GENUINE Blur 150 User manual

Blur 150 & 220i Service Manual

PERIODICAL MAINTENANCE TABLE
In order to achieve safe riding, good performance and reduce pollution, please execute the recommended
maintenance accordingly. MONTHS/DISTANCE(IN KM)FOR CHECKING
Item
Model
4T
Checking Content 1 or
190
mile
3 or
1865
mile
6 or
3730
mile
9 or
5595
mile
12 or
7460k
mile
15 or
9320k
mile
18 or
11185
mile
Engine oil* 4T BLUR-150:800cc, total 1000cc
BLUR-220: 1,000CC, total1,200cc
R Replace it initially 300km,
and then replace it per 3000 km
Oil Filter BLUR -150
BLUR -220
Replace R replace it per 6000km
Coarse oil filter*
(on
oil draining bolt) 4T Clean or replace it if necessary C clean it initially 300km, and then replace it per 6000 km if necessary
Air cleaner 4T Crack and blockage check. I I I I I I
Air filter 4T Clean or replace it if required I I I R I I
Gear oil* 4T BLUR -150: 90cc, total 110 cc
BLUR -220: 90cc, total 110 cc R R R R
Disk & drum brake 4T Leaking and function check I I I I I I
Clutch shoes* 4T Check or replace it if necessary I R I
Tires 4T Worn-out check or replace it if
necessary I I 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
4T 1 or
190
mile
3 or
1865
mile
6 or
3730
mile
9 or
5595
mile
12 or
7460k
mile
15 or
9320k
mile
18 or
11185
mile
Steering head bearing* 4T Check looseness. Adjust it if
required A A A
Rear absorber* 4T Leaking and function check I I I
Main/Side Stand 4T Function check or replace it if
required I L I L I L
Nuts, bolts, fasteners 4T Tighten it if required I I I I I I
Battery 4T Recharge the battery it required.
Clear the poles. I C I C I C
Valve gap* 4T BLUR -150: 0.08mm/ IN&EX
BLUR 220: 0.08mm/ IN&EX Adjust it when necessary
Spark plug* 4T Clear or replace if required I R I R I R
V belt* 4T Worn out check or replace if
necessary. A A A
Fuel feeding system* EXCEPT
EMS Crack and blockage check. Replace it if necessary. I R I
Fuel feeding system * EMS ONLY
(Injection)
Inspect hose, clamp, and replace
the filter per 15,000km I I R
Engine idle speed* 4T 4T engine: 1700±100 rpm A A A A A A A
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 I I I I I
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.
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.
Exhaust control system (only be valid for the bike equipped catalyst):
Catalyster will not be possible to be withdrawn individual, the only you have to do is to maintain fuel,
ignition, intake/exhaust system periodically.
1. Maintenance procedure of air clearer (see page 33).
2. Spark plug’s checking: please repair or replace if spark plug is dirty.
3. Fuel system’s checking: please repair or replace if fuel pipe is jammed or broken.
4. Muffler’s checking: please fix tightly once or renew a gasket if it is leaking.
5. Idle rpm’s checking: please fix tightly once or renew a gasket if throttle cable.
6. Exhaust density checking while idle: please left the job to any service center of anti-pollution inspection
for carburetor adjusting.

PREFACE
This manual provides every service specialist with professional
techniques of maintenance and repairing for BLUR . It provides a detailed
guide for those who may concern with how to maintain, repair, reassemble, and
change parts of their scooters.
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.
At every section, we illustrate each important point by assembling
procedures, explosive diagrams and photographs.
Although we have tried our best to make this manual as perfect as
possible, please kindly inform us if any fault needs to be corrected
in this manual.
Thank you for purchasing our Genuine scooters.
FACTORY
Motive Power Industry Co.,Ltd.

CONTENTS：
Ⅰ
ⅠⅠ
Ⅰ.
..
.The specification of BLUR (ALLORO)
Ⅱ
ⅡⅡ
Ⅱ.Service information
(1)The operation notice
(2)Locking torque value
(3)Lubrication instruction
(4)Periodical maintenance table
(5)Troubleshooting
Ⅲ
ⅢⅢ
Ⅲ.Checking and adjustment
(1)Regular checking table
(2)Battery
(3)Cleaning 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
(11)Rear brake adjustment
(12)Tire
Ⅳ
ⅣⅣ
Ⅳ.Dismantling, maintaining, repairing and assembling operation
(A). Plastic parts
(B). BLUR 150 Engine dismantling
(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
(9) Crankcase, crank shaft
(10) Carburetor
(C)Steering column, front wheel, front brake comp, front fork
(D)Rear wheel, rear brake, rear damper

(E)Fuel supply`
Ⅴ
ⅤⅤ
Ⅴ.Electric equipment
(1)Troubleshooting
(2)Battery
(3)Recharge system
(4)Ignition system
(5)Starting system
(6)Switch operation
(7)Wiring diagram
Ⅴ
ⅤⅤ
ⅤI
II
I. BLUR-220 characteristics , dismantle & inspection
(1) Engine dismantling
(2) engine inspection
(3) Electric system
(4) Maintenance
(5)Engine Management System(EMS)
(6)EMS diagnostic
(7)EMS system Repairing tool
(8)EMS General Electric units

1.1 BLUR 150
SPECIFICATION
BRAND Genuine FRAME STEEL PIPE
MODEL BLUR-150 FRONT TELESCOPE
LENGTH 1885 mm
SUSP
ENSI
ON
REAR SWING
WIDTH 730 mm PRIMARY DIRECT
HEIGHT 1170 mm 2ND 42/15*42/13
DIMENSION
AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL
FRONT 55 KG
TRANSMISSI
SHIFTING V-BELT C.V.T
REAR 77 KG FRONT 120/60-13
GROSS
TOTAL 132 KG
TIRE
REAR 130/60-13
PASSENGER 2 (110KG) FRONT DISK
FRONT 95 KG
BRA
KE
REAR DISK
REAR 147 KG SPEEDOMETER 140 km/hr
WEIGHT
TOTAL
TOTAL 242 KG HEAD(HI、LO) 12V-35W/35W
TOP SPEED 87 km/hr REAR 12V-5W
FUEL
CONSUMPTION
40 km/l BRAKE 12V-21W
PERFORMAN
GRADIENT 24°
LIGGHT
SIGNAL 12V-10W*4
ENGINE MODEL
C5M HORN DC 12V
FUEL 92 UNLEADED SILENCER DIFFUSER
STROKE 4TAIR FORCED PARTICLE BELOW 15 %
BORE φ57.5 mm CO BELOW 4.5%
STROKE 58.6 mm
EXHAUS
HC BELOW 7000 ppm
CYLINDE
CYLINDER SINGLE EXHAUST LAYOUT RIGHT
DISPLACEMENT 152.1 cc LUBRICATE SEPARATE PUMP
C.R. 9.4：1 & SPLASH
MAX H..P. 7.7kw/7250rpm FUEL TANK 7.5 L
MAX TORQUE 10.6N-M/6250rpm
LAYOUR HORIZONAL
IGNITION CDI
ENGINE
STARTING ELECTRIC & KICK

1.2 BLUR220
SCOOTER SPECIFICATION
BRAND Genuine FRAME STEEL TUBE
MODEL BLUR
BLURBLUR
BLUR-
--
-SS
SSSS
SS22
2222
220
00
0I
II
I FRONT TELESCOPE
LENGTH 1885 mm SUSPENSION REAR UNI-ABSORBER
WIDTH 730 mm 1ST REDUCTION 0.81~2.43
HEIGHT 1170 mm 2ND REDUCTION 8.077
SCALE
WHEEL BASE 1365 mm CLUTCH CENTRIFUGAL
FRONT 57 KG
TRANSMISSIO
GEARBOX C.V.T.
REAR 87 KG FRONT 120/60-13
MASS OF VEHICLE
TOTAL 144 KG TYRE REAR 130/60-13
RIDER 2 (150KG) FRONT DISK
FRONT 115 KG
BRAKE
REAR DISK
REAR 179 KG SPEEDOMETER 199 km/hr
MASS
TOTAL
MASS
TOTAL 294 KG HEAD LAMP 12V-60W/55W
TOP SPEED 110 km/hr TAIL LAMP 12V-5W
FUEL CONSUMPTION 33 km/l BREAKING LAMP 12V-21W
PERFORMA
NCE
HILL CLIMB 30°↑
LIGHT
TURNING LIGHT 12V-16W*4
TYPE C8E5 HORN DC 12V
FUEL 92 UNLEADED MUFFLER C-D ABSORPTION
CYCLE/COOLING 4T/FORCE AIR&OIL COOL PARTICLE BELOW 15 %
BORE φ67.5 mm CO BELOW 3.0%
STROKE 61.5 mm
IDLE
EMISSION
HC BELOW 1600 ppm
CYLINDER
NUMBER SINGLE EXHAUST DIRECTION
RIGHT HAND SIDE&
BACKWARD
DISPLACEMENT 220 cc LUBRICATION COMPRESS &
SPLASH
COMPRESSION RATIO 10.0：1 E. E. C. NO
MAX POWER 11.0kw/7000rpm P. C. V. YES
MAX TORQUE 16.5N-M/5500rpm CATALYST YES
ARRANGEMENT HORIZONTAL S. A. I. YES
IGNITION TRANSISTOR
ENGINE
STARTER ELECTRIC
RREMARK 1. FUEL SUPPLY：INJECTION

Ⅱ.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 & driven pulley
6.Handlebar steering was astray when running
7.Front and rear damper not balanced
8.Brake disorder
9.Oil indicator malfunction
10. Fuel indicator malfunction
11. Starting motor malfunction
12.No sparking
13.Charging abnormal

(1)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.
4.After dismantling, please clean all parts involved or used for checking and
grease all contact surfaces when reassembling.
5.Use grease recommended by PGO.
6.When removing the battery, please disconnect the negative pole(-) first.
However, please connect the positive pole(+) first when assembling.
7.Before installing a new fuse, please be sure that the specification is correct.
8.After reassembling, please re-confirm that all connecting point, locking parts,
circuits, polar characteristics are functioning well before selling out.

NO Locking location Q’ty
Thread dia.
(mm) Locking torque (kg-m)
1 Fixing nut (Tappet screw nut) 2 5 0.7~0.8
2 Nut of oil pump sprocket 1 6 0.7~1.0
3 Cylinder head bolt A (intake) 2 6 0.9~1.1
4 Guiding pin bolt, chain extensioner 1 6 0.4~0.6
5 Screw, chain extensioner 2 6 0.9~1.1
6 Cylinder head bolt B (Exhaust) 2 8 2.0~2.3
7 Flange nut, cam shaft holder 4 8 2.0~2.3
8 Gear oil drain bolt 1 8 1.7~2.0
9 Spark plug 1 10 1.2~1.3
10 Nut of fly wheel 1 12 5.0~6.0
11 Fixing nut, clutch outer 1 12 5.0~6.0
12 Nut, driving plate 1 12 5.0~6.0
13 Bolt of engine oil drain 1 12 2.5~3.0
14 Bolt of 2nd oil filter 1 12 0.8
15 Nut (LH thread), one-way clutch 1 22 9.0~10.0
16 Cap, coarse oil filter 1 30 1.5~2.0
(2) Locking Torque Value:
1. 4T Engine (150/220CC)

NO Locking location Q’TY
Thread dia.
(mm) Locking torque (kg-m)
1 Air bleed bolt of caliper 1 6 0.6
2 Brake arm bolt, front drum 1 6 0.8~1.0
3 Brake arm bolt , rear drum 1 6 0.8~1.0
4 Nut of starter relay 2 6 0.5~0.6
5 Front brake caliper bolt 2 8 2.0 ~ 3.0
6 Bolt of disk 3 8 2.5~3.0
7 Locking nut, steering stem 1 10 3.5~4.5
8 Rear shock absorber bolt(lower) 1 10 3.5 ~ 4.5
9 Rear shock absorber bolt(upper) 1 10 3.5~4.5
10 Chassis bolt, engine hanger bracket 2 10 4.5 ~ 5.0
11 Engine bolt, engine hanger bracket 1 10 3.0 ~ 4.0
12 Hose bolt, master cyl. & caliper 2 10 2.5 ~ 3.0
13 Front axle nut 1 12 4.5 ~ 5.5
14 Nut, swing arm & connecting rod 1 14 4.5 ~ 5.5
14 Rear axle nut 1 16 10.0~11.0
2. Chassis
3. Other parts standard torque values:
No Item Torque
kg-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 3.0-4.0
5 12mm bolt and nut 5.0-6.0
6 5mm screw 0.35-0.5
7 6mm screw 0.7-1.4
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

(3)Lubrication instruction
A. 4T Engine (150 /220cc)
NO Lubrication location Oil type Remarks
1 Crankcase: rotating part,
Sliding part
2 Cylinder: rotating part,
Sliding part.
premium 4 stroke
motorcycle oil
or SAE15W40
Auto-Separated
Lubrication
BLUR-150
Total 900 c.c.
Replacement 800c.c
BLUR220
Total 1400 c.c.
Replacement 1000c.c
3-1 Drive gear box(BLUR-150) SAE85-140 Total 110 c.c.
Replacement 90c.c
3-2 Drive gear box(BLUR-220) SAE85-140 Total 130 c.c.
Replacement 110c.c
4 Gasket of starter shaft Clean grease (#3)
5 Start idle gear sliding
parts Clean grease (#3)

C. Chassis appearance
1. Apply oil : #1, #2
2. Apply grease (#3, #4, #5. #6 ,#7, #8)
1 2
3 4 5 6 7 8

D.Wheel bearing
錯誤
錯誤錯誤
錯誤!
Final transmission mechanism gear oil
Speedometer gear: clean grease

(4)PERIODICALMAINTENANCE TABLE MONTHS/DISTANCE(IN KM)FOR CHECKING
Item
Model
4T
Checking Content 1 or
190
mile
3 or
1865
mile
6 or
3730
mile
9 or
5595
mile
12 or
7460k
mile
15 or
9320k
mile
18 or
11185
mile
Engine oil* 4T BLUR 150:800cc, total 1000cc
BLUR 220: 1,400CC, total 1,000cc
R Replace it initially 300km,
and then replace it per 1,000 km
Oil Filter BLUE-150 Replace R replace it per 5000km
Coarse oil filter*
(on
oil draining bolt) 4T Clean or replace it if necessary C clean it initially 300km, and then replace it per 3,000 km 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 BLUR-150: 90cc, total 110 cc
BLUR-220: 110cc, total 130 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
Nuts, 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 BLUR150: 0.08mm/ IN&EX
BLUR220: 0.08mm/ IN&EX Adjust it when
necessa
ry
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, and replace
the filter per 15,000km 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.
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.

(5)Trouble shooting:
1.difficult starting or can’t start:
check there is fuel or not
pipe between ful tank and
carburetor is blocked
Float is blocked
Fuel gauge is blocked
fuel pump is malfunctioned
spark plug out of order
dirty
CDI unit out of order
A.C. generator out of order
ignition coil disconnect or
short circuit
ignition coil disconnect or
short circuit
main switch out of order
defective magneto coil
starting clutch out of order
piston ring stuck
reed valve deteriorated
cylinder, piston, piston
ring worn out
cylinder gasket leakage
cylinder body has sand hole
bad action of auto choke
air trapped in intake manifold
wrong ignition timing
bad adjustment of carburetor’s
fuel adjusting screw
carburetor fuel level too high
malfunction of auto choke
throttle valve open too largely
Check and adjust Trouble condition The reason
Loose carburetor dr
aining
Screw, check if in side of
Carburetor have fuel or not
The fuel supply in carburetors
Is enough or smooth
No fuel supply in
carburetor
Remove spark plug, insert
Spark plug cover, and touch
With engine check there is
Any spark
There is sparking
In spark plug No sparking or
Weak sparking
Measurement of
Compression pressure
Pressure is
normal
Insufficient or
No Pressure
Start engine: follow the
Instruction of starting
engine
Engine has no
knocking
Engine knocking
But can
’
t start
Remove spark plug
And check again
d
r
y
wet

2.Weak acceleration:
air cleaner blocked
fuel supply system abnormal
fuel tank cover blocked
muffler blocked
fuel pump is malfunctioned
auto chock is malfunctioned
CDI unit is out of order
alternator flywheel magneto
out of order
cylinder, piston ring worn out
cylinder gasket leakage
cylinder body has sand hole
Reed valve malfunction(2T engine)
Clean the carburetor
clean the dirt
specification is not correct
Check and Adjust
Trouble condition
The reason
Start engine and open throttle
Gradually, check and inspect
Engine can rotate up
Engine can
’
t rotate
Up completely
Check ignition timing, check
With ignition timing lam
p
Timing is correct
Timing is not correct
Check cylinder
Compression pressure
(use cylinder compression
pressure gauge)
Pressure is normal
Pressure is
Not normal
Check carburetor
Is blocked or not
No blocked
blocked
Remove spark plug and Check it
No dirty and no color change Dirty, color change