PGO Bugracer 500
SERVICE MANUAL
BUGGY PGO BUGRACER 500 - SERVICE MANUAL - Service Manual, Owners Manual, Manuel de Instructions and Spare Parts Catalogue to Buggy PGO BugRacer 500. CONTENTS: OWNERS MANUAL 1.Foreword 2. A Few Words About Safety 3.Important Safety Information 4.Safety Lavels 5.Are You Ready To Drive? 6.Is Your Vehicle Ready To Drive? 7.Safe Driving Precautions 8.Operation 9.Service Instructions 10. Repair 11. Periodical Check And Service 12. Electric Parts 13. Appendix MANUEL D’UTILISATION Complement D'information Pour Bugracer Avant-Propos Sticker Operation A. Commandes D'utilisation B. Inspection Avant De Conduire C. Emplacement Des Composants D. Passagers E. Ajustement Du Siege F. Commandes Pour La Conduite G Levier De Vitesse H. Levier De Controle Du Blocage De Differentiel I. Parking J. Instruction De Demarrage Et D'utilisation Entretien A. Systeme De Refroidissement B. Entretien Du Filtre A Air C. Entretien De L'huile Et Du Filtre Du Moteur D. Entretien De L'huile De Boite De Vitesse E. Bougie F. Ajustement Du Ralenti G. Instructions De Nettoyage H. Lubrification Du Buggy I. Lubrification De L'arbre D'entrainement J. Ajustement Des Amortisseurs Avant Et Arriere K. Instruction De Stockage L. Remplacement De La Roue Avant M. Remplacement De La Roue Arriere N. Alignement De La Roue Avant Tableau De Maintenance Periodique Du Br-500 Informations D'entretien Circuit Electrique (Index De Traduction SERVICE MANUAL Characteristics Operation Maintenance Cooling System Electric System Vehicle Engine Steering Wheel And Suspensions Braking System Injection Engine Prior To Delivery Time Chart ENGINE SERVICE MANUAL General Information Maintenance Specific Tools Automatic Transmission Final Reduction Flywheel Starting System Thermal Unit Timing System Crankcase Driving Shaft Injection Lubrication Flywheel Cover Cooling System Starter PARTS MANUAL PART NAME engine complete gasket set and oil seals thermic gasket set and oil seals PART NAME crankcase assy-cm1145215002 u crankcase assy-class 3×9 500 u catergory 4 crankcase 4 category 1 crankcase category 2 crankcase ring for rear wheel axle (25×26.9×1.2) ring for rear wheel axle (47×50.5×1.75) pin x electrical starter motor-d9.5 h15 plug pin vespa gt 125/200 nozzle dowel bearing ball bearing o-ring mag side ball bearing 20×42×12 ball bearing for engine case 17×47×14 cylinder stud pulley side seal sidecase studs bearing runner 180 m.02 0.4 gasket for case bolt for secring sidecase m6-6g×65 t.fla plastic oil dipstick et4 125/mc3 m.02 packing nozzle for engine sidecase clamp bracket PART NAME crankshaft category 1x9 500 woodruff key for flywheel nut spacer race for crankshaft steel shim for crankshaft bolt for secring timing gear m6×25 t.s PART NAME fc1 piston assy. x9 500 fc2 piston assy. x9 500 fc4 piston assy. x9 500 fc3 piston assy. x9 500 piston scraper ring piston scraper ring wristpin for piston wristpin retaining clip piston ring complete cylinder assembly w/piston-mst 0.8 cylinder base gasket 0.4 cylnder base gasket 0.6 cylinder base gasket nut for muffler assy. (m=6/h=7) bracket-.82650r packing packing screw PART NAME cylinder head assy.(bv-500) cylinder head assy. cone half ning sfera u valve spring lower valve cap exhaust valve for cylinder head breather valve for cylinder head uppver valve cap exhaust stud studd for cylinder head clamp screw cap for breather screw x9 500 speedo sensor oil sensor radiator hose clamp for cylinder hood themostat (bv-500) clinder head gasket screw m6×90 t.e.flange nut for securing cylinder head washer PART NAME rocker arm assy rocker arm shaft timing gear x9 500 encoder for x9 screw for camshaft centr. Weights-m5×30 bolt for securing decompression bell counter weight bushing for counterweight decompression bell spring for timing shaft plate for cam upper rocker arm assy. nut screw nut screw PART NAME cylinder head cover screw buffer cylinder head cover gasket spark plug rg6yc champion-.438073 ngk spark plug PART NAME roller container assembly spacer for pulley rollers for pulley shoe for rollers roller cover damping pulley guide bolt for belt stabilizer pulley m8×25 t. half pulley washer 42×18.1×3 washer 36×22.05×2 spring cup washer nut for secuning front pulley assy. transmission v belt for x9 500 beverly PART NAME screw for fuel tank assy. (m6×22) circlip bearing for sidecase defector inside transmission cover screw for fuel tank assy. (m6×22) clamp self tapping screw (d3.85×16) plastic transmission cover filter for transmission cover sounproof material sounproof material screw screw m8×70t.e.es.10h 8.5 screw m8×100t.e.es.10h 8.5 block out plug for sidecase PART NAME oil pump assy.(bv-500) screw for oil pump (m5×30) gasket for oil pump gasket for oil pump oil wall franged hes.head screw(m5×16) chain tensioner guide bolt for securing timing gear m6×25t.s lower chain guid steel spacer for chain guide timing chain PART NAME waterpump cover waterpump fan washer 16×10×1 drive shaft for water pump ring pump screw (m5×16) gasket for waterpump cover PART NAME starter motor-. 82699r starting gear bracket torque limiter x9 500 u cable wiring loom \ hamess bv-500 screw screw m5×12 screw washer for brake disc (5.3×20×0.5) PART NAME magneto and stator assy. (flywheel assy) stator plate bv-500 key flywheel securing washer 30×14.1×3 nut for nut for retaining clutch drum washer 9.9×6.1×3.5 flywheel assy. nut for securing flywheel m6×25 t.c.e. screw m6×30 t.c.e. i PART NAME flywheel case cover x9 gasket for flywheel cover gasket for flywheel cover plug oil seal 8×16×7 oil dip stick x9 packing for oil pan plug (lower) oil filter packing for oil filter (20.35×1.78) oil filter plug (bv-500) oil seal for oil filter screw screw for electrical starter motor-m6×25 screw screw spring clamp clamp breatehr tube for crankase screw m5×12 o-ring for breather x9 oil cartridge plate for stator screw for outer h.t. coil (m5×10) panel for valve screw PART NAME washer oil pressure valve leader 125/180 .04/02 oil pressure valve release spring timing plug assembly packing for oil pan plug (lower) oil temperature sensor master + leader reed case bracket ceramic insert ring pump PART NAME transmission cover x9 circlip radial bearing oil seal 38×50×7 bearing for transfer gear 20×52×15 screw m8×50 t.e.flange clamp screw m8-6g×35 t.flange breather pip for gearbox gasket for gearbox cover gasket for gearbox cover transfer gear driven pulley shaft rear wheel shaft screw (m8×12) washer (brake-shoes) PART NAME plastic throttle body x9 500 franged hes.head screw(m5×16) union pipe fuel injector with support screw for electrical starter motor-m6×30 screw for electrical starter motor-m6×25 PART NAME air cleaner assy. (bv-500) clamp clamp clamp screw air filter b125 packing pipe b 125 clamp bush bv-500 intake sleeve for aibox airbox cover spacer self tapping screw (d3.85×16) clamp radiator hose runner 180 2t m.02 oil tube washer screw washer for starter relay (6.4×12×1) washer for rear mudguard (6.4×11×0.5) screw for airbox (m6×50) hexag. bv.-500 washer 12×4.5×1 screw for air cleaner fitting (m6×50) plate for stator screw stirrup PART NAME Engine Hanger Assy. Spacer Plastic Plug Hexagon Flange Bolt Shockproof Pedestal Comp. Hexagon Flange Nut (Looseproof Hexagon Flange Bolt Hexagon Flange Bolt (M8*45l) Hexagon Flange Bolt (M8*15l) Plastics Plug Plastics Plug Seal Between Muffler And Head Front Section Muffler Hexagon Cap Nut Muffler Assy,Rr Section Hexagon Flange Bolt Hexagon Flange Bolt Washer(21d*2t) Washer Lock Nut Shockproof Pedestal Comp. Hexagon Flange Bolt (M8*15l) Closed Gasket Connector Assy Heat Protector Cr Pan Hd. Screw Washer(Temperature-Enduring) Socket, Muffler Assy PART NAME Ceiling Cover(Orange 2r) Ceiling Cover(Benz-Black 69) Ceiling Cover(White 71) Bolt With Washer Ceiling Cover Rubber Mat Rear Body Cover,Lh(Orange 2r) Rear Body Cover,Lh(Benz-Black 69) Rear Body Cover,Lh(White 71) Rear Fender,Lh Bracket,Rear Body Cover,Lh Cr Round Hd Tapping Screw Rear Body Cover,Rh(Orange 2r) Rear Body Cover,Rh(Benz-Black 69) Rear Body Cover,Rh(White 71) Rear Fender,Rh Bracket,Rear Body Cover,Rh Left Cover Right Cover Left Down Fender Left Up Fender(Orange 2r) Left Up Fender(Benz-Black 69) Left Up Fender(White 71) Down Fender Fiexd Bracket Cr Round Hd Tapping Plate Side Lh Plate Side Rh Right Down Fender PART NAME Right Up Fender(Orange 2r) Right Up Fender(Benz-Black 69) Right Up Fender(White 71) Down Fender Fiexd Bracket Windshield,Frt Above(Orange 2r) Windshield,Frt Above(Benz-Black 69) Windshield,Frt Above(White 71) Windshield,Frt Lower Fixed Plate Cr Round Hd Tapping PART NAME Non-Roll Tube Comp.Lh Side Non-Roll Tube Comp.Lh Side Up Across Tube Comp. Washer Pipe B Hexagon Flange Bolt Hexagon Flange Nut Interior Mirror Assy Hexagon Scoket Head Cap Screw Washer Pipe B Hexagon Flange Bolt Hexagon Flange Nut Back Mirror Comp Lh Back Mirror Rh Back Mirror Tool Box Hexagon Flange Bolt(M6*1.0p*12l) Driver Seat Assy. Passenger Seat Assy. Spring Washer(8d*14d*2.2t) Hexagon Flange Nut (M8) Belt.Safety Frame Assy Hexagon Scoket Head Cap Screw Washer Pipe A Bush Pipe Hexagon Scoket Head Cap Screw Lh Non-Roll Fixed Tube Comp. Frame Bottom Plate (A). Left Frame Bottom Plate (A). Right Hexagon Flange Bolt (M6*15l) Tool Kit Assy. PART NAME Throttle Cable Reverse Gear Pull-Wire-Dish Comp. Bushe Compressing Spring Washer Hexangon Flange Bolt Hexagon Flange Nut (M6*1.0p) Differential Lock Cable Gear Shafting Assy. Hexagon Scoket Screw Gear Shifting Cable Lever Assy.Parking Brake Hexagon Flange Bolt (M6*15l) Snap Plug Cable Assy. Rr Brake Differential Lock Cable Hexagon Flange Bolt (M6*15l) Packing, Differential Cable PART NAME Master Cylinder Back Break Tube Fr, Right Brake Fluid Hose Comp Fr, Left Brake Fluid Hose Comp Washer(10d*15d*1.5t) Joint Bolt,Brake Hose Hexagon Flange Bolt (M8*26l) Hexagon Flange Nut (M8) Hexagon Flange Bolt Hexagon Flange Nut (Looseproof Paddle Assy,Acc Paddle Assy,Brake Torsion Spring Pedal Fixed Bolt Cotter Pin Lock Pin Cotter Pin Hexagon Flange Bolt(M6*20l) Braking Sensor PART NAME Steering Axlel(Rh) Fixed Plate Ball Joint Cri Clip External(34*1.5t) Spring Washer(8d*14d*2.2t) Hexagon Flange Bolt(M8*20l) Rh Turing Restriction Plate Lh Turing Restriction Plate Hexagon Flange Bolt (M6*15l) Front Hub Assy. Brake Disc Screw, Fr Brake Disk Turn Mechanism Ass,Y Hexagon Flange Bolt (M10*1.25p*40l) Slotting Lock Nut Cotter Pin Turn Base Hexagon Flange Bolt (M8*15l) Connect Shaft, Universal Joint Hexagon Scoket Hd. Cap Bolt(M8*25l) A Turn Signal Synthetic Switch Combination Steering Wheel Lock Nut Turn Mechanism Ass,Y Hexagon Scoket Hd. Cap Bolt(M8*25l) Steering Axlel(Lh) Nut Hexagon Flange Bolt(M8*20l) Handel Cover PART NAME A-Arm Assy. Lower,Fr Upper A Arm (R) Hexagon Flange Bolt Lock Nut(M12*1.25p) Caliper Ass'y-Fr Brake Inner Brake Pad Outer Brake Pad Slotting Lock Nut Cotter Pin Front Suspension (Orange) Front Suspension (Red) Hexagon Flange Bolt Lock Nut(M12*1.25p) Upper A Arm (L) A-Arm Assy. Upper,Fl Front Hub Assy. Brake Disc Screw, Fr Brake Disk Caliper Ass'y-Fl Brake Inner Brake Pad Outer Brake Pad Hexagon Scoket Screw Plain Washer PART NAME Swing Arm Down. Lh Swing Arm Down. Rh Swing Arm Spacer Tube Hexagon Flange Bolt U Type Flange Nut Hexagon Flange Bolt Lock Nut(M12*1.25p) Driving Gear Assy Driving Gear Bush Slotting Lock Nut Cotter Pin Fixed Plate Sensor Magnetic Hexagon Flange Bolt (M5*12l) Brake Disc Screw, Fr Brake Disk Rear Hub Body Assy. Hub Inner Seat Assy, Rear Hexagon Scoket Screw U Type Flange Nut(M10*1.25p) PART NAME Head Light Ass'y(W/O Position Lamp) Hexagon Flange Nut (M6*1.0p) Protect Plank, Front Hexagon Flange Bolt (M8*12l) Hexagon Flange Bolt (M8*20l) PART NAME Fuel Tank Packing Fuel Pump Comp Fuel Pump Cap Heat Insulation Aluminum Foil Hexagon Flange Bolt(M8*20l) Clip Gas Cap Gas Cap Connecting Pipe Cr Pan Hd Machine Screw(M5*12l) Tank Cover Comp Hexagon Scoket Screw Gasoline Hose(B) Gasoline Hose(A) Oil Tank Hexagon Flange Bolt(M6*1.0p*12l) Tank Bracket(A) Tank Bracket(B) Hexagon Flange Bolt (M8*12l) Rubber Mat Hexagon Flange Bolt (M8*15l) PART NAME Plate Bottom Speedmeter Spark Switch Speedmeter Assy. Spark Switch Switch Water Meter Bush Water Meter U Type Spring Nut Cr Truss Hd Tapping Screw (M5*16l) Cr Truss Hd Tapping Screw (M5*16l) Speedometer Cover (L) U Type Spring Nut Hexagon Flange Bolt(M6*1.0p*12l) PART NAME Water Pipe Clip Water Connecting Pipe(2) Water Pipe Clip Water Pipe Clip Water Connecting Pipe(1) Water Pipe Clip Clip Water Pipe Clip Water Pipe Clip Water Pipe Hose Clamp Cap Comp. ,Radiator Hexagon Flange Bolt(M6*1.0p*12l) Radiator Assy. Water Tank For Fan Safe Hairnet Comp. Cover Hexagon Flange Bolt(M6*1.0p*12l) Washer Hexagon Scoket Screw Hexagon Scoket Screw Hexagon Flange Bolt(M6*1.0p*12l) PART NAME Auxiliary Cool Tank. Safe Cover U Type Spring Nut Cr Truss Hd Tapping Screw (M5*16l) Washer (5.5d*12d*1t) Oil Cover Auxiliary Cool Tank Water Pipe Clip Hexagon Flange Bolt(M6*1.0p*12l) Rubber Washer
PGO BugRacer 500 Buggy - Service Manual - Owners Manual - Manuel de Instructions - Parts Catalogue
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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