SERVICE MANUAL
Contents
1. NO CI INESE NAMIE ENGLISH NAME SPACER BALL L3 pi CH DUST SEAL BALL INUT CASTLE Mun STEERING TIE ROD ASSEMBLY STEERING TIE ROD ASSEMBLY 1 1 WASHER FLAT 7 SPRING WASHER Em gii M NUT CASTLE MIO L4 NUN O WHEEL ASSY I FR WHEEL ASSY R WASHER FLAT NUT FLANGE LOCK MIO STEERING WHEEL COVER STEERING BOLT REAR CARGO RACK TOT Wi a pun BOLT 1 25 55 1 9 RI X 107 ROL L CAGE CROSS BAR FR n A ROLL CAGE BAR LH 2 i BOLL CAGE CROSS BAR RR El ROLL RAB L R SIDE Cas E R WASHER 10 3 HEWN PE 8 1 25 55 BOLT STRAP MBN 1 25455 s AIT Seet M8X1 25X55 BOLT WASHER 1 25 55 E TIS FLANGE LOCK _ i RR SWING ARM COMP UNDER GER jii CUSHION ASSY RR pco mh BOLT WASHER MIOXI 25X40 EE z NUT FLANGE LOCK MID SENI 3 FENDER RR BOLT WASHER MBX 25X43 REAR WHEELASSY 1 2 35 HOL DER Ri COVER SPACER RR WHEEL CASTLE 6 CUSHION BATTERY UNDER Lip COVER BATTERY E BAND UO ee See SC Gm E THEE 25X20 s M8X1 25X20 ROM SPRING WASHER SCH BERE I FENDER FR EE 2 Pep m E ess pr om en pg i en a ee emm Buexter BR 152. ransmission System ePrimary CVT eFinal reduction gear clutch in GV CVT top speed Engine inspection Transmission System Reverse gear is engaged Driving chain dismantle 1 4 Dismantle 2 bolts 5 Push the reverse box to right hand approximately 10 amp mm Driving chain dismantle 2 6 Dismantle the bolt 16 amp nut 10 Lock torque 15 25103 0kg m REAR SWING ARM ASSY UPPER And make sure part 9 can rotate in pivot 17 7 Replace the collar 17 3 eee 8 Assemble the engine mount link by reverse step to 6 Driving chain dismantle 3 And make sure part 9 can rotate in pivot 17 Driving chain dismantle 4 9 Adjust the chain slack by this nut Driving chain dismantle 5 10 10 Lock lower nuts by 5 0 to 6 0 kg m Driving chain dismantle 6 When installing the lock pin of driving keep the close end forward Close end Engine inspection Engine layout eCylinder head amp cover LHEAD Cow CYLI 13 CARB 25LOKK PI N 2 GU EXH VALVE 14 QN TI CN PLUG 26 HOLDER 30 RI NG 15PLAI WASHER 27 N VIASHER 4 QU IN VALVE 16 SPRI NG VALVE 28HEXAGON FLANGE 17RETA SPRI NG 29CYL HEAD COVER COM VE INET 1 VALVE 30CYL HEAD 7GNSKET HEAD CYL 19 CAM SHAFT ASSY
3. o o MAX POWERRPM wem o AMX TORQUERPM SPAKPLUG 1 _ COOLING jFORCEAIRROIL STARTER ELECTRIC 1 o FUEL MIXING 1 LUBRICATION SEPARATED f 1 1 The operation notice 1 Always replace gasket O ring cotter pins and clip whenever reassembled 2 When tighten screws or nuts lock tightly as per specified locking torque and in the sequence of cross direction 3 Use PGO or PGO Recommended parts 4 After dismantling please wash all parts necessary for checking and grease all contact surface when reassembling 5 Use grease recommended by P G O 6 When removing battery please dismantle the negative pole first when assembling please connect positive pole first 6 Before installing a new fuse confirm the specification 1s correct or not 7 After reassembling please re check that all connecting point locking parts circuits polar characteristics are good before selling out 1 2 TORQUE VALUE Engine sou 6 DS _ 3 Djoesrmesw o _ 5 Fixing nut air valve adjustment Guiding pin bolt inner chain adjustment a 6 0 9 1 1 Dom sooo _ 8 swm Tes i 2 General parts please refer the following tabl
4. steering Inspection amp Adjustment When checking the alignment of front wheel Keep the vehicle at flat surface From the top view wake sure C D and A B 1 8 1 4 Steering Inspection amp Adjustment Adjusting the toe in Loosen unit 2 and 3 Rotating 4 to adjusting the toe in 3 3 Brake inspection and adjustment Brake system Brake cylinder Adjust the hand brake to rear brake disk cable if necessary Brake adjustment Hand Park Front end Loosen nut 1 Adjust bolt 2 out to increase park power Lock tight nut 1 Brake adjustment Hand Park Caliper end Loosen nut 1 Adjust the cable to front to increase hand brake power Lock tight nut 2 Brake inspection Check the brake fluid level add 1t when below MIN level Brake inspection and adjustment front brake rear brake Adjusting braking power Loosen nut Adjust the length of bolt screw it 1n can get bigger brake power Lock the nut Brake inspection and adjustment e Make sure there is not any fluid leakage from the bolt Brake inspection and adjustment Specification of front brake caliper Replace the pad of disk 1f necessary Brake inspection and adjustment Specification of rear brake caliper Replace the pad of disk 1f necessary Wheel dismantle 1 e Withdraw the cap Dismantle the 4 nuts Wheel dismantle 2 e You don t need to dismantle the whe
5. Content Chapter 1 Service notation Specification Locking torque Chapter 2 Engine dismantle amp inspection Engine dismantle Engine inspection Transmission dismantle inspection Carburetor adjustment Chapter 3 Chassis inspection Operation Steering inspection amp adjustment Brake inspection amp adjustment Installation Chapter 4 Electric Parts location Charging inspection amp adjustment Ignition inspection Wiring diagram PREFACE This manual offers all service specialists with the technological procedures of maintenance repairing for 150 show those whom may concern how to maintain in detail repair change parts troubleshoot and reassemble etc At every important section we illustrate by assembly explosion diagrams and photographs if necessary please check the diagrams already shown Though we have tried our best please kindly instruct us any faults found this manual MOTIVE POWER INDUSTRY CO LTD BUGXTER SPECIFICATION E TYPE RBE SUSPENSION SYSTEM DIMENSION FRONT SINGLE TOTAL HEIGHT RPIMARY RATIO 1 SECONDARY RATIO E DRY WEIGHT 263KG CLUTCH mm we Pr men CLIMBING ABILITY m HEAD 12V 35W 35W 2 LIGHT H L ee um TAILLIGHT 12V5W CYLINDERNUMBER 1 ARRANGEMENT HORIZONTAL DISPLACEMENT ioe oOo een Il 88mm Il COMPRESSIONRATIO 94 1 J
6. H BATTERY TJAH 30 GENS i AUTO SYST en 4 RESISTOR 28 87 45 Lb Pi A 2 1 1 d IGNITION COL Bud with Red ro Blue mth Black iraco O owe mih White irocer B 77 Bus miih Yeloy irocor Ral Dort irem TAL ARAKE LIGHT LH RR SIANAL LAMP LH RR SIGNAL Br WiBrown with White trocer Do Dork uun G W Green with White tracer Lb Light ur key 0 _ D Gre IU wesw 5 R W with White tracer Pi Pak REMARK DC LIGHTING CIRCUIT et XZ lYelow with Black tracer Wire X G Nelon with Green tracer Y Yelpw 3 1 OPERATION I OPERATION LAYOUT a ILLIS M MELT GAS PEDAL POSITION RS BRAKE PEDAL POSITION C HAND BRAKES POSITION REVERSE POSITION CYLINDER POSITION HYDRAULIC 2 Digital Speedometer I Symbol description 1 speed indication high beam indicator 2 signal lamp indicator reverse gear indicator 3 3 parking indicator RESET button 1 MODE button display area 2 Setting Press RESET 2 sec then can get into the setting procedure Unit km h or mile h switched by MODE and RESET to confirm Wheel circumstance from to 3999 mm 4 digitals individually set by RESET to increase one by one and MODE to next digital Finally press MODE 2 sec to escape setti
7. 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 Change the brake fluid hose every four years Content Chapter 1 Service notation Specification Locking torque Chapter 2 Engine dismantle amp inspection Engine dismantle Engine inspection Transmission dismantle inspection Carburetor adjustment Chapter 3 Chassis inspection Operation Steering inspection amp adjustment Brake inspection amp adjustment Installation Chapter 4 Electric Parts location Charging inspection amp adjustment Ignition inspection Wiring diagram
8. 0 SEAT BELT INSTALL INSTRUCTION VERSION 2 0 SEAT BELT INSTALL INSTRUCTION TO SECURE PART A VIA PART 5 kg m AT THE FIXED POSITION OF HUB d Bugxter BR 150 TOW BALL INSTALL INSTRUCTION VERSION Z U bk E LE TOW BALL INSTALL INSTRUCTION 1 SECURE PART VIA PART BHCHD T 10 kg m AT THE FIXED POSITION REAR ARM ASSY 2 4 Carburetor dismantle amp inspection 1 dismantle Remove carburetor assembly pipes cables and wires Remove high tension wire 2 adjustment there are two screws might be adjusted to tuning the engine intake mixture 1 is the stop screw to adjust the engine idle speed recommended idle speed is 1600 to 1800 rpm e 2 is the air screw to adjust the air fuel ratio 3 Auto by start function check the carburetor 1s equipped with auto by start to improve the engine cold start it shall be warm after the engine has been starting for 5 minutes 4 Float chamber function check fuel level 15 controlled by float assembly and stopped by valve set Whenever there is any flooded fuel leaks check if there 15 any dirty element or valve set is worn out 5 Whenever the carburetor 15 exploded be careful to install all the parts properly to the original sequence CARBURETOR PRINCIPLE Functions 1 Fuel atomization 2 Air Fuel Ratio 3 Engine Output E
9. 31 PACK NG CYL HEAD COVER PI N 20 SHAFT EX ROCKER ARM 32HEXAGON FLANGE QHEXAGON FLANGE 21 RXKER ARM 33VALVE SEAL 10STUD BOLT 22SCREWTCPPED AD USTER 340 P 1510 BOLT 23HEXAGON 35TUBE CYL COMP 121 NSULATCR CARB GASKET 24 SHAFT EX ROCKER ARM Engine inspection eCylinder head inspection eDifferent view of cylinder head Cylinder head data Valve Clearance Before warm up Compression pressure 11kg 700rpm 26 625 Height of the cani s convex part 4 975 4 900 4 955 4 970 26 53 Inner diameter of rocker arm shaft Outer diameter of rocker arm shaft M NN diameter of valve stem Inner diameter of valve guide 5 000 5 012 Clearance between valve stem and 0 010 0 037 Valve guide Engine inspectior Valve train Valve clearance IN 0 08mm EX 0 08mm CYLINDER amp CYLINDER HEAD INSTALLATION Installing camshaft the valve timing shall be adjusted Rotate the magneto maketo RH crankcase allied position CYLINDER amp CYLINDER HEAD INSTALLATION Ensure 2 line marks of camshaft parallel to cylinder head refer to photo And the hole shall be the top position refer to photo CYLINDER amp CYLINDER HEAD INSTALLATION nstalling camshaft holder mark shall face to exhaust valve Tighten 4 nuts crossly lock torque is 2 0 kg m Engine inspection Oil lubric
10. E PASSING OUTSIDE END OF PART 38 AND TO SECURE PART 39 AT THE THE FIXED POSITION OF 34 TO PUT PART 32 VIA PART 30 3 kg m SECURED AT THE FIXED POSITION OF PART 28 TO SECURE PART 14 VIA PART 15 T 0 3 kg m AT THE DEFINED POSITION OF FIXING SOCKET i THEN TO PRESS PART 16 INTO THE FIXED POSITION OF PART 14 TO BE SECURED UNTIGHT PART 45 THEN MOVE PART 17 TO THE STANDARD POSITION LAST FIX PART 17 BY PART 18 T 4 19 45 T 4 kg m TO PUT PART 21 AT THE LH RH FIXED POSITION OF FRAME SEPARARELY 2 TO PASS PART 26 T 4 kg m THRU PART 24 21 27 SECURED TOGETHER BUT NOT FASTEN TIGHTLY TOSECURE PART 20422 VIA PART 24425 T 4 kg m AT THE LH RH BOTH SIDE OF FIXED POSITION OF PART 21 BUT NOT FASTEN TIGHTLY TO SECURE PART 23 VIA PART 24425 T 4 kg m 26 T 4 kg m 27 AT THE FIXED POSITION BETWEEN PART 21 WITH FRAME THE TO SECURE ALL OF THE BOLTS BY SORTING 1 TO PUT PART 44 INTO THE DEFINED HOLE OF SEAT TO PUT PART 40 41 INTO THE FIXED POSITION OF PART 28 TO SECURE THE POWER CORD OF MAIN WIRE HARNESS WITH PART 41 TO COVER PART 42 ON THE UPPER OF TO CLIP PART 43 SECURELY TO SECURE PART 47 VIA PART 48 T 2 kg m AT THE FIXED POSITION OF HUB TO SECURE PART 49 VIA PART 50 T 0 5 kg m AT THE FIXED POSITION OF PART 21 P3 EL Ir D in 7 2 4 GA E T Abe Fie go Sep Se a Bugxter BR 150 PART INSTALL LIST version 2 0
11. MBLY 2 Loosen nut of one way clutch with special tool part no 56204016015 Remove way clutch comp and starting idle gear The nut 15 LH thread 11 OIL PUMP DISASSEMBLY 1 Loosen 2 C R recess screws of oil separator Removeoil separator OIL PUMP DISASSEMBLY 2 Loosen nut of oil pump driving gear Remove oil pump driving gear and chain 12 OIL PUMP DISASSEMBLY 3 2 hexagon screws of oil pu e Remove oil pump CRANKSHAFT DISASSEMBLY 1 2 hexagon screws of RH crankcase Remove RH crankcase with plastic hammer 13 CRANKSHAFT DISASSEMBLY 2 e Pull out crankshaft from LH crankcase e Remove camshaft chain CRANKSHAFT INSTALLATION 1 Put camshaft chain in LH crankcase CRANKSHAFT INSTALLATION 2 Assemble crankshaft in LH crankcase Crankshaft inspection data ITEM Standard Limit of value mm use mm Clearance of connecting rod big end 0 10 0 35 0 55 axle direction Clearance of connecting rod big end vertical direction Swingness of the crank shaft journal 15 CRANKSHAFT INSTALLATION 3 Assemble RH crankcase into crankshaft Tight 2 hexagon Screws 4 torque 151 Replace the oil seal and packing CRANKSHAFT INSTALLATION 4 To avoid the oil seal detected shall assemble the oil seal after crankshaft is fixed crankcase SERVICE MANUAL
12. SERVICE MANUAL 4 Electric inspection Parking button Operation panel Headlamp switch Main switch 12 power supply Horn button Panel terminal wiring Panel terminal wiring BR 150 TERMINAL CONNECTION A T F d 2 Parts location speedometer Signal lamp 2 Parts location Relay 2 Parts location Starting safety device e 2 Parts location Head lamp Optional device Reverse shifting safety device Parking sensor Electric inspection Check the coupling prevent losing connection of the terminals Spray some anti dust wax if necessary Electric inspection Flasher relay starting motor relay 2 Charging Adjustment of BR150 Start the engine keep in idle speed turn on the headlamp Disconnect the red white wire Use the pocket tester to measure the charging current as photo shown 1 Black to battery 2 Red to wire harness Adjust the idle speed to 1600 to 1800 rpm then the charging current shall be positive 3 Ignition gnition wiring For CDI unit you don t have to adjust the ignition timing 1 DIG TAL INSTRUMEN LEE POSTON LAM SWITCH Q m CR ER WEADLANP 4 TION L 19 9 L Lo1 11 LL LS 7114 ES ses Een 1 4 13 FLYWHEEL DENM 14
13. UE E Brake performance Leaking and function check I I 3 UUPPID hose master replace it if neces 1 1 1 Tires Worn out check or replace it if necessary L Su qb gp m a a Driving chain Lubricate amp check the sack 1 1 CAL TEAL 1 CAL Chassis suspension arm Check looseness Add grease if I I C A L I C A L I C A L ptt required Parking Function check or replace it if required Nuts bolts fasteners Tighten it if required Make sure that the voltage stayed over 12 8V Recharge the battery it required Clear the poles Valve gap Check and adjust when engine is cool 0 08mm for IN amp EX Spark plug Clear or replace if required LKE ROG qp BI TIT necessary emnt D rp pe m it if necessary 1700 100 rpm A A A JA A A TOA EES EA EA Pe Adjustment CO HC Percentage A adjust C clean I inspect clean or replace if necessary L lubricate replace 1 Items with mark indicate our recommendation to have it done by PGO dealer 2 P denotes that function check or replace it when the engine performance reduces significantly NOTE 1 The engine oil shall be changed completely after run in period 300 km or one month later This can make sure the engine runs smoothly NOTE 2 The exchange of brake fluid 1 After disassembling of brake main cylinder
14. ated System by pump amp splash Make sure the oil path is through amp clean Engine inspection Intake amp Exhaust system Inspect element per 1 000km replace it if necessary If the vehicle 15 often used dusty area decrease the inspection interval Engine inspection Exhaust muffler Make sure the flange 1 1s well locked with the cylinder head to avoid leakage Lock muffler at 4 with engine LH Engine inspection Engine oil cooler Always clean the cooling fin to increase the cooling efficiency Replace the oil filter per 5 000 kms Lock torque 10 N m Inspect the oil leakage Engine inspection e Pulse air system Keep the air in path clean Keep the vacuum pipe Au c A T well connected to intake manifold Never jam the vacuum pipe Cylinder amp piston inspection data Part name description Standard SE Ke Cylindrility P 1 D W 0 and i Piston ring pa section ES Piston ring Measuring location of piston outer dia 5 mm from the lower end of skirt Clearance b w piston and cylinder 0 025 0 035 Piston pin hole inner dia 15 006 15 012 15 030 0020 0017 0 025 Clearance between piston and piston pin 15 010 15 028 15 060 Engine inspection Cylinder CYLINDER amp CYLINDER HEAD INSTALLATION Notice the marks f 5 Ki upon piston 4 1 IN mark shallin the intake direction i EX mark shallin the exha
15. e vo 10mm bolt and nut LA 12mm bolt and nut 5 0 6 0 10mm flange bolt and screw 3 0 4 0 I standard Chassis mE m 1 nut 3 Front absorberbot 4 w so 4 Lower suspension arm bot 2 10 60 5 6 3 os 6 s s 39 o 7 Jupersupemioam 2 8 30 8 4 00 50 epom fet s UU 10 Rearswingarm tower 2 02 Lal 1 Engine hanger with frame 2 0 35 45 I2 Engine hanger with engine 1 10 35 45 13 Rearabsorber 4 0 3545 M 4 s 30 I5 Chain adjusting bols uper 1 2 6o _ 16 Chain adjusting bott lower 1 2 60 17 Bmkecdiprfxue 6 Lian I8 Brakehosebott 6 8 2530 19 Revesegearstt 11 20 Rearsprocket 4 8 30 m dse s swo 1 3 In order to achieve safe riding good performance and reduce pollution please execute the following recommended maintenance table base upon average driving condition Driving in unusual dusty areas require more frequent servicing MONTHS DISTANCE IN KM FOR CHECKING ULT 3 or 6 or 9 120r 15 18 or hei Cooke Replace it per 5 000km Coarse EE EE Clean or replace it if necessary Clean it per 3 000km or replace it if required draining bolt GE Ic Airfilter Replaceitifrequired TI _ Replace it per 1 oim DON LL MERCEDE R 3 NE
16. el nut Wheel dismantle 3 e Withdraw the wheel Wheel dismantle 4 e Withdraw the cotter pin e Dismantle the nut e Withdraw the hub LTD MOTIVE POWER INDUSTRY CO Z 5 z E t un Z i N 2 e D x O ve o MOTIVE POWER INDUSTRY CO LTD 150 INSTALL INSTRUCTION versiona Bugxter BR 4 1 5 6 Bugxter 150 INSTALL INSTRUCTION AERATE ALL THE FOUR TIRES STANDARD PRESSURE ON ROAD 0 5Kg cm R 0 8Kg em OFF ROAD 0 25Kg cm 0 25K g cm TO PUT PART I PART 2 INTO THE FIXED POSITION OF RH LH SUPPORTING AXLE THEN TO PASS THE LOWER END OF SUPPORTING AXLE THRU THE DEFINED HOLE OF LH RH LOWER SUSPENSION SECURED BY PART3 46 T 5 THEN TO PASS PARTS THRU THE DEFINED HOLE OF SUPPORT STRUT AND SPINDLE AND MAKE THE PASSING OUTSIDE END OF PART 31 TO PASS R L SIDE ROD OF PART 4 5 THRU THE DEFINED HOLE OF RH LH SUPPORTING ROD FIXED BY PART 6 7 8 T 5 kg m IN ORDER THEN TO PASS PART 9 THRU THE DEFINED HOLE OF PART 4 5 AND MAKE THE PASSING OUTSIDE END OF PART TO SECURE PART 10 11 VIA PART 12413 6 AT THE FIXED POSITION OF HUB TO PUT PART 39 INTO THE FIXED POSITION OF PART 10 11 TO SECURE PART 29 VIA PART 30 T 6 ke m 31 AT THE FIXED POSITION OF PART 28 TO SECURE PART 35 36 37 T 8 ke m VIA PART 34 AT THE FIXED POSITIN OF RR AXLE THEN TO PASS PART 38 THRU THE DEFINED HOLE OF RR AXLE AND MAKE TH
17. n 2 hexagon screws and 2 C R recess pan hd tapping screws Remove fan cover MAGNETO DISASSEMBLY 2 Loosen 4 hexagon screws of cooling fan e Remove cooling fan MAGNETO DISASSEMBLY 3 Loosen nut of magneto When installing tighten lock torque is 5 5 kg m MAGNETO DISASSEMBLY 4 Pull out the magneto with special tool part no 620402G01A tool should be tighten lock MAGNETO DISASSEMBLY 5 3 hexagon screws of stator Remove stator Stator flywheel cooling fan CYLINDER AND HEAD DISASSEMBLY 1 Loosen hexagon screw and 2 tapping screws of cooling _ cowl 2 Remove cooling cowl 2 CYLINDER AND HEAD DISASSEMBLY 3 Loosen 4 hexagon screws of cylinder head cover Remove cylinder head cover assy CYLINDER AND HEAD DISASSEMBLY 4 Loosen 1 hexagon 7 amp screw of chain adjuster Loosen 2 hexagon screws fixed in cylinder e Remove chain adjuster comp CYLINDER AND HEAD DISASSEMBLY 5 Loosen 4 nuts of camshaft holder Loosen 2 hexagon screw of cylinder head e Remove camshaft holder camshaft and cylinder head CYLINDER AND HEAD DISASSEMBLY 6 e Remove cam chain 1 ju e E D Es Wa guide comp e Remove cylinder and piston rings ONE WAY CLUTCH DISASSEMBLY 1 Loosen 8 hexagon screws of RH crankcase cover e Remove RH crankcase cover CYLINDER AND HEAD DISASSE
18. ng If without pressing any button during 20 sec it will escape to main menu automatically Button operation Situatio Setting Main menu Button to next parameter switch display 2 escape digital 1 no function 2 no function 2 Reset RT MAX TRIP means press button one time e 20 means press button and hold 2 seconds Display description switched by MODE in main menu sequence SPD TRIP MAX ODO SPD RT gt SPD TRIP SPD real time speed TRIP trip distance from last RESET press RESET to zero again ODO accumulated distance from this speedometer been used MAX maximum speed press RESET to zero again RT operating time from last RESET press RESET to zero again 3 2 Steering Inspection amp Adjustment Dismantle Lock tight the bolts of steering handle Torque 0 5 kg m Steering Inspection nspect the coupling joint knuckle o USE Maintenance Add grease into upper suspension arm per 10 000km from grease valve Inspection nspect the absorber function check and oil leakage check Inspection Lock tight the nut of tie rod with steering spindle support Inspect the clearance of tie rod with the steering spindle support steering Inspection amp Adjustment steering Inspection amp Adjustment Lock tight the bolt 8 e Add grease into lower suspension arm per WP 10 000km
19. ngine inspection Carburetor Assembly Idle adjustment stop screw 1700 100rpm e Pilot screw DLE AD USTMENT Remarks 1 For 4 stroke engine more opening turns of PS A F ratio 15 richer 2 Clean the jets and body with compressed air Remarks 1 leakage of vacuum piston comp with body 2 Keep jets and paths clean 3 Don t miss small parts like O ring spacer etc E6 4 8 125 150 CARBURETOR 3 pilot screw assy 4 vacuum piston assy 5 jet needle 8 cover 13 main jet 14 pilot jet 15 float 19 by start cap p s 27 4 1 27 20 auto by start zs gt CVT TRANSMISSION DISASSEMBLY I Loosen 9 hexagon flange screws of LH cover Remove engine LH cover CVT TRANSMISSION DISASSEMBLY 2 loosen nuts of driving pulley and clutch outer When installing nuts tighten torque is 5 5 kg m CVT TRANSMISSION DISASSEMBLY 3 e Remove drive face driving pulley assy driven pulley assy V belt CVT The inner dia Of slide driving 24 011 24 052 24 10 plate inspection data outer dia Of boss movable 23 960 23 974 Driving plate RS outer diameter of driven 33 965 34 025 33 95 Plate sets The inner diameter of slide 34 000 34 025 34 06 Driven plate The outer diameter of weight 17 920 18 080 17 40 Roller set CVT inspection data Belt width Lining thickness Outer dia Spring length Engine inspection m
20. ust direction CYLINDER amp CYLINDER HEAD INSTALLATION Piston rings shall be installed according to marks Ist ring is marked 2nd ring 1s marked The marks shall face to piston head CYLINDER amp CYLINDER HEAD INSTALLATION 10 1202 The opening end of piston rings shall CG face to intake valve and allied to 120 degree And shall not allied to the piston pin Engine Dismantle Loosen the bolt of connecting rod with upper swing arm Engine Dismantle Dismantle the nut Withdraw the engine from the upper swing arm Engine Dismantle bolt of upper swing arm with the lower swing arm rear Engine Dismantle 2 bolts of oil cooler OP of Replacing Rear Engine Hanger Collar for BR150 the lock nut OP of Replacing Rear Engine Hanger Bush for BR150 2 Dismantle the bolt 3 Loosen the nut Lock torque is 11 0 kg m Muffler DISASSEMBLY 1 2 wm bolts of 139 muffler with 5 cylinder head Muffler DISASSEMBLY 2 Loosen hexagon bolt of muffler with LH COVer Remove muffler Air cleaner removal 1 Loosen 9 hexagon flange screws of LH cover Remove engine LH cover Air cleaner removal 2 Outside end is sponge clean it if necessary Inside end 1s paper element replace it if necessary MAGNETO DISASSEMBLY 1 Loose
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