PGO LIGERO-50 User manual

PREFACE
This manual offers all service specialists with the technological
procedures of maintenance, repairing for LIGERO-50 detailedly show
those whom may concern how to maintain, 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 in this manual.
MOTIVE POWER INDUSTRY CO., LTD.

CONTENTS
1. The specification 4
2. Service information 5
(1)The operation notice 6
(2)Looking torque value 7
(3)Lubrication instruction 9
(4)Wiring diagram 12
(5)Troubleshooting 13
3. Checking and adjustment 19
(1)Checking table 20
(2)Battery 24
(3)Clean the air cleaner 25
(4)Oil screen 26
(5)The final reduction mechanism oil 26
(6)Spark plug 27
(7)Compression pressure measurement 27
(8)Valve clearance 28
(9)Ignition timing 28
(10)Idle Adjustment 29
(11)Front brake adjustment 29
(12)Rear brake adjustment 30
(13)Tire 30
(14)Throttle cables adjustment 31
4. Dismantling, maintaining, repairing and assembling operation 32
(1)Lubrication system 33
(2)Plastic parts of chassis 37
(3)Engine dismantling 42
(4)Drive pulley, starter, clutch,driven pulley 44
(5)Cylinder head and valve 53
(6)Cylinder and piston 58
(7)AC generator flywheel 63
(8)Final transmission mechanism 66
(9)Crankcase, crank shaft 70
(10)Carburetor 74
(11)Steering stem, front wheel, front brake comp., front fork 78
(12)Rear wheel, rear brake, rear damper 87
(13)Fuel tank, oil tank 92

5. Electric equipment 95
(1)Troubleshooting 96
(2)Battery 97
(3)Recharge system 99
(4)Ignition system 101
(5)Starting system 103
(6)Starting clutch 105
(7)Handle bar switch 107

SPECIFICATIONS
Model LIGERO-50 Transmission
Overall Length 1780mm Primary
reduction Direct
Overall width 645mm
Overall height 1060mm Secondary ratio 52/13*44/13
110CC
Seat height 770mm
Wheelbase 1210mm Reverse
differential NA
Dry weight 99kgs Frame Steel pipe
Engine Model P2 Front fork Telescopic
Piston displacement 49CC Rear cushion Uni-absorber
Bore 40.0mm Front tire 3.50-10*1
Stroke 39.2mm Rear tire 3.50-10*1
Compression ratio 6.8:1
Ignition CDI Fuel
Capacity Unleaded gas 6.3L
Clutch Centrifugal / CVT Front brake Hydraulic disk brake
Shifting Drive Rear brake Durm brake
Lubricant Auto seperated Head light 12V-35W*1
Steering angel
Left
Right
、
41
41
Tail light 12V-21W/5W

Vehicle model reorganization:
1. Movable model
2. Fixed model

2. Service information:
(1)The notice for operation--------------------------------------------------------------------6
(2)Locking torque value-----------------------------------------------------------------------7
a. For engine
b. For chassis
c. Others
(3)Lubrication instruction---------------------------------------------------------------------9
a. For engine
b. For chassis
c. Wheel bearing -------------------------------------------------------------------------12
(4)Wiring diagram----------------------------------------------------------------------------13
(5)Troubleshooting
1. Hard starting or no starting
2. Not smooth rotation(weak acceleration; inefficient horse)
3. Engine running not smoothly(low speed)
4. Engine running not smoothly(high speed)
5. Charging abnormal(battery over charging or over discharging)
6. No Sparking, spark plug

(1) The operation notice:
1. Always replace gasket, Oring, 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, confirmthe 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.

(2) TORQUE VALUE
1. Engine:
No Locking location
Thread
Dia (mm) Locking
torque kg-m
Remarks
1Cylinder head 71.0~1.4 When the engine is cold
2Flywheel outer 10 3.2~4.0
3Rear brake lever 61.0~1.2
4Driving pulley 10 3.2~4.0
5Clutch outer 10 3.5~4.0
6Right crankcase 61.0~1.2
7Drive gear box cover 61.0~1.2
8Left crankcase 61.0~1.2
9Draining and filler bolt 81.8 When the engine is cold
10 Inlet pipe 61.0~1.2
11 Flywheel magneto stator 61.0~1.2
12 Cooling fan 61.0~1.2
13 Muffler nut on cylinder head 61.0~1.2 When the engine is cold
14 Starting motor 61.0~1.4 When the engine is cold
15 Bracket between eng. and
Rubber pad of central stand 61.0~1.2
16 Spark plug 14 2.5~3.0
17 Fan cover 61.0~1.2
18 Fixed plate, drive clutch 61.0~1.4
19 Nut of rear wheel axle 14 11~13 U TYPE NUT
20 Kick starter 61.0~1.2
2. Chassis:
NO Locking location Q’TY Thread dia. (mm) Locking torque (kg-m) Remark
1Locking nut, steering stem 110 4.5
2Front axle nut 112 4.5 ~5.5 U type nut
3Rear axle nut 116 11~ 13 U type nut
4Rear shock absorber bolt(upper) 110 4.0
5Rear shock absorber bolt(lower) 182.4 ~3.0
6Front brake caliper bolt 282.0 ~3.0
7Chassis bolt, engine hanger bracket 210 3.5 ~4.5
8Engine bolt, engine hanger bracket 110 3.0 ~4.0
9Brake hose bolt 210 3.0 ~ 3.5
10 Air release valve 160.6
11 Front drum brake arm bolt 161.0
12 Rear drum brake arm bolt 161.0

3.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

(3)Lubrication instruction:
A. Engine
NO Lubrication location Oil type Remarks
1Crankcase:rotating part,
Sliding part
2Cylinder:rotating part,
Sliding part.
Premium 2 stroke
Motorcycle oil
Or SAE#30
Auto-separated
Lubrication
3Drive gear box SAE85-140 Total 110 c.c.
Replacement 90c.c
4Gasket of starter shaft Clean grease (#3)
5Start idle gear sliding
parts Clean grease (#3)

B.CHASSIS
Front brake cam
Steel ball, steering
Front brake fluid

C.WHEEL BEARING
Final transmission mechanism
gear oil
Speedometer gear-clean grease
Front wheel bearing-clean grease
Motor oil

(5)Trouble shooting:
1.Hard starting or can’t start:
•check there is fuel or not
‚pipe between fuel tank and
carburetor is blocked
ƒfloat is blocked
„Fuel gauze is blocked
…Auto cock is malfunctioned
•sparkplugoutoforder
‚dirty
ƒCDI unit out of order
„pulsegeneratoroutoforder
…ignition coil cable disconnect
or short circuit
†Ignition coil disconnect or
short circuit
‡mainswitchoutoforder
ˆdefective magneto coil
•startingclutchoutoforder
‚valve is too tight,no clearance
ƒvalvebaseoutoforder
„Cylinderpiston,piston ring out
out oforder
…cylinder gasket leakage
†valveburnsout
‡wrongvalvetiming
•bad action of auto choke
‚air trapped in intake manifold
ƒwrong ignition timing
„bad adjustment of carburetor’s
fueladjustingscrew
•carburetor fuel leveltoo high
‚malfunctionofautochoke
ƒthrottle valve open too largely
Check and adjust Trouble condition The reason
The fuel supplies carburetor
enough or smooth
loosencarburetor draining
screw, check if inside of
carburetor have fuel or not
No fuel supplies
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
unsufficient or no
pressure
start engine as the
instruction of starting
engine
engine has no
knocking
engine knocking
and can’t start
Remove spark plug and
check again
dry wet

2.Unsmooth rotation(Weak acceleration ; inefficient horsepower)
•air cleaner blocked
‚fuel supply system abnormal
ƒfuel tank cover blocked
„muffler blocked
…auto cock is malfunctioned
†auto chock is malfunctioned
•CDI unit is out of order
‚alternator flywheel magneto is
out of order
•Valve clearance adjustment is
not correct.
‚Valve base is over worn out.
(Clearance valve is over extruded.)
•cylinder, piston worn out.
‚cylinder gasket leakage.
ƒvalve base is malfunctioned
„wrong valve timing
clean the carburetor
•clean the dirt.
‚specification is not correct.
•oil level is too high.
‚oil level is too low.
ƒoil does not interchange.
•oil route is blocked.
‚insufficient oil pumping from
oil pump.
•piston and cylinder worn out.
‚mixture is too lean.
ƒbad quality of the fuel.
„toomuch carbon in the combustion room.
…ignition timing is too early
•too much carbon in the combustion room.
‚bad quality of the fuel.
ƒclutch slip
„mixture is too lean.
…ignition timing is too early.
Check and Adjust
Trouble condition
The reason
start engine and open
throttle gradually.
check and inspect
engine can rotate
up
engine can’t rot-
ate up completely
Check ignition timing, check
with ignition timing lamp
Timing is correct
Timing is
not correct.
bad adjustment
on valve
Valve clearance is correct.
Valve clearance is incorrect
Check cylinder compression
pressure
(use cylinder compre-
ssion 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
Check the oil level in crankcase
Is too much or dirty
Oil level is
Normal.
Oil level is
Notnormal.
Normal
Abnormal
Check the lubrication
Of cylinder head
Check engine overheat
Ornot
Not overheat
overheat
Running accelerately or
High speed continuously
Noknocking
knocking

3.Engine running not smoothly(low speed and idling):
•CDI faulty
‚pulse generator faulty
•mixture too rich
(loosenthe screw)
‚mixture too lean.
(tighten the screw)
•heat protector gasket
broke
‚carburetor locking nut
loose
ƒgasket crack
„hose ruptured
•spark plug is dirty
‚CDI out of order
ƒAc magneto abnormal
„ignition coil faulty
…H.T. coil faulty or
short circuit
†main switch is abnormal.
•A.C.V. faulty
‚hose is damaged.
ƒair pipe is blocked or
damaged
Check and adjust
Trouble condition
The reason
Check ignition timing
Adjust carburetor oil screw
good
adjustment
faulty
adjustment
Check if there is air
Leakage on carburetor
gasket
No leakage leakage
Good sparking
Sparking abnormal
Or no sparking
Check A.C.V
faultgood
correct
Not correct

4.Engine running unsmoothly(high speed)
•CDI sets faulty
‚pulse generator faulty
•bad adjustment
‚valve base faulty
•fuel level is too low
‚fuel pipe or fuel filter
is blocked
ƒauto cock faulty
clean and wash it
the mark of cam’s timing
gear does not align
Spring faulty
Check and adjust Trouble condition The reason
Check ignition
timing
Adjust valve gap
correct Not correct
Check auto cock,
Fuel supply system
good unsmoothly
Check carburetor
Is blocked or not
No blocked
blocked
Check valve timing
correct Not correct
Check the valve’s
Reverse spring
good
Spring broke or fatigue
not correctcorrect

5.Charging abnormal(battery over charing, or over discharging)
•Battery is dead
‚Battery malfunction
•poor connection
‚red cable disconncet
•voltage rectifier
malfunction
‚while cable disconnect
•defective coil
‚
poor connection
charging abnormal(over charging) ƒA.C. generator’s
white cable
disconnect
•cable poor connection
‚poor connection of
green cable
Voltage rectifier
faulty
Check and adjust Trouble condition
The reason
Measure batter’s
Voltage then start
engine
Voltage remain
The Same
Voltage goes up
To normal value,
But after engine
Stop ,the Voltage
Goes down again
Check voltage rectifier
Plug is loose or not
good
loose
Check the voltage
Between chassisΘand
The red cable⊕of
Voltage rectifier
Check the resistivity
Of A .C . generator coil
normal
abnormal
Start engine, connect
Green cable to
Chassis, then measure
The voltage between
ChassisΘ
and red cable
⊕of voltage of
rectifier.
Voltage higher
Than specification
Voltage normal
Check the connection
Of the cable of
Voltage rectifier
good Poor connection
Check the resistivity
Of the body of
Voltage rectifier
Out of spec
good
No voltage

6.No sparking, spark plug
spark plug faulty
spark plug cap loosen
plug is poor
connection
•main switch faulty
‚defective magneto
coil
ƒpulse generator faulty
„defective ignition
coil
•main cable broke
‚poor connection of
joints or sockets
defective CDI
defective ignition
coil
Check and adjust Trouble condition
The reason
Replace new spark
Plug, then check
again
Good sparking
Weak sparking
Or no sparking
Check spark plug, cap
And H.V. cable is
Loosen or not
good loose
Check the CDI plug
Is loosen or not
good
loose
Check the connection
Between CDI Plug and
Each terminals, check
The resistivity of
Each terminals good abnormal
Check relative parts
good abnormal
good abnormal
Check ignition coil
By the CDI tester
abnormal

3.Checking and Adjustment:
(1)Periodical checking table
(2)Battery
(3)Clean air cleaner
(4)Oil screen
(5)The final reduction mechanism oil
(6)Spark plug
(7)Cylinder pressure
(8)Valve clearance
(9)Ignition timing
(10)Idle adjustment
(11)Front brake adjustment
(12)Rear brake adjustment
(13)Tire
(14)Throttle cable adjustment