PGO G-MAX 50 Service Manual
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PGO G-MAX 50 Service Manual

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Manufactured by Motive Power Industry Co., Ltd

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Summary of Contents for PGO G-MAX 50

  • Page 1 Manufactured by Motive Power Industry Co., Ltd...
  • Page 2 This manual includes 3 kinds of engine displacement: G-MAX 50 (ALLORO 50): abbreviated as “M2-50” is 2 stroke engine (2T), 50cc displacement. G-MAX 125 (ALLORO 125): abbreviated as “M2-125” is 4 stroke engine (4T), 125cc displacement.
  • Page 3 (8)Throttle cables adjustment (9)Idle adjustment (10)Front brake adjustment (11)Rear brake adjustment (12)Tire Ⅳ.Dismantling, maintaining, repairing and assembling operation A. Plastic parts B. G-MAX 50 Engine dismantling (1)Lubrication system (2)Engine dismantling (3)Drive pulley, starter, clutch, (4)Cylinder and, piston (5)AC Generator (6)Final transmission mechanism (7)Crankcase, crankshaft.
  • Page 4 (6) Cylinder and piston (7) AC generator (8) Final transmission mechanism (9) Crankcase, crank shaft (10) Carburetor (D)Steering column, front wheel, front brake comp, front fork (E)Rear wheel, rear brake, rear damper (F)Fuel supply Ⅴ.Electric equipment (1)Troubleshooting (2)Battery (3)Recharge system (4)Ignition system (5)Starting system (6)Switch operation...
  • Page 5 1.1 G-MAX 50 SPECIFICATION BRAND FRAME STEEL PIPE MODEL M2-50D FRONT TELESCOPE LENGTH 1885 mm REAR SWING WIDTH 730 mm PRIMARY DIRECT HEIGHT 1170 mm 52/13*44/13 AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 47 KG SHIFTING V-BELT C.V.T REAR 58 KG...
  • Page 6 1.2 G-MAX 125 SPECIFICATION BRAND FRAME STEEL PIPE MODEL M2-125 FRONT TELESCOPE LENGTH 1885 mm REAR SWING WIDTH 730 mm PRIMARY DIRECT HEIGHT 1170 mm 43/14*42/13 AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 54 KG SHIFTING V-BELT C.V.T REAR 76 KG FRONT 120/60-13 TOTAL...
  • Page 7 1.3 G-MAX 150 SPECIFICATION BRAND FRAME STEEL PIPE MODEL M2-150 FRONT TELESCOPE LENGTH 1885 mm REAR SWING WIDTH 730 mm PRIMARY DIRECT HEIGHT 1170 mm 42/15*42/13 AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 55 KG SHIFTING V-BELT C.V.T REAR 77 KG FRONT 120/60-13 TOTAL...
  • Page 8 1.4 G-MAX200 SPECIFICATION BRAND FRAME STEEL PIPE MODEL M2-200 FRONT TELESCOPE LENGTH 1885 mm REAR SWING WIDTH 730 mm PRIMARY DIRECT HEIGHT 1170 mm 40/16*42/13 AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 58 KG SHIFTING V-BELT C.V.T REAR 82 KG FRONT 120/60-13 TOTAL...
  • Page 9 1.5 G-MAX220 SCOOTER SPECIFICATION BRAND P G O FRAME STEEL TUBE M2-220BAE MODEL FRONT TELESCOPE SUSPENSION LENGTH 1885 mm REAR UNI-ABSORBER WIDTH 730 mm REDUCTION 0.81~2.43 HEIGHT 1170 mm REDUCTION 8.077 WHEEL BASE 1365 mm CLUTCH CENTRIFUGAL FRONT 57 KG GEARBOX C.V.T.
  • Page 10 1.6 G-MAX250 SPECIFICATION BRAND FRAME STEEL PIPE MODEL M2-250 FRONT TELESCOPE LENGTH 1990 mm REAR SWING WIDTH 730 mm PRIMARY DIRECT HEIGHT 1170 mm 39/15*43/16 AXLE DISTANCE 1365 mm CLUTCH CENTRIGUAL FRONT 58 KG SHIFTING V-BELT C.V.T REAR 90 KG FRONT 120/60-13 TOTAL...

  • Page 11: Service Information

    Ⅱ.Service information： (1)The operation notice (2)Locking torque value 1.For engine 2. For chassis 3. Others (3) Lubrication instruction a.For engine b. For chassis c. Wheel bearing (4)Periodical Maintenance Table (5)Troubleshooting 1.Difficult starting or starting 2.Weak acceleration 3.Engine running not smoothly (low speed) 4.Engine running not smoothly(high speed) 5.Clutch, drive &...
  • Page 12 2.When trying to tighten screws or nuts, please lock tightly according to each recommended locking torque and in the sequence of the ”X” pattern. 3.Please use PGO or PGO recommended parts. 4.After dismantling, please clean all parts involved or used for checking and grease all contact surfaces when reassembling.
  • Page 13 Locking Torque Value: 1. 2T Engine (50CC) Thread Locking Remarks Locking location torque kg-m Dia (mm) 1 Cylinder head 1.0~1.4 When the engine is cold 2 Flywheel outer 3.2~4.0 3 Rear brake lever 1.0~1.2 4 Driving pulley 3.2~4.0 5 Clutch outer 3.5~4.0 6 Right crankcase 1.0~1.2...
  • Page 14 2. 4T Engine (125/150/200/220CC) Thread dia. Locking torque Locking location Q’ty (mm) (kg-m) 1 Fixing nut (Tappet screw nut) 0.7~0.8 2 Nut of oil pump sprocket 0.7~1.0 3 Cylinder head bolt A (intake) 0.9~1.1 4 Guiding pin bolt, chain extensioner 0.4~0.6 5 Screw, chain extensioner 0.9~1.1...
  • Page 15 3. Chassis Thread dia. Locking torque Locking location Q’TY (mm) (kg-m) Air bleed bolt of caliper Brake arm bolt, front drum 0.8~1.0 Brake arm bolt , rear drum 0.8~1.0 Nut of starter relay 0.5~0.6 Front brake caliper bolt 2.0 ~ 3.0 Bolt of disk 2.5~3.0 Locking nut, steering stem...
  • Page 16 (3) Lubrication instruction A. 2T Engine (50 cc) NO Lubrication location Oil type Remarks Crankcase: rotating part, Separated-pump Sliding part Premium 2 stroke Lubrication Motorcycle oil Cylinder: rotating part, Or SAE#30 Sliding part. Drive gear box SAE85-140 Total 110 c.c. Replacement 90c.c Gasket of starter shaft Clean grease...
  • Page 17 C. Chassis appearance 1. Apply oil : #1, #2 2. Apply grease (#3, #4, #5. #6 ,#7, #8)
  • Page 18 D.Wheel bearing Final transmission mechanism gear oil Speedometer gear: clean grease...
  • Page 19 Inspect EMS function, and clear (Injection) the defect memory if necessary REMARKS： 1. A: adjust C: clean I: inspect, or replace if necessary L: lubricate R: replace 2. Items with “*” mark indicate our recommendation to have it done by PGO dealer.
  • Page 20 NOTE 1： For 4T engine, the engine oil shall be changed completely after run-in period 300km or one month later. This can make sure the engine runs smoothly. NOTE 2： The exchange of brake fluid After disassembling of brake main cylinder or caliper, do change the new fluid. Check the fluid level often, Refill if necessary.
  • Page 21 (5)Trouble shooting: 1.difficult starting or can’t start: Check and adjust Trouble condition The reason Loose carburetor draining Screw, check if in side of Carburetor have fuel or not check there is fuel or not pipe between ful tank and carburetor is blocked The fuel supply in carburetors No fuel supply in Float is blocked...
  • Page 22 2.Weak acceleration: Trouble condition Check and Adjust The reason Start engine and open throttle Gradually, check and inspect air cleaner blocked fuel supply system abnormal fuel tank cover blocked Engine can’t rotate Engine can rotate up muffler blocked Up completely fuel pump is malfunctioned auto chock is malfunctioned Check ignition timing, check...
  • Page 23 For 4T engine only: Check the oil level in crankcase Is too much or dirty oil level is too high oil level is too low Oil level is oil does not interchange Not normal Oil level is normal Check the lubrication of cylinder head oil route is blocked insufficient oil pumping from...
  • Page 24 3.Engine running unsmoothly (low speed and idling) Check and adjust Trouble condition The reason Check ignition timing CDI faulty Correct Not correct AC generator faulty Adjust carburetor air screw mixture too thick Good Faulty ( loose the screw) adjustment Not correct mixture too lean ( tight the screw) Check if there is air...
  • Page 25 4.Engine running unsmoothly (high speed) Check and adjust Trouble condition The reason Check ignition timing CDI sets faulty correct Not correct AC generator faulty Check fuel pump, Fuel supply system fuel level is too low fuel pipe, fuel filter is blocked good unsmoothly fuel pump faulty...
  • Page 26 5.Clutch, drive and driven pulley Trouble condition The reason driving belt worn out, distortion Engine can start but can’t driven plate worn-out driven plate spring distorted Move the vehicle driven lining worn-out driving pulley shaft gear teeth cracked final gear damage driven lining spring cracked or Engine runs, but it stops worn out...
  • Page 27 6.Handlebar steering astrayed when running. Trouble condition The reason (front and rear wheel pressure are normal) steering column lock screw locked too tightly Handlebar operates heavily steel ball cracked rear, front wheel bearing swings Front and rear wheel swings front, rear wheel rim distorted loosen front axle nut front and rear wheel center not well- Handlebar astrayed to one direction...
  • Page 28 9.Oil indicator malfunction (Only available for 2T engine) (a)The oil lamp doesn’t light up, (when the main switch is at “ON”position) Check and adjust Trouble condition The reason Turn the signal lamp On. Check wiring Of battey fuse burn-out Normal battery has no power Lamp dims, light does main switch abnormal...
  • Page 29 10.Fuel indication malfunction (a)wrong fuel level indication(when the main switch is “ON”) Check and adjust Trouble condition The reason Turn the signal lamp On; check wiring of battery fuse burn-out battery has no power normal main switch abnormal Lamp dims, light circuit plug dropped off Not flash, not light main wiring disconnected...
  • Page 30 (b)Fuel gauge needle is not steady and sometimes moves up and down (when the main switch is “ON”) The reason Check and adjust Trouble condition Turn signal lamp on, Check wiring of fuse burn-out battery battery has no power main switch abnormal normal No motion circuit plug dropped off or...
  • Page 31 11.The starting motor abnormal (a)Starting motor can not rotate Check and adjust Trouble condition The reason Check brake switch fuse burn-out Brake lamp Brake lamp battery has no power Lights up no light main switch abnormal circuit plug dropped off main wiring disconnected Turn signal lamp No to check wiring...
  • Page 32 (b)Starting motor running slowly or no pick-up Check and adjust Trouble condition The reason Turn signal lamp On, to check wi- ring of battery normal Lamp dims, no battery has no power Flashing, no light Starting Connect motor to the starting motor to Battery directly electric;...
  • Page 33 12.No sparking Check and adjust Trouble condition The reason Replace new spark Plug, then check again Good sparking Weak sparking Spark plug faulty Or no sparking Check spark plug, cap And H.V. cable is Loose or not Spark plug cap is loose good loosen Check the CDI plug...
  • Page 34 13.Charging abnormal(battery over charging or over discharging) Check and adjust Trouble condition The reason Measure battery’s Voltage then start engine Voltage remain Voltage goes up The same To normal value, battery is dead But after engine battery malfunction Stop, the voltage Goes down again Check voltage rectifier Plug is loose or not...
  • Page 35 3. Checking and Adjustment: (1)Regular checking table (2)Battery (3)Clean air cleaner (4)The final reduction mechanism oil (5)Spark plug (6)Compression pressure measurement (7)Ignition timing (8)Throttle cables adjustment (9)Idle adjustment (10)Front brake adjustment (11)Rear brake adjustment (12)Tire...
  • Page 36 (1)Regular checking table: 1.【O】mark indicates periodical checking 2.【※】indicates changing the parts Checking period en-era first home office Judgement month Item every6 every12 every1 every3 every12 Remark standard che-cki months months months months months Initial 300km 5000km 10000km 1000km 2500km 10000km ○...
  • Page 37 Checking period en-era first home office Judgement month Item every6 every12 every1 every3 every12 Remark standard chec-ki months months months months months Initial 300km 5000km 10000km 1000km 2500km 10000km Clearance on ○ ○ ○ ○ ○ ○ Front axle Bearing Clearance on ○...
  • Page 38 1.0-1.2KG-m Condition M2125&150 Cam holder nut: &200/220 2.0-2.3kg-m Using Compression ○ ○ 6kg/c ㎡ starting Pressure (G-MAX 50) motor @ 600rpm Using Compression ○ ○ 12kg/c ㎡ starting Pressure G-MAX 125 motor @ 750rpm Using Compression ○...
  • Page 39 Checking period en-era first home office Judgement month Item every6 every12 every1 every3 every12 Remark standard che-cki months months months months months Initial 300km 5000km 10000km 1000km 2500km 10000km ○ ○ ○ ○ ○ ○ Function Lamp system ○ ○ ○...
  • Page 40 (2)Battery: Recharge when power is out 1.Remove the rear luggage cover by hand. 2.Screwing out the two screws on the battery cover. Remove the battery cover. (G-MAX125/150/200/220) 3.Remove the negative cable and then the positive cable,→take out the battery to recharge. 4.To re-assemble the battery, please follow the opposite procedure of disassembling after recharging.
  • Page 41 G-MAX125/150 (3)Cleaning air cleaner 1.Remove air cleaner cover 2.Take out the air cleaner filter G-MAX50 3.Clean the filter by the compressor air. M2-250 M2-200/220 4.Assemble the air cleaner by the opposite procedure. Note: Do not start the engine when the air cleaner is Not installed...
  • Page 42 (4)The final reduction mechanism oil 1.Change the oil in the gear box: a. Turn off the engine after warm up. b. Put a bowl under the engine. c. Remove the draining bolt and Filler bolt to drain the gear oil off. d.
  • Page 43 (6)Compression pressure measurement: 1.Measure it when the engine is warm. 2.Remove the cover. 3.Remove spark plug then place compression pressure gauge. 4.Fully open the throttle, and using starting motor 5 seconds continuously, measure the compression pressure. 5.Compression pressure: 50cc: 6 kg/c ㎡ @600rpm 125cc: 12 kg/c ㎡...
  • Page 44 (7) Ignition timing: This scooter is using CDI set, it is no need to adjust ignition timing. If ignition timing is not correct, check the CDI sets and AC magneto, change it if it is checking ignition timing: 1.remove seat the luggage compartment 2.Remove right body cover 3.Remove the fan case.
  • Page 45 (9) Idle adjustment: Note: adjust it when the engine is warm. 1.remove left body cover 2.start the engine and connect the tachometer 3.adjust the throttle valve screw to the specified revolution 1900±100rpm. (M2-50) 1700±100rpm. (M2-125&150&200&250) 1600±100rpm. (M2-220) 4.if the idling rpm is still unsteady or fuel up is not smooth, please adjust it by followings.
  • Page 46 (12)Tire: 1.Check the tire air pressure(when it’s cold) 2.Tire pressure: Front tire: 2.0 kg/c ㎡ Rear tire: 2.0 kg/c ㎡ 3.Tire dimension: G-MAX 50: Front tire: 120/70-12 Rear tire: 130/70-12 G-MAX 125/150/200/220: Front tire: 120/60-13 Rear tire: 130/60-13 G-MAX 250:...
  • Page 47 Plastic part dismantle Overview Dismantle the plastic parts according to above figure sequence by sub-assembly, especially pay attention to followings: Before dismantle front fender, dismantle the front wheel assy. First. (G-MAX125/150 only) Windshield & frt signal lamp cover shall be dismantled together. LH &...
  • Page 48 Actual dismantle procedure: Dismantle the upper cover & windshield. Loosen 2 tapping screws at the upper with the inner cover. Withdraw the windshield decorated cover. Dismantle the handle upper cover. Loosen 5 tapping screw under the handle. Dismantle windshield & turn signal front cover.
  • Page 49 Loosen 3(LH) & 3(RH) tapping screws of front inner cover. Loosen 3(LH) & 3(RH) tapping screws of front inner cover. Loosen 1 machine screw in the middle of windshield. Dismantle windshield & front turn signal cover together.
  • Page 50 Dismantle the front fender. Only for G-MAX125/150: Loosen nut of front wheel, dismantle the front wheel & brake disc together. Loosen screws at LH & RH of front fender, dismantle front fender Open the seat. Loosen 3 bolts of rear luggage bracket, dismantle it.
  • Page 51 Loosen 2 bolts of rear luggage compartment Lift the cover with finger, withdraw the cover of rear luggage compartment. Withdraw the rear luggage compartment. Turn the tank inner cover counterclockwise a little bit, dismantle it. Dismantle the tank upper cover by releasing coupling ribs Withdraw fuel tank decorated cover.
  • Page 52 Dismantle the keel cover. Loosen 2(LH) & 2(RH) screws at the front upper section. Loosen 2(LH) & 2(RH) inner socket screws, dismantle the keel cover. Dismantle the LH & RH lower cover Loosen 4 tapping screws on the top of LH & RH lower cover Dismantle quick plastic screw(2 EA in each side)
  • Page 53 Dismantle 1 tapping screw in the front side. Withdraw LH & RH lower cver. Dismantle other PP covers. Dismantle the license plate Push the middle of quick plastic screw. Loosen 2 screws at the rear of vehicle. Withdraw the license plate.
  • Page 54 B. G-MAX 50 Engine dismantle, maintenance, repair and assembly: (1)Lubrication system (2)Engine dismantling (3)Drive pulley, starter, clutch, (4)Cylinder and, piston (5)AC Generator (6)Final transmission mechanism (7)Crankcase, crankshaft. (8)Carburetor, reed valve...
  • Page 55 (1) Lubrication system and oil pump 1.Lubrication system diagram. 2.Trouble shooting. A. If there is too much white fume from exhaust system, which means too much Carbon piled up on the spar plug or the oil quality is not good. B.
  • Page 56 3.Removing the oil pump. Clean the oil pump and Crank case before operation a. Remove the luggage. b. Remove the input/output oil pipe. c. Take out the oil pump by removing The locking screw on oil pump and Oil gauge cable. 4.check the oil pump.
  • Page 57 5.Assemble the oil pump. a. Assemble the oil pump by reversing above procedure. O-ring of oil pump should be lubricated by grease or oil, then place on crankcase. The contact surface of oil pump and crankcase should be assembled firmly. The gears of oil pump should be lubricated by grease.
  • Page 58 (2)Engine Dismantling A. Dismantling engine. 1.Take off the luggage compartment. 2.Take off the left and right body covers. 3.Take off the lower mudguard fender. 4.Remove vacuum pipe, fuel pipe, auto choke, cap of spark plug, rear Brake cable carburetor pipe, engine flywheel shelf’s nut, starter Motor cable plate and rear damper bolt.
  • Page 59 (3)Drive pulley, starter & clutch A. Troubleshooting: a. Engine starts, but vehicle does not move. 1.driving belt worn out 2.driven plate worn out 3.clutch lining worn out 4.driving plate’s spring broken b. The vehicle stops or trembles when running, 1.clutch lining spring cracked or broken. c.
  • Page 60 C. Driving pulley. 1.Take off the 10 screws of left Cover, remove the left cover. 2.Take off the left cover.
  • Page 61 3.Remove the fixing nut of the clutch. 4.Take off the ramp plate. 5.Take off the belt and the rear clutch. 6.Take off the driving plate. • Take off the driving gear start set.
  • Page 62 7.Remove the start idle gear fixing plate. 8.Take off the idle gear.
  • Page 63 9.To assemble the driving pulley, please reverse above procedure. Locking torque: 1.Nut of driving pulley:M10: 3.2~4.0kg-m 2.Locking nut of clutch:M10: 3.5~4.0kg-m 10.Checking the driving belt (1)check whether it is cracked or not or its rubber and fiber are loose or not check also if they are extraordinarily worn out.
  • Page 64 13.Assemble the slide driving plate. (1)Clean the inner surface of slide driving plate, then assemble the roller. (2)Assemble the ramp plate. (3)Please reverse the procedures of disassembling to finish assembling.
  • Page 65 D. Starter dismantling 1.Dismantle the left crankcase cover 2.Remove the hexagon nut, then remove the starter lever. 3.Remove five screws of isolating plate. 4.Remove the stater spring from the start returning positioner. 5.Remove the driven gear comp of kick starter. 6.Remove the retaining c-type clip 7.Remove the spindle comp.
  • Page 66 E. Clutch driven pulley 1.Dismantle the clutch a. Remove left crankcase cover. b. Remove driving plate. c. Remove driving belt. d. Remove the M10 locking nut, then the clutch. 2.Assembling the clutch: please follow the opposite procedure of dismantling. Locking torque: M10: 3.5~4.0kg-m 3.Checking the clutch: Dismantling the clutch needs the special...
  • Page 67 c. Check driven spring free length: standard: 87.9mm Limit of use:change it as it Is below 82.5mm(50cc) d. Check wearing condition of driving plate set. Outer diameter measurement: Limit of use:change it as it Is above 33.950mm e. Check wearing condition of slide driven plate.
  • Page 68 (4)Cylinder and piston: A. Troubleshooting. a. compression pressure is too low, difficult to start engine and running unsmoothly. 1. Cylinder head gasket cracked. 2. Spark plug is not well-locked. 3. Piston ring worn out or cracked. 4. Cylinder, piston worn out. 5.
  • Page 69 D. cylinder head, cylinder, and piston dismantling. 1.Remove the engine. 2.Screwing out the two M6-bolt of cooling cowl. 3.Screwing out the two M6-blot of fan cover. 4.Remove the cooling cowl and fan cover.
  • Page 70 5.Remove the spark plug. 6.Remove the two M6 nuts on the muffler and cylinder. Also remove the two M8-bolt of crankcase. 7.Remove muffler. 8.Remove the four M7-nut on the cylinder head, then remove the cylinder head and cylinder head gasket.
  • Page 71 9.Remove the Cylinder and the gasket. 10.Remove the c type clip on the piston and piston pins by the nipper. •Take off piston. 11.Dismatling of the piston ring Take off the first piston ring then the second ring. 12.When assembling please reverse the procedures of dismantling. Locking torque: Opening end of piston ring M7:1.0-1.4kg-m...
  • Page 72 E. Check for the flatness of cylinder head & cylinder. Check the flatness of contact surface of cylinder head & cylinder. Limit of use: If it exceeds 0.1mm Change a new one. F. Combustion chamber cleaning Clean out the carbon piled up in combustion chamber. Do not scratch the combustion chamber and contact surface of the cylinder during cleaning operation...
  • Page 73 G. Check cylinder and piston: 1.Check the wearing and damage condition on the contact surface of the cylinder and piston. 2.Clean out the carbon on the cylinder exhausting port. Be careful not to scratch the inner Surface of cylinder. 3.Cylinder bore measurement: (1)Measure each point (A)(B)(C) orderly, and in X.Y.
  • Page 74 4.Piston outer diameter measurement: (1)Measure at the skirt area where is 12 mm from the skirt lower end of skirt. (2)Limit of use: 50cc-change if when below 39.895mm (3)Calculate the clearance between the cylinder and piston. Limit of use: change it when over 0.100mm 5.Inner diameter measurement of the piston pin hole Limit of use: change it when over 14.032mm...
  • Page 75 6.Outer diameter measurement of the piston pin limit of use: change it when under 9.970mm(G-MAX 50cc) 7.Check piston ring: Measure piston ring gap: Limit of use: change new ones when the first ring and second ring are over 0.4mm Push the piston ring into the cylinder By piston, the measure the gap...
  • Page 76 8.Check connecting rod small end (1) lnstall piston pin, bearing onto the connecting rod small end, then check the looseness of the piston pin. (2) Measure the inner diameter of the connecting rod small end. Limit of use: replace a new one when over 14.025mm.(G-MAX 50cc) H.
  • Page 77 (5)A.C. Generator, Flyweel A. Dismantling AC generator 1.Remove fan cowl. 2.Remove the M6 screws(4) 3.Remove Screws of flywheel magneto 4.Remove the AC flywheel magneto by special tool.
  • Page 78 5.Remove the flywheel. 6.Remove the electric plug of AC Flywheel magneto. Take out the magneto. B. Install AC generator To install, please reverse the dismantling procedures. Locking torgue: M6: 1.0~1.2kg-m M10: 3.2~4.0kg-m...
  • Page 79 (6)Final Transmission Mechanism A. Trouble shooting Engine can be started, but vehicle doesn’t move. 1.Gear worn-out or cracked. 2.Gear burnt out. Noise occurs when running. 1.Gear worn out, burnt or gear surface damaged. 2.Bearing worn out or loosen. Oil leakage 1.Too much oil.
  • Page 80 3.Remove the 6 bolt in gear box cover 4.Take off the gear box. 5.Take out the final reduction gear and idle gear shaft. 6.Clean up the gear box...
  • Page 81 C. Check the final transmission mechanism 1.Check the wearing condition of the driving shaft and gears. 2.Check the wearing condition of the idle gear shaft and idle gears. 3.Check the wearing condition of the final reduction gear. 4.Check the wearing condition of the oil seal and bearing. D.
  • Page 82 (7)Crankcase, Crankshaft: A. Disassembling diagram...
  • Page 83 B. Troubleshooting. Engine noise: 1.The bearing of final transmission mechanism is loose. 2.Crank pin bearing is loose. 3.The bearing of gear box is loose. C. Data Measuring Item Standard value Limit of use.(mm) Clearance of connecting rod big end 0.20-0.50 0.71(50cc) (Parallel direction to rod) Clearance of connecting rod big end...
  • Page 84 D. Dismantle the crankcase and crankshaft please follow the following procedures: 1.Remove the engine. 2.Remove the left crank case, the driving pulley (driving plate) clutch and belt. 3.Remove the air cleaner.
  • Page 85 4.Remove the carburetor. 5.Remove the intake manifold and reed valve. 6.Remove the oil pump, fan cowl and fan itself.
  • Page 86 7.Remove the AC flywheel magneto. 8.Dismantle the right and left crankcase. There are all together 7 bolts. 9.Remove center stand, left and right crankcase and take out the crankshaft.
  • Page 87 E. Check the crankshaft: 1.measure the clearance between crank shaft and co-rod big end.(Parallel direction to rod) Limit of use: Replace a new when above 0.71mm 2.check the looseness on X.Y. axis of the connecting rod big end(Perpendicular directions to rod) Limit of use: Replace a new one when above 0.04mm...
  • Page 88 3.measure the swingness of crank shaft neck. Limit of use Change it when Change it when Above 0.1mm Above 0.1mm 60mm 4.check the slackness of crankshaft bearing, if it is slack, change a new one. F. Assemble the crankcase. 1.To assemble the crankcase, please reverse the procedures of disaseembling. 2.The locking torque value for bolts and nuts are all described in the previous chapters Please refer.
  • Page 89 (8)Carburetor, Reed Valve A: Carburetor dismantling diagram CARBURETOR ASSY. HOLDER, NEEDLE JET TOP SET MAIN JET SPG., COMP. FLOAT VALVE SET PLATE SET PIN, ARM TUBE SET FLOAT SET JET NEEDLE FLOAT CHAMBER SET THROTTLE VALVE TUBE SET SCREW SET "SCREW, WASHER"...
  • Page 90 B. Troubleshooting: Engine can not be started. 1.No fuel in the fuel tank. 2.Fuel pipe is blocked. 3.There is too much fuel in the cylinder. 4.Air cleaner is blocked. Engine idling(RPM) unsteady, running not smoothly 1.Improper adjustment of the carburetor idling. 2.Ignition disorder.
  • Page 91 C. Dismantling carburetor 1.Remove the luggage box. 2.Loose the hose clamp between the carburetor and the air cleaner. Then remove the air cleaner. 3.Unscrew the fuel draining screw of the carburetor. Drain off the fuel inside the carburetor. 4.Remove the fuel pipe and the vacuum pipe on the carburetor.
  • Page 92 E. Reed valve 1.Dismantling reed valve. (1)Take off the luggage box (2)Remove the air cleaner (3)Remove the carburetor. (4)Unscrew the locking screw of the intake manifold. (5)Remove the intake manifold. (6)Remove the reed valve. 2.checking for the reed valve. change a new one when the reed valve is worn out or distorted. change a new one too when the base of the reed valve is cracked, injured or distorted.
  • Page 93 4. G-MAX 125/150 engine Dismantling, Maintaining, Repairing and assembling operation (1) Lubrication system (2) Engine dismantling (3) Install Engine (4) Drive pulley, starter, clutch, driven pulley (5) Cylinder head and valve (6) Cylinder and piston (7) AC generator (8) Final transmission mechanism (9) Crankcase, crank shaft (10) Carburetor...
  • Page 94 (1) Lubrication System...
  • Page 95 Oil Pump Dismantling 1.Remove the rear section of muffler. 2.Remove the AC flywheel magneto. 3.Remove the AC generator coil. 4.Tale off the locking bolts of the right crankcase cover. 5.Remove the crankcase cover 6.Remove the washer, lock pin 7.Remove starter reduction gear and the starting clutch.
  • Page 96 8.Remove oil pump separate plate by taking off the 2 bolts. 9.Remove the bolts from oil pump driving gear 10.Take off the driving gear and chain. 11.Remove the oil pump by taking off the locking bolt of the oil pump. Oil pump Assembly 1.Install the inner and outer of the oil pump.

  • Page 97: Troubleshooting

    Measurement data Standard Value Limit of use item ( mm ) ( mm ) Clearance between the inner gear 0.12 And outer gear Clearance between the outer gear 0.045-0.10 0.12 And oil pump body pump Clearance between gear end and 0.045-0.10 0.12 Oil pump body...
  • Page 98 (2) Engine dismantling 1.Take off the luggage compartment. 2.Take off the left and right body covers. 3.Take off the air cleaner fixing screws. 4.Loosen 2 nuts of intake manifold, withdraw intake system assembly. 5.Remove vacuum pipe, fuel pipe ,auto choke, cap of spark plug, rear brake cable carburetor pipe, starter motor cable.
  • Page 99 Drive pulley, starter clutch. driven pulley A. Troubleshooting B. Measurement data C. Driving pulley D .Starter E. Clutch driven pulley...
  • Page 100 A.Troubleshooting: a.Engine starts, but vehicle don’t move. 1.driving belt worn out 2.driving plate worn out 3.clutch lining worn out 4.driving plate’s spring broken b.the vehicle stops or tremble when running. 1.clutch lining spring cracked or broken. c.Can’t reach high speed, no pick-up 1.driving belt worn out.
  • Page 101 (C)Driving Pulley 1.Take off the screws of left cover, remove the left cover. 2.Remove the lock nuts of driving Plate and the nuts of Starter gear And clutch. 3.Take off the ramp plate, Belt and clutch.
  • Page 102 4.Take off the boss and driving plate. 5.Continuous Various Transmission engagement speed inspection Connect an electric tachometer. Seated on the motorcycle with on level ground, increase the engine’s speed slowly and notice the RPM at which the motorcycle begins to move forward.
  • Page 103 5.To assemble the driving pulley, reverse the whole procdeure. Locking torque: 1.Nut of driving pulley M12: 4.0-5.5kg/m. 2.Locking nut of clutch M12: 4.0-5.5kg/m 6.Checking driving belt (1)check driving belt is cracked or not rubber and fiber is loosened or not also check if they are extraordinary worn out.
  • Page 104 (2)Check gasket inner dia of slide driving plate: limit of use : change it over 24.1mm. (3)Check the driving pulley surface wearing condition. (4)Check the outer diameter of the contact surface of the movable driving plate. limit of use : change it below 23.94mm.
  • Page 105 D.Starter dismantle 1.Dismantle left crankcase cover 2.Remove hexagon nut, then remove the starter lever. 3.Remove five screw of separated plate. 4.Remove start spring from start returning position. 5.Remove driven gear comp. of kick starter. 6.Remove the retaining C-type Ring. 7.Remove spindle comp. of kick starter.
  • Page 106 E. Clutch driven pulley 1.Dismantling the clutch a. Remove left crankcase cover. b. Remove driving plate. c. Remove driving belt. d. Remove locking nut, then remove clutch. 2.Assemble the clutch : follows the opposite procedure of dismantling. Locking torque: M12: 4.0~5.5kg.m 3.Checking clutch: dismantling tool a.Check clutch driving face.
  • Page 107 c.Check driving spring free length. Standard: 151mm Limit of usage: Change it below 127 mm Check wearing condition of driving plate sets. And measure outer diameter. limit of use: change it above 33.95mm. e.Check wearing condition of slide driven plate. And measure its Inner diameter.
  • Page 108 (5)Cylinder head and valve A.Trouble shooting B.The operation data information C.Dismantling and installing HEAD COMP. CYLINDER 19 "CAM,SHAFT ASSY." "GUIDE,EXH VALVE " 20 "SHAFT,EX.ROCKER ARM" O-RING 21 VALVE RXKER ARM "GUIDE,IN VALVE " 22 SCREW TOPPED ADJUSTER VALVE EXHAUST 23 HEXAGON NUT VALVE INLET 24 "SHAFT,EX.ROCKER ARM "...
  • Page 109 A.Troubleshooting. If the cylinder head is malfunctioned, usually it can tell from the measurement of the Compression pressure or from the noise that comes from the upper part of the engine. 1.Unsmooth idle speed Compression pressure is too low. 2.Insufficient compression pressure. 5.Abnormal noise -Poor adjustment of valve clearance -Poor adjustment of valve clearance...
  • Page 110 C.Dismantling and installing the Cam shaft 1.Take off the left cover. 2.Remove the intake pipe from the Cylinder head cover. 3.Take off the 4 bolts of the cylinder head cover and take off the cylinder head cover. 4.Turn the flywheel counterclockwise and let the ”T”...
  • Page 111 Check cam shaft Check the convex surface and the height and see whether it has Been damaged. Limit of Use: IN :replace it below 25.90(125CC), 26.23mm(150CC) EX :replace it below 25.90(125CC), 26.13mm(150CC) Check camshaft. If the bearing is loosen or worn out, change the whole set if necessary. Check cam shaft holder 1.Check the cam shaft holder, cam rocker arm, and cam Rocker arm shaft and see whether it is loosen or worn...
  • Page 112 Dismantling the cylinder head: 1.Remove the carburetor. 2.Remove the muffler. 3.Remove the fan cover. 4.Remove the bolts on the engine cover. 5.Remove the camshaft. 6.Remove the cylinder head 7.Remove the lock pin, cylinder head gasket. 8.Remove cam chain guide Notice: Not to injure the contact Surface of the cylinder.
  • Page 113 (6)Cylinder and piston A.Trouble shooting B.The Operation notice C.Data D.Dismaniling cylinder, piston E.Installing cylinder, piston C.Data (150CC) Part name /description Standard value Limit of use ( mm ) ( mm ) Bore 57.490~57.510 57.600 Curve 0.005 Cylinder Cylindrility 0.005 Roundness 0.005 Clearance b/w Piston lst ring...
  • Page 114 A.Troubleshooting. a.Compression pressure is too low, difficult to start engine and engine running unsmoothly. 1.Cylinder head gasket cracked 2.Spark plug is not well locked 3.Piston ring worn out or cracked 4.Cylinder, piston worn out. 5.Reed valve is out of order. b.Compression pressure is too high;...
  • Page 115 D.Dismantling a.Dismantling Cylinder 1.Remove the cylinder head. 2.Remove 2 bolts, then the camshaft chain adjuster 3.Remove CAM chain guide. 4.Remove cylinder. 5.Remove the cylinder gasket, lock pin and clean the gasket on the cylinder. b.Dismantling piston 1.Remove the piston pin clip. NOTICE: Dot’...
  • Page 116 5.The difference between the X and y is the roundness. 6.The cylindrility is the max value of the difference between the upper, Middlle and lower position of the inner dia in X or Y direction. Limit of use : Roundness:change it when above 0.005mm.
  • Page 117 E.Installing Cylinder and piston a.Installing piston and piston rings 1.Lubricate the piston rings by motor oil. NOTICE: a.Be careful not to scratch the piston and not to break the piston ring. b.The mark (on the ring) should be upward when installing. c.after installing, the ring should be smoothly rotated.
  • Page 118 (7)A.C. Generator A.Dismantling AC generator B.Installing AC generator...
  • Page 119 Dismantling AC generator 1. Dismantle the rear section of muffler. 2. Remove fan cowl. 3. Remove the M6 screws 4. Remove screws of flywheel magneto. 5. Remove the AC flywheel magneto by special tool. 6. Remove the flywheel. 7. Remove the electric plug of AC flywheel magneto.
  • Page 120 B.Installing AC generator To install, please reverse the dismantling procedure. Locking torque: 1.0~1.2kg/m M12: 3.2~4.0kg/m...
  • Page 121 (8)Final transmission mechanism A. Troubleshooting. B. Dismantle the final transmission mechanism. C. Check the final transmission mechanism. D. Assemble the final transmission mechanism. A. Troubleshooting Engine can be started, but the vehicle doesn’t move. 1.Gear worn-out or cracked. 2.Gear burnt out. Noise occur when running.
  • Page 122 B. Disassemble the final transmission mechanism: 1.Remove the rear wheel. 2.Drain the oil in the gear box. 3.Remove the bolt in the gear box cover. Take off the gear box.
  • Page 123 3.Remove the final reduction gear And idle gear. 5.Clean up the gear box. C. Check the final transmission mechanism 1.Check the wearing condition of driving shaft and gears. Gear teeth number: 14 T (125CC) ; 15 T (150CC)
  • Page 124 2.Check the wearing condition of idle gear shaft and idle gears. Gear teeth number 43 T (125CC) ; 42 T (150CC) 3.Check the wearing condition of the final reduction gear. 4.Check the wearing condition of the oil seal and bearing. D.
  • Page 125 (9)Crankcase, Crankshaft: A. Disassembling diagram. B. Troubleshooting. C. Data D. Remove crankcase and crankshaft. E. Check crankshaft. F. Assemble the crankcase.
  • Page 126 A. Disassembling diagram Torque: 1.0~1.2kg-m B. Troubleshooting Engine noise: 1.The bearing of final transmission mechanism is loosen. 2.Crank pin of bearing is slack. 3.The bearing of gear box is loosen.
  • Page 127 C.Data Item Standard value(mm) Limit of use.(mm) Clearance of connecting rod big end 0.10~0.35 0.55 axle direction Clearance of connecting rod big end 0.04 vertical direction. Swingness of the crank shaft journal. 0.03 0.10 D. Remove the crankcase and crankshaft by the following procedures: 1.Remove the engine.
  • Page 128 E.Check crankshaft 1.Measure the difference of the connecting rod big end between the X and Y Limit of use : replace it when above 0.04mm. Measure the swing ness of the crankshaft journal. Limit of use Change it when above Change it when above 0.1mm 0.1mm...
  • Page 129 (10)Carburetor: A.General theory B.Troubleshooting. C.Dismantling the carburetor. D.Dismantling the float and nozzle. CARBURETOR SPECIFICATIONS: ITEM SPECIFICATION SPECIFICATION Model M2-125 M2-150 Carburetor type KEIHIN CVK24 KEIHIN CVK24 Bore size 24mm 24 mm I.D. NO 1700 ± 100 1700 ± 100 Idle r/min 18.0 ±...
  • Page 130 General theory DIAPHRAGM AND PISTON OPERATION The carburetor is a variable-venturi type, whose venturi cross sectional area is increased or decreased automatically by the piston valve . The piston valve moves according to the negative pressure present on the downstream side of the venturi A. Negative pressure is admitted into the diaphragm chamber through an orifice provided in the piston valve .
  • Page 131 SLOW SYSTEM This system supplies fuel during engine operation when the throttle valve is closed or slightly opened. The fuel from the float chamber is metered by the pilot jet where it mixes with air coming in through the pilot air jet .
  • Page 133 MAIN SYSTEM As the throttle valve is opened, engine speed rises and negative pressure in the venturi A increases. This causes the piston valve to move upward. The fuel in the float chamber is metered by the main jet . The metered fuel enters the needle , mixes with the air admitted through the main air jet and forms an emulsion.
  • Page 134 AUTO-ENRICHENER (AUTO-CHOKE) SYSTEM The automatic enrichener (automatic choke) device consists of the PTC heater A, the thermo-wax B and the plunger/needle . When the thermo-wax B is cold, the plunger/needle moves upward, Fuel is drawn into the enrichener circuit from the float chamber Enrichener jet meters this fuel, which then flows into fuel pipe and mixes with the air...
  • Page 135 FLOAT SYSTEM The float and needle valve work in conjunction with one another. As the float chamber the float rises and the needle valve pushes up against the valve seat. When this occurs, no fuel enters the float chamber . As the fuel level falls, the float lowers and the needle valve unseats itself;...
  • Page 136 ACCELERATOR PUMP SYSTEM This system works only when the rider opens throttle grip quickly as pump send the necessary amount of fuel to the carburetor bore for correcting fuel/air mixture ratio. When the rider open the throttle grip quickly, the intaken air volume becomes large and air velocity at the bottom of the throttle valve (piston valve)is slow and sucking volume of fuel is less.

  • Page 137: Carburetor Cleaning

    INSPECTION Check the following parts for damage and clogging. * Pilot jet * Piston valve * Main jet * Starter jet * Main air jet * Gaskets and O-rings * Pilot air jet No.1 & No.2 * Pilot outlet and bypass * Needle jet holder * Coasting enrichement valve * Float...

  • Page 138: Float Height Adjustment

    AUTO-ENRICHENER INSPECTION Disconnect the lead wire coupler . Remove the cover . Connect the positive ♁ terminal of a 12V battery to Yellow/white lead and the negative Θ terminal to Black/ White. Check that the auto-enrichener section (PTC heater built-in area)is heated in 5 minutes after the battery has been connected.
  • Page 139 (B) Troubleshooting Difficult to start 1.No sparking in spark plug. 2.Compression pressure too low. 3.No fuel in the carburetor -air cleaner blocked -oil pipe blocked -bad adjustment of the fuel level float valve is jell Mixed air too dilute 1.Main jet blocked 2.Float valve blocked 3.Fuel level too low 4.Fuel system blocked...
  • Page 140 (D)The float nozzle 1.Dismantling Remove the screws to take off the float chamber. Remove the float, the float pin, and float valve. 2.Checking Check the float valve, valve base to see whether it is blocked or damaged. Check the float valve, valve base surface if sectional worn out or dirty.
  • Page 141 (D)Handle bar, front wheel, front brake and front fork: A. Troubleshooting 1.steering handlebar is abnormal, too tight. a.steering mechanism; washer of conical bush locked too tightly. b.steering mechanism; steel ball is cracked. c.steering mechanism; steel ball base and washer of conical base is damaged. d.
  • Page 142 C. Change the speedometer cable: 1.Remove the front handle cover. 2.Remove the nut of the speedometer cable. 3.Remove the fixed screw of the speedometer cable on the front wheel. 4.Pull out the damaged speedometer cable. 5.To assemble the new cable, please follow the opposite of dismantling procedures. Note: Put some grease onto the inner cable before assembling.
  • Page 143 (D)Steering handlebar 1.Remove the LH/RH back mirrors. 2.Remove the upper handle cover. 3.Remove the nuts on front fork and handlebar. 4.Take off the fixing bolt. 5.Remove the nut and bolt of the front fork fixed on The handlebar. 6.Take off the handle bar. 7.When assembling, please follow the opposite procedures.
  • Page 144 (E)Front wheel 1.Remove the locking nut of the front wheel on the right side. 2.Draw out the axle of front wheel, remove the ring and take off the gear sets of speedometer. 3.Remove the front wheel assy. 4.Assemble the front wheel follows the opposite procedure of dismantling.
  • Page 145 6.Front wheel bearing checking Turn the tire. If the bearing is Loosen or any occurrence for noise, Please change a new one. 7.Front wheel rim checking (1)Check the swing of the front wheel rim. (2)Limit of use: Horizontal direction: Change a new one when above 2.0mm. Vertical direction: Change a new one when above 2.0mm.
  • Page 146 3.Front fork checking: If it is bent or cracked, please replace with a new one. 4.Front shock absorber checking Check is there any unusual damage or worn-out condition, and whether the guide rod of the Front fork is crooked or not. Fork oil type: SAE 10W20 Capacity (each side): 84 CC (M2-50) Capacity (each side): 95 CC (M2-125/150/200/250)
  • Page 147 5.Disassembling and assembling the front brake-disk. Remove the front wheel. Remove bolts on the disk. Remove the disk. Assemble the disk follows the disassembling procedure. Locking torque M8: 2.0~3.0kgm 6.Checking the front brake-disk. Standard thickness of disk: 3.5 mm (M2-50); 4.0 mm (M2-125/150/200/220/250) Limit of usage: change it when below 3.0 mm (M2-50);...
  • Page 148 (C)Dismantling the carburetor 1.Remove the auto starter connector. 2.Remove the throttle cable, then the fuel pipe from the carburetor. 3.Remove the screws on the intake manifold. 4.Unscrew the fixing belt on the connecting pipe. 5.Remove the carburetor. Assembling the carburetor To assemble the carburetor, please follow the reversed procedures of the dismantling and do the following adjustment after installation is finished: -Adjust the throttle cable...
  • Page 149 (E)Rear wheel, rear brake, rear damper: A. Troubleshooting. 1.Rear wheel swings. a. Wheel rim is distorted. b. Tire worn out. c. The wheel axle is improperly assembled. 2.rear damper is too soft. a. Spring fatigue. 3.Bad braking a. The adjustment of brake is not proper. b.
  • Page 150 C. Disassembling and assembling the rear wheel. 1.Remove the rear mudguard and the exhaust pipe. 2.Remove the locking nut of the rear wheel 3.Remove the rear wheel 4.To assemble the rear wheel please reverse the dismantling procedure. Locking torque: M6 : 0.7-1.1kg-m M14: 8.0-10.0kg-m D.
  • Page 151 E. Rear brake: (M2-50) 1.Rear brake disassembling diagram. (1)Checking the rear brake hub: a. measure the inner diameter of rear brake hub. b.Limit of use: change it when above 111.0mm 2.Checking the brake lining: (M2-50) a. measure the thickness of the rear brake lining. b.linit of use: As the thickness is less than 2.0 mm, change it.
  • Page 152 F. Rear absorber 1. Check the locking torque of rear absorber at lower & upper. 2. Both locking torque is 3.5~4.5 kg-m. 3. Oil leakage check is always necessary. M2-250 M2-50/125/150/200/220...
  • Page 153 (F)Fuel supply A. Troubleshooting. 1.Engine can’t start: a. No fuel in fuel tank. b. Fuel pipe is blocked. c. Auto cock and filter is blocked. d. The membrane of fuel pump is over swell. 2.The membrance of auto cock is over-extended. a.

  • Page 154: Fuel Tank

    C. Dismantling and assembling Fuel Tank 1.Remove the front luggage box. Open the fuel tank cover cap 2.Remove the fuel tank cover.. 3.Remove the fuel pipe. 4.Remove the connecting terminal of the fuel gauge. 5.Remove the fuel gauge. 6.Remove the fixing blot of the fuel tank. 7.Take off the fuel tank.
  • Page 155 D. Oil tank disassembling diagram: (only available for M2-50) E.Dismantling and assembling oil tank: (only available for M2-50) 1.Drain off the oil. 2.Disconnect plug of oil gauge. 3.Remove the oil tank. 4.Clean the oil tank. 5.To assemble the oil tank, please follow the opposite procedures of dismantling.
  • Page 156 V. Electric equipment: (1)Troubleshooting (2)Battery 1.Check the cells of battery 2. recharging 3.Test the recharging performance (3)Recharge system 1. the wiring diagram of recharge system 2. check A.C. flywheel magneto. 3. Check regulator/rectifier. (4)Ignition system 1. the wiring of ignition 2.
  • Page 157 (1)Troubleshooting: Currency is unstable. A. Recharge system: The wiring of batter connection is not good. No power: 2.Ignition system connection is not good. 1.Battery over discharging 3.Ignition system is short circuit. No electrolyte in battery. 4.Lamp system connection is not good or Battery is bleached short circuit.
  • Page 158 (2)Battery: 1.Check the cells of battery. Always remove the battery negative Cable(-)first, then positive cable (+). But connect the positive cable (+)first, then connect the Negative cable(-) when assembling. M2-50 125/150/200/220/250...
  • Page 159 2.Recharge Connection procedure: connect the positive cable(+) of the negative cable(+) of the battery, and the negative cable(-) of the recharge to the negative cable(-) of the battery. Recharging currency: Please recharge (12V) according to the following current and time. Standard: 0.4A * 4~10Hr or Rapid:3A * 60min(50cc) Standard: 0.7A * 5~10Hr or Rapid:3A * 60min(125/150cc) Standard: 0.9A * 5~10Hr or Rapid:3A * 60min(200/220/250cc)
  • Page 160 3.Testing the recharging performance This test needs to be done when the battery is fully recharged. This test needs to be done after engine is warm-up. a. Disconnect the orange cable of regulator. b. Open the fuse box, to remove the white cable. c.
  • Page 161 BATTERY CONSTRUCTION PGO sscooters uses an MF (Maintenance Free) battery. As shown in the right illustration, the battery consists of electrodes, separators, safety valve, filter, etc. Fine glass fiber is used for constructing the separator which holds electrolyte inside. When a discharged conventional open type battery is re- charged fully, lead sulfate turns to lead dioxide and sponge- like lead.
  • Page 162 Insert the nozzles of the electrolyte container into the battery’s electrolyte filler holes, holding the container securely. ! CAUTION Take precaution not to allow any of the fluid to spill. Insert the nozzles squarely to the battery. Check that air bubbles are coming up from each electrolyte container and leave in this position for more than 20 minutes.
  • Page 163 PRECAUTION FOR HANDLING BATTERY The battery produces combustible gasses and therefore can explode if handled improperly. Use Caution for the following in addition to general service precautions. Never allow the battery to short-circuit. Keep away from sparks and fire. Charging of the battery must be operated in an open and well ventilated area and never operate in an closed indoor.
  • Page 164 (3)Recharge system: A. Recharge system diagram for M2-50...
  • Page 165 B. Recharge system diagram for M2-125/150...
  • Page 166 2.Check A.C. Generator a. Open the seat cover and remove the luggage box. b. Measure the resistance value of terminals. Yellow V.S. black 0.1-1.0 White V.S. black 0.2-2.0 ACG inside 3.Check regulator Measure the resistance value between each terminal, It should be in the specified range, otherwise change a new one. M2-125/150/200/220/250 M2-50...
  • Page 167 (4)Ignition system: 1.the wiring or ignition 2.Check spark plug. 3.Check the H.V. cable and H.V. coil by using the CDI tester. 4.CDI sets checking. Check with the CDI tester and please follow the instruction manual. If the CDI test failed, please change a new one. Ignition coil...
  • Page 168 (5)The starting system: 1.The wiring of starting 2.Make sure the Engine RUN/OFF switch is in “Run” position. 3.Check the safety switch by operating the brake lever, and the brake lamps shall light on.
  • Page 169 4.check the starting relay a. Find the control coil by measuring the resistance. b. Connect green/white cable to positive pole of battery, connect black cable of negative pole of battery, It means starter is function well if above connection and both Red Black cable of staring motor have currency passing through.
  • Page 170 Wiring diagram for M2-50:...
  • Page 171 Wiring diagram for M2-125/150:...
  • Page 172 Wiring diagram for M2-150(4V):...
  • Page 173 Wiring diagram for M2-200:...
  • Page 176 Wiring diagram for M2-250:...
  • Page 177 ⅤI. GMAX-200/220 characteristics , dismantle & inspection (1) Engine dismantling (2) Engine inspection (3) Electric system (4) Maintenance (5) Engine Management System(EMS) (6) EMS diagnostic (7) EMS system Repairing tool (8) EMS General Electric units...
  • Page 178 PGO-200/220 engine dismantle Engine assembly 1.dismantle the chassis parts connected to engine 2.take off engine assembly Front section muffler 1.dismantle 2 castle nuts 2.take off front section oil cooler 1.loosen 2 bolts remark：there are 2 washers 2.dismantle the oil cooler Second Air Injection (SAI) 1.dismantle 1 bolt...
  • Page 179 PGO-200/220 engine dismantle Cooling cowl 1.dismantle 3 tapping screws 2.dismantle 1 upper hexagon bolt 3.take off upper cooling cowl 4.dismantle 1 lower hexagon bolt 5.take off lower cooling cowl...

  • Page 180: Cylinder Head Cover

    PGO-200/220 engine dismantle Cylinder head cover 1.loosen 4 hexagon bolts 2.dismantle cylinder head cover Chain tensioner 1.loosen the middle bolt 2.dismantle the spring 3.loosen 2 bolts of the body 4.dismantle the chain tensioner body 5.take off the packing --------------------------- Recover the chain tensioner 1.dismantle the bolt &...

  • Page 181: Cylinder Head

    PGO-200/220 engine dismantle Camshaft holder 1.loosen 4 nuts & washers 2.dismantle the holder 3.dismantle 2 lock pins 4.dismantle the camshaft Cylinder head 1.loosen 2 hexagon bolts 2.dismantle cylinder head 3.dismantle 2 lock pins 4.take off the gasket...
  • Page 182 PGO-200/220 engine dismantle Cylinder 1.dismantle the lower chain tensioner 2.take off the cylinder 3.dismantle 2 lock pins 4.take off the packing Piston 1.dismantle 2 clips 2.dismantle piston pin 3.take off the piston Attention! To prevent clip falling down the crankcase, use clothes to cover the crankcase.
  • Page 183 PGO-200/220 engine dismantle 2.loosen right 2 hexagon bolts 3.dismantle the engine lower hanger Cooling fan 1.loosen 4 bolts 2.dismantle the fan Generator outer 1.Loosen 1 nut & washer 2.use special tool: turn the outer counterclockwise， lock the inner bolt clockwise 3.
  • Page 184 PGO-200/220 engine dismantle Generator stator 1.loosen 2 bolts & washers of pulser 2.dismantle the bracket of pulser 3.loosen 3 socket bolt 3.dismantle the stator Starting motor 1.loosen 2 hexagon bolts 2.dismantle starting motor...
  • Page 185 PGO-200/220 engine dismantle Right crankcase cover 1.loosen 9 bolts 2.dismantle the right crankcase cover 3.dismantle 2 lock pins 4.dismantle the packing Attention! Be careful of the surface, don＇t defect it to avoid oil leaking. Starting idle gear 1.dismantle the shaft 2.dismantle the body...
  • Page 186 PGO-200/220 engine dismantle and counterclockwise to lock 2.use the compressed air wrench to loosen nut, or use the tool to fix the crankshaft. Special tool (one way clutch) S620504G01 Sprocket of oil pump 1.dismantle E clip & washer 2.dismantle the sprocket & chain...

  • Page 187: Oil Pump

    PGO-200/220 engine dismantle Oil pump 1.loosen 2 bolts 2.dismantle oil pump body Attention! 定位銷 There is a lock pin in the shaft of oil pump, don＇t miss it. Right crankcase 1.loosen 2 bolts 2.dismantle the right crankcase 3.dismantle 2 lock pins 4.take off the packing...
  • Page 188 PGO-200/220 engine dismantle crankshaft from the left crankcase, don＇t damage the oil & impact the crankshaft!
  • Page 189 6.2 Engine inspection data CVT parts I n sp ectio n d ata standard( m m ) using limit( m m ) Item 27.011~27.021 27.10 The inner dia. Of slide drivingplat The outer dia. Of boss, 26.970~26.990 26.95 movable Driving 17.70 Belt width 18.7~19.3...
  • Page 190 Piston & Cylinder inspection (200CC) Part name /description Standard value Limit of use ( mm ) ( mm ) Bore 64.990~65.010 65.100 Curve 0.005 Cylinder Cylindrility 0.005 Roundness 0.005 lst ring 0.04~0.08 0.15 Clearance b/w Piston and Piston ring ring 0.02~0.06 0.15 lst ring...
  • Page 191 Crankshaft Item Standard value(mm) Limit of use.(mm) Clearance of connecting rod big end 0.005~0.013 0.05 axle direction Clearance of connecting rod big end 0.10~0.40 vertical direction. Swingness of the crank shaft journal. 0.03 0.10...
  • Page 192 6.3 Electric system Carburetor model electric General maintenance Engine Management System...

  • Page 193: Electric System

    6.3 Electric system What is transistor ignition? Transistor Ignition System Transistor: a kind of semi-conductor that can control electric current, has the switch function Apply transistor to engine ignition control, called transistor ignition...
  • Page 194 Major components of Transistor ignition Digital ignition controller Ignition coil DC-generator, with longer pulse flange TPS: Throttle Position Sensor (optional part of Carburetor) Ignition coil Digital ignition controller...
  • Page 195 Comparision of Transistor V.S. CDI ignition item parts Traditional CDI G-MAX 200/220 transistor Digital controller ACG flange shorter longer Ignition coil Less coils More coils More coils longer Digital controller Traditional C.D.I Transistor ignition...
  • Page 196 G-MAX 200/220 Electric system Headlamp & choke (carburetor) diagram When engine speed > 1000rpm,the digital controller permits the relay to conduct the circuit 12V from battery fuse Green/ Headlamp Digital black switch controller relay 1000 Control timing To headlamp & choke...
  • Page 197 Charging system diagram Charging to battery yellow ＋ － 3-phase yellow Regula- generator battery yellow Battery feedback voltage ground ground...
  • Page 198 Fuse wire: Main fuse layout relay fuse layout reserved fuse layout Red/white white Red/black Red/white white...
  • Page 199 G-MAX 200/220 Electric parts relay fuse(15A-) Digital controller Seat lamp controller battery diode Remarks: If dismantle the battery, engine will cease fire!

  • Page 200: General Maintenance

    6.4 General maintenance G-MAX 200/220 G-MAX125/150 Replace 1000cc Replace 800cc Engine oil Total 1400cc Total 1000cc Replace 110cc Replace 90cc Gear oil Total 130cc Total 110cc Oil filter filter filter Air element Wet paper(bigger) Wet paper CVT sponge Circle shape Oval shape headlamp 55W/60W...
  • Page 201 G-MAX 200/220 Specified engine oil (synthetic 1000ml)
  • Page 202 Engine oil、gear oil: Gear oil filling Replace 110cc total 130cc Drain of engine oil drain of gear oil...
  • Page 203 Engine oil、gear oil: Engine oil filling & gauge replacement 1000cc total 1400cc Check the oil level: 1.park in flat area 2.keep in idle for 3 minutes 3.cold down 3 minutes 4.take off the gauge upper lowest 5.when lower the lowest limit, add oil to upper limit...
  • Page 204 Replace the 2 oil filter 1.dismantle the right lower cover 2.replace the filter ＊keep the surface clean 　apply grease to the O-ring before installing!
  • Page 205 Air element 1.loosen 8 screws Don’t forget to install the 2.dismantle the cover, black-rubber packing Take off the element back to the element...
  • Page 206 CVT sponge 1.loosen 3 bolts Clean with compressed air, or replace a new one 2.take off the sponge...
  • Page 207 CVT dismantle 1.loosen the outer bolts Don’t miss the lock pin 2.dismantle the cover falling into the 3.loosen 2 hexagon nuts crankcase...
  • Page 208 CVT install notes: 1.keep the words of belt facing to operator 2.push the belt to bottom 3.lock the nuts Rotation direction...

  • Page 209: Spark Plug

    Spark plug Dismantle the right lower cover Loosen with the special tool Spark plug: C7E(carburetor) or CR7E(EMS model)

  • Page 210: Ignition Coil

    Ignition coil: Dismantle the right lower cover You can see the ignition coil clearly...
  • Page 211 Front brake system: Service data: ◎tire pressure:2.0 kg/cm ◎using limit of Disk thickness: 3.5mm ◎ using limit of pad thickness: to groove bottom...
  • Page 212 Replace the front pads ●dismantle 1.dismantle clip 2.take off the pin 3.take off the yoke 4.dismantle the pads ●install reverse procedure of dismantle...
  • Page 213 Front brake system: Service data: ◎ tire pressure:2.0 kg/cm ◎ using limit of Disk thickness: 3.5mm ◎ using limit of pad thickness: to groove bottom...
  • Page 214 Replace the rear pads ●dismantle 1.dismantle clip 2.take off the pin 3.take off the yoke 4.dismantle the pads ●install reverse procedure of dismantle...
  • Page 215 6.5 Engine Management System (EMS)
  • Page 216 EMS index ◇PGO 2 -stage EMS structure ◇EMS units ◇EMS diagnostic...
  • Page 217 Feature of PGO 2 -stage EMS ＊feature 1.small, light 2.integrity 3.accuracy 4.simple...
  • Page 218 EMS structure (A) Fuel supply 5 sensors ignition injector Crank speed sensor coil Engine temperature air control sensor Throttle position sensor Idle speed control Intake pressure sensor Oxygen sensor...
  • Page 219 EMS structure (B) (ISC) Electric control unit Spark coil plug injector Intake pressure sensor Throttle position sensor Engine temperature sensor Oxygen sensor Crank speed sensor...
  • Page 220 EMS units...
  • Page 221 ※ Intake pressure sensor Idle Speed Controller ※噴油嘴 injector Throttle position ※ sensor...
  • Page 222 ※Fuel pump Assy ※Transistor ignition coil comp ※crank speed sensor ※Engine temperature sensor ※Oxygen sensor...
  • Page 223 ※ Second air solenoid ※ECU Electronic Control Unit ※ Topple snsor...
  • Page 224 Important PIN no.# of ECU ＊ECU (PIN) 1 PIN 18 PIN 19 PIN 36 PIN...
  • Page 225 Important PIN no.# of ECU ＊ Important PIN no.# of ECU PIN NO. function Control pole of fuel pump Control pole of headlamp relay supply(5V) voltage to sensors Control pole of injector Control pole of coil Input voltage from battery...
  • Page 226 Function of Crank speed sensor ＊function：induct the engine speed, tell ECU to control inject fuel & ignition ＊theory：calculate the interval time of each flange on the outer...
  • Page 227 Engine temperature sensor ＊function：induct engine oil temperature, then ECU knows engine is cold or hot ＊theory：different temperature vary resistence...
  • Page 228 Measure engine temperature sensor T(℃) resistance(KΩ) -20℃ 18.800 KΩ 40℃ 1.136 KΩ 100℃ 0.155 KΩ usually 1.5~5.5 KΩ...
  • Page 229 Throttle position sensor (TPS) ＊function：induct throttle angle, provides the road load condition to ECU ＊theory：angle changes, resistance changes!
  • Page 230 Throttle position sensor (TPS) Lb(+) / Gr(-) throttle output(V) 0.6 ±0.02V close 3.8 ±0.10V ＊Lb <output> ＊Pu <power(5V)> ＊Gr <ground>...
  • Page 231 Intake pressure sensor ＊function： induct intake air pressure, ECU judge intake or compress stroke to decide injection & ignition ＊theory：different pressure outputs diferent resistance...
  • Page 232 Intake pressure sensor ＊Pu G/B(+) / Gr(-) <output(5V)> press(KPa) output(V) ＊G/B 13.3KPa 0.5V <output> ＊Gr <ground> 120 KPa 3.4V 壓力特性 絕對壓力 (kPa)
  • Page 233 Intake pressure sensor ＊Pu <output(5V)> ＊G/B ＊average resistance in ambient <output> wire R(KΩ) ＊Gr <ground> Pu(+)+Gr(-) 2~4KΩ G/B(+)+Gr(-) 2~4KΩ...
  • Page 234 Oxygen sensor ＊function：induct the A/F ratio, feedback to ECU , and decide the injection time; modify to the best 14.7 ratio ＊others：there is heater inside, help it reach the working temperature quickly...
  • Page 235 Oxygen sensor ＊W <heater(12V)> 2 couple~8Ω ＊Gr <ground> ＊B <output>...
  • Page 236 injector ＊function：inject the gas, mixed with air＊ theory：control the opening time interval to decide the gas amount...
  • Page 237 injector ＊R/B(+) <output(12V)> ＊Br/W(+) <output(12V)> ＊each terminal virus ground is 12V time(msec) injecting feeding...
  • Page 238 Draining cap of injector ＊bleed the air Used when replace the fuel pump, pipe…etc. ＊drain the gas The gas inside the pipe may become poor quality after storage, drain it before start the engine...

  • Page 239: Fuel Pump

    Fuel pump ＊function：pumping the gas to injector, and keep the constant pressure as 3kgf/cm ＊theory：the regulator keeps constant pressure regulator pump filter...
  • Page 240 Fuel pump ＊R/B(+) R/B(+)+B(-) <output(12V)> voltage ~12V ＊B(-) resistance <1KΩ <ground>...
  • Page 241 Fall down sensor ＊function：when vehicle fall down more than 65degree, then EMS cut off the power and cease the engine ＊theory：there is ball mechanism inside the sensor, act by gravity and conduct the wiring.
  • Page 242 Fall down sensor ＊O power degree output(+) <input(12V)> +ground(-) ＊Bl/W <output> ＊B <65 <grounding> >65 ＊to recover the sensor function after fall down： 1.turn OFF the key 2.turn ON the key...
  • Page 243 ISC(Idle Speed Control) ＊W <ISC-A*> ＊R/B ＊ISC unit <ISC-B*> ＊G <ISC-B> ＊Gr A(+) + A*(-) ~80Ω <ISC-A> B(+) + B*(-) ~80Ω...
  • Page 244 ISC(Idle Speed Control) ＊what is ISC ? 　 (IDLE SPEED CONTROL) ＊control method of ISC when engine is at idle, ECU refer the sensors and decide how much air is required, then tell the ISC to act forward or backward. ＊sample when cold engine, ECU tell ISC enrich the by-pass air to increase the engine speed.
  • Page 245 ISC(Idle Speed Control) By-pass air Throttle body Step motor Air flow engine Throttle valve...
  • Page 246 ISC initialization timing ＊timing when used scooter occur: 　1. Hard to start the engine 　2. Engine Idle speed is unstable 　3. Other unstable situation 　To initialize the ISC, then the ISC reset to control zero point.
  • Page 247 Procedure of ISC initialization diagnostic 1.don’t plug quick- 2.wide open throttle; turn on the key; the ISC sounds “da da…” 3.release the throttle after the ISC stop acting. 4.turn off the key, finish initialization! throttle Release throttle Wide open Key ON Key OFF Main key ISC off...
  • Page 248 EMS fuses 7.5A 10A...
  • Page 249 Main purpose of EMS fuses ＊ (FUSE) 1A / 5A / 7.5A / 10A / 15A protect the units when extra-current occurs ： protect the (ECU) 1A <Y+G/B> ： protect fuel pump & injector 5A <R/W+G/B> ： protect ignition wiring(EMS) 7.5A <O+G/B>...
  • Page 250 6.6 EMS diagnostic...
  • Page 251 Quick diagnostic part no.：S320840G01 name：quick diagnostic...
  • Page 252 How to use quick diagnostic 4.turn on the key 1. Prepare quick diagnostic 5.wait for about 8 seconds 2. Open the rubber cover beside 6.observe the EMS led on dash the battery board 3. Plug in the quick-diagnostic...
  • Page 253 PC diagnostic PC diagnostic assy.： S320891G01 + S320838G01 (software & adapter + connect cable) KEIHIN RS232 or USB adapter software PGO vehicle connect cable...
  • Page 254 PC diagnostic part number：S320891G01 name： (software & adapter ) ＊software　　　　 　 ＊adapter...
  • Page 255 PC diagnostic part number：S320838G01 name：connect cable...
  • Page 256 Quick diagnostic table part Defect code Throttle position sensor 0 long 6 short Intake manifold pressure sensor 0 long 9 short Engine temperature sensor 1 long 1 short Oxygen sensor 1 long 7 short injector 3 long 3 short Ignition coil 3 long 7 short Fuel pump 4 long 1 short...
  • Page 257 Clear the defect code memory 1.plug quick diagnostic into vehicle seat 2.wide open the throttle, turn on the key 3.after the EMS led off, release the throttle 4.don’t turn off the key until EMS led on again. 5.turn on the key to confirm again. throttle EMS led on EMS led off...
  • Page 258 6.7 EMS system Repairing tool...
  • Page 259 pocket tester wiring ＊pocket tester wiring part no.：S905310005...
  • Page 260 Ignition gauge ＊connect ＊minimum distance 6mm Plug cap. ground...
  • Page 261 Fuel pressure gauge ＊fuel pressure gauge part no.：S905330008...
  • Page 262 Connect to the vehicle ＊measure the fuel pressure standard 3kgf/cm ＊usage 1.dismantle the hose to injector 2.connect the gauge assembly to the pipe 3.turn on the key 4.read the pressure...
  • Page 263 6.8 General Electric units...
  • Page 264 G-MAX 220 made in electric Storage light controler fuse Fuel pump Assy & fuel jet relay relay diode...
  • Page 265 Signal flasher relay (LED) ＊ dismantle the leg-shield cover first ＊ within the leg-shield cover...
  • Page 266 regulator ＊dismantle 1.luggage comp. 2 rear rack 3.body cover ＊within the right body cover...

  • Page 267: Fuel Gauge

    Fuel gauge ＊dismantle 1.middle cover ＊below the middle cover...
  • Page 268 Measure the fuel gauge ＊gray(+) gray(+)+black(-) <output> ＊black(-) 4~10Ω <ground> 80~90Ω...
  • Page 269 Starting relay ＊dismantle 1.luggage comp. 2.middle cover 3.rear rack 4.body cover ＊within the right body cover...
  • Page 270 (F)Front brake 1. Disassembling and assembling of the front brake comp. a. Remove two bolts fixed on the front brake comp and the front fork. b. Remove the front brake comp. c. Assemble the front brake comp. Follows the opposite procedure of dismantling.
  • Page 271 EMS relays ＊dismantle 1.luggage comp. 2.middle cover 3.rear rack 4.body cover ＊within the right body cover...
  • Page 272 EMS relays wiring ＊A.EMS system Gr/B Bl/W ＊B.fuel pump/injector ＊C.headlamp...
  • Page 273 Control of relays ＊ (Relay) 15A Big current ＊theory： use small current to control big current ＊Usage： fuel pump & injector EMS whole system headlamp Small current(ECU)
  • Page 274 Measure the relays ＊use the pocket tester 2.fit 12V to the control coil 3.the relay sounds “ka” 1.find the control coil 4.measure the resistance <disconnect-->NG connected-->OK> Ω Ω...

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