PGO PMX Sport 50 User manual

PREFACE
This manual offers all service specialist with professional technigues
techniguess of maintenance and repairing for PM50 &PM110. It provides a
Detailed guide for those whom may concern with how to maintain, repair,
Reassemble, and exchange parts of their scooters.
At every section, we illstrate 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 POG scooters.
FACTORY：
Motive Power Industry Co.,Ltd.

CONTENTS：
1.The specifications
2.Service information
(1)The operation notice
(2)Torque value
(3)Lubrication instruction
(4)Wiring diagram
(5)Troubleshooting
3.Checking and Adjustment
(1)Regular checking table
(2)Battery
(3)Cleaning air cleaner
(4)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
4.Dismantling, maintaining, repairing and assembling operation
(1)Lubrication system
(2)Plastic parts of chassis
(3)Engine dismantling
(4)Drive pulley, starter, clutch, driven pulley
(5)Cylinder head, cylinder, piston
(6)AC generator, flywheel magneto
(7)Final transmission mechanism
(8)Crankcase, crankshaft
(9)Carburetor
(10)Steering column, front wheel, brake comp, front fork
(11)Rear wheel, rear brake, rear damper

(12)Fuel tank, oil tank
5.Electric equipment
(1)Troubleshooting
(2)Battery
(3)Recharge system
(4)Ignition system
(5)Starting system

SCOOTER SPECIFICATION(1)
Name PMX SPORT50 ERAME STEEL
TYPE PM-50D SUSPENSION SYSTEM
DIMENSION FRONT TELESCOPIC
TOTAL LENGTH 1820 REAR UNIT-ABSORBER
TOTAL WIDTH 660 TRANSMISSION
TOTAL HEIGHT 1090 RPIMARY RATIO 1
WHEELBASE 1220 SECONDARY RATIO 52/13*44/13
DRY WEIGHT 94KG CLUTCH C.V.T.
FRONT 37KG TIRE
REAR 57KG FRONT 120/70-12
TOTAL 94KG REAR 130/70-12
LOAD 2 PERSONS(110KG) BRAKE SYSTEM
LOADED WEIGHT FRONT DISC BRAKE
FRONT 69KG REAR DRUM BRAKE
REAR 135KG LIGHT
TOTAL 204KG HEAD LIGHT(H/L)
12V-18W/18W*2
TAIL LIGHT 12V-5W
CYCLE 2BRAKING LIGHT 12V-21W
FUEL UNLEADED TURN LIGHT 12V-10W
CYLINDER NUMBER 1
ARRANGEMENT HORIZONTAL
DISPLACEMENT 49C.C.
BORE Í40.0mm
STROKE 39.2mm
COMPRESSION RATIO 6.8:1
MAX. POWER/RPM 3.0KW/7000RPM
AMX. TORQUE/RPM 5.2N.m/6500RPM
IDLE RPM 1900±100
IGNITION CDI
SPARK PLUG NGK BP7HS
COOLING FORCE AIR
STARTER ELECTRIC、KICK
FUEL MIXING OIL PUMP
LUBRICATION SEPARATED
VEHICLT PERFORMANCE
TOP SPEED 65KM/H
FUEL CONSUMPTION 43KM/L
CLIMBING ABILITY 20°

SCOOTER SPECIFICATION (2)
Name PMX SPORT110 ERAME STEEL
TYPE PM-110DSUSPENSION SYSTEM
DIMENSION FRONT TELESCOPIC
TOTAL LENGTH 1820 REAR UNIT-ABSORBER
TOTAL WIDTH 660 TRANSMISSION
TOTAL HEIGHT 1090 RPIMARY RATIO 1
WHEELBASE 1220 SECONDARY RATIO 49*16*43/13
DRY WEIGHT 94KG CLUTCH C.V.T.
FRONT 37KG TIRE
REAR 57KG FRONT 120/70-12
TOTAL 94KG REAR 130/70-12
LOAD 2 PERSONS(110KG) BRAKE SYSTEM
LOADED WEIGHT FRONT DISC BRAKE
FRONT 69KG REAR DRUM BRAKE
REAR 135KG LIGHT
TOTAL 204KG HEAD LIGHT(H/L)
12V-18W/18W*2
TAIL LIGHT 12V-5W
CYCLE 2BRAKING LIGHT 12V-21W
FUEL UNLEADED TURN LIGHT 12V-10W
CYLINDER NUMBER 1
ARRANGEMENT HORIZONTAL
DISPLACEMENT 106.2C.C.
BORE Í52.0mm
STROKE 50.0mm
COMPRESSION RATIO 6.6:1
MAX. POWER/RPM 5.7KW/7000RPM
AMX. TORQUE/RPM 8.4N.m/6500RPM
IDLE RPM 1900±100
IGNITION CDI
SPARK PLUG NGK BP7HS
COOLING FORCE AIR
STARTER ELECTRIC、KICK
FUEL MIXING OIL PUMP
LUBRICATION SEPARATED
VEHICLT PERFORMANCE
TOP SPEED 82KM/H
FUEL CONSUMPTION 38KM/L
CLIMBING ABILITY 20°

2.Service information：
(1)The operation notice
(2)Locking torque value
a.For engine
b. For chassis
c. Others
(3) Lubrication instruction
a.For engine
b. For chassis
c. Wheel bearing
(4)Wiring diagram
(5)Troubleshooting
1.Difficult starting or can’t
2.Weak acceleration
3.Engine running unsmoothly (low speed)
4.Engine running unsmoothly(high speed)
5.Clutch, drive, driven pulley
6.Handlebar steering astrayed when running
7.Front, rear damper not balanced
8.Bad braking
9.Oil indicator malfunction
10. Fuel indicafor malfunction
11.The 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 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 P.G.O.
6.When removing battery, please disconnect the negative cable(-) first.
However, please connect the positive cable(+) 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 befor selling out.

(2)Locking Torque Value:
1.Engine
No Locking location Thread dia
(mm) Locking torque kg-mRemarks
1Cylinder head 71.0~1.4 When the engine is cold
2Flywheel plate 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 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 Spark plug 14 2.5~3.0
16 Fan cover 61.0~1.2
17 Fixed plate, drive clutch 61.0~1.4
18 Nut of rear wheel axle 16 8.0~10.0 U TYPE NUT
19 Kick starter 61.0~1.2
20 Muffler bolt on crankcase 8
2.chassis
1Steering stem nut 10mm 3.0~4.0
2Front axle nut 12mm 5.0~6.0
3Fixed nut fasten eng. and
chassis 12mm 5.0~6.0
4Fixed bolt fasten hanger and
chassis 10mm 3.5~4.5
5Rear shock absorber(upper)
Rear shock absorber(lower) 10mm 8mm 3.0~4.5 2.4~3.0
6Lock nut faster frt. brake disk
and frt. wheel rim 8mm 2.0~3.0
7Lock bolt between frt. brake
caliper and frt. absorber 8mm 2.0~3.0
8Lock bolt of frt braking hose 10mm 3.0~3.5

3.Other parts: Please refer the following table:
Standard torque values:
No Item Torque kg-m
15mm bolt and nut 0.45-0.6
26mm bolt and nut 0.8-1.2
38mm bolt and nut 1.8-2.5
410mm bolt and nut 3.4-4.0
512mm bolt and nut 5.0-6.0
65mm screw 0.35-0.5
76mm screw 0.7-1.1
86mm flange bolt and screw 1.0-1.4
97mm 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

B. Chassis parts

C. Wheel bearing part

(5)Trouble shooting:
1.difficult starting or can’t start:
•check there is fuel or not
‚pipe between ful tank and
carburetor is blocked
ƒFloat is blocked
„Fuelgauge is blocked
…auto cock is malfunction
•spark plug out of order
‚dirty
ƒCDI 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
ˆdefective magneto coil
•starting clutch out of order
‚piston ring stuck
ƒreed 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
ƒwrong ignition timing
„bad adjustment of carburetor’s
fuel adjusting screw
•carburetor fuel level too high
‚malfunction of auto choke
ƒthrottle valve open too largely
Check and adjust Trouble condition The reason
Loose carburetor draining
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
dry
wet

2.Weak acceleration:
•air cleaner blocked
‚fuel supply system abnormal
ƒfuel tank cover blocked
„muffler blocked
…auto chock 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
ƒcylinder body has sand hole
„Reed valve malfunction
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 lamp)
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

•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
„too much carbon in the combustion room
…ignition timing is too early
•too much carbon in the combustion room
‚bad quality ofthe fuel
ƒclutch slip
„mixture is too lean
…ignition timing is too early
Check the oil level in gear box
Is too much or dirty
Oil level is normal
Oil level is
Not normal
Check thecombustion
color of cylinder head
Normal
Abnormal
Check engine overheat
Or not
Not overheat
overheat
Running accelerately or
High speed continuously
No knocking
knocking

3.Engine running unsmoothly (low speed and idling)
•CDI faulty
‚AC generator faulty
•mixture too rich
(to loose the screw)
‚mixture too lean
(to tight the screw)
•gasket broken
‚carburetor locking nut
loosen
ƒhose ruptured
„lntake manifold gasket
broken
…Carburetor Oring distorted
•spark plug dirty
‚CDI out of order
ƒAC magnet abnormal
„ignition coil faulty
…H.V. coil disconnect or
short circuit
†main switch abnormal
•A.C. generator malfanction
‚hose is damaged
ƒair pipe is blocked or
damaged
△
Check and adjust
Trouble condition
The reason
Check ignition timing
Correct
Not correct
Adjust carburetor air 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. Generator
good
fault

4.Engine running unsmoothly (high speed)
•CDI sets faulty
‚AC generator faulty
•fuel level is too low
‚fuel pipe, fuel filter
is blocked
ƒautocock faulty
•clean and wash it
Check and adjust
Trouble condition
The reason
Check ignition
timing
correct
Not correct
Check auto cock,
Fuel supply system
good
unsmoothly
Check carburetor
Is blocked or not
No blocked
blocked

5.Clutch, drive and driven pulley
•driving belt worn out, distortion
‚driven plate worn-out
ƒdriven plate spring distorted
„clutch lining worn-out
…driving pulley shaft gear teeth
cracked
†final gear damage
•clutch lining spring cracked or
worn out
‚weight rollers melt and stick to
driving face
ƒshaft worn out
(rear wheel rotates while idling)
•driving belt worn-out, distorted,
slipping
‚weight roller worn-out
ƒdriving plate worn-out
„driving plate spring distorted
…driving pulley shaft worn-out
•driving belt worn-out or slipping
‚weight roller worn-out
ƒdriving pulley shaft worn-out
•additionalgrease on driving belt,
pulley
‚driving belt worn-out
ƒdriven plate spring distorted
„driving pulley shaft worn-out
Trouble condition
The reason
Engine can start but can’t
Move the vehicle
Engine runs, but it stops
And seemsto rush out
Climbing is not smoothly
Can’t reach high speed
Noise, or bad smell when
running

6.Handlebar steering astrayed when running.
(front and rear wheel pressure are normal)
•steering column lock nut locked too
tightly
‚steel ball cracked
•rear, front wheel bearing swings
‚front, rear wheel rim distorted
ƒfront axle nut is loose
•front and rear wheel center not well-
aligned
‚front fork crooked
7.Front, rear damper not in balanced
(front and rear wheel pressure is normal)
•damper spring is too soft
‚carrying weight is too large
ƒdamper oil leakage
•front fork guide rod crooked
‚damper and damper cover cracked
•problems in damper tube and spring
‚damper and damper cover cracked
8.Brake disorder.
(adjustment according to standard procedure)
•brake lining worn-out
‚bake lining cam worn-out
ƒbrake cam worn-out
„brake hub worn-out
•brake lining worn-out
‚Alien material attached on brake lining
ƒ Contact surface of the wheel hub becomes
rough
• brake cable over stretching or moving
unsmoothly
‚ brake lining contacting surface not
evenly
ƒ water or sand drop into brake system
„ some grease on brake lining surface
Trouble condition
The reason
Handlebar operates heavily
Front and rear wheel swings
Handlebar astrayed to one direction
Trouble condition
Damper is too soft
Damper is too heavy
Damper has abnormal noise
The reason
Trouble condition
The reason
Brake plate”△”mark
points
Noise when brake
Faulty performance

9.Oil indicator malfunction
(a)The oil lamp doesn’t light up, (when the main switch is at “ON”position)
•fuse burn-out
‚battery has no power
ƒmain switch abnormal
„circuit plug dropped off
…main wiring disconnected
•bulb burn out
•electric plug is loose
or disconnected
‚main wiring disconnected
ƒwrong wiring connection
Float upward: lamp •float faulty
Extinguishes ‚oil gauge switch dis-
Float downward: lamp turn on connected or short circuit
(b)Oil is enough but the indicator turns on all the time (when the main switch is “ON”)
•electric plug is loose
or drop-off
‚main wiring disconnected
ƒwrong wire connection
•float faulty
‚oil gauge switch
disconnected or short circuit
Float upward: lamp
Extinguishes •oil tank distorted
Float downward: lamp ‚some impure material
Turns on dropping in
Check and adjust
Trouble condition
The reason
Turn the signal lamp
On. Check wiring
Of battey
Normal
Lamp dims, light does
Not flash, no light
Remove the oil lamp,
And connect with
Battery directly
Lamp lights
Lamp does not light up
Check electric plug
Good condition
No good
Remove oil gauge,
Check the lamp light
Up or not by moving
The float
Good
No good
Check and adjust
Trouble condition
The reason
Check all electric
plug
Good
Disorder
Remove oil gauge,
Check the lamp by
Moving the floating
Good
Disorder