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