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    4K views114 pages

    PGO T Rex 125 - 150 Service Manual PDF

    Uploaded by

    Rigoberto Mejia Hernandez

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    | ebhed cp-125/cP-150 SERVICE MANUAL H. x4 I ae LG est (GF oe” ee \ TS EP scocorens PREFACE This service manual offers all service specialist with the procedure of maintenance, repairing for PGO SCOOTERS T-REX 125 & T-REX 150. Details show those whom may concern how to maintain, repair, change parts, trouble shoot and reassemble, etc, Whenever the information for TREX 125 and T-REX 150 are different, 125 cc or 150 ce will be remarked behind respectively. The information without remarking means they are applied to both T-REX 125 and T-REX 150. 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, FACTORY: MOTIVE POWER IMDUSTRY CO., LTD. SOLE EXPORT AGENT: SOCIETE COMMERCIALE EURO-TAIWANAISE January ,2001 otis . The specification of T-REX 125 /150 -- + Service information « + Checking and adjustment . Dismantling, maintaining, repairing and assembling operation -- CONTENTS (1)The operation notice - (Looking torque value « (QLubrication instruction + (@Wiring diagram (@Troubleshoot ing +» (DChecking table -- (Battery -- (MClean the air cleaner - (Oil screen-- (The final reduction mechan (Spark plug----- (NCompression pressure measurement - (@Valve clearance (Ignition timing QOIdle Adjustment Q)Front brake adjustment -- (ORear brake adjustment (Tire QThrottle cables adjustment (Lubrication system-- (QPlastic parts of chassis (Engine disnant] ing - (Drive pulley, starter, clutch,driven pulley - (Cylinder head and valve (Cylinder and piston -- (NAC generator flywheel -- (Final transmission mechanism (@Crankcase, crank shaft dOCarburetor : Steering stem, front wheel, front brake comp., front fork (Rear wheel, rear brake, rear damper - (Fuel tank, oil tank -- 5. Electric equipment “(Troubleshoot ing (Battery + (Recharge system : 101 | ignition system (Starting system (@Starting clutch (Handle bar switch 106 108 10 1. Specification (T-REX125) Name T-rex 125 Model cP-125D © Dimension overall length: 1890nm overall width: 696mm overall height:1145mm overall base: 1121mm Weight Total net weight :108kg front: 4dkg rear 64kg Carrying capacity: 2 passengers: 150kg Total weight: 258kg front: ekg rear: 164kg @ Performance Fuel consumption: 42ka/L Gradient ability:22 eEngine Model: cl Fuel: unlead for catalyst converter : or lead fuel , Cooling system:forced air cooling by fan Cylinder bore: 51.Smm Dia stroke 60.0mm number: 1 arrangement: horizontal displacement: 124.9ce compression ration:9.4:1 ignition: Dl start kick or electric start Lubrication: pressuring and Spraying @Chassis steel pipe Suspension front: telescopic rear: 4-bar linkage, uni-absorber © Transmission primary reduction:direct drive second reduction:42/15*42/13 clutch type: centrifugal dry type selector : V belt,C.V.T. © Wheel front: —120/70-12 rear: 130/70-12 oTire front —-2.0kg/em?2 rear 2.0kg/em2 Brake front: 190mm hydraulic disk brake rear: drum brake @Speedometer 140km/hr @Lamp front: 12v-18W/18WX2 or 12v-35W/35WX1 license plate: 12V-5WX1 brakelamp: 12v-10W/3WX2 signallamp: 12V-10WX4 © Horn AC12V Silencer: diffusibel absorption closed type Ll Specification (T-REX150) Name ‘T-rex 150 | © Model cP-150D Dimension overall length:1890mm overall width: 696mm overall height:1145am overall base: 1284mm © Weight Total net weight: 115kg front: 46kg rear: 69kg Carrying capacity: 2 passengers: 150g Total weight: 265k | front 96kg rear: 169kg, © Performance Fuel consumption: 40kn/L Gradient ability: 25° @Engine Mode! : cs Fuel: Unlead for catalyst converter or lead fuel Cool ing system:forced air cooting by fan and oil assistant Cylinder cooling system bore: 257mm, stroke: $7.8mm number 1 arrangement: horizontal displacement: 147.5ce/150.lec compression ration:9.4:1 ignition: ool start Lubrication: pressuring and | start: kick or electric Spraying Chassis steel pipe © Suspension front: telescopic rear: 4-bar linkage, uni-absorber © Transmission primary reductionsdirect drive second reduction:42/15*42/13 clutch type: centrifugal dry type selector : V belt,C.V.T. © Wheel front: 120/70-12 rear: 130/70-12 eTire front 2.0kg/em2 rear 2.0kg/em2 Brake front: 190mm hydraulic disk brake rear: drum brake @Speedometer 140km/hr eLamp front: 12v-18W/18WX2 or 12v-35W/35WX1 license plate: 12V-5WX2 brakelamp: 12v-l0W/3WX2 signallamp: 12V-10WX4 ®Horn AC12V @Silencer: — diffusibel absorption closed type 2. Service information: ()The notice for operation (@Locking torque value a.For engine b.For chassis c.0thers @Lubrication instruction a.For engine b.For chassis c.Wheel bearing’ (Wiring diagram (Troubleshooting Hard starting or no starting 2.Unsmooth rotation(weak acceleration, 3.Engine running not smoothly(lon speed) 4 Engine running not smoothly(high speed) 5.Charging abnormal (battery over charging or over dlischarging) 6.No Sparking, spark plug 10 inefficient horse) (The operation notice: L.Always replace gasket, 0 ring, cotter, pins and circlip whenever reassembled. 2.When tighten screws or nuts, lock tightly as per specified locking torgue, 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.lse grease recomended by P.G.0. 6.¥hen removing battery, please dis-connect the-negative pole(-) first, when i assenblying please connect positive pole(+) first. ' T.Before installing a new fuse,confirm the specification is correct or not. | | 8.dfter reassemblying, please re-check that all connecting point, locking parts, | circuits, polar characteristics are good, before selling out. (2)Torgue value: 4.Engine: NO Locking location Q’TY Thread dia(un)Loocking torgue(kg-a)) Remark 1, |oylinder head bolt A(Intake) 2 6 0.9 2, [Cylinder head bolt B(Exhaust) 2 8 0.9 3. |cap, oi! filter gauze 1 30 15 4. \Flange nut, cam shaft base 4 8 2.0 5, [Fixing nut, air valve adjustuent 2 5 0.9 reasing on thread 6. [Guiding pin bolt, imer chain adjustuent_| 1 5 1.0 7. [oil bolt 1 8 13 8, [Fixing nut, clutch outer 1 12 5.5 9. [Net, driven plate 1 12 5.5 10, [Nut, driving plate 1 12 5.5 11, [Spark plug 1 10 1.2 72. |Nut, drive clutch 1 22 9.5 |Left thread 13, [Serer, inner chain adjuster 1 6 | 0.4 i i 2.Chassis: ! NO. Locking location QTY [fhread dia(amJlooking Torgue(te-a)| Remark 1, [locking aut, steering stem 1 10 45 2, [front axle nut 1 2 6.0 __|U type nut 3. [Rear axle aut 1 16 11 __[U type nut 4, [Rear shock absorber bolt (upper) 1 10 4.0 5, |Rear shock absorber bolt (lover) 1 8 25 6. [Front brake caliper bolt 2 8 25 7, [chassis bolt, engine suspension bracket | 2 10 45 i! 8. [Engine bolt, engine suspension bracket 1 10 4.5 | 9, [Brake hose bolt 2 10 3.0 10, [Air release valve 1 6 0.6 11, [front drum brake ara bolt 1 6 1.0 12, [Rear drup brake ara bolt 1 | 6 1.0 ~8~ 3.Other parts please refer the following table: “Standard torque values: No. Item Torque kgf-n 1 Sam bolt and aut 0.45-0.6 2] 6mm bolt and nut 0.8-1.2 3 | 8un bolt and nut 1.82.5 4 10un bolt and nut 3.0-4.0 5 12m bolt and nut 5.0-6.0 6 5un screw 0.35-0.5, 7 60a screw 0.7-L.1 8 6am flange bolt and screw 10-14 9 Tom flange bolt and screw 10-14 10 8un flange bolt and screw 2.0-3.0 ity 10xm flange bolt and screw 3.0-4.0° ~o~ (3)Lubrication instruction: A€ngine No. | Lubrication location Oil type Remarks |crankcase:rotating part, premium 4 stroke auto -separted 1 lubrication sliding part. © Total volume:1000ce cylinder:rotating part, motorcycle oil * Exchange volume 2 |* de » 1 New Oil filter :900ce slinding part. SAEISw40 2.01 filter no changed:800ce: . © Total Volume:1i0ce 3 |drive gear box SAE 85n-140 * BechangeVolume:90ce 4 |gasket of starter shaft clean grease start idle gear sliding 5 clean grease parts ~10~ B.Chassis Front brake fluid ~~ C.Wheel bearing Speedometer gear-clean grease Front wheel bearing-clean grease ~12~ (4)Wiring diagram. ~B~ Cpe ; | fo eee PER i =a cc ") 7 Hig (5)Trouble shooting: 4.Hard starting or can't start: Check and adjust | [ Trouble condition The reason Tioose carburetor draining iscrew, check if inside of 0 1 ;—Ocheck there is fuel or not t—Q@pipe between fuel tank and ‘The fuel supplies carb uretor enough or smooth No fuel supplies carburetor | carburetor is blocked }—@float is blocked FHemove spark plug, insert | park plug cover and touch ith engine check there is @Fuel gauze is blocked “@auto cock is malfunctioned — spark plug out of order j— Odirty —@ODI unit out of order t—@pulse generator out, of order —@ignition coil cable disconnect or short circuit there is sparking in spark plug No sparking or weak sparking @lgnition coil disconnect or 1-4} short circuit }—- @uain switch out of order Measurement of co- impression pi “ @uefective magneto coil r—Qstarting clutch out of order valve is too tight,no clearance unsufficient or no pressure @valve base out of order @Cylinder piston, piston ring out out of rdér - @cylinder gasket leakage tart eng: }—Qvalve burns out } instruction of starting } engine 1 wrong valve timing bad action of auto choke engine has no | knocking engine knocking and can’t start @air trapped in intake manifold @wrong ignition timing ‘@bad adjustment of carburetor’s oe iRenove spark plug and! icheck again f wet ~l4~ fuel adjusting screw [—Qcarburetor oil level too high + @nalfunction of auto choke _@throttle valve open too largely 2.Unsmooth rotation(Weak acceleration; inefficient horsepower) (Frowle condTeToa] irott le. gradual ly’ check and’ inspect yp Mair cleaner blockded t— fuel supply system abnormal fengine can rotate engine can,t For @fuel tank cover blocked ap - ate up comletely! 1 @euffler blocked ieee eee [— @auto cock is malfunctioned fcheck ignition timing, check | “—@auto chock is malfunctioned EEE D0 ani is out of order @alternator flywheel magneto is out of order bad adjustment : p—OValve clearance adjustment is valve clearance valve clearance [reizateseieecel] Wiiscorsece™ © |} not correct. Cc ____, ‘—@Valve base is over worn out. (Clearance valve is over extruded.) faaie cylinder coapression! Mise cylinder compre- - sion pressure gauge.) } p-Ocylinder, piston vorn out. pressure Ts pressure js |__[~Qcylinder gasket leakage. | [ert Luar @valve base is malfunctioned L_ @rrong valve tiving [oieeecarbireter fis blocked q — Blocked clean the carburetor Ne eee ee aneaee po gTrey and wo arty, coler|_p—Oclean the dirt. eolor change sbange I Qspecification is not correct. {check the of i “ievei” in craakease | Tie ie i 7 7 —@oil level is too high. norwal,~ tot nersal.® @oil level is too lor. \—@oil does not interchange = Doi! route is blocked, Abnorsal |—{“@insufficient oil punping from oil pump, [Opiston and cylinder worn out. }—@nixture is too lean overheat Qbad quality of the fuel. t~@too auch carbon in the combustion room —®ignition timing is too early f= Dtoo auch carbon in the combustion room. [-@bad quality of the fuel. Gclutch slip [—@uixture is too lean. ~1S~ —@ignition timing is too early. igh speed continuously! mocking 3.Engine running not smoothly (low speed and idling) [Check and adjust Trouble condition | ‘The reason check ignition timing’ just carburetor oil screw}. Fcheck if there is air ! | leakage on carburetor $ { gasket, {remove spark plug, insert | to spark plug cover and connect with ground ‘Start engine, then check 0 [eae correct | {not correct @CDI faulty \— @pulse generator faulty oot Taney ‘Omixture too thick Hitstwene | [22]uS%nene (loose the screw) _ @nixture too lean (tight tlie screw) ;——Dheat protector gasket broke ino leakage] | leakage =, sparking abnormal @carburetor locking nut loosen — @gasket crack {_@hose ruptured —Qspark plug is dirty }—@OdI out of order [—Q@AC magneto abnormal or no sparking }-— @ignition coil faulty. Pcheck A.C. good @H.T. coil faulty or short circuit “— @nain switch is abnormal —A.C.V. faulty @hose is damaged. fault ~16~ \— @air pipe is blocked or damaged 4,Engine running unsmoothly (high speed) Check and adjust_| Tcheck ignition ti ming 1 Teheck the reverse spring adjust valve gap check auto cock, ! check carburetor is blocked or not [Trouble condition L The reason [Correct not correct | @CDI sets faulty ‘@pulse generator faulty not correct | | ‘bad adjustment fnot correct] valye’s STN @valve base faulty [—Ofuel level is too iow good lunsnoothly || __ @fuel pipe or fuel filter is blocked @auto cock faulty clean and wash it the mark of cams’s timing gear does not align —————_lL—___ | Spning broke or fatigue}— Spring faulty 5.Charging abnormal(battery over charing, or over discharging) check and adjust Trouble condition the reason voltage then start | fd iP. ‘check the voltage ibetween chassis@an¢ ithe red cable® of voltage rectifier ‘check the resistivi tof A.C. generator coi art engine, connect igreen cable to ichassis, then measure ithe voltage between ichassisand red cable! 1@of voltage of i {check the connection fof the cable of ck the resistivity} tof the body of b ivoltage rectifier ° pr Obattery is dead @Battery malfunction |__r-—— poor connection @red cable disconncet voltage rectifier malfunction ‘—@shife cable disconect ;—— Ddefective coil Ee al Voltage remain] [te nofeaf rates Bue afeer enging| [the Sane Stop, the Voltage goes’ corn again good Toosen [good No Voltage normal abnormal CTarging abtorna over charging) poor connection -—@A.C. generator’s white cable disconnect voltage higher ease voltage normal than specificat ion| ‘good poor connection} cable poor connection out of spec @poor connection of green cable Voltage rectifier faulty No sparking, spark plug Freplace new spark { plug, then check jand HV. cable is {loosen or not Fcheck the CDI plug } fcheck the connection + {between CDI Plug and teach terminals, check ithe resistivity of jeach terminals jcheck relative parts check ignition coil by the CDi tester Trouble condition the reason ° good sparking] [grei,S2arkine, spark plug faulty good] [ loosen spark plug cap loosen oT plug is poor conection main switch faulty @defective magneto coil [— @pulsé generator faulty —@defective ignition coil @zain cable broke [geod | [atuorma! H ator connection of a joints or sockets [good abuorzal }———defective CDI a defective ignition coil ~19~ 3. Checking and Adjustment: (Periodical checking table (Battery (Clean air cleaner (Oil screen (The final reduction mechanism oi! (@Spark plug (Cylinder pressure (Valve clearance @ignition timing (Wldle adjustnent WFrt brake adjustment (aRr brake adjustment taTire (éThrottle Cables Adjustment. ~20~ (Periodical checking table: 1{O] mark indicates periodical checking 2.DX] indicates changing the parts checking period T fgen-| first [_home office Judgenent check item eral | 68 Dt ec pT Renark che ita] | Est ant standard ting Saha A Suspension | loose, swing | O O;O/}O steering handlebar | performance | O O}O}O suspension: turning angle fe a.cracked OJO!O [B. share Tixed . [from Stearag| front fork | * condition O}ojo column c.shaft: loose} | O}O B: Brake check from — O° OJO}O steering a.clearance colum brake lever B.novenent oF brake Ojo}ojo}o sal loose or damage O}O]O}o rake Pareles % per 2 years brake cam | worn out ° wclearance Beta | run and plate Olo}olfo|o brake d Trake sioe and brake deus [9 oe at of fofoy shoe [e.brake drum standard da; | — Of | folate | sar on rear:111. 0am Front axle dan] 5 age or cracked [rear axle:wor O check Fear or dazage axle “ 1 wits gfe Py Tver lee! pressure] OO] 0/0} OO] © [font sted rar ze 20 2.0 | wheel cracked ama [©] [o[o[ofolo — heel gap an j Geglints front eel: wheel Norn © ° OFO}O1O | 0 [ear rear vee: Ca Intel surface |G] lor other netatsj OQ} |O}O{O|O}O | | front are torque} laxle nut screw 5.66. 0kg-n Nut pin tightness O}O}O) 0} O leer azie tara location 1.013 0ien F Tor front wheel ria swi- eee |rear wheel i, ngness and da- O}O}O) OO lee ta seg belo Image condition) | orizontal": Zan bleow ~21~ checking period T ; hone | office judgement check item FEELERS] standard Remark | itt ls) standart sat oe | 20h 0h : front | wheel } bearing of axle, O/OJO;OJO\O looseness | | rear O° rear damper spring oO | awe [ge EO] [0 ofo]olo | ass'y part loose or_danage emis iee | connecting part | aan © ° racket 100s oF damage ° ° \ suspen |connect ing} ( sion part loose ° ° 1 joil leakage ° oo damper | cracked | o| [ojo ss"y part, y i i ose. 9 O|o : eluth and) O}Oj;Oj;O|O power a | : hee o}o/ajoj;o } {transmi-|nechanism ssion supply somply OfO}O]O]O] xper 2 year electric Ignition o}olojo}o install- ment starting | start . nechan isn PoterPinio ° ojo i meshing wiring | Pegharee ofo[o|o]o \ jelectroly-] [evel between lke quantity O]0]O} 0] O Pipree an “Lowey battery felectroly- ) | jwhen 20°C ites. gra-| O° ©] O specific gravity: Wvity 11.270-1.290 ire. our} wire | ecting circuit | loose or 0J0)0}0/o cracked |__| i ~22~ checking period T hee s2n-[ ir | home. office Judgement oe Sete SERS cae | ng Sian ea lengine)engine| performance, | parts} aoise OJO}O}/a;O low speed, idling: accleration O}O}O]O}O idling: 1700 100rpaj leheck the colo exhaustion | O Oj;O};O}ojo lof exhaust ing La air cleaner O;O;O;O}O Tocking torque cylinder, cyl- cylinder head: inder head inlet O (cold) pipe, locking 1.0-1.2kg/a condition inlet pipe: (cold) 10-1 2kg/ compression io Olle Deeseure, ‘Teg/e mt (500rpn) oil leakage ofolojojo lubr-| oil quantity, | jcat-| dirty O}O}O} 0/0 ion ~ Exchang every S35" oil quantity, | O}O °. oooh oil cleaner | blocked Lt] ° o}9 fuel | fuel quantity | O | en fuel leakage O;O!O;o}o carburetor | | parts dirty 9} O}0;0}0 carburetor thr-| lottle and choke| O}O}O;O;O performance | | carburetor | float height QJE/O] Oo carburetor adjustment 9/9/0;0}0 | fuel pipe changing | *per 4 years ~23~ checking period = en- first] home office judgement check ites eral bontil pee [oe | | Remark cehe-| or_ | ints] aunts ests mths standard ckina00 Sagi performance |O| |O}O/O}O/O lamp system dirty, cracked] OQ OJO]O}O]} oO] horn turn horn signal | performance |} |O|O/O);O}O . reflector 1 turn signal lock | performance O}o}o}ojo} rear view check the oO} jojojofojo mirror illumination } blinker linc-) dirty | Rese plate nu-| O° wberdmark cracked Tnstrument | performance |O| |O|O|O}O}O Ass’y part oOlo|ololo avffler loose cracked) | silencer performance lo} jo}o loose or chassis oO] jo}o cracked j the earlier |confirm it does abnormal jot. happen 1® condition jagain chassis : ofo}ojojo lubrication others \decoking mixer| wwifler, ° ° silencer ~24~ (2)Battery:Recharge when out of power 1.Remove the floor mat. 2.Screwing out the two screws on the battery cover; remove the battery cover 3.Remove the negative cable and then the positive cable,~take out the battery to recharge. 4.Re-assemb| ing the battery as the opposite procedure of disassembling after recharging. Note A.Do not take out the sealed bolt when recharging B.Without refilling water for the. battery Please recharging(12¥) as the following current. Time standard:0,54X5-10 hr or rapid: 3Ax30min.(125 cc) 0,7Ax5-10 hr of rapid:3Ax30min.(150 co) ~25~ (3)Clean air cleaner 1.Remove air cleaner cover 2.Take out the air cleaner filter. 3.Clean the filter by compressor air 4.assemble the air cleaner by the opposite procedure. MOTOR OIL Oil volume ner is not insti Aetn:Do not start engine when air clea Note ‘The vehicle must park on the flat ground before checking B.Start engine for 2-3 min., and stop engine for 2-3 min., then check the oi! volume L.Take out the of! meter to check the oil volume. Q.Refill of! to upper limit when oil volume is below the lower limit Exchange Oil Vote: The oi! will flow out easier when the engine is ara. L.furn off the engine and remove the oi] meter / 2 Screw out the oi! draining bolt on the bottom oll meter | upper limit lower limit Torque:1.5kg-a Engine oil volune:Disassembl ing:1.00 iter Exchanging:0.90liter(new oil filter) Exchanging:0.80liter(without changing oil filter) age of oil, start the engine Wheb checking the leak: ‘tes, then check the oil volume. at idling for a few minu ~26~ (4)Oi screen Cleaning for the oil screen “Drain the Oil in the engine, remove the Oil draining bolt the spring and the screen “If any adherent material is found, please use detergent to clean the screen. “Check the O-ring. If it is damaged, change a new one -Re-install the screen, the spring, 0 ring and the Oil draining bolt Locking torgue:1.5 kg-» (4-1)Oil Filter change the 2nd oil filterrevery $000k Locking torgue:2.0kg-m a“ | oo \ ade Draining Oving Soreen Bolt | (5)The final reducing mechanism oil 1.Change the oil in the gear box: | a.lurn off the engine after warm up. } b-Put a bowl under the engine. |} c.Reaove the draining bolt and filling | bolt to drain the gear oil off | d.Lock the draining bolt before refill | 90ce-. gear oil and then lock the j filling bolt. e.Locking torque:1.8kg.a | ~27~ (6)Spark plug L.Remove spark plug. 2.Check the spark plug electrode and sée whether it is burnt out/ carbonized or not. 3.Clena the electrode, if it is dirty. + Spark plug specification NGK:BP7HS..or eguivalent (T-REX125):NGK C7HSA or eguivalent (T-REX150) Gap of spark plug:0.6~0. 7am spark plug i Electrode burnt out LS Carbon piled up or not Washer is distorted | or not procelain is cracked or not (7)Cylinder Pressure l.Measure it when the engine is warm. _2.Renove the cover at the right hand of, the step floor. 3.Remove the spark plug then place cylinder pressure gauge. Then fully open the throttle and act on the starter motor to measure the compression pressure Compression pressure: 12kg/cu-T50rpm (125ec)s1Lke/om-700rpm(150¢c) “When the compression pressure is too low, check the following a.Valve leakage or not b.Valve clearance c.Gasket of the cylinder head is damaged. d.Piston ring vorn-out e.piston or cylinder worn-out.

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