PGO LIGERO 50 Scooter Full Service & Repair 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. Downloaded from www.Manualslib.com manuals search engine

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 Downloaded from www.Manualslib.com manuals search engine

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 Downloaded from www.Manualslib.com manuals search engine

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 Downloaded from www.Manualslib.com manuals search engine

Vehicle model reorganization: 1. Movable model 2. Fixed model Downloaded from www.Manualslib.com manuals search engine

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 Downloaded from www.Manualslib.com manuals search engine

(1) The operation notice: 1. Always replace gasket, O ring, 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, confirm the 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. Downloaded from www.Manualslib.com manuals search engine

(2) TORQUE VALUE 1. Engine: No Locking location Thread Dia (mm) Locking torque kg-m Remarks 1 Cylinder head 7 1.0~1.4 When the engine is cold 2 Flywheel outer 10 3.2~4.0 3 Rear brake lever 6 1.0~1.2 4 Driving pulley 10 3.2~4.0 5 Clutch outer 10 3.5~4.0 6 Right crankcase 6 1.0~1.2 7 Drive gear box cover 6 1.0~1.2 8 Left crankcase 6 1.0~1.2 9 Draining and filler bolt 8 1.8 When the engine is cold 10 Inlet pipe 6 1.0~1.2 11 Flywheel magneto stator 6 1.0~1.2 12 Cooling fan 6 1.0~1.2 13 Muffler nut on cylinder head 6 1.0~1.2 When the engine is cold 14 Starting motor 6 1.0~1.4 When the engine is cold 15 Bracket between eng. and Rubber pad of central stand 6 1.0~1.2 16 Spark plug 14 2.5~3.0 17 Fan cover 6 1.0~1.2 18 Fixed plate, drive clutch 6 1.0~1.4 19 Nut of rear wheel axle 14 11~13 U TYPE NUT 20 Kick starter 6 1.0~1.2 2. Chassis: NO Locking location Q’TY Thread dia. (mm) Locking torque (kg-m) Remark 1 Locking nut, steering stem 1 10 4.5 2 Front axle nut 1 12 4.5 ~ 5.5 U type nut 3 Rear axle nut 1 16 11~ 13 U type nut 4 Rear shock absorber bolt(upper) 1 10 4.0 5 Rear shock absorber bolt(lower) 1 8 2.4 ~ 3.0 6 Front brake caliper bolt 2 8 2.0 ~ 3.0 7 Chassis bolt, engine hanger bracket 2 10 3.5 ~ 4.5 8 Engine bolt, engine hanger bracket 1 10 3.0 ~ 4.0 9 Brake hose bolt 2 10 3.0 ~ 3.5 10 Air release valve 1 6 0.6 11 Front drum brake arm bolt 1 6 1.0 12 Rear drum brake arm bolt 1 6 1.0 Downloaded from www.Manualslib.com manuals search engine

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 Downloaded from www.Manualslib.com manuals search engine

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

PGO LIGERO 50 Scooter Full Service & Repair Manual

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