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G-MAX200
Service manual
PGO G-MAX200 Service Manual
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Table Of Contents
276
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276
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Contents
G-Max 50 Specification
G-Max 125 Specification
G-Max 150 Specification
G-Max 200 Specification
G-Max 220 Specification
G-Max 250 Specification
Service Information
The Operation Notice
Locking Torque Value
4T Engine (125/150/200/220CC)
Chassis
Other Parts Standard Torque Values
Lubrication Instruction
Chassis Appearance
Wheel Bearing
Periodic Maintenance Table
Troubleshooting
Difficult Starting or Can’t Start
Weak Acceleration
Engine Running Unsmoothly (Low Speed and Idling)
Engine Running Unsmoothly (High Speed)
Clutch, Drive and Driven Pulley
Handlebar Steering Astrayed When Running
Front, Rear Damper Not in Balanced
Brake Disorder
Oil Indicator Malfunction
Fuel Indication Malfunction
The Starting Motor Abnormal
Starting Motor Running Slowly or no Pick-Up
Starting Motor Can Not Stop after Starting
No Sparking
Charging Abnormal(Battery over Charging or over Discharging)
Checking and Adjustment
Regular Checking Table
Battery: Recharge When Power Is out
Cleaning Air Cleaner
The Final Reduction Mechanism Oil
Spark Plug
Compression Pressure Measurement
Ignition Timing
Throttle Cables Adjustment
Idle Adjustment
Front Brake Adjustment
Rear Brake Adjustment (Drum Brake Only)
Tire
Plastic Part Dismantle Overview
Actual Dismantle Procedure
G-MAX 50 Engine Dismantle, Maintenance, Repair and Assembly
Lubrication System and Oil Pump
Lubrication System Diagram
Removing the Oil Pump
Check the Oil Pump
Assemble the Oil Pump
Releasing Air in the Oil Pump
Engine Dismantling
Drive Pulley, Starter & Clutch Troubleshooting
CVT Parts Measurement Data
Driving Pulley
Cylinder and Piston Troubleshooting
Piston & Cylinder Datas
Cylinder Head, Cylinder, and Piston Dismantling
Check for the Flatness of Cylinder Head & Cylinder
Combustion Chamber Cleaning
Check Cylinder and Piston
Installing Cylinder and Piston
A.C. Generator, Flyweel
Install AC Generator
Final Transmission Mechanism Troubleshooting
Disassemble the Final Transmission Mechanism
Check the Final Transmission Mechanism
Assemble the Final Transmission Mechanism
Crankcase, Crankshaft Disassembling Diagram
Crankcase, Crankshaft Troubleshooting
Crankcase, Crankshaft Data
Dismantle the Crankcase and Crankshaft
Check the Crankshaft
Assemble the Crankcase
Carburetor, Reed Valve
Carburetor Dismantling Diagram
Carburetor, Reed Valve Troubleshooting
Dismantling Carburetor
Dismantling Float, Nozzle
Dismantling Reed Valve
Checking for the Reed Valve
G-MAX 125/150 Engine Dismantling, Maintaining, Repairing and Assembling Operation
Lubrication System
Oil Pump Dismantling
Oil Pump Assembly
Measurement Data
Reduction in Fuel Oil Volume
Engine Burning-Out
Troubleshooting
Installing Engine
Drive Pulley, Starter Clutch. Driven Pulley
Drive Pulley, Starter Clutch. Driven Pulley Troubleshooting
Drive Pulley, Starter Clutch. Driven Pulley Measurement Data
Starter Dismantle
Clutch Driven Pulley
Cylinder Head and Valve
Cylinder Head and Valve Troubleshooting
The Operation Data Information
Dismantling and Installing the Camshaft
Check Camshaft
When Installing
Dismantling the Cylinder Head
Further Dismantling
Cylinder and Piston
Cylinder and Piston Operation Notice
Cylinder and Piston Data
Dismantling Cylinder
Dismantling Piston
Piston Outer Dia Measurement
Checking the Flatness of Cylinder Contact Surface
Connecting Rod Small End Inner Diameter Measurement
A.C. Generator
Dismantling AC Generator
Installing AC Generator
Final Transmission Mechanism
Crankcase, Crankshaft
Remove the Crankcase and Crankshaft
Check Crankshaft
Assemble Crankcase
Carburetor Specifications
General Theory
Diaphragm and Piston Operation
Slow System
Coasting Enrichment System
Main System
Auto-Enricher (Auto-Choke) System
Float System
Accelerator Pump System
Inspection
Carburetor Cleaning
Auto-Enrichener Inspection
Float Height Adjustment
The Float Nozzle
Handle Bar, Front Wheel, Front Brake and Front Fork
Change the Speedometer Cable
Steering Handlebar
Front Wheel
Dismantling the Carburetor
Adjustment of Fuel Volume Adjusting Screws
Rear Wheel, Rear Brake, Rear Damper
Fuel Supply Troubleshooting
Fuel Supply System Diagram
Dismantling and Assembling Fuel Tank
Oil Tank Disassembling Diagram
Dismantling and Assembling Oil Tank
Electric Equipment
Battery
Testing the Recharging Performance
Battery Construction
Electrolyte Filling
Inserting Cap (Sealing Plug)
Precaution for Handling Battery
Recharging
Battery Removal
Recharge System Diagram for M2-50
Recharge System Diagram for M2-125/150
Check A.C. Generator
Check Regulator
Ignition System
The Wiring of Ignition
The Starting System
Wiring Diagram for M2-50
Wiring Diagram for M2-125/150
Wiring Diagram for M2-150(4V)
Wiring Diagram for M2-200
Wiring Diagram for M2-22CEFI
Wiring Diagram for M2-22CEFI (ECU)
Wiring Diagram for M2-250
GMAX-200/220 Characteristics , Dismantle & Inspection
PGO-200/220 Engine Dismantle
Cooling Cowl
Cylinder Head Cover
Chain Tensioner
Recover the Chain Tensioner
Camshaft Holder
Cylinder Head
Cooling Fan
Generator Outer
Generator Stator
Starting Motor
Right Crankcase Cover
Starting Idle Gear
One Way Clutch
Sprocket of Oil Pump
Oil Pump
Right Crankcase
Crankshaft
Engine Inspection Data
Piston & Cylinder Inspection (200CC)
Electric System
What Is Transistor Ignition?
Electric System
Major Components of Transistor Ignition
Comparision of Transistor V.S. CDI Ignition
G-MAX 200/220 Electric System
Headlamp & Choke (Carburetor) Diagram
Charging System Diagram
Fuse Wire
G-MAX 200/220 Electric Parts
General Maintenance
G-MAX 200/220 Specified Engine Oil (Synthetic 1000Ml)
Engine Oil, Gear Oil
Engine Oil Filling & Gauge
Replace the 2Nd Oil Filter
Air Element
CVT Sponge
CVT Dismantle
CVT Install Notes
Spark Plug
Ignition Coil
Front Brake System
Replace the Front Pads
Replace the Rear Pads
Engine Management System (EMS)
EMS Index
Feature of PGO 2Nd-Stage EMS
EMS Structure (A)
EMS Structure (B)
EMS Units
Intake Pressure Sensor
Throttle Position
Important PIN No.# of ECU
Function of Crank Speed Sensor
Engine Temperature Sensor
Measure Engine Temperature Sensor
Throttle Position Sensor (TPS)
Oxygen Sensor
Injector
Draining Cap of Injector
Bleed the Air
Drain the Gas
Fuel Pump
Fall down Sensor
Isc(Idle Speed Control)
ISC Initialization Timing
Procedure of ISC Initialization
EMS Fuses
Main Purpose of EMS Fuses
EMS Diagnostic
Quick Diagnostic
PC Diagnostic
Quick Diagnostic Table
Clear the Defect Code Memory
EMS System Repairing Tool
Pocket Tester Wiring
Ignition Gauge
Fuel Pressure Gauge
Connect to the Vehicle
General Electric Units
Storage Light Controler
Signal Flasher Relay (LED)
Regulator
Fuel Gauge
Measure the Fuel Gauge
Starting Relay
Front Brake
EMS Relays
EMS Relays Wiring
Control of Relays
Measure the Relays
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Quick Links
1
G-Max 50 Specification
2
G-Max 150 Specification
3
G-Max 200 Specification
4
G-Max 220 Specification
Download this manual
See also:
User Manual
Manufactured by Motive Power Industry Co., Ltd
Table of
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Table of Contents
Troubleshooting
Troubleshooting
21
Drive pulley, starter & clutch troubleshooting
59
Cylinder and piston troubleshooting
68
Final Transmission Mechanism Troubleshooting
79
Crankcase, Crankshaft Troubleshooting
83
Carburetor, Reed Valve Troubleshooting
90
Measurement data
97
Drive pulley, starter clutch. driven pulley troubleshooting
100
Cylinder head and valve troubleshooting
109
Fuel supply troubleshooting
153
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