MOTIVE POWER INDUSTRY CO., LTD

Transcription

1 Dear customers: MOTIVE POWER INDUSTRY CO., LTD acknowledges your purchases of motorcycles manufactured by PGO and particularly reminds you of the absolute relationship between a driver s driving and one motorcycle s performance or service life. In this manual, PGO provides you the methods of correctly maneuvering the motorcycle and knowledge of easy adjustment, maintenance or reparation and expects you carefully read and refer to it from time to time. For any problem with respect to use or service, please contact any PGO dealer or the seller. The instructions of this manual are prepared for the model as follows: J-BU BU (J3-110BAE): Four-stroke cycle; 113.5cc; 4-valve electronic engine control MOTIVE POWER INDUSTRY CO., LTD

2 CONTENTS PRE-DELIVERY CHECKLIST....,4 WARRANTY REPLY... 5 LIMITED WARRANTY FOR PGO SCOOTERS SAFETY DRIVING ALL COMPONENTS IN A MOTORCYCLE IDENTIFICATION OF A MOTROCYCLE FUNCTIONS OF EACH CONTROLLER MAIN SWITCH (FOR IGNITION & ILLUMINATION) FUEL CAP LOCK FOR STEERING HANDLEBAR SEAT LOCK LUGGAGE CABINET HAFT SWITCH FRONT (REAR) BRAKE SHAFT POWER-FAILURE SWITCH POWER SUPPLY OUTLET (12V) POWER DISCONNECTION SWITCH INSTRUCTIONS OF SPEEDOMETER S FUNCTIONS INDICATION OF SPEEDOMETER PRE-USE CHECK BRAKE THROTTLE ENGINE OIL TIRE HEADLIGHT & TURN SIGNAL LIGHT FUEL TANK CATALYTIC CONVERTER ESSENTIALS FOR USE AND DRIVI... 22

3 7-1 START-UP OF THE ENGINE WARM-UP DRIVING ACCELERATION USE OF BRAKES BREAKING-IN OF ENGINE PARKING CHECK AND ADJUSTMENT BRAKE CUSHION REPLACEMENT OF FUSES BATTERY PERIODIC MAINTENANCE AND EASY REPARATION PERIODIC MAINTENANCE SCHEDULE PERIODIC MAINTENANCE SCHEDULE FOR EXHAUST CONTROL NON-PERIODIC MAINTENANCE SCHEDULE FOR EXHAUST CONTROL MAINTENANCE AND CALIBRATION OF THE EXHAUST CONTROL SYSTEM MAINTENANCE OF THE EVAPORATIVE EMISSION CONTROL (EEC) SYSTEM CLEANING OF AIR FILTER CHECK OF SPARK PLUG REPLACEMNET OF GEAR OIL REPLACEMNET OF ENGINE OIL SPECIFICATIONS OF J-BUBU PERIODIC MAINTENANCE RECORD... 36

4 MOTIVE POWER INDUSTRY CO., LTD PRE-DELIVERY CHECKLIST Owner Name: TEL: Age: Gender: Address: Dealer: Model: Engine No.: Delivery Date: (MMM) (DD) (YYYY); License Plate No.: Vehicle Identification No.: NO Item OK NG NO Item OK NG 1 Handlebar s Turning rightward & leftward 7 Tire Pressure 2 Back-play (Front or Rear Brake) 8 Engine No. & Certificates 3 Lamps & Horn 9 User Manual 4 Fuel Tank; Fuel Category 10 Instructions of Maneuvering 5 Engine Oil 11 Instructions of Periodic Maintenance 6 Brake Oil (Disk) 12 Instructions of Warranty Seller s Signature: Date: Customer s Signature: Date: Recommendation: Please subscribe the Seller s and the Customer s names. The after-sales service shall be valid since the Pre-Delivery Checklist and the Warranty Reply returned to PGO by the vehicle owner.

5 WARRANTY REPLY Name TEL Date of the License Plate issued (MMM) (DD) (YYYY) Address License Plate No. Model Displacement c.c. Engine No. Vehicle Identification No. Dealer General Agent MOTIVE POWER INDUSTRY CO., LTD

6 LIMITED WARRANTY FOR PGO SCOOTERS This is to be presented by the authorized PGO dealer to the purchaser of PGO scooters. We provide the following services: 1. TO OBTAIN THE WARRANTY SERVICE A. Effectiveness of the warranty a. After completing the warranty card, the PGO selling dealer will give you the warranty card. b. Please bring your scooter back to the original dealer for initial maintenance within 30 days after purchase, then the warranty is effective. B. Warranty period For the detail warranty condition, please check with your dealer. 2. PROCEDURE OF THE WARRANTY a. The customer must maintain scooter periodically according to PGO user s book and keep the complete maintenance record. b. The dealer shall check the warranty card, periodically maintenance record, license card for the customer. c. Only the PGO authorized dealer can accept the warranty application. 3. THINGS NOT COVERED IN THIS WARRANTY A. Any of the followings are not covered: Defects caused by inappropriate maintaining or any artificial damages. Any accidents caused by natural disasters or out of human s control. Did not use fuel or spare parts provided or recommended by the PGO, or made any modification of the scooter. Scooters used for competition, performance or rental vehicle. Any re-assembling or dismantling of scooters which violates the rules of PGO service manual. Defects caused by unlicensed rider.

7 Improper storage or transport. Not following the riding rules of Government or PGO Manual Guide. B. The following expenses are not covered: (1) Consumable goods(including battery, bulbs, rubbers, cables, screws, piston rings, spark plugs, gaskets, brake pads, brake linings, clutch lining, springs, V-belt, CVT-rollers, fuses, air filter elements, oil filter, fuel filter) (2) Material of periodic maintenance and inspection, such as fuel, lubricant and fluid. (3) Any costs caused by the break down of the scooter. (including telephone bill, travel fee, transportation fee, rental fee, fines) 4. INTERRUPTION OF THE WARRANTY PERIOD The user should send the scooter to repair immediately after the defects are found. If the defect worsens due to the delay of the repair, the PGO will not be responsible for the damage. IF THERE IS A MAJOR CHANGE IN THE WARRANTY COVERAGE, THE PGO WILL MAKE OFFICIAL ANNOUCEMENT TO ALL DEALERS AND WILL NOT

8 1. SAFETY DRIVING Please give significant signals prior to any action shown as follows. a driver (or passenger) inside the vehicle. 4. Please slow down and carefully pass through a wet steel plate laid on a construction site s ground or a manhole accessed by workers; keep your motorcycle at a vertical position without rollover. 5. Check brake linings, which might be wetted during cleaning of the motorcycle, prior to driving. 6. The driver shall wear a safety helmet, gloves, protective trousers (with bottoms of the trouser legs around ankles fastened) and a brightly colored jacket. Attention: Please activate any turn signal light to hint other vehicles in front and behind at 20m before the motorcycle turning. 1. Do not immediately stop the motorcycle which is driven on a wet roadway in order to avoid rollover. Please carefully and slowly apply the brake on a wet roadway. 2. Please slow down before the motorcycle arriving at a corner or a crossroad; accelerate the motorcycle slowly after the vehicle has made a turn. 3. Please carefully drive the motorcycle while passing through other vehicles parked on the roadside in order to avoid any incident out of a car door suddenly opened by 7. Do not carry excessive luggage on the motorcycle in order to stabilize the vehicle. The luggage shall be fastened on shelves with robust ropes, or the loosened luggage might adversely affect stability or a driver s attention. 8. It is not recommended to warm up the motorcycle before movement of the vehicle in consideration of the vehicle s improved technology and environmental protection. If necessary, please stay beside the motorcycle or slowly drive it without rapid acceleration or immediate high-speed driving.

9 2. ALL COMPONENTS IN A MOTORCYCLE Front Brake Shaft Throttle Exhaust Rear Fender Rear Brake Shaft Footrest Back Mirror Speedometer Headlight Seat Turn Signal Light (Front) Front Fender Rear Armrest Tail Light Turn Signal Light (Rear) Rear Cushion Front Cushion Side Stand Center Stand The components mentioned above are representative parts only. Please refer to the real motorcycle for detailed components.

10 3. IDENTIFICATION OF A MOTROCYCLE 3-1 VEHICLE IDENTIFICATION NUMBER Each motorcycle manufactured by PGO has been marked with a vehicle identification number whose position is shown as follows: 1. Central position below the front luggage 2. Steel frame in the middle section (17 alphanumeric codes found with the cover on the vehicle identification number removed) 3-2 ENGINE NUMBER The engine number is printed on the left crankcase s upper rear position. Upper alphanumeric codes: Model; lower alphanumeric codes: Manufacturing series numbers. Please record these codes as references to order any component from a PGO dealer. Engine No

11 4. FUNCTIONS OF EACH CONTROLLER 4-1. MAIN SWITCH (FOR IGNITION & ILLUMINATION) The instructions of the ignition switch used to control ignition and illumination are shown as follows: 1. : Power disconnected; key removable 2. : Power connected; engine ready to be started; key not removable 3. : Handlebar locked; power disconnected; key removable. Please refer to Steering Handlebar (P-12) for correct operations. 4. : PUSH & turn left: Open the seat with the key kept at A, B, or C. 5. B : Press and turn the key clockwise to open the fuel cap. 6. Remove the key and press the E tab rightward to protect the key hole from any intrusive foreign object and activate anti-theft status. 7. Plug the shutter magnetic lock on the key shank into F and turn it rightward to open the cover. Attention: Turn the key to OFF or LOCK and remove it when the motorcycle is not driven. 4-2 FUEL CAP 1. With the key remained at, press PUSH and turn the key clockwise to open the fuel cap. 2. Press the fuel cap frontward and downward to close the fuel cap.

12 4-3 LOCK FOR STEERING HANDLEBAR 4-5 LUGGAGE CABINET Turn the steering handlebar far left prior to locking it. The luggage cabinet is located under the seat. Turn the key to LOCK from OFF and remove it. Please put your helmet straight inside the luggage cabinet and Turn the key clockwise to unlock the steering handlebar. keep the helmet s front toward the back direction of the motorcycle. 4-4 SEAT LOCK 1. Push and turn the key counterclockwise, which is at any position, in order to lift and open the seat. 2. Please properly use the seat lock to protect any private objects inside the luggage cabinet and activate the anti-theft function prior to leaving your motorcycle. 3. Please lay down and press the seat gently in order to activate the seat lock and extend its service life. Attention: Restrict articles inside the luggage cabinet not exceeding the maximum load. Maximum load: 5kg Attentions for use of the luggage cabinet: 1. Do not store any object weakly heat-resistant or inflammable inside the luggage cabinet because of the luggage heated under sunshine or the engine running. 2. Do not store any object precious or fragile inside the luggage cabinet. 3. Wrap objects inside the luggage cabinet with waterproof materials due to intrusion of moisture at a rainy day or during cleaning of the motorcycle. 4. Store any wet article which has been wrapped with waterproof materials inside the luggage. Attention: Please properly close the seat prior to leaving the motorcycle.

13 4-6 HAFT SWITCH 4-7 FRONT (REAR) BRAKE Lever 1. High / low beam 2. Turn signal light Restore the switch at the central position to deactivate a turn signal. 3. Horn 4. Start-up Hold the brake shaft (front or rear) and press Start-Up simultaneously to start up the engine. 5. Illumination Activate parking lamps (first-stage) and the headlight (second-stage) while driving the motorcycle at a bad weather or night. 6. PASS light Press PASS and activate the headlight to give a warning signal. 1 Rear brake lever Left lever: Rear brake. Grip the brake shaft backward to activate the rear brake. Front brake lever Right lever: Front brake. Grip the brake shaft backward to activate the front brake

14 4-8 POWER-FAILURE SWITCH Function: Enhance the anti-theft function. Use: 1. Keep the Power-Failure Switch at O to disable start-up after the motorcycle is parked. O : Start-up disabled; - : Start-up enabled 2. Power-Failure Switch at O : EMS--- & indicated on the display panel; Power-Failure Switch at - : EMS OK only (no other icons) indicated on the display panel. 1. The outlet is available with the power switch enabled. 2. Remove the unused outlet. 3. Provide the fuse (1A) to the power supply outlet only without other appliances connected. 4. Do not connect any appliance prior to start-up in order to protect it from damage. 5. It is not recommended to use the outlet but bring the motorcycle to any PGO dealer for check in the event of the voltage value greater than 15V indicated on the display panel. Attention: Do not change the switch s position during the engine still running until the motorcycle is parked. 4-9 POWER SUPPLY OUTLET (12V) As one optional device, the vehicle power supply adapter outlet could supply 12V to other appliances. Attention: 4-10 POWER DISCONNECTION SWITCH The power disconnection switch will be activated to stall the motorcycle within 6 seconds in case of rollover of a running motorcycle. It is necessary to disconnect and reconnect the power supply for next start-up with the stalled motorcycle supported. Attention: Some error messages (Code: P0261) will be indicated on the display panel with the power disconnection switch activated. These messages are not disadvantageous to the vehicle. Bring the tumbled motorcycle to any PGO dealer for further check.

15 5. INSTRUCTIONS OF SPEEDOMETER S FUNCTIONS 5-1. INDICATION OF SPEEDOMETER Speed per hour Information for functions Functional icon Engine oil indicator High beam indicator EMS indicator Low beam indicator Turn signal light (left) Fuel level Turn signal light (right) Mileage information Function key

16 EMS Information Injection diagnosis function automatically activated with power connected. Any error will be indicated on the display panel. Time Information Press the button on the display panel to indicate Time. Refer to Set-Up for adjustment of Time. Millage Information The millage Information is always indicated at the bottom for any mode. Press and hold the button to switch km or mile at the ODO mode. Switch of mileages between ODO and TRIP: Continuously press the button on the display panel to switch ODO or TRIP. Press the button to reset the mileage on the display panel at the TRIP mode. Voltage Information RPM Fuel Level Press the button on the display panel to indicate Voltage. Voltage alarm: Battery voltage lower than 11.5V or greater than 15.5V Press the button on the display panel to indicate RPM. Fuel Level is always indicated at the left-hand side of the display panel for any mode. Low fuel level: Fuel Level blinking and a symbol for low level indicated on the upper right corner in case of one scale only.

17 Set-Up Disconnect the power supply. Press and hold the button to enable power and enter the page for set-up. Reset of Oil Indicator The oil indicator ON implies the engine oil to be replaced. Enter the page for time set-up; (1) Short press for adjustment of time; (2) Long press for switch between HR and MIN. Adjustment of the display panel s contrast: Continuous long press Adjustment of the display panel s contrast Reset the oil indicator with service completed. Press and hold the button under ODO (total mileage) for 3 seconds until the oil indicator blinks. When the oil indicator blinking, press and hold the button for another 5 seconds in order to eliminate blinking. Attention: Please drive your motorcycle to a PGO dealer for check in case of any EMS error message shown on the display panel during a drive. Attention: Do not change the speedometer s any function during a drive for the purpose of safety.

18 6. PRE-USE CHECK Item Procedure Page Front Brake Check brakes functions, free plays, brake oil level and any leakage. If necessary, fill 13;19;25 the brake oil tank with FMVSS DOT4 brake oil. Rear Brake Check brakes functions, free plays, brake oil level and any leakage. If necessary, fill 13;19;25 the brake oil tank with FMVSS DOT4 brake oil. Throttle Check the throttle s functions. Add any lubricant and adjust the throttle, if necessary. 19 Lubricant Check the lubricant level or add any lubricant based on consumption. 19 Tire Check tires air pressures, wear or damage. 20 Haft Switch / Speedometer Check functions. 13 Center Stand Check functions; add any lubricant or adjust the center stand, if necessary. - Assembled Part / Fastener Check all assembled parts and fasteners; fasten or adjust them, if necessary. - Fuel Tank Check the fuel level; add any fuel as per requirements. 21 Headlight & Turn signal light Check functions. 20 Brake Shaft Check functions; add any lubricant, if necessary. 13;19 Note: Conduct check before each drive. The said checks could be finished in a short period and substantially enhance safety compared with time you spent. In case of any item failed or any component contrary to normal operations, please check it immediately prior to the next drive.

19 6-1. BRAKE (Refer to P-25 for details.) 1. Front (Rear) Brake Lever Check free plays of front & rear brake shafts; make sure of their functions. Check brakes of a motorcycle driven at a low speed. Please correct any improper free play. Attention: A loosened brake lever implies some errors of the brake system. Do not drive your motorcycle until these troubles are removed. Bring the motorcycle to any PGO dealer for checks. A loosened brake shaft is equivalent to risks in the brake system. 2. Brake fluid (Disk brake) Check the brake oil level; add brake oil, if necessary. Brake fluid designated: FMVSS DOT4 3. Leakage of Brake fluid Check any joint along the brake hose for any brake fluid leaking from the joint or the brake cylinder; leakage possibly occurs in case of wet oil or oxidized fluid sludge. 4. Check of Disc Brakes (P-25) Note: Please contact a PGO dealer to repair disc brakes. Attention: Please contact a PGO dealer to repair leakage of brake fluid, if any. The leakage implies any potential risk in the brake system. 6-2 THROTTLE Turn the throttle to check its functions and free play. Make sure of the released throttle returning to its original position by means of elasticity. If necessary, the throttle should be adjusted by a PGO dealer. 6-3 ENGINE OIL Attention: The motorcycle with the engine oil level to be checked should be parked on a flat surface. Allow the engine to run 2~3 minutes first; check the engine oil level with the engine stopped for 2~3 minutes. Total volume: 1000 c.c Oil to be replaced: 800 c.c Remove the dipstick and check the engine oil level. Add the engine oil provided by PGO to the upper limit in case of the oil level under the lower limit.

20 6-4 TIRE Please check the following conditions in order to make sure of maximum performance, service life and safety: 1. Tire Pressure: Check if tire pressure is in conformity with standards (1 driver only) prior to a drive. Appropriately increase the tire pressure for any heavy object loaded. Normal air pressure Front tire: 1.8~2.0 kg/cm 2 Rear tire: 1.8~2.0 kg/c m 2 2. Check Check tires conditions prior to a drive. Bring the motorcycle with some troubles on tires such as excessive wear, nail, cullet or crack to a PGO dealer for immediate reparation or replacement with the same model, if necessary. 3. Check tread patterns (depths): The motorcycle with the tire tread depths too shallow might slide on a wet road or a brick paving with filthy objects covered. In the case of tread wear indicators indicating tread patterns excessively worn, please contact a PGO dealer for replacement. Minimum depth of tread patterns (front & rear) = 0.8 mm Attention: 1. It is very dangerous to drive a motorcycle with tire treads excessively worn. In the case of tread wear indicators displaying a worn tire, please contact a PGO dealer for replacement. 2. It is a normal situation that a driver who drives a motorcycle with tires block patterns worn feels slight vibration at the handlebar. 6-5 HEADLIGHT & TURN SIGNAL LIGHT 1. Check functions of the headlight, turn signal lights, rear lights, brake lights, display panel lights and all indicators. 2. Switch Check switches for headlight, turn signal light, brake light, horn, and start-up. Headlight Turn Signal Light (Front) Turn Signal Light (Rear) Brake Light Attention: Do not touch the surface of the headlight housing which has been turned on because of high temperature.

21 6-6 FUEL TANK Make sure of fuel sufficient. catalytic converter is to reduce pollutants in exhaust fume. Attention: 1. Do not make gasoline spill from the fuel tank or touch the high-temperature engine. The level of fuel added into the fuel tank should be lowered than the oil gun s nozzle, or the gasoline heated and expanding will spill. 2. The spilled fuel shall not touch the exhaust because the high temperature on the surface of a catalytic converter installed at the exhaust s rear section results in combustion of gasoline. 6-7 CATALYTIC CONVERTER(optional device) As one device to control fume, the catalytic converter on the motorcycle is installed in the exhaust pipe. The purpose of the Attention: To avoid burn, please park the motorcycle in one place where pedestrians or children cannot contact high temperatures of its exhaust. Attention: Please follow the following instructions in order to avoid damage of a catalytic converter and other dangers. 1. Add unleaded gasoline only rather than leaded gasoline which results in ageing or failure of a catalytic converter. 2. Do not drive, idle, or park a motorcycle on inflammables. 3. Keep the engine s perfect running status. (The imperfect systems such as engine circuit, ignition or fuel might cause high temperatures at the catalytic converter.) 4. Perform periodic maintenance and check of the motorcycle in order to make sure of good performance of the catalytic converter and the whole exhaust control system.

22 7. ESSENTIALS FOR USE AND DRIVING A driver must be familiar with skills to drive and control the motorcycle and the functions. For any problem not realized, please contact a PGO dealer. Attention: 1. Do not start the engine at a weakly-ventilated place in which the toxic fume discharged from the motorcycle might make a person lose consciousness or be killed in a short period. Please always operate the motorcycle at a well-ventilated place. 2. Make sure of the side stand properly retracted prior to a drive; an extruded side stand of the motorcycle which is making a turn might cause serious accident. 7-1 START-UP OF THE ENGINE 1. Turn the main switch clockwise to connect power supply. 2. Totally close the throttle; hold the front (or rear) brake shaft and press the start-up button to start the engine. 3. The throttle could be slightly advanced to easily start the engine at low temperatures (<0 ) or high mountains (>2000m). Note: Release the start-up button and try again several seconds later in case of the engine not started. The start-up should be completed within 5 seconds for the purpose of no excessive electricity in a battery consumed. 7-2 WARM-UP It is not recommended to warm up the motorcycle at rest for reduced exhaust or pollutant. On the other hand, the sudden acceleration of the motorcycle at cold-start status should be avoided to make sure of the engine s longest service life. Attention: Please refer to Breaking-In of Engine (P-23) prior to the first drive of the motorcycle.

23 7-3 DRIVING 1. Hold the motorcycle s handlebar by the right hand; push the motorcycle forward and retract the center stand from the ground. 2. Straddle the motorcycle and check angles of back mirrors. 3. Carefully observe the traffic in front; activate a turn signal light prior to the motorcycle driven on a road. 4. Slowly turn the throttle (right) and turn off the turn signal light. 7-4 ACCELERATION Adjust the vehicle speed by turning the throttle. Acceleration (deceleration): Throttle turned backward (forward). 7-5 USE OF BRAKES Attention: 1. Do not stop the motorcycle suddenly or abruptly with brakes to avoid slide or rollover. 2. Generally speaking, it is recommended to apply front and rear brakes simultaneously for the best brake and safety. 3. Carefully apply brakes when the motorcycle deviates from the normal direction. Stopping the vehicle improperly might results in a slide. 4. Slow down and pass through a metal plate laid on a construction site s ground, rails or a wet manhole. 5. Carefully and deliberately apply brakes of the motorcycle driven on a wet pavement. 6. Decelerate the motorcycle driven on a descent. 7-6 BREAKING-IN OF ENGINE The stage critical to a motorcycle s service life is from the beginning of the vehicle being driven to the end of breaking-in. As a result, the following information shall be carefully read. It is recommended the loading should not be too heavy during the breaking-in period in view of all new components installed in the engine. The key point in this stage is breaking-in of components inside the engine in order to establish the best running conditions. Therefore, a driver should avoid the long-term driving at a full throttle or any status causing the engine bearing heavy load. Attention: For the engine s any problem in the breaking-in period, please contact a PGO dealer ~50km: Do not run the engine at the 3/4 full throttle or more. Change speeds frequently and avoid the engine to be run at the same RMP. 2. Keep the engine away from long-term heavy load before the first maintenance with the motorcycle driven for 300km. Attention: With the motorcycle running over 300km, change both gear oil and engine oil recommended by PGO. Attention: For the engine s any problem in the breaking-in period, please contact a PGO dealer.

24 7-7 PARKING 1. Center stand Correct Incorrect Parking Turn off the engine and remove the key with the motorcycle parked. Incorrect 2. Do not leave any heavy object or a child on the motorcycle supported by the side stand. Attention: The motorcycle should be parked at one place away from pedestrians or children. Do not park the motorcycle on a slope or soft earth to prevent the vehicle from rollover.

25 8. CHECK AND ADJUSTMENT 8-1 BRAKE Keep the free play of the front (or rear) brake shaft between 5 and 15mm, or contact a PGO dealer for reparation. Disc Brake 1. Apply any brake and check the wear indicator during inspection. Replace the disc brake at a PGO dealer in case of the wear indicator almost contacting the disc brake. 2. Any significant scratch on a disc brake implies the brake possibly affected. Replace the disc brake at a PGO dealer forthwith. Attention: An incorrect free play implies risks in the brake system. Do not drive a motorcycle with the free play incorrect and contact a PGO dealer for reparation immediately. Brake pads Check each brake wear indicator. Replace any brake pads whose wear has been warned by a brake wear indicator at a PGO dealer: 1. Brake pad s bottom groove worn 2. Brake pad s thickness < 2mm Attention: In case of high-frequency noise out of the brake system heart during stopping the motorcycle, check the brake lining s thickness first. Remove and clean the brake lining whose thickness is greater than the standard value with a high-pressure Attention: Water permeating the brake might cause temporary brake failure and further threaten driving safety. Brake fluid Air might be introduced into the brake system and cause brake failure in case of the brake fluid level lower than the standard. Check the brake fluid level prior to a drive; add any brake fluid to the standard level, if necessary. Please follow the precautionary measures as follows: 1. Press a brake shaft to make sure of the brake fluid tank at the horizontal position during inspection. 2. The specific brake fluid with constant quality is applicable, or the rubber seal deformed might cause leakage and brake failure. Brake fluid designated: FMVSS DOT4

26 3. The brake fluid to be added should be the same model. The mixture of brake oil with different specifications will generate hazardous chemicals which causes brake failure. 4. Moisture should not be introduced into the brake fluid tank during addition of brake oil because the boiling point of brake oil reduced by moisture results in air lock. 5. Wipe any spilled brake fluid and flush the affected surface with clean water forthwith because the brake oil erodes painted surface or plastic. 6. In the case of the standard level of brake fluid not reached, please contact a PGO dealer for inspection. 8-2 CUSHION 1. Visual inspection Check the front fork s inner surface for any wear, damage or leakage. Check the rear cushion s appearance for any leakage. 2. Park the motorcycle on a flat surface prior to inspection. A. Hold the handlebar by hands and keep the motorcycle at the vertical position. Apply the front brake by the right hand. B. Press and release the motorcycle s front fork several times and check the front cushion. C. Hold the rear armrest by hands and press it several times to check the rear cushion. Attention: Securely support the motorcycle to avoid any danger during inspection. Attention: Contact a PGO dealer for the front fork s functions not smooth or the component damaged.

27 8-3 REPLACEMENT OF FUSES 2. The battery status is over discharge in case of the engine 1. Fuses are installed beside the battery (inside the luggage difficultly started, weak honk, dim light, etc. Please follow cabinet s rear section). the standard procedure to charge the battery. 2. Disconnect both the main switch and any switch connected 3. Please charge the motorcycle s battery and disconnect the to circuits failed in case of any fuse broken. Install a new cable which is connected to the negative terminal before fuse corresponding to correct Ampere. Turn on the switch leaving the motorcycle unused for a long period. Charge and check the appliance s functions. Contact a PGO dealer the battery once every three months during this period. in case of the new fuse burned immediately. 4. Two black grounding cables connected to the battery s negative terminal should be securely fixed to the ground stud, or the engine cannot be started. Attention: Do not use any fuse out of spec. compared with the original one. An unqualified fuse in place of the real fuse might seriously damage the electrical system or even fires. 8-4 BATTERY 1. It is unnecessary to add any electrolyte or distilled water into the sealed battery which is installed on the motorcycle. In case of any sign of leakage of battery acid, please contact a PGO dealer. Attention: Disassembling any sealant on the battery without permission will damage the battery.

28 Methods and Notices for Electrolyte Added into a Battery HOW TO ADD ELECTROLYTE Attention: (1) Remove the battery from the motorcycle prior to addition of any electrolyte; (2) Check if electrolyte to be added is in conformity with specifications. 1. Prepare the battery Place the battery on a flat surface; rip seal tapes. Filling apertures 4. Confirm added electrolyte Make sure of bubbles generated from at least one from 6 tubes (3 tubes on the right/left-hand sides, respectively); keep the battery stable for 20 minutes. Attention: Tap the electrolyte container s bottom 2 or 3 times in case of no bubble observed in any tube. 2. Prepare electrolyte Remove the batten on the electrolyte container and take the batten as sealant covering the battery. Attention: Do not rip or poke diaphragm seals at filling apertures. Batten Diaphragm seals at 6 orifices of the electrolyte container 3. Add electrolyte Lift and reverse the electrolyte container; align the container s orifices with 6 filling apertures on the battery; apply pressure on the container to make diaphragm seals on orifices broken and electrolyte injected into the battery. Attention: Do not tilt the electrolyte container or electrolyte flow is interrupted. Do not use pliers to cut any connected portions. 5. Remove the electrolyte container With electrolyte added completely, tap the container s bottom several times to discharge remaining electrolyte and remove the container. 6. Seal the battery Correctly align the batten with the battery s six filling apertures; apply pressures to press the batten; make sure of both the batten and the battery s top on the same horizontal. * Do not remove seals or add any other water or electrolyte with addition of electrolyte completed. DANGER Notices for use of chemicals: Sulfuric acid contacting skin directly or through clothes will result in serious burn. Accordingly, an operator shall wear a mask or an overall. Flush the victim s eyes on which electrolyte sprinkles at least 15 minutes and transport him (her) to a hospital. Emergent measures: Flush clothes or skin with electrolyte contacting. Drink a great deal of water (or milk) and then vegetable oil (or milk) containing magnesia in case of electrolyte swallowed. * Keep electrolyte at one place where a child cannot touch.* DANGER

29 9. PERIODIC MAINTENANCE AND EASY REPARATION To keep your motorcycle at the safest and most efficient status, please perform periodic maintenance, adjustment and lubrication. Any driver is responsible for personal safety. The Periodic Maintenance Schedule should be taken as a guideline for maintenance and lubrication. Additionally, other factors such as climate, geographic environment and purpose of driving a motorcycle which may change from time to time should be considered in the schedule. In this section, the key points with respect to inspecting, adjusting and lubricating a motorcycle are particularly interpreted. Attention: Any driver who is not familiar with inspecting a motorcycle should bring the motorcycle to a PGO dealer for detailed checks. Attention: This small-size motorcycle is designed to be driven on general pavement. In the case of a motorcycle driven in sludge or other moist conditions, the air filter should be cleaned or replaced frequently, or the engine might deteriorate speedily. Please contact a PGO dealer for an appropriate service cycle. Note 1: To make sure of smooth running of the engine, replace the total engine oil after the first 300km. (Refer to specifications (quantity to be replaced) or a sticker on the engine.) Please contact a PFO dealer for change of engine oil. (Oil or components provided by PGO only) Note 2: Replace brake fluid: 1. Please replace brake fluid during disassembling a brake master cylinder or a brake caliper. 2. Replace seals for the brake master cylinder and the brake caliper every two years. 3. Replace the brake fluid hose every four years (or replace any damaged hose immediately). Note 3: Check the cooling system (engine oil) 1. Check the cooling tubes for leakage during the periodic maintenance. 2. Check the engine oil cooler for any trouble like leakage. 3. Clean and clean the engine oil cooler for any filthy cooling fans with soft cloths in order to keep the cooling effects.

30 9-1 PERIODIC MAINTENANCE SCHEDULE Item Content First 300 (1 Month) 3,000km (3 Months) 6,000km (6 Months) Mileages or Months 9,000km (9 Months) 12,000km (12 Months) Engine Oil* Replacement (Refer to Note 1 on P-32) Replacement every 1,000kn 15,000km (15 Months) Oil Filter* Cleaning; replacement (if necessary) Cleaning every 2000~3,000km; replacement (if necessary) Filter (Belt Den) Cleaning or replacement Gear Oil* Replacement Front Brake; Rear Check brake linings for wear & functions or leakage of brake oil. Cleaning Brake (Disc Brake) or reparation (if necessary). Cooling System Check the cooler and hoses for leakage or ageing. Replacement (if (Engine Oil) necessary). (Refer to Note 3 on P-32.) Check every 6000kn. V Belt * Check for damage or wear; clean the belt prior to lubrication; replace the R belt, if necessary. Clutch Check functions; clean the clutch, if necessary. Brake Shaft Pivot* Check functions; adjust the pivot, if necessary. (Drum Brake Only) Tire * Check balance, damage and circular degree; replace the tire, if necessary. Tire Bearing * Check assembly or any loose. Front Fork & Rear Check functions and leakage. Cushion * Steering Bearing * Adjust tightness, if necessary. Main (Side) Stand * Check functions; replace the main (side) stand, if necessary. Tightness * Check tightness of all components; adjust any component, if necessary. Battery * Check if the MF battery s voltages are greater than 12.8V. Charge the battery, if necessary; clean terminals. *: Service available in a PGO dealer only R: Part changed every 12,000km or checked every 6,000km for driving security. To keep a motorcycle s good performance, a motorcycle driven in any disadvantageous environment such as dust shall be maintained according to a short cycle. : Mileage for service The complete inspection (minor inspection) based on the said service schedule is applicable every 6,000km (3,000km). Please refer to the frequency mentioned herein for other mileages beyond the upper limits. 18,000km (18 Months)

31 9-2 PERIODIC MAINTENANCE SCHEDULE FOR EXHAUST CONTROL Item Valve Clearance* Spark Plug Positive Crankcase Ventilation Device* Fuel System* Content Check and adjust the valve clearance with the engine cooled down. Check functions; adjust the gap and clean the spark plug. Replace any spark plug, if necessary. Check the hose for crack or jam. Replace the hose, if necessary. Check the hose for crack or jam. Replace the hose, if necessary. First 300 (1 Month) 3,000km (3 Months) 6,000km (6 Months) Mileages or Months 9,000km (9 Months) 12,000km (12 Months) 15,000km (15 Months) 18,000km (18 Months) Air Filter* Cleaning; replacement (if necessary) Evaporative Emission Control System* Exhaust System* Check the control system for damage. Replace the control system, if necessary. Check for leakage. Fasten or replace the washer, if necessary. Idle* Check and adjust the engine s idle speed. EMS* Check all sensors functions (for the motorcycle model with EMS only). Throttle Valve* Check and clean the throttle every 6000km; clean the throttle every 12000km. C C C *: Service available in a service station designated by PGO C: Part checked (cleaned) every 6000km (every 12000km) R: Part changed every 12,000km or checked every 6,000km for driving security. To keep a motorcycle s good performance, a motorcycle driven in any disadvantageous environment such as dust shall be maintained according to a short cycle. 9-3 NON-PERIODIC MAINTENANCE SCHEDULE FOR EXHAUST CONTROL Item Content Removal of carbon deposit in It is necessary to maintain or check the ignition system in case of ignition failure, engine fire, overheat, etc. constantly occurring. Remove carbon deposit on the cylinder head, the the ignition system piston head, and the exhaust system in the event of the engine s power significantly dropped for the mileage between 5,000 and 10,000km. *: Service available in a PGO dealer only

32 9-4 MAINTENANCE AND CALIBRATION OF THE EXHAUST CONTROL SYSTEM In the series of motorcycles with catalytic converters installed, catalysts fixed in an exhaust cannot be removed for separate maintenance. As a result, the motorcycle needs to be correctly employed and regularly maintained in order to keep well-performed catalyst. The subjects to be particularly or periodically cleaned, checked and adjusted contain fuel, air supply system and ignition system. (1) Refer to P-36 for cleaning of an air filter. (2) Check the spark plug; remove any carbon deposit; adjust the gap. Replace the used spark plug, if necessary. (3) Check the fuel system for any cracked or jammed hose; replace the hose, if necessary. (4) Check the exhaust for any leakage; fasten or replace the washer, if necessary. (5) Check if the engine s idle speed is within the spec. If not, bring the motorcycle to the mechanic for inspection. (6) Check the exhaust concentration at the idle speed; adjust or repair the motorcycle at a service station for exhaust fume. (7) Method to check and adjust exhaust fume: The adjustment shown as follows is performed with the engine warmed up. (Standard for warming up: Temperature: 110 C (spark plug adapter) or 90 C (engine oil); engine warmed up for at least 10 minutes) The adjustment of RPMs at idle is not available for one motorcycle conforming to the Phase 5 Exhaust Emission Standards. (8) Standards for inspection of exhaust fume: Model Spec. Idle Speed (RPM) CO% HC (ppm) Sampling * Rated Value - < 3.0 <1600 After Catalysis J3-110 BAE Realistic Value 1650±100 < After Catalysis 9-5 MAINTENANCE OF THE EVAPORATIVE EMISSION CONTROL (EEC) SYSTEM 1. As one device to control hydrocarbon exhaust fume, EEC collects evaporative oil gases from the fuel tank and guides them to the engine for re-combustion without oil gas emitted into the atmosphere or pollution (Right). 2. Periodic inspection: Check hoses and joints for secure connections or damages. If any, please fasten or replace them. Active carbon can: Give a puff to test ventilation. In case of poor ventilation or jam, please replace it with a new one. Isolating valve (for overflow oil): Slant the motorcycle to test fuel overflow. Replace the failed isolating valve with a new one in case of the overflow > 15cc/min. 3. Non-periodic inspection: Check the EEC system and components for break or loose in case of any incident; follow instructions for periodic maintenance. Active Carbon Can Isolating Valve (for Fuel Overflow)

33 9-6 CLEANING OF AIR FILTER 9-7 CHECK OF SPARK PLUG 1. Remove set screws fixing the air filter cover. 2. Remove the cover. 3. Take out the air filter paper. 4. Check the air filter paper. 5. During installation of a new filter paper in place of the old one, the filter washers should be properly installed or the dirty air might be absorbed into the engine. Replace the filthy filter paper with a new one and install the air filter cover. Make sure of the air-tight packing installed properly and fasten screws to avoid unfiltered air absorbed into the engine. Attention: Do not start the engine in case of the air filter not properly installed, or the piston or the cylinder is excessively worn. As one important component of the engine, the spark plug can be easily inspected. The engine s status could be determined from conditions of a spark plug. For one motorcycle normally driven, the ideal color of the white ceramics around the center electrode should be moderate brown or light brown. Do not diagnose a motorcycle s trouble but bring it to a PGO dealer for inspections. The spark plug should be removed for inspections periodically due to the spark plug gradually damaged or eroded by heat and deposits. Replace the used spark plug, which is eroded excessively or contains too much carbon deposits or others, with a correct model. Prior to installation of a spark plug, the gasket s surface and filth inside threads should be cleaned or removed and the spark plug should be fastened according to a standard torque. * Standard spark plug with a gap between 0.6 and 0.7mm * Standard torque to fasten a spark plug: 1.2kgf-m Note: Gently turn a spark plug to be installed onto correct threads by fingers; fasten the spark plug with one wrench according to a standard torque.

34 9-8 REPLACEMNET OF GEAR OIL 9-9 REPLACEMNET OF ENGINE OIL 1. Check gear oil for leakage regularly; bring the motorcycle 1. Check the engine oil level prior to each drive; bring the to a PGO dealer for inspections in case of any trouble. motorcycle to a PGO dealer for inspection in case of too 2.Replace the new motorcycle s gear oil with the oil provided much oil consumed. by PGO at the first 300km and every 2,000 ~ 3,000km 2. Replace the new motorcycle s engine oil with the oil later. provided by PGO at the first 300km and every 1000km 3. Quantity of gear oil: later. Total quantity: 110.c.c 3. Quantity of engine oil: Quantity to be replaced: 90.c.c Total quantity: 1000.c.c Quantity to be replaced: 800.c.c Filler Plug Filler Plug Drain Plug Upper Limit Lower Limit Bolt (Drain Plug)

35 SPECIFICATIONS OF J-BUBU Category Item Specifications Dimension & Weight Engine Fuel Device Appliance Length Width Height Seat Height Axle Distance Weight Model Fuel available Number of Cycles & Cooling Displacement Compression Ratio Bore Stroke Number & Arrangement of Cylinders Lubrication Fuel Tank Capacity Fuel Supply Ignition Spark plug model Start-up 1720 mm 710 mm 1060 mm 750 mm 1215 mm 103 kg J3 #92 unleaded gasoline (or higher-level) Air-cooled four-stroke engine (with engine oil cooling system) cc 10: mm 54.5 mm Single Cylinder Compression & splash 5.5 l Fuel injection system Transistor ignition CR7E Power-driven Category Item Specifications Transmission Suspension Device Brake Light & Illumination Tire Dimension First Reduction Device Second Reduction Device Clutch Gearbox Front Suspension Rear Suspension Front Rear Headlight (High / Low Beam) Rear Light / License Plate Lamp Brake Light Turn Signal Light (Front / Rear) Front Tire Rear Tire 0.75~2.6 49/16*47/15=9.596 Dry centrifugal govern weight V-belt C.V.T Extensible Swinging Hydraulic disc brake Hydraulic disc brake 12V-35W/35W 12V-0.2W/12V-5W 12V-2W 12V-2W/12V-2W 90/ /90-10

36 PERIODIC MAINTENANCE RECORD * A motorcycle usually driven in any disadvantageous environment such as dust shall be maintained according to a short cycle in order to keep the motorcycle s good performance. Reference Mileage for Service Actual Mileage Date Service Item Dealer s Stamp 300km (MMM) (DD) (YYYY) 1000km (MMM) (DD) (YYYY) 2000km (MMM) (DD) (YYYY) 3000km (MMM) (DD) (YYYY) 4000km (MMM) (DD) (YYYY) 5000km (MMM) (DD) (YYYY) 6000km (MMM) (DD) (YYYY) 7000km (MMM) (DD) (YYYY) 8000km (MMM) (DD) (YYYY) 9000km (MMM) (DD) (YYYY)

37 PERIODIC MAINTENANCE RECORD * Copy the periodic maintenance record for further applications, if necessary. Reference Mileage for Service Actual Mileage Date Service Item Dealer s Stamp 10000km (MMM) (DD) (YYYY) 11000km (MMM) (DD) (YYYY) 12000km (MMM) (DD) (YYYY) 13000km (MMM) (DD) (YYYY) 14000km (MMM) (DD) (YYYY) 15000km (MMM) (DD) (YYYY) 16000km (MMM) (DD) (YYYY) 17000km (MMM) (DD) (YYYY) 18000km (MMM) (DD) (YYYY) 19000km (MMM) (DD) (YYYY)

38 Please bring this service instruction with the motorcycle for any reference. Maintain your motorcycle periodically and fill in the Periodic Maintenance Record for checks of service records. The proper maintenance allows your motorcycle to be kept at the best performance and guarantee your driving security. Please contact the PGO service center around Taiwan for any problem. PGO sincerely supply the complete service for each user.