) / Gr(-) <output(5V)> Press (KPa) output(V) ＊G/B 13.3KPa 0.5V <output> ＊Gr <ground> 120 KPa 3.4V 壓力特性 絕對壓力 (kPa)
  • Page 190 Intake pressure sensor ＊Pu <output(5V)> ＊G/B ＊average resistance in ambient <output> wire R(KΩ) ＊Gr <ground> Pu(+)+Gr(-) 2~4KΩ G/B(+)+Gr(-) 2~4KΩ...
  • Page 191 Oxygen sensor ＊function：induct the A/F ratio, feedback to ECU , and decide the injection time; modify to the best 14.7 ratio ＊others：there is heater inside, help it reach the working temperature quickly...
  • Page 192 Oxygen sensor ＊W <heater(12V)> 2 couple~8Ω ＊Gr <ground> ＊B <output>...
  • Page 193 injector ＊function：inject the gas, mixed with air＊ theory：control the opening time interval to decide the gas amount...
  • Page 194 injector ＊R/B(+) <output(12V)> ＊Br/W(+) <output(12V)> ＊each terminal virus ground is 12V time(msec) injecting feeding...
  • Page 195 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 storage, drain it before start the engine...

  • Page 196: Fuel Pump

    Fuel pump ＊function：pumping the gas to injector, and keep the constant pressure as 3kgf/cm ＊theory：the regulator keeps constant pressure regulator pump filter...
  • Page 197 Fuel pump ＊R/B(+) R/B(+)+B(-) <output(12V)> voltage ~12V ＊B(-) resistance <1KΩ <ground>...
  • Page 198 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.
  • Page 199 Fall down sensor ＊O power degree output(+) <input(12V)> +ground(-) ＊Bl/W <output> ＊B <65 <grounding> >65 ＊to recover the sensor function after fall down： 1.turn OFF the key 2.turn ON the key...
  • Page 200 ISC(Idle Speed Control) ＊W <ISC-A*> ＊R/B ＊ISC unit <ISC-B*> ＊G <ISC-B> ＊Gr A(+) + A*(-) ~80Ω <ISC-A> B(+) + B*(-) ~80Ω...
  • Page 201 ISC(Idle Speed Control) ＊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. ＊sample when cold engine, ECU tell ISC enrich the by-pass air to increase the engine speed.
  • Page 202 ISC(Idle Speed Control) By-pass air Throttle body Step motor Air flow engine Throttle valve...
  • Page 203 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.
  • Page 204 Procedure of ISC initialization diagnostic 1.don’t plug quick- 2.wide open throttle; turn on the key; the ISC sounds “da da…” 3.release the throttle after the ISC stop acting. 4.turn off the key, finish initialization! throttle Release throttle Wide open Key ON Key OFF Main key ISC off...
  • Page 205 EMS fuses 7.5A 10A...
  • Page 206 Main purpose of EMS fuses ＊ (FUSE) 1A / 5A / 7.5A / 10A / 15A protect the units when extra-current occurs ： protect the (ECU) 1A <Y+G/B> ： protect fuel pump & injector 5A <R/W+G/B> ： protect ignition wiring(EMS) 7.5A <O+G/B>...

  • Page 207: Ems Diagnostic

    (6)EMS diagnostic...
  • Page 208 Quick diagnostic part no.：S320840G01 name：quick diagnostic...
  • Page 209 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 beside 6.observe the EMS led on dash the battery board 3. Plug in the quick-diagnostic...
  • Page 210 PC diagnostic PC diagnostic assy.： S320891G01 + S320838G01 (software & adapter + connect cable) KEIHIN RS232 or USB adapter software PGO vehicle connect cable...
  • Page 211 PC diagnostic part number：S320891G01 name： (software & adapter ) ＊software　　　　 　 ＊adapter...
  • Page 212 PC diagnostic part number：S320838G01 name：connect cable...
  • Page 213 Quick diagnostic table part Defect code Throttle position sensor 0 long 6 short Intake manifold pressure sensor 0 long 9 short Engine temperature sensor 1 long 1 short Oxygen sensor 1 long 7 short injector 3 long 3 short Ignition coil 3 long 7 short Fuel pump 4 long 1 short...
  • Page 214 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 215: Ems System Repairing Tool

    (7)EMS system Repairing tool...
  • Page 216 pocket tester wiring ＊pocket tester wiring part no.：S905310005...
  • Page 217 Ignition gauge ＊connect ＊minimum distance 6mm Plug cap. ground...
  • Page 218 Fuel pressure gauge ＊fuel pressure gauge part no.：S905330008...
  • Page 219 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 220 (8)General Electric units...
  • Page 221 BLUR 220 HELMET CASE ASSY,BR ELECTRICALS COMPONENT luggage lighting lamp CONTROL FUSE MAIN RELAY FUEL PUMP & INJECTOR RELAY BATTERY 12V9A HEAD LAMP CONTROL DIODE...
  • Page 222 Signal flasher relay (LED) ＊ dismantle the leg-shield cover first ＊ within the leg-shield cover...
  • Page 223 regulator ＊dismantle 1.luggage comp. 2 rear rack 3.body cover ＊within the right body cover...

  • Page 224: Fuel Gauge

    Fuel gauge ＊dismantle 1.middle cover ＊below the middle cover...
  • Page 225 Measure the fuel gauge ＊gray(+) gray(+)+black(-) <output> ＊black(-) 4~10Ω <ground> 80~90Ω...
  • Page 226 Starting relay ＊dismantle 1.luggage comp. 2.middle cover 3.rear rack 4.body cover ＊within the right body cover...
  • Page 227 EMS relays ＊dismantle 1.luggage comp. 2.middle cover 3.rear rack 4.body cover ＊within the right body cover...
  • Page 228 EMS relays wiring ＊A.EMS system Gr/B Bl/W ＊B.fuel pump/injector ＊C.headlamp...
  • Page 229 Control of relays ＊ (Relay) 15A Big current ＊theory： use small current to control big current ＊Usage： fuel pump & injector EMS whole system headlamp Small current(ECU)
  • Page 230 Measure the relays ＊use the pocket tester 2.fit 12V to the control coil 3.the relay sounds “ka” 1.find the control coil 4.measure the resistance <disconnect-->NG connected-->OK> Ω Ω...

  • Page 231: Wiring Diagram

    6.Wiring diagram Wiring diagram for BLUR-150(4V):...
  • Page 232 Wiring diagram for BLUR-SS220I:...

This manual is also suitable for:

Blur ss220

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