CHICAGO SCOOTER CO PUG 50 User manual

Owner’s Manual

1
This owner's manual contains important safety, operational and maintenance information. Any person
operating or riding as a passenger on your scooter should carefully read and fully understand the entire
contents of this manual prior to riding the vehicle. For your safety, follow all safety warnings contained
within the owner's manual and the labels applied to your scooter. You should always keep this owner’s
manual in your vehicle, and it should be considered a permanent part of the vehicle.
If you have any questions, please ask your dealer for assistance.
Safety symbols and notes. Please observe the following:
Failuretofollowinstructions with aWARNINGsymbolcouldresultin seriousinjuryordeath. Precautionary
measures are required.
CAUTION
Important instructions and precautionary rules to avoid damage to the vehicle. Non-observance can lead to
an unsafe vehicle condition.
NOTE
WARNING
!

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Congratulations on your purchase of the Chicago Scooter Company Pug 50!
Please read this manual carefully prior to riding so that you will understand how to safely operate your scooter,
understand its capabilities and limitations, and become aware of all vehicle controls and features.
This owner's manual contains important maintenance information. The efficiency and longevity of your scooter
will depend heavily on your operating methods and periodic maintenance. Failure to operate and maintain your
scooter as instructed in this owner's manual may void the limited warranty and reduce the efficiency and reliability
of your vehicle.
The first 500 miles are the most important in the life of your scooter. Proper break-in during this time will ensure
maximum life. Please refer to the break-in section for specific break-in procedures prior to riding.
You should always use original Chicago Scooter Company OEM parts for all maintenance and repairs as they
have been designed specifically for your vehicle.
Genuine Motor Oil is the official lubricant of Chicago Scooter Company vehicles. Genuine Motor Oils have been
specially formulated to keep your vehicle operating at maximum efficiency with minimal engine wear. Genuine
Motor Oils are synthetic oils that utilize the best-known lubrication technology to increase fuel mileage and
produce minimum exhaust emissions.
Prima is the official accessories supplier for Chicago Scooter Company vehicles. Prima accessories have been
specifically designed to fit your Chicago Scooter.
Your authorized Chicago Scooter Company dealer is the primary resource for information, parts, and
service. If you have any questions, please ask your dealer for assistance.
Introduction

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NOTICE .......................................................................... 1
INTRODUCTION ........................................................... 2
TABLE OF CONTENTS ................................................ 3
VEHICLE SAFETY
Accessories, Modification, Noise Regulation..................... 4
Loading, Maintenance, Pre-ride Inspection ...................... 5
Carbon Monoxide Gas........................................................ 5
SAFE RIDING
Wear Safety Gear, Make Yourself Visible..................... 6
Know Your Limits, RoadConditions................................. 6
IDENTIFICATION NUMBERS ...................................... 7
VEHICLE LAYOUT
IgnitionSwitch............................................................... 8
Dashboard........................................................................ 9
Handlebar Controls....................................................... 10
Front and RearBrakeControls.................................. 11
Kick Start, Seat Lock...................................................... 12
Primary Storage………………………………………............................... 13
Fuel Fill……………………………….................................................. 14
PRE-RIDE INSPECTION
Pre-ride Inspection Checklist.......................................... 15
Front BrakeInspectionandAdjustment...................... 16,17
Rear BrakeInspectionandAdjustment........................ 17,18
PRE-RIDE INSPECTION (CONTINUED)
Throttle Inspection and Adjustment...................................... 19
Engine Oil Type, Level Check, and Fill ................................ 20
Tire Inspection and Pressure Adjustment............................. 21
Cable Inspection and Lubrication......................................... 22
Vehicle Center and Side Stand, Assembly Check................ 22
Fuel, Lighting, Switches, and Loading.................................. 23
OPERATION
Engine Starting .................................................................... 24
Engine Run-in, Engine Life................................................... 25
Engine Warm-up, Riding, Throttle....................................... 26
Braking................................................................................. 27
Engine Stop, Parking............................................................ 28
PERIODIC MAINTENANCE
Periodic Maintenance Key.................................................... 29
Periodic Maintenance Table..................................... 30, 31, 32
Air Cleaner, Gear Oil, Transmission.................................... 33
Spark Plug, Front Brake........................................................ 34
Brake Fluid, Suspension....................................................... 35
Fuses, Battery....................................................................... 36
Storage Guide....................................................................... 37
Maintenance Record............................................................ 38
TECHNICAL DATA..................................................... 39
REPORTING SAFETY DEFECTS............................. 40
Table of Contents

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Accessories
The addition of unsuitable accessories can result in unsafe
operating conditions.
Chicago Scooter Company approved accessories such as
Prima brand have been designed for and approved by CSC
for use on your scooter. Always install CSC approved
accessories on your scooter. Your dealer can assist you in
selecting and properly installing accessories.
Modification
Modification of your scooter or removal of original
equipment may render the vehicle unsafe or illegal. Do not
install any part or component where the principle effect is to
bypass, defeat, or render inoperative any device or element
of design installed on or in a motor vehicle or motor vehicle
engine in compliance with regulations. Obey all applicable
equipment laws and regulations. Only use accessories that
have been approved by CSC for this scooter.
Motorcycle Noise Regulation
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal lawprohibits thefollowingacts or thecausingthereof: (1)
Theremovalorrenderinginoperativebyanypersonother
thanfor
purposesofmaintenance,repair,orreplacement of
any deviceor
element of design incorporated into any new
vehicle for the
purpose of noise control prior to its sale or
delivery to the ultimate
purchaser or while it is in use or (2) the
use of the vehicle after
suchdeviceor element of designhas
been removed or rendered
inoperative by any person.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE
TAMPERING ARE THE ACTS LISTED BELOW.
These acts include tampering with the following systems, i.e.,
modification, removal, etc.
Exhaust System - Muffler, Exhaust pipe, Silencer
Intake System-Air cleaner case, Air filter, Intake duct.
Vehicle Safety

Vehicle Safety
5
Properly Load Your Scooter
You and any passengers
should utilize the
floorboard and
footrests for
your feet. Do not exceed
the load limits of the
vehicle. Properly secure all
cargo.
Maintain Your Vehicle
Perform maintenance as required per the maintenance
schedule or as otherwise necessary to keep your scooter
in a safe operating condition. If you notice any leaks or
notice odd sensations such as vibration, immediately stop
your vehicle.
Pre-Ride Inspection
Always perform a pre-ride inspection of your scooter prior
to each ride. Review the pre-ride inspection instruction
section contained within this manual for more information.
Carbon Monoxide Gas
The exhaust gasses from this vehicle contain carbon
monoxide, a colorless, odorless, and highly toxic gas.
An enclosed area such as a garage can quickly fill up with
carbon monoxide gas. Do not run the engine in enclosed
areas that are poorly ventilated. Move the vehicle outdoors
before operation.
WARNING
Not performing a pre-ride inspection, altering your vehicle from
the stock configuration, or failure to properly maintain your
vehicle can result in serious injury or death. Check your vehicle
regularly and have any problems corrected as soon as possible.
WARNING
Carbon monoxide gas is toxic. Breathing carbon monoxide can
cause unconsciousness and even kill you. Avoid running your
engine within enclosed areas and other activities that expose
you to carbon monoxide.

Safe Riding
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Not wearing safety apparel increases the chance of serious
injury or death in a crash. Be sure you and any passengers
always wear helmets and protective gear properly.
Your scooter can provide many years of riding enjoyment.
You must take responsibility for your own safety and the
safety of others. There are many steps you can take to
protect yourself and others while riding. Here are some very
important safety precautions:
Wear a Helmet
Rider safety begins with quality head protection. A head
injury is one of the most serious injuries that can occur.
Always wear a quality DOT approved helmet that is
properly buckled. If the helmet does not have a face shield,
wear suitable eye protection.
Wear Riding Apparel
Choose quality gloves, boots, pants, jackets, and other riding
apparel specifically designed with protective features. Loose
clothing can be unsafe when riding your scooter.
Make Yourself Visible
Wear bright, reflective apparel to make yourself more
visible to fellow drivers. Position yourself on the road where
other drivers can easily see you. Use your turn signals,
hand signs, horn, and other methods to help others locate
you and understand your driving actions.
WARNING
Know Your Limits
Ride within the boundaries of your own skill at all times. Do
not ride under the influence of drugs or alcohol. Strictly
observe all traffic regulations. Always adapt your riding to
account for traffic and road conditions.
Road Conditions
Road conditions can vary greatly with weather, foreign
material, elevation etc. Your riding stability and braking power
are limited by the grip of the tires on the road surface.
When encountering slippery road surfaces, braking distance
will increase significantly, and riding stability will be reduced.
Reduce vehicle speed and perform all actions in a gradual
and deliberate manner to prevent accidents.
Use extreme caution on painted surfaces or metal objects
such as manhole covers or train rails when they are wet.

Identification Numbers
7
VehicleIdentification Number ( VIN ) is located on the VIN plate ( 1 ) or inside the inner front cover ( 2 ).
Record your Vehicle Identification Number:
The Engine Serial Number (ESN) is located on the left side of the engine immediately
above the center stand pivot.
Record your Engine Serial Number: _________________________________________

Vehicle Layout
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CAUTION
Ignition Switch Operation
Insert the key and select ON ( 1 ), OFF ( 2 ), LOCK ( 3 ),
or ( 4 ) ANTI-THEFT IGNITION COVER.
1. Turn key to ON position ( 1 ) to operate the vehicle. In
this position, the key cannot be removed. The vehicle
will have power and the engine can be started.
2. Turn key to OFF position ( 2 ) to cease vehicle
operation. In this position, all vehicle power will be off,
the engine will not run, and the key can be removed
from the ignition switch.
3. Turn handlebars fully to the left steering-stop. With
the key in the OFF position ( 2 ), press key inward
toward front of the scooter and turn key left to LOCK
position ( 3 ) to lock the handlebars as a theft
deterrent. The fork is now locked and cannot be
turned. The key can be removed from the ignition
switch in the LOCK position. Insert and rotate the key
clockwise from the LOCK position to the OFF or ON
position to unlock the steering.
Turn handlebars gently to confirm steering is locked
after following locking procedure. Lock your vehicle
whenever you leave it unattended.

Vehicle Layout
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Dashboard
1. Directional Indicator
Illuminates green when turn signal button is pressed
to the left or right and signal is on.
2. High Beam Indicator
Illuminates blue when high beam switch is selected.
3. Check Engine Indicator
Illuminates orange if there is an engine problem.
4. Fuel Level Indicator
Current fuel level indicated by F – Full to E - Empty.
5. Odometer
Distance traveled during the life of the vehicle
measured in miles.
6. Speedometer
Current vehicle speed in miles per hour (mph) or
kilometers per hour (km/h).

Vehicle Layout
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CAUTION
Handlebar Controls
1. Headlight Switch Left Handlebar Controls Right Handlebar Controls
Press up for HIGH Beam.
Press down for LOW Beam.
2. Turn Signal Switch
Press switch left to signal a LEFT turn.
Press switch right to signal a RIGHT turn.
Press center button to turn indicator OFF.
3. Horn
Press in to sound the HORN.
4. Emergency Stop Switch
Press switch right to select RUN position to operate vehicle.
In an emergency, press switch left to STOP to stop the engine.
5. Engine Start Button
Press button in with the ignition key in ON position and at
least one brake lever engaged in to START the engine.
Do not press and hold start button for more than 5 seconds
at a time as this can damage the start system. Follow
starting procedure found on page 26.

Vehicle Layout
11
The brake lever should not touch the handlebar. If the brake
lever feels soft or touches the handlebar, have your brake
system inspected and adjusted or repaired immediately.
Front & Rear Brake Controls
Extend your fingers over the brake lever.
Pull lever toward the grip to actuate brake.
The brake lever will slow the vehicle with firm pressure.
REAR BRAKE LEVER FRONT BRAKE LEVER
11
WARNING

Vehicle Layout
12
Kick Start
The kick-start lever can be used to start your engine as
an alternative to the electric-start option.
Pull the kick-start foot peg (1) outward, away from the
engine cover.
While facing forward and holding both handlebar grips,
press down quickly with your foot to start the engine (2).
Seat Lock
To access the under-seat storage area, insert key into
the lock on the left-hand side of the rear body panel
and press the key inward while simultaneously turning
the key clockwise. The seat will release from its latch.
Raise the seat forward toward the handlebar to expose
the storage area.
Return the seat to rest on the latch and press down
firmly on the rear portion of the seat to securely close it.

Vehicle Layout
13
Primary Storage
The primary storage compartment is located under the
seat.
The maximum storage load capacity is 20 lbs.
The storage compartment can become very hot when
the ambient temperature is high, and the engine has
been operating for a long period. Do not place
perishable or temperature-sensitive items in the primary
storage compartment.
The storage compartment is not waterproof. When it
rains or after washing your vehicle, the storage
compartment may get wet with moisture. Do not store
water-sensitive items in the storage compartment.

Vehicle Layout
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Fuel Fill
The fuel tank fill location is in the rear tail section.
Insert key into gas cap at tail section, and turn key
counterclockwise while pushing down. Lift up to
remove gas cap with key. To lock gas cap, turn key
counterclockwise and line up arrow on gas cap with
arrow on body panel while pushing down. Remove
key.
Turn the fuel cap counterclockwise to open.
Fill with unleaded fuel 90 octane or higher.
Take special care not to overfill fuel tank.

Pre-Ride Inspection
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Perform a pre-ride inspection prior to every ride. This isa checklist. Detailed procedures are in the pages that follow.
ITEM PROCEDURE
FRONT / REAR BRAKE
Check the brake function, clearance, brake-fluid level, inspect for fluid leaks, if necessary, add
DOT 4 or higher brake fluid. Check brake lever free-play and adjust if necessary. Check brake
pad wear. If the brake pads are worn down past the wear marks, replace pads immediately.
THROTTLE
Check to make sure the throttle actuates freely through the range. Lubricate throttle cable if
necessary. Check throttle free-play. Adjust throttle cable tension if necessary.
LUBRICANTS
Check the engine oil level before each ride. If the engine oil level is low, refill with
JASO MB 15W-40 engine oil
TIRES
Check tire pressure in both the front and rear tire, add air if necessary. Inspect tires.
CABLES
Check operation of all cables. Lubricate cables and adjust tension as necessary.
CENTER / SIDE STAND Check center and side stands for operation, lubrication, and secure mounting.
ASSEMBLY
Check all vehicle assembly to ensure fasteners are secure and assemblies function properly.
FUEL SYSTEM Check fuel level. Fill if necessary. Ensure no fuel leaks are present.
LIGHTING
Check the function of all lights. Clean lenses as necessary.
SWITCHES
Check the function of all switches.
LOADING
Ensure your vehicle is not overloaded, is loaded in a balanced manner, and cargo is secured.

Pre-Ride Inspection
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Perform a pre-ride inspection prior to every ride.
Front Brake
The front brake is a hydraulic disk type. Inspect the brake
system prior to each ride.
Properly functioning brake systems are vitally important to
your personal safety.
Check for fluid leaks, fluid level, brake pad wear, and rotor
condition. Also check lever free-play frequently.
Pull the brake lever lightly until you feel tension, then check
the lever free-play.
10 – 20mm
Front Brake lever free-play: 10 - 20mm
If the brake lever has no free-play or is too loose, there is a
potential brake system fault. Inspect brake system
thoroughly.
Front Brake Fluid
Check all joints along the brake hose for any fluid leaking
from the joint or the brake cylinder. Leakage has occurred
if you see wet or oxidized fluid sludge.
Check brake fluid level
sight glass at base of
lever to determine brake
fluid level. Fluid should
be above the bottom half
of the sight glass.
Add brake fluid if
necessary.
Brake Fluid specification: DOT4
WARNING
WARNING

Pre-Ride Inspection
17
Perform a pre-ride inspection prior to every ride.
Front Brake Disc and Pads
Inspect the brake disc for wear, glazing and/or warping.
Inspect the brake pads to ensure the pad thickness is not
beyond the wear limit:
Wear Limit: 2mm
If the brake pad wears
entirely before
replacement,
damage to the disc and
loss of braking ability
can occur.
Rear Brake
The rear brake is a cable-actuated drum brakesystem.
Inspect the brake system prior to each ride.
Properly functioning brake systems are vitally important to
your personal safety.
Checkrearbrakecableconditionandbrakewear.
Check lever
free-play and adjust as necessary.
Pull the brake lever lightly until you feel tension, then check
the lever free-play.
10 – 20mm
Rear Brake Lever Free-Play: 10 - 20mm
If the brake lever has no free-play or is too loose, there is a
potential brake system fault. Inspect brake system.

Pre-Ride Inspection
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If lever free-play is too large or too little, adjust free-play by
turning the adjustment nut on the cable near the rear wheel.
Check cable and pivotfor lubricant. Lubricateregularly to
ensure cable moves easily, without binding.
Rear Brake Drum and Shoes
Rear Brake Wear
Thereis a wearindicator installed on the brake actuator shaft.
When the opening on the indicator lines up with the triangle on
theengine case,your brakeshoes haveworn beyondthe usable
rangeandshouldbereplaced.
Failure to replace the brake shoes can result in damage to the
hub and a loss of braking ability.

Pre-Ride Inspection
19
Perform a pre-ride inspection prior to every ride.
Throttle
Check the throttle cable for ease of movement by turning
the twist grip from fully close to fully open.
Move the handlebar from left to right to ensure throttle is
not applied when bars turn.
Measure throttle free-play by opening the grip slightly until
resistance can be felt.
Throttle free-play: 1.5 - 3.5 mm
Adjust throttle as necessary to ensure proper free-
play. Lubricate throttle cable tube and cable ends to
ensure ease of operation.
Throttle Adjustment
Slide the protective rubber cover ( 1 ) to expose the throttle
adjustment screw.
Loosen the lock nut ( 2 )
on the throttle cable.
Turn the adjustment
screw ( 3 ) until the
throttle free-play is
within the proper range
of movement.
Measure throttle free-
play again by opening
the grip slightly until resistance can be felt.
Throttle free-play: 1.5 - 3.5 mm
Once throttle free-play has been adjusted within the proper
range, tighten lock nut ( 2 ).
Return the protective cover ( 1 ) to cover the throttle
adjustment screw.
1
2
3
WARNING