Motive Power Industry BLUR 150 User manual

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：
1.The specification of BLUR (ALLORO) ……………………………………………….. 1
2.Service information ………………………………………………. 3
(1)The operation notice ………………………………………………. 4
(2)Locking torque value .……………………………………………… 5
(3)Lubrication instruction ……………………………………………….. 7
(4)Periodical maintenance table ………………………………………………. 10
(5)Troubleshooting ………………………………………………. 12
3.Checkingandadjustment ….……………………………………………..39
(1)Regular checking table …………………………………..……………40
(2)Battery …………..……………………………………44
(3)Cleaning air cleaner ………………………………………………..45
(4)The final reduction mechanism oil ……………………………………………….46
(5)Spark plug ……………………………………………….46
(6)Compression pressure measurement ……………………………………………….47
(7)Ignition timing ……………………………………………....48
(8)Throttle cables adjustment ………………………………………………48
(9)Idle adjustment ……………………………………………….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 . ……………………………………………73
(6) Cylinder and piston ……………………………………………..78
(7) AC generator ………………………………...……………83
(8) Final transmission mechanism ……………………………………………..86
(9) Crankcase, crank shaft ……………………………………………..90
(10) Carburetor …………………………………………….94
(C)Steering column, front wheel, front brake comp, front fork ……………………………...107
(D)Rear wheel, rear brake, rear damper ……………………………………………115

(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
(6)EMS diagnostic …………………………...…………………..203
(7)EMS system Repairing tool ………………………………………………211
(8)EMS General Electric units ………………………………………………216
6.Wiringdiagram ……………………………………………….227

1、The specification of BLUR (ALLORO)
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

1.2 BLUR220
SCOOTER SPECIFICATION
BRAND Genuine FRAME STEEL TUBE
MODEL BLUR-SS220I 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
2

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 & 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
3

(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.
4

(2) Locking Torque Value:
1. 4T Engine (150/220CC)
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
5

2. Chassis
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
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
6