Genuine Scooter Company Buddy 170 User manual

PREFACE
This manual offers all service specialists with the technological procedures of
maintenance, repairing for Buddy170 detailedly show those whom may concern
how to maintain, repair, change parts,troubleshoot and reassemble, etc.
At every important section we illustrate by assembly, explosiondiagrams and
photographs, if necessary, please check the diagrams already shown.
Though we have tried our best, please kindly instruct us any faults found in this
manual.
MOTIVE POWER INDUSTRY CO., LTD.

CONTENTS
1. The specification 1
2. Serviceinformation 2
(1)The operation notice 3
(2)Looking torque value 4
(3)Lubrication instruction
(4)Periodical maintenance table 9
(5)Wiringdiagram 11
(6)Troubleshooting 12
3. Checkingandadjustment 25
(1)Checkingtable 26
(2)Battery 30
(3)Clean the air cleaner 31
(4)Oilscreen 32
(5)The final reduction mechanism oil 32
(6)Sparkplug 33
(7)Compression pressure measurement 33
(8)Valve clearance 34
(9)Ignitiontiming 34
(10)Front brake adjustment 35
(11)Rear brake adjustment 36
(12)Tire 36
(13)Throttlecablesadjustment 37
4. Dismantling, maintaining, repairing and assembling operation 38
(1)Lubricationsystem 39
(2)Plasticpartsofchassis 43
(3)Engine dismantling 48
(4)Drive pulley, starter, clutch,driven pulley 50
(5)Cylinderheadandvalve 59
(6)Cylinder and piston 64
(7)ACgeneratorflywheel 69
(8)Final transmission mechanism 72
(9)Crankcase, crank shaft 76
(10)Steering stem, front wheel, front brake comp., front fork 82
(11)Rear wheel, rear brake, rear damper 91
5. Engine Management System(PGO 2nd-stage EMS) 96
(1)PGO 2nd-stage EMS structure 97
(2)EMSunits 98
(3)EMS diagnostic 99
6. Electricequipment 122
(1)Troubleshooting 123

(2)Battery 124
(3)Rechargesystem 126
(4)Startingsystem 128
(5)Startingclutch 130
(6)Handlebarswitch 132

1. Specification yChassis steel pipe
ySuspension
yName PA-170DAAE front: telescopic
yModel PA-170 rear: 4-bar linkage,
yDimension uni-absorber
Overall length: 1710mm yTransmission
Overallwidth: 645mm primary reduction :direct drive
Overall height: 1090mm second reduction:40/16*43/13
Overall base: 1210mm clutch type: centrifugal dry type
yWeight selector : V belt ,C.V.T.
Totalnetweight: 107kg yWheel
front: 40kg front: 100/90-10
rear: 67kg rear: 100/90-10
Carryingcapacity: yTire
2 passengers:150kg
Total weight:257kg front 1.50 kg/cm2
Front: 81kg rear 1.75 kg/cm2
Rear: 176kg yBrake
yPerformance front: 190mm hydraulic
Fuelconsumption:40km/L diskbrake
rear: drumbrake
yGradient ability:26∘ySpeedometer 90mile
yEngine yLamp
Model:C9 front: 12V-35W/35W*1
Fuel: unleaded or leaded
Cooling system: forced air cooling
byfan licenseplate: 12V-5W*1
brakelamp: 12V-21W/5W*1
Cylinder signallamp: 12V-10W*4
bore: 61.0mm yHorn AC12V
stroke: 57.8mm ySilencer: diffusible absorption
number 1 closedtype
Arrangement: horizontal
Displacement: 168.9cc Trail: 71mm
Compression ration 10.5:1 Front wheel travel: 55.5 mm
Ignition: ECU Rear wheel travel: 61 mm
Start: electric start
Lubrication: pressuring and spraying
1

2. Service information:
(1) The notice for operation3
(2) Locking torque value
a. For engine
b. For chassis
c. Others
(3) Lubrication instruction6
a. For engine
b. For chassis
c. Wheel bearing
(4) Periodical maintenance table
(5) Wiring diagram
(6) Troubleshooting
1. Engine not running or slowly running during start-up
2. Engine running but start-up failing during start-up
3. Trouble of hot start
4. Trouble of cold start
5. Trouble of start-up anytime despite RPM normal
6. Start-up normal but idle speed unstable anytime
7. Start-up normal but idle speed unstable during warm-up
8. Start-up normal but idle speed unstable with warm-up finished
9. Start-up normal but idle speed unstable or stall with load such as front lamp applied
10. Start-up normal but idle speed too high
11. RPM low or stall during acceleration
12. Acceleration slow
13. Acceleration powerless; performance bad
2

(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 is correct or not.
7.After reassembling, please re-check that all connecting point, locking parts,
circuits, polar characteristics are good, before selling out.
3

(2) Torque value:
a. Engine:
NO Locking location Q’TY Thread dia.
(mm) Locking torque (kg-m) Remark
1 Cylinder head bolt A (intake) 2 6 0.9~1.1
2 Cylinder head bolt B (Exhaust) 2 8 2.2
3 Cap, oil filter graze 1 30 1.5~2.0
4 Flange nut, cam shaft base 4 8 2.2
5 Fixing nut, air valve adjustment 2 5 0.7 Greasing on thread
6 Guiding pin bolt, inner chain adjustment 1 6 0.9~1.1
7 Oil bolt 1 8 1.7~2.0
8 Fixing nut, clutch outer 1 12 5.0~6.0
9 Nut, driven plate 1 12 5.0~6.0
10 Nut, driving plate 1 12 5.0~6.0
11 Spark plug 1 10 1.2~1.3
12 Nut, drive clutch 1 22 9.0~10.0 Left thread
13 Screw, inner chain adjuster 1 6 0.4~0.6
b. Chassis:
NO Locking location Q’TY Thread dia.
(mm) Locking torque (kg-m) Remark
1 Locking nut, steering stem 1 10 4.5
2 Front axle nut 1 12 4.5 ~ 5.5 U type nut
3 Rear axle nut 1 16 11~ 13 U type nut
4 Rear shock absorber bolt(upper) 1 10 4.0
5 Rear shock absorber bolt(lower) 1 8 2.4 ~ 3.0
6 Front brake caliper bolt 2 8 2.0 ~ 3.0
7 Chassis bolt, engine hanger bracket 2 10 3.5 ~ 4.5
8 Engine bolt, engine hanger bracket 1 10 3.0 ~ 4.0
9 Brake hose bolt 2 10 3.0 ~ 3.5
10 Air release valve 1 6 0.6
11 Front drum brake arm bolt 1 6 1.0
12 Rear drum brake arm bolt 1 6 1.0
4

c. Other parts please refer the following table:
Standard torque values:
NO Item Torque (kgf-m)
1 5mm bolt and nut 0.45-0.6
2 6mm bolt and nut 0.8-1.2
3 8mm bolt and nut 1.8-2.5
4 10mm bolt and nut 3.4-4.0
5 12mm bolt and nut 5.0-6.0
6 5mm screw 0.35-0.5
7 6mm screw 0.7-1.1
8 6mm flange bolt and screw 1.0-1.4
9 7mm flange bolt and screw 1.0-1.4
10 8mm flange bolt and screw 2.0-3.0
11 10mm flange bolt and screw 3.0-4.0
5

(3)Lubrication instruction:
A. Engine
NO Lubrication location Oil type Remarks
1 crankcase:rotating part,
sliding part premium 4 stroke
Auto-separated
Lubrication
2 cylinder:rotating part,
sliding part.
motorcycle oil
or SAE15W40
Total: 1000 c.c.
Replacement 800c.c
3 drive gear box SAE85-140 Total 110 c.c.
Replacement 90c.c
4 gasket of starter shaft clean grease (#3)
5 start idle gear sliding
parts
clean grease (#3)
6

B. Chassis
Steel ball, steering item
Front brake fluid
Front brake cam
7

C. Wheel bearing
Final transmission mechanism
gear oil
Motor oil
Speedometer gear-clean grease
Front wheel bearing-clean grease
8

(4) PERIODICAL MAINTENANCE TABLE
MONTHS/DISTANCE(IN MILE)FOR CHECKING
Item
Model
4T
Checking Content 1 or
200 mile
3 or
1800
mile
6 or
3600
mile
9 or
5400
mile
12 or
7200
mile
15 or
9000
mile
18 or
10800
mile
Engine oil* 4T
Replace 800cc total 1000cc
R Replace it initially 200 mile,
and then replace it per 1800mile
Oil Filter Replace R replace it per 3600mile
Coarse oil filter*
(on oil draining
bolt)
4T Clean or replace it if necessary C clean it initially 200mile
and then replace it per 3600mile if necessary
Air cleaner 4T Crack and blockage check. I
Air filter 4T Clean or replace it if required I I I I I I
Gear oil* 4T 90cc, total 110 cc R R I I R I I
Disk & drum
brake 4T Leaking and function check I I I R I I
Clutch shoes* 4T Check or replace it if necessary I I I I I
Tires 4T Worn-out check or replace it if
necessary I I I I
Wheel bearing* 4T Fasten tightly if loosen I I I I I I
Front fork* 4T Leaking and function check I I I I I I
Steering head
bearing* 4T Check looseness. Adjust it if required I I I
Rear absorber* 4T Leaking and function check A A A
Main/Side Stand 4T Function check or replace it if
required I I I I
N
uts, bolts,
fasteners 4T Tighten it if required I L I L I L
Battery 4T Recharge the battery it required.
Clear the poles. I I I I I I
Valve gap* 4T 0.08mm/ IN&EX Adjust it
when
necessary
C I C I C
Spark plug* 4T Clear or replace if required I A A A
V belt* 4T Worn out check or replace if
necessary.
R I R I R
Fuel feeding
system* EXCEPT
EMS Crack and blockage check. Replace it if necessary.
Fuel feeding
system * EMS ONLY
(Injection)
Inspect hose, clamp I R I
Engine idle
speed* 4T 4T engine: 1700±100 rpm A A
I I R
Carburetor idle
A/F
Adjustment*
4T Check and adjust referring to
CO/HC Percentage. A A A A A A A
EMS function
check* EMS ONLY
(Injection)
Inspect EMS function, and clear
the defect memory if necessary I
A A A A A
REMARKS：
1. A: adjust C: clean I: inspect, or replace if necessary L: lubricate R: replace
2. Items with “*” mark indicate our recommendation to have it done by Genuine dealer.
NOTE 1：
For 4T engine, the engine oil shall be changed completely after run-in period 300km or one month later.
This can make sure the engine runs smoothly.
9

NOTE 2：
The exchange of brake fluid
1. After disassembling of brake main cylinder or caliper, do change the new fluid.
2. Check the fluid level often, Refill if necessary.
3. Change the oil seal of main cylinder and caliper every two years.
4. Change the brake fluid hose every four years.
10

(5) Wiring diagram.
11

(6) Trouble shooting:
Procedure to maintain the Electronic Management System (EMS)
 Systematic procedure to diagnose any troubles for reparation
Items to be checked first prior to any diagnoses for engine troubles:
1. Make sure of the engine trouble indicator normally running;
2. Check with a trouble diagnosis meter to ensure no trouble information recorded;
3. Check any trouble phenomenon hinted by the vehicle owner and trouble-related conditions.
External check:
(1) Check any leakage from a fuel hose.
(2) Check any leakage from a vacuum pipe.
(3) Check any jam, leakage, flattening, or damage at an air inlet.
(4) Check the ignition system for break or aging of any high-voltage cable and ignition status.
(5) Check grounding of any wire harness clean and securely fixed.
(6) Check any sensor or actuator’s connector loosened or poorly contacted.
Note: Repair any trouble specified herein first which may affect the subsequent diagnoses or reparation.
 Diagnosis assist:
1. Make sure of no engine-related trouble records;
2. Make sure of any offered troubles;
3. Follow the said procedure to complete inspections and find no any unconformable situation;
4. Do not ignore any effect from maintenance, cylinder pressure, mechanical timing, or fuel on the
system;
5. Replace ECU for tests.
In the event of any trouble eliminated, ECU should be the source of trouble; if not, install the original
ECU and repeat the procedure to recheck.
 Trouble:
 Engine not running or slowly running during start-up
 Engine running but start-up failing during start-up
 Trouble of hot start
 Trouble of cold start
 Trouble of start-up anytime despite RPM normal
 Start-up normal but idle speed unstable anytime
 Start-up normal but idle speed unstable during warm-up
 Start-up normal but idle speed unstable with warm-up finished
 Start-up normal but idle speed unstable or stall with load such as front lamp applied
 Start-up normal but idle speed too high
 RPM low or stall during acceleration
 Acceleration slow
 Acceleration powerless; performance bad
12

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:
No. Operating Procedure Detection
Results Subsequent Steps
Yes Next step
1 Check the voltage between two battery terminals with a
multi-meter to ensure the voltage between 11 and 12V
during start-up of the engine. No Replace the battery.
Yes Next step
2 Keep the power switch “ON” and check the voltage at the
positive terminal on the start motor over 8V. No Fix or replace wiring
harness.
Yes Fix or replace the start
motor.
3 Remove the start motor and check its status for open
circuits or jam attributed to lubrication insufficient. No Next step
Yes Change applicable
lubricant.
4 For any trouble in winter only, check lubricant in the engine
wrong for big resistance of the start motor. No Next step
Yes Correct resistance inside
the engine.
5 Check mechanical resistance inside the engine causing the
motor not running or slowly running. No Repeat the said step.
2. Engine running but start-up failing during start-up
General trouble location: 1. Oil tank empty; 2. Fuel pump; 3. RPM sensor; 4. Ignition coils; 5. Engine
mechanism.
Procedure for general diagnoses:
No. Operating Procedure Detection
Results Subsequent Steps
Yes Next step
1 Connect a fuel pressure gauge before the fuel inlet of the
nozzle; press the power switch repeatedly if necessary or start
the engine to check the fuel pressure at 300kPa or so. No Repair the fuel supply
system.
Yes Next step
2 Connect the EMS diagnosis tester and check “Engine RPM”;
start the engine to check any RPM signal output. No Correct circuits of the
RMP sensor.
Yes Next step
3 Disconnect the ignition cable and connect a spark tester; start
the engine and check any high-voltage flash (blue/white). No Repair the ignition
system.
Yes Eliminate any
mechanical trouble of
the engine.
4 Check pressure of the engine cylinder and find any possibility
of pressure insufficient. No Next step
Yes Diagnosis assist
5 Connect an EMS adapter and press the power switch to check
voltages at Pins 5#, 10#, and 23#; check grounding at Pins 2#
and 21#. No Repair the relevant
circuits.
13

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:
No. Operating Procedure Detection
Results Subsequent Steps
Yes Next step
1 Connect a fuel pressure gauge before the fuel inlet of the nozzle;
start the engine to check the fuel pressure at 300kPa or so. No Repair the fuel
supply system.
Yes Next step
2 Disconnect the ignition cable and connect a spark tester; start the
engine and check any high-voltage flash (blue/white). No Repair the
ignition system.
Yes Correct circuits
or replace the
sensor.
No Next step
3
Press the engine temperature sensor connector and start the
engine; check if the engine successfully started. (Or install a
series-connected resistor (300Ω) in lieu of the engine
temperature sensor at the engine temperature sensor
connector. Check if the engine is successfully started.) No Next step
Yes Replace fuel.
4 Check fuel and observe any trouble attributed to fuel just added. No Next step
Yes Diagnosis assist
5 Connect an EMS adapter and press the power switch to check
voltages at Pins 1#, 19#, and 29#; check grounding at Pins 8# ﹐
35#and 36#. No Repair the
relevant circuits.
14

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:
No. Operating Procedure Detection
Results Subsequent Steps
Yes Next step
1 Connect a fuel pressure gauge before the fuel inlet of the
nozzle; start the engine to check the fuel pressure at 300kPa
or so. No Repair the fuel system.
Yes Next step
2 Disconnect the ignition cable and connect a spark tester;
start the engine and check any high-voltage flash
(blue/white). No Repair the ignition system.
Yes Correct circuits or replace
any sensor.
3
Press the engine temperature sensor connector and start the
engine; check if the engine successfully started. (Or install
a series-connected resistor (2500Ω) in lieu of the engine
temperature sensor at the engine temperature sensor
connector. Observe if the engine is successfully started.) No Next step
Yes Clean the air throttle and
the idle air bypass.
4 Slightly pull the throttle to check if the engine is easily
started. No Next step
Yes Replace the defective
nozzle.
5 Disassemble the nozzle and check any leakage or jam in
the nozzle with a nozzle cleaner & analyzer. No Next step
Yes Change fuel.
6 Check fuel and observe any trouble attributed to fuel just
added. No Next step
Yes Eliminate any mechanical
trouble of the engine.
7 Check pressure of the engine cylinder and find any
possibility of pressure insufficient. No Next step
Yes Diagnosis assist
8 Connect an EMS adapter and press the power switch to
check voltages at Pins 1#, 19#, and 29#; check grounding
at Pins 8# ﹐35#and 36#. No Repair the relevant circuits.
15

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.
Procedure for general diagnoses:
No. Operating Procedure
Detection
Results Subsequent Steps
Yes Repair the air intake
system.
1 Check any jam of the air filter and leakage of the air intake.
No Next step
Yes Next step
2 Connect a fuel pressure gauge before the fuel inlet of the
nozzle; start the engine to check the fuel pressure at 300kPa or
so. No Repair the fuel supply
system.
Yes Next step
3 Disconnect the ignition cable and connect a spark tester; start
the engine and check any high-voltage flash (blue/white). No Repair the ignition
system.
Yes Next step
4 Check the spark plug in the cylinder and its model and gap
conformable to specifications. No Adjust or change the
spark plug.
Yes Correct circuits or
replace the sensor.
5 Press the engine temperature sensor connector and start the
engine; check if the engine is successfully started. No Next step
Yes Clean the air throttle
and the air intake for
idle speed.
6 Slightly pull the throttle to check if the engine is easily started.
No Next step
Yes Change the defective
nozzle.
7 Disassemble the nozzle and check any leakage or jam in the
nozzle with a nozzle cleaner & analyzer. No Next step
Yes Change fuel.
8 Check fuel and observe any trouble attributed to fuel just
added. No Next step
Yes Eliminate any
mechanical trouble of
the engine.
9 Check pressure of the engine cylinder and find any possibility
of pressure insufficient. No Next step
Yes Next step
10 Check if mechanical ignition timing of the engine is
conformable to specifications. No Correct ignition
timing.
Yes Diagnosis assist
11 Connect an EMS adapter and press the power switch to check
voltages at Pins 1#, 19#, and 29#; check grounding at Pins
8# ﹐35#and 36#. No Repair the relevant
circuits.
16