PGO Bug Rider BR-250 User manual

BR-250 / BR-250SS / M2-250
SERVICE MANUAL
Manufactured by PGO
of Motive Power Industry Co., Ltd

1. INSPECTION/ADJUSTMENT
0
BR & M2 250 ENGINE
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
INSPECTION/ADJUSTMENT
__________________________________________________________________________________
SERVICE INFORMATION ------------------------------------------------- 1-1
MAINTENANCE SCHEDULE---------------------------------------------- 1-2
FUEL LINE/FUEL FILTER-------------------------------------------------- 1-3
THROTTLE OPERATION-------------------------------------------------- 1-3
ENGINE OIL-------------------------------------------------------------------- 1-4
AIR CLEANER----------------------------------------------------------------- 1-5
SPARK PLUG------------------------------------------------------------------ 1-5
VALVE CLEARANCE-------------------------------------------------------- 1-6
CARBURETOR IDLE SPEED---------------------------------------------- 1-6
CYLINDER COMPRESSION----------------------------------------------- 1-7
FINAL REDUCTION GEAR OIL------------------------------------------ 1-8
DRIVE BELT ------------------------------------------------------------------- 1-8
HEADLIGHT AIM------------------------------------------------------------- 1-9
CLUTCH SHOE WEAR------------------------------------------------------ 1-9
COOLING SYSTEM---------------------------------------------------------- 1-9
BRAKE SYSTEM-------------------------------------------------------------- 1-10
NUTS/BOLTS/FASTENERS------------------------------------------------ 1-11
WHEELS/TIRES--------------------------------------------------------------- 1-11
STEERING HANDLEBAR -------------------------------------------------- 1-11
SUSPENSION------------------------------------------------------------------ 1-11
1

1. INSPECTION/ADJUSTMENT
1
BR & M2 250 ENGINE
SERVICE INFORMATION
GENERAL
！ WARNING
•Before running the engine, make sure that the working area is well ventilated.
Never run the engine in a closed area. The exhaust contains poisonous carbon
monoxide gas, which may cause death to people.
•Gasoline is extremely flammable and is explosive under some conditions. The
working area must be well ventilated and do not smoke or allow flames or sparks
near the working area or fuel storage area.
SPECIFICATIONS
ENGINE
Throttle grip free play : 2∼6mm
Spark plug : NGK: DPR7EA-9
Spark plug gap : 0.9mm
Valve clearance : IN: 0.1mm EX: 0.1mm
Idle speed : 1450±50rpm
Engine oil capacity: Cylinder compression : 16.5±2kg/cm²
At disassembly : 1.1 liter Ignition timing : repeatedly
At change : 0.9 liter Coolant capacity : 1165cc
Gear oil capacity :Radiator capacity : 825cc
At disassembly : 0.20 liter Reserve tank capacity : 340cc
At change : 0.18 liter
TIRE FOR M2-250
1 Rider 2 Riders
Front 1.75kg/cm²1.75kg/cm²
Rear 2.00kg/cm²2.25kg/cm²
TIRE SPECIFICATION:
Front : 120/60-13
Rear : 140/60-13
TORQUE VALUES
Front axle nut : 14.8∼68.6N-m
Rear axle nut : 107.8∼127.4N-m

1. INSPECTION/ADJUSTMENT
2
BR & M2 250 ENGINE
MAINTENANCE SCHEDULE
Perform the periodic maintenance at each scheduled maintenance period.
I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary.
A: Adjust C: Clean R: Replace T: Tighten
Regular Service Mileage (km)
Frequency
Item
comes
first ð
ò
1000 2000 4000 6000 8000 10000
Engine oil RNew
motorcycle
300km
R R R R R
Engine oil filter screen CC
Fuel filter screen R
Gear oil Note 3 RNew
motorcycle
300km
R
R
Valve clearance AAA
Carburetor II
Air Cleaner Note 2,3
IRR
Spark plug Clean at every 3000km and replace if necessary
Brake system IIIIII
Drive belt I
Suspension II
Nut, bolt, fastener I
Tire II
Steering head bearing III
Brake fluid Perform pre-ride inspection daily
Radiator coolant Replace every year or at every 10000km (R)
Radiator core II
Radiator cap II
Brake lever II
Brake pad wear II
Shock absorber II
•In the interest of safety, we recommend these items be serviced only by an authorized KYMCO
motorcycle dealer.
Note: 1. For higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in dusty or rainy areas.
3. Service more frequently when riding in rain or at full throttle.
Whichever

1. INSPECTION/ADJUSTMENT
3
BR & M2 250 ENGINE
FUEL LINE/FUEL FILTER
Remove the center cover.
Check the fuel lines and replace any parts, which
show signs of deterioration, damage or leakage.
Check for dirty or clogged fuel filter and replace
with a new one if it is clogged.
THROTTLE OPERATION
Check the throttle grip for smooth movement.
Measure the throttle grip free play.
Free Play: 2∼6mm
Major adjustment of the throttle grip free play is
made with the adjusting nut at the carburetor side.
Adjust by loosening the lock nut and turning the
adjusting nut.
Minor adjustment is made with the adjusting nut
at the throttle grip side.
Slide the rubber cover out and adjust by
loosening the lock nut and turning the adjusting
nut.
ENGINE OIL
Lock Nut
Adjusting Nut
Fuel Filter
•Do not smoke or allow flames or sparks
in your working area.
＊
Fuel Line
Lock Nut
Adjusting Nut

1. INSPECTION/ADJUSTMENT
4
BR & M2 250 ENGINE
OIL LEVEL INSPECTION
Stop the engine and support the motorcycle
upright on level ground.
Wait for 2∼3 minutes and check the oil level
with the dipstick. Do not screw in the dipstick
when making this check.
OIL CHANGE
Remove the oil drain bolt to drain the engine oil.
Install the aluminum washer and tighten the oil
drain bolt.
Torque:14.7N-m
Pour the recommended oil through the oil filler
hole.
Oil Capacity:
At disassembly: 1.1 liter
At change: 0.9 liter
Recommended Oil:
SAE: 15W40#
API: SG/CD
Start the engine and check for oil leaks.
Stop the engine and recheck the oil level.
OIL FILTER SCREEN INSPECTION
Drain the engine oil.
Remove the oil filter screen and spring.
Clean the oil filter screen.
Install the oil filter screen, spring, and filter screen
cap.
Fill the engine with recommended engine oil.
AIR CLEANER
Remove the eight air cleaner case cover screws
and the cover.
Spring
•
Drain the oil while the engine is warm.
＊
•Replace the aluminum washer with a new
one if it is deformed or damaged.
＊
Oil Filter Screen
Oil Dipstick
Oil Filter Screen Cap

1. INSPECTION/ADJUSTMENT
5
BR & M2 250 ENGINE
Remove the air cleaner element.
Check the element and replace it if it is
excessively dirty or damaged.
CHANGE INTERVAL
More frequent replacement is required when
riding in unusually dusty or rainy areas.
SPARK PLUG
Remove the frame center cover.
Remove the spark plug cap and spark plug.
Check the spark plug for wear and fouling
deposits.
Clean any fouling deposits with a spark plug
cleaner or a wire brush.
Specified Spark Plug: NGK: DP7EA9
Measure the spark plug gap.
Spark Plug Gap: 0.9mm
Torque: 7.8∼9.8N-m
VALVE CLEARANCE
｝
Gap
Wear
Fouling
Deposits
Spark Plug
Cracks
Damage
•The air cleaner element has a viscous type
paper element. Do not clean it with
compressed air.
•Be sure to install the air cleaner element
and cover securely.
＊
•When installing, first screw in the spark
plug by hand and then tighten it with a
spark plug wrench.
＊
Deformation
•Inspect and adjust valve clearance while
the engine is cold (below 35℃).
＊
0.9mm
Air Cleaner Element

1. INSPECTION/ADJUSTMENT
6
BR & M2 250 ENGINE
Remove the cylinder head cover.
Turn the A.C. generator flywheel to the top dead
center (TDC) on the compression stroke so that
the “T” mark on the flywheel aligns with the
index mark on the left crankcase cover.
Inspect and adjust valve clearance.
Valve Clearance:IN: 0.1mm
EX: 0.1mm
Loosen the lock nut and adjust by turning the
adjusting nut
Valve Wrench
CARBURETOR IDLE SPEED
Lift up the seat and remove the inspection cover.
Warm up the engine before this operation.
Start the engine and connect a tachometer.
Turn the throttle stop screw to obtain the
specified idle speed.
Idle Speed:1450±50rpm
When the engine misses or run erratic, adjust the
pilot screw.
CYLINDER COMPRESSION
Warm up the engine before compression test.
Remove the center cover and spark plug cap.
Throttle Stop Screw
Pilot Screw
•Check the valve clearance again after the
lock nut is tightened.
＊
•The engine must be warm for accurate
idle speed inspection and adjustment.
＊
Top Dead Center
Valve Wrench
Special

1. INSPECTION/ADJUSTMENT
7
BR & M2 250 ENGINE
Remove the spark plug.
Insert a compression gauge.
Open the throttle valves fully and pushes the
starter button to test the compression.
Compression: 16.5±2kg/cm²
If the compression is low, check for the
following:
•Leaky valves
•Valve clearance to small
•Leaking cylinder head gasket
•Worn pistons
•Worn piston/cylinder
If the compression is high, it indicates that carbon
deposits have accumulated on the combustion
chamber and the piston head.
Compression Gauge

1. INSPECTION/ADJUSTMENT
8
BR & M2 250 ENGINE
FINAL REDUCTION GEAR OIL
Stop the engine and remove the oil checks bolt.
The oil level shall be at the oil check blowhole.
If the oil level is low, add the recommended oil
SAE90# to the proper level.
Install the oil check bolt.
OIL CHANGE
Remove the oil check bolt.
Removes the oil drains bolt and drain the oil
thoroughly.
Install the oil drain bolt.
Torque: 9.8N-m
Fill the final reduction with the recommended oil
SAE90#.
Gear Oil Capacity:
At disassembly : 200cc
At change : 180cc
Reinstall the oil check bolt and check for oil
leaks.
DRIVE BELT
Remove the left crankcase cover.
Inspect the drive belt for cracks or excessive
wear.
Replace the drive belt with a new one if
necessary and in accordance with the
Maintenance Schedule.
HEADLIGHT AIM
Turn the ignition switch ON.
Drive Belt
•Place the motorcycle on its main stand on
level ground.
＊
Oil Drain Bolt/Sealing Washer
•Make sure that the sealing washer is in
good condition.
＊
•Make sure that the sealing washer is in
good condition.
＊

1. INSPECTION/ADJUSTMENT
9
BR & M2 250 ENGINE
Turn on the headlight switch.
Adjust the headlight aim by turning the headlight
aim adjusting bolt.
CLUTCH SHOE WEAR
Start the engine and check the clutch operation
by increasing the engine speed gradually.
If the motorcycle tends to creep or the engine
stalls, check the clutch shoes for wear and
replace if necessary.
COOLING SYSTEM
COOLANT LEVEL INSPECTION
Place the motorcycle on its main stand on level
ground.
Check the coolant level of the reserve tank and
the level should be between the upper and lower
level lines.
If necessary, fill the reserve tank with
recommended coolant to the “F” level line.
Recommended Coolant: SIGMA Coolant
(Standard Concentration 30%)
COOLANT REPLACEMENT
Remove the front cover.
Remove the radiator cap.
Remove the drain bolt to drain the coolant and
tilt the motorcycle to the right and the coolant will
drain more easily.
Drain the coolant in the reserve tank.
Reinstall the drain bolt.
Fill the radiator with the specified coolant.
Coolant capacity : 1165cc
Radiator capacity : 825cc
Reserve tank capacity : 340cc
Lower Line
Upper Line
Radiator Cap
•The coolant level does not change no
matter the engine is warm or cold. Fill to
the “F” (upper) line.
＊
•The coolant freezing point should be 5℃
lower than the temperature of the riding
area.
＊
•Perform this operation when the engine is
cold.
＊
Reserve Tank

1. INSPECTION/ADJUSTMENT
10
BR & M2 250 ENGINE
Start the engine and check if there are no
bubbles in the coolant and the coolant level is
stable. Reinstall the radiator cap.
If there are bubbles in the coolant, bleed air from
the system.
Fill the reserve tank with the recommended
coolant up to the upper line.
BRAKE SYSTEM
BRAKE LEVER
Measure the front and rear brake lever free
plays.
BRAKE FLUID
Turn the steering handlebar upright and check if
the front/rear brake fluid level is at the upper limit.
If the brake fluid is insufficient, fill to the upper
limit.
Specified Brake Fluid: DOT-3
BRAKE DISK/BRAKE PAD
Check the brake disk surface for scratches,
unevenness or abnormal wear.
Check if the brake disk rubout is within the
specified service limit.
Check if the brake pad wear exceeds the wear
indicator line.
NUTS/BOLTS/FASTENERS
Check all important chassis nuts and bolts for
looseness.
Wear Indicator Line
Drain Bolt
Rear Brake Reservoir
Brake Disk
•The brake fluid level will decrease if the
brake pads are worn.
＊
•Keep grease or oil off the brake disk to
avoid brake failure.
＊
Front Brake Reservoir

1. INSPECTION/ADJUSTMENT
11
BR & M2 250 ENGINE
Tighten them to their specified torque values if
any looseness is found.
WHEELS/TIRES
Check the tires for cuts, imbedded nails or other
damages.
Check the tire pressure.
Tire Pressure
1 Rider 2 Riders
Front 1.75kg/cm²1.75kg/cm²
Rear 2.00kg/cm²2.25kg/cm²
STEERING HANDLEBAR
Raise the front wheel off the ground and check
that the steering handlebar rotates freely.
If the handlebar moves unevenly, binds, or has
vertical movement, adjust the steering head
bearing.
SUSPENSION
Check the action of the front/rear shock
absorbers by compressing them several times.
Check the entire shock absorber assembly for oil
leaks looseness or damage.
Jack the rear wheels off the ground and move the
rear wheel sideways with force to see if the
engine hanger bushings are worn.
Replace the engine hanger bushings if there is any
looseness.
•Tire pressure should be checked when
tires are cold.
＊

2. INSPECTION/ADJUSTMENT
0
BR 250 ENGINE
1
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
INSPECTION/ADJUSTMENT
__________________________________________________________________________________
SERVICE INFORMATION ------------------------------------------------- 2-1
MAINTENANCE SCHEDULE---------------------------------------------- 2-2
FUEL LINE/FUEL FILTER-------------------------------------------------- 2-3
THROTTLE OPERATION-------------------------------------------------- 2-3
ENGINE OIL-------------------------------------------------------------------- 2-4
AIR CLEANER----------------------------------------------------------------- 2-5
SPARK PLUG------------------------------------------------------------------ 2-5
VALVE CLEARANCE-------------------------------------------------------- 2-6
CARBURETOR IDLE SPEED---------------------------------------------- 2-6
CYLINDER COMPRESSION----------------------------------------------- 2-7
FINAL REDUCTION GEAR OIL------------------------------------------ 2-8
DRIVE BELT ------------------------------------------------------------------- 2-8
HEADLIGHT AIM------------------------------------------------------------- 2-9
CLUTCH SHOE WEAR------------------------------------------------------ 2-9
COOLING SYSTEM---------------------------------------------------------- 2-9
BRAKE SYSTEM-------------------------------------------------------------- 2-10
NUTS/BOLTS/FASTENERS------------------------------------------------ 2-11
WHEELS/TIRES--------------------------------------------------------------- 2-11
STEERING HANDLEBAR -------------------------------------------------- 2-11
SUSPENSION------------------------------------------------------------------ 2-11
2

2. INSPECTION/ADJUSTMENT
1
BR 250 ENGINE
SERVICE INFORMATION
GENERAL
！ WARNING
•Before running the engine, make sure that the working area is well ventilated.
Never run the engine in a closed area. The exhaust contains poisonous carbon
monoxide gas, which may cause death to people.
•Gasoline is extremely flammable and is explosive under some conditions. The
working area must be well ventilated and do not smoke or allow flames or sparks
near the working area or fuel storage area.
SPECIFICATIONS
ENGINE
Throttle grip free play : 2∼6mm
Spark plug : NGK: DPR7EA-9
Spark plug gap : 0.9mm
Valve clearance : IN: 0.1mm EX: 0.1mm
Idle speed : 1450±50rpm
Engine oil capacity: Cylinder compression : 16.5±2kg/cm²
At disassembly : 1.1 liter Ignition timing : repeatedly
At change : 0.9 liter Coolant capacity : 1165cc
Gear oil capacity :Radiator capacity : 825cc
At disassembly : 0.20 liter Reserve tank capacity : 340cc
At change : 0.18 liter
TIRE FOR BR-250
Off road On road
Front 0.3kg/cm²0.5kg/cm²
Rear 0.3kg/cm²0.5kg/cm²
TIRE SPECIFICATION:
Front : 19x7-8on road or 20x7-8off road
Rear : 255/60-10 on road of 22*10-10 off road
TORQUE VALUES
Front axle nut : 14.8∼68.6N-m
Rear axle nut : 107.8∼127.4N-m

2. INSPECTION/ADJUSTMENT
2
BR 250 ENGINE
MAINTENANCE SCHEDULE
Perform the periodic maintenance at each scheduled maintenance period.
I: Inspect, and Clean, Adjust, Lubricate or Replace if necessary.
A: Adjust C: Clean R: Replace T: Tighten
Regular Service Mileage (km)
Frequency
Item
comes
first ð
ò
1000 2000 4000 6000 8000 10000
Engine oil RNew
motorcycle
300km
R R R R R
Engine oil filter screen CC
Fuel filter screen R
Gear oil Note 3 RNew
motorcycle
300km
R
R
Valve clearance AAA
Carburetor II
Air Cleaner Note 2,3
IRR
Spark plug Clean at every 3000km and replace if necessary
Brake system IIIIII
Drive belt I
Suspension II
Nut, bolt, fastener I
Tire II
Steering head bearing III
Brake fluid Perform pre-ride inspection daily
Radiator coolant Replace every year or at every 10000km (R)
Radiator core II
Radiator cap II
Brake lever II
Brake pad wear II
Shock absorber II
•In the interest of safety, we recommend these items be serviced only by an authorized KYMCO
motorcycle dealer.
Note: 1. For higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in dusty or rainy areas.
3. Service more frequently when riding in rain or at full throttle.
Whichever

2. INSPECTION/ADJUSTMENT
3
BR 250 ENGINE
FUEL LINE/FUEL FILTER
Remove the center cover.
Check the fuel lines and replace any parts, which
show signs of deterioration, damage or leakage.
Check for dirty or clogged fuel filter and replace
with a new one if it is clogged.
THROTTLE OPERATION
Check the throttle grip for smooth movement.
Measure the throttle grip free play.
Free Play: 2∼6mm
Major adjustment of the throttle grip free play is
made with the adjusting nut at the carburetor side.
Adjust by loosening the lock nut and turning the
adjusting nut.
Minor adjustment is made with the adjusting nut
at the throttle grip side.
Slide the rubber cover out and adjust by
loosening the lock nut and turning the adjusting
nut.
ENGINE OIL
Lock Nut
Fuel Filter
•Do not smoke or allow flames or sparks
in your working area.
＊
Fuel Line
Adjusting Nut

2. INSPECTION/ADJUSTMENT
4
BR 250 ENGINE
OIL LEVEL INSPECTION
Stop the engine and support the motorcycle
upright on level ground.
Wait for 2∼3 minutes and check the oil level
with the dipstick. Do not screw in the dipstick
when making this check.
OIL CHANGE
Remove the oil drain bolt to drain the engine oil.
Install the aluminum washer and tighten the oil
drain bolt.
Torque:14.7N-m
Pour the recommended oil through the oil filler
hole.
Oil Capacity:
At disassembly: 1.1 liter
At change: 0.9 liter
Recommended Oil:
SAE: 15W40#
API: SG/CD
Start the engine and check for oil leaks.
Stop the engine and recheck the oil level.
OIL FILTER SCREEN INSPECTION
Drain the engine oil.
Remove the oil filter screen and spring.
Clean the oil filter screen.
Install the oil filter screen, spring, and filter screen
cap.
Fill the engine with recommended engine oil.
AIR CLEANER
Remove the eight air cleaner case cover screws
and the cover.
Spring
•
Drain the oil while the engine is warm.
＊
•Replace the aluminum washer with a new
one if it is deformed or damaged.
＊
Oil Filter Screen
Oil Dipstick
Oil Filter Screen Cap

2. INSPECTION/ADJUSTMENT
5
BR 250 ENGINE
Remove the air cleaner element.
Check the element and replace it if it is
excessively dirty or damaged.
CHANGE INTERVAL
More frequent replacement is required when
riding in unusually dusty or rainy areas.
SPARK PLUG
Remove the frame center cover.
Remove the spark plug cap and spark plug.
Check the spark plug for wear and fouling
deposits.
Clean any fouling deposits with a spark plug
cleaner or a wire brush.
Specified Spark Plug: NGK: DP7EA-9
Measure the spark plug gap.
Spark Plug Gap: 0.9mm
Torque: 7.8∼9.8N-m
VALVE CLEARANCE
｝
Gap
Wear
Fouling
Deposits
Spark Plug
Cracks
Damage
•The air cleaner element has a viscous type
paper element. Do not clean it with
compressed air.
•Be sure to install the air cleaner element
and cover securely.
＊
•When installing, first screw in the spark
plug by hand and then tighten it with a
spark plug wrench.
＊
Deformation
•Inspect and adjust valve clearance while
the engine is cold (below 35℃).
＊
0.9mm

2. INSPECTION/ADJUSTMENT
6
BR 250 ENGINE
Remove the cylinder head cover.
Turn the A.C. generator flywheel to the top dead
center (TDC) on the compression stroke so that
the “T” mark on the flywheel aligns with the
index mark on the left crankcase cover.
Inspect and adjust valve clearance.
Valve Clearance:IN: 0.1mm
EX: 0.1mm
Loosen the lock nut and adjust by turning the
adjusting nut
Valve Wrench
CARBURETOR IDLE SPEED
Lift up the seat and remove the inspection cover.
Warm up the engine before this operation.
Start the engine and connect a tachometer.
Turn the throttle stop screw to obtain the
specified idle speed.
Idle Speed:1450±50rpm
When the engine misses or run erratic, adjust the
pilot screw.
CYLINDER COMPRESSION
Warm up the engine before compression test.
Remove the center cover and spark plug cap.
Throttle Stop Screw
Pilot Screw
•Check the valve clearance again after the
lock nut is tightened.
＊
•The engine must be warm for accurate
idle speed inspection and adjustment.
＊
Top Dead Center
Valve Wrench
Special