CHICAGO SCOOTER CO PUG 50

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

The provided document is an owner's manual for the Chicago Scooter Company Pug 50 scooter.

Function Description

The Chicago Scooter Company Pug 50 is a motor vehicle designed for personal transportation. It is equipped with an internal combustion engine and various controls for operation, including a throttle for acceleration, brake levers for slowing and stopping, and handlebars for steering. The scooter is designed for safe and efficient operation, with an emphasis on regular maintenance and proper usage to ensure longevity and reliability.

Important Technical Specifications

Engine:

Type: QMB
Displacement: 49 cc
Bore: 39 mm
Stroke: 41.4 mm
Compression Ratio: 10.5:1
Cooling: Forced Air
Lubrication Method: Separated Pump
Fuel Delivery: Carburetor
Idle Speed: 1600 ± 100 rpm
Spark Plug: NGK C7HSA
Electrode Gap: 0.5-0.7 mm
Start System: Electric and Kick

Chassis:

Length: 1730 mm / 68 in
Width: 674 mm / 26.5 in
Height: 1145 mm / 45 in
Wheelbase: 1205 mm / 47.5 in
Curb Weight: 95 kg / 209 lb
Max Loading: 132 kg / 293 lb
GVWR: 228 kg / 502 lb
GAWR - Front: 82 kg / 181 lb
GAWR - Rear: 146 kg / 321 lb
Front Tire: 120/70-12
Rear Tire: 120/70-12

Transmission:

Type: Continuously Variable (CVT)
Clutch: Dry, Centrifugal

Fluids:

Engine Oil Type: JASO MB 15W-40 Motor oil
Engine Oil Capacity: ~900 Milliliters
Gear Oil Type: SAE 80W-90 GL-5
Gear Oil Capacity: 120cc (100cc replacement volume)
Fuel Type: Unleaded fuel, 90 Octane or higher
Fuel Capacity: 5 liters

Electrical:

Ignition System: CDI
Generator: Flywheel Magnet Stator
Battery Type: 12V 5Ah
Main Fuse: 15A Tube

Usage Features

Ignition Switch Operation: The ignition switch has ON, OFF, and LOCK positions.

ON (1): Powers the vehicle, allows engine start. Key cannot be removed.
OFF (2): Turns off all vehicle power, engine stops. Key can be removed.
LOCK (3): Engages a theft deterrent by locking the handlebars to the left steering-stop. Requires pressing the key inward and turning it left from the OFF position. Key can be removed.

Dashboard:

Directional Indicator (1): Green light for turn signals.
High Beam Indicator (2): Blue light for high beam.
Check Engine Indicator (3): Orange light for engine problems.
Fuel Level Indicator (4): Shows fuel level from Full (F) to Empty (E).
Odometer (5): Records total distance traveled in miles.
Speedometer (6): Displays current speed in mph or km/h.

Handlebar Controls:

Headlight Switch (1): Up for HIGH Beam, down for LOW Beam.
Turn Signal Switch (2): Left for left turn, right for right turn. Center button to turn off.
Horn (3): Press to sound horn.
Emergency Stop Switch (4): Right for RUN, left for STOP (emergency engine stop).
Engine Start Button (5): Press with ignition key ON and at least one brake lever engaged to start the engine. Do not hold for more than 5 seconds to prevent damage.

Brake Controls:

Front & Rear Brake Levers: Pull toward the grip to actuate brakes. The brake lever should not touch the handlebar. If soft, inspect immediately.

Starting the Engine:

Electric Start: Ensure kill switch is in RUN, insert key to ON, pull a brake lever, and press the start button.
Kick Start: Pull kick-start foot peg (1) outward, then press down quickly with foot (2) while holding handlebars.

Engine Run-in (First 500 miles): Crucial for engine longevity.

0-100 miles: Avoid wide-open throttle and high engine temperatures. Cool down engine for 10 minutes after every 30 minutes of operation.
100-300 miles: Avoid wide-open throttle for extended periods. Do not open throttle beyond 1/2.
300-500 miles: Avoid opening throttle beyond 3/4.
Over 500 miles: Avoid long periods of wide-open throttle operation.

Engine Warm-Up: After starting, idle for at least 1 minute, then use mild acceleration for the first 3 minutes. Adjust mirrors while warming up.

Riding: Use throttle for speed, brakes for slowing/stopping, and handlebars for direction. Consider weather, road conditions, and traffic.

Braking: Release throttle, gradually pull brake levers. Both brakes simultaneously provide shorter stopping distances.

Engine Stop: Turn ignition key to OFF (2) and remove key. The kill switch is for emergencies only.

Parking: Park on a center stand for stability. Position exhaust away from pedestrian traffic. Park in front of larger vehicles for visibility. Consider surface firmness and incline.

Storage:

Primary Storage: Under the seat, max load 20 lbs. Can get hot, not waterproof.

Fuel Fill: Fuel tank in the rear tail section. Insert key into gas cap, turn counter-clockwise while pushing down to open. Fill with unleaded 90 octane or higher fuel. Do not overfill.

Maintenance Features

Pre-Ride Inspection (Always perform before each ride):

Front / Rear Brake: Check function, clearance, fluid level (DOT 4), pad wear, and adjust free-play (10-20mm).
Throttle: Check smooth actuation, free-play (1.5-3.5mm), and ensure it doesn't apply when handlebars turn. Lubricate cable.
Lubricants: Check engine oil level (JASO MB 15W-40).
Tires: Check pressure (Front: 25 psi, Rear: 32 psi) and inspect for wear (T.W.I. indicator), cracks, bubbles, or foreign material.
Cables: Check integrity, connection, and lubrication.
Center / Side Stand: Check mounting bolts, spring tension.
Assembly: Check all fasteners, inspect engine, fork, shock, wheels, handlebar for tightness and unusual movement.
Fuel System: Check fuel level, inspect for leaks in tank, hoses, petcock, filter.
Lighting: Check all lights (turn signals, head, tail, brake, speedometer backlighting, indicators) and clean lenses.
Switches: Check function of all switches.
Loading: Ensure balanced weight distribution, secure fasteners, no bulky loads, and no obstruction of lighting or components.

Periodic Maintenance (Refer to table for intervals):

Fuel: Add premium unleaded fuel (91 octane or higher).
Valve Gap: Check and adjust.
Air Filter: Inspect and replace (every 3750 miles or sooner).
Oil Screen: Clean.
Exhaust System: Check mounting bolts, check for leaks.
Air Box: Clean, replace cover gaskets.
Engine Oil: Replace at intervals, check level daily. Use JASO MB 15W-40.
Gear Oil: Replace (every 3750 miles or sooner), check level. Use 80W-90 GL-5.
Brake System: Check pads and discs for wear, replace as necessary. Inspect calipers, brake lines, and fluid level.
Transmission Variator / Clutch: Check rollers, sliders, clutch pads, and other transmission parts. Replace as necessary.
Rear Shock Absorber: Check for leaks/functionality.
Main / Side Stand: Check functionality, tighten, repair/replace.
Nuts, Bolts, Fasteners: Tighten if required.
Tire Condition: Check wear using tread wear indicators, inspect for cracks, bubbles, anomalies.
Tire Pressure: Check and adjust daily.
Decarbonization: Clean carbon build-up when engine output is reduced.
Spark Plug: Set gap, clean, or replace (every 3750 miles or sooner).
V Belt: Inspect. Replace every 3750 miles or sooner.
Fuel System: Inspect for hose cracks, fuel filter blockages.
Idle Speed: Check engine idle speed set (1700±100 rpm).
Cables: Check and adjust free play, lubricate.
Wiring: Inspect for damage/connection integrity.
Battery: Check voltage (should exceed 12.8V), recharge/clean poles if required.
Engine Compression: Measure pressure.
Axle / Wheel Bearings: Tighten axle if loose. Check wheel runout/bearing free-play and replace if necessary.
Front Fork: Check for leaks/functionality.
Steering Head Bearing: Check for play, adjust if necessary.

Air Cleaner and Air Filter: Remove screws, clean housing, inspect gasket, inspect/replace air filter, reinstall.

Gear Oil: Remove fill and drain screws, drain oil, reinsert drain screw, fill with SAE 80W-90 GL-5 (120cc), reinsert fill screw. Inspect for leaks.

Transmission: Check belt and roller wear, measure belt width, inspect belt for cracks/frays/damage, inspect clutch pads for wear/glazing.

Spark Plug: Inspect electrode color (ideal is light brown), clean, measure gap (0.5-0.7mm), reinstall and torque (11.7N-m / 8ft-lb).

Brake Check: Actuate brakes, observe pad grooves (replace if gone or thickness < 2mm). Inspect rotor for scratches, warping, hot-spots.

Brake Fluid Check: Check fluid level (above bottom half of sight glass), add DOT4 fluid if necessary. Inspect for leaks. Do not mix brake fluid types.

Suspension: Check inner surface of front fork and rear shock for damage/leakage. Park on flat surface, hold handlebar, apply front brake, press and release front fork several times. Hold rear grab-rail, press and release rear shock several times.

Fuse Replacement: Main fuse located next to battery in floorboard. Replace broken fuses with correct amperage. If new fuse burns immediately, contact dealer.

Battery Maintenance: Sealed battery, no electrolyte addition needed. If leakage, contact dealer. If difficulty starting, charge battery. Use trickle charger for daily non-use. Disconnect for long-term storage, store in warm location, charge every three months. Do not disassemble or jump start.

Storage Guide:

Replace oil and oil filter.
Fill gas tank, add fuel stabilizer, run engine briefly, drain carburetor.
Inflate tires to recommended pressure, turn every couple of weeks.
Prevent cylinder rusting: remove spark plug, pour tablespoon of clean engine oil, crank engine several times, reinstall spark plug.
Remove battery, store in area out of direct sunlight and above freezing, use trickle charger.
Use scooter cover, store in area free of excessive moisture, minimal temperature variations, and out of direct sunlight.

Safety Information: The manual includes warnings about carbon monoxide, improper loading, maintenance, and modification. It also contains information on motorcycle noise regulation and reporting safety defects to NHTSA. Warranty information is provided separately.