PGO BugRacer 500 Buggy - Workshop Manual - User Manual - Manuel de Instructions - Parts Catalogue

BUGGY PGO BUGRACER 500 - SERVICE MANUAL

- Workshop Manual, User Manual, Manuel de Instructions and Spare Parts Catalogue to Buggy PGO BugRacer 500.

INDEX:

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