PGO G-MAX 150 - Service Manual

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Manufactured by Motive Power Industry Co., Ltd

Main Page

Contents3
G-Max 50 Specification5
G-Max 125 Specification6
G-Max 150 Specification7
G-Max 200 Specification8
G-Max 220 Specification9
G-Max 250 Specification10
Service Information11
The Operation Notice12
Locking Torque Value13
4T Engine (125/150/200/220CC)14
Chassis15
Other Parts Standard Torque Values15
Lubrication Instruction16
Chassis Appearance17
Wheel Bearing18
Periodic Maintenance Table19
Troubleshooting21
Difficult Starting or Can’t Start21
Weak Acceleration22
Engine Running Unsmoothly (Low Speed and Idling)24
Engine Running Unsmoothly (High Speed)25
Clutch, Drive and Driven Pulley26
Handlebar Steering Astrayed When Running27
Front, Rear Damper Not in Balanced27
Brake Disorder27
Oil Indicator Malfunction28
Fuel Indication Malfunction29
The Starting Motor Abnormal31
Starting Motor Running Slowly or no Pick-Up32
Starting Motor Can Not Stop after Starting32
No Sparking33
Charging Abnormal(Battery over Charging or over Discharging)34
Checking and Adjustment35
Regular Checking Table36
Battery: Recharge When Power Is out40
Cleaning Air Cleaner41
The Final Reduction Mechanism Oil42
Spark Plug42
Compression Pressure Measurement43
Ignition Timing44
Throttle Cables Adjustment44
Idle Adjustment45
Front Brake Adjustment45
Rear Brake Adjustment (Drum Brake Only)46
Tire46
Plastic Part Dismantle Overview47
Actual Dismantle Procedure48
G-MAX 50 Engine Dismantle, Maintenance, Repair and Assembly54
Lubrication System and Oil Pump55
Lubrication System Diagram55
Removing the Oil Pump56
Check the Oil Pump56
Assemble the Oil Pump57
Releasing Air in the Oil Pump57
Engine Dismantling58
Drive Pulley, Starter & Clutch Troubleshooting59
CVT Parts Measurement Data59
Driving Pulley60
Cylinder and Piston Troubleshooting68
Piston & Cylinder Datas68
Cylinder Head, Cylinder, and Piston Dismantling69
Check for the Flatness of Cylinder Head & Cylinder72
Combustion Chamber Cleaning72
Check Cylinder and Piston73
Installing Cylinder and Piston76
A.C. Generator, Flyweel77
Install AC Generator78
Final Transmission Mechanism Troubleshooting79
Disassemble the Final Transmission Mechanism79
Check the Final Transmission Mechanism81
Assemble the Final Transmission Mechanism81
Crankcase, Crankshaft Disassembling Diagram82
Crankcase, Crankshaft Troubleshooting83
Crankcase, Crankshaft Data83
Dismantle the Crankcase and Crankshaft84
Check the Crankshaft87
Assemble the Crankcase88
Carburetor, Reed Valve89
Carburetor Dismantling Diagram89
Carburetor, Reed Valve Troubleshooting90
Dismantling Carburetor91
Dismantling Float, Nozzle91
Dismantling Reed Valve92
Checking for the Reed Valve92
G-MAX 125/150 Engine Dismantling, Maintaining, Repairing and Assembling Operation93
Lubrication System94
Oil Pump Dismantling95
Oil Pump Assembly96
Measurement Data97
Reduction in Fuel Oil Volume97
Engine Burning-Out97
Troubleshooting97
Installing Engine98
Drive Pulley, Starter Clutch. Driven Pulley99
Drive Pulley, Starter Clutch. Driven Pulley Troubleshooting100
Drive Pulley, Starter Clutch. Driven Pulley Measurement Data100
Starter Dismantle105
Clutch Driven Pulley106
Cylinder Head and Valve108
Cylinder Head and Valve Troubleshooting109
The Operation Data Information109
Dismantling and Installing the Camshaft110
Check Camshaft111
When Installing111
Dismantling the Cylinder Head112
Further Dismantling112
Cylinder and Piston113
Cylinder and Piston Operation Notice114
Cylinder and Piston Data114
Dismantling Cylinder115
Dismantling Piston115
Piston Outer Dia Measurement115
Checking the Flatness of Cylinder Contact Surface116
Connecting Rod Small End Inner Diameter Measurement116
A.C. Generator118
Dismantling AC Generator119
Installing AC Generator120
Final Transmission Mechanism121
Crankcase, Crankshaft125
Remove the Crankcase and Crankshaft127
Check Crankshaft128
Assemble Crankcase128
Carburetor Specifications129
General Theory130
Diaphragm and Piston Operation130
Slow System131
Coasting Enrichment System131
Main System133
Auto-Enricher (Auto-Choke) System134
Float System135
Accelerator Pump System136
Inspection137
Carburetor Cleaning137
Auto-Enrichener Inspection138
Float Height Adjustment138
The Float Nozzle140
Handle Bar, Front Wheel, Front Brake and Front Fork141
Change the Speedometer Cable142
Steering Handlebar143
Front Wheel144
Dismantling the Carburetor148
Adjustment of Fuel Volume Adjusting Screws148
Rear Wheel, Rear Brake, Rear Damper149
Fuel Supply Troubleshooting153
Fuel Supply System Diagram153
Dismantling and Assembling Fuel Tank154
Oil Tank Disassembling Diagram155
Dismantling and Assembling Oil Tank155
Electric Equipment156
Battery158
Testing the Recharging Performance160
Battery Construction161
Electrolyte Filling161
Inserting Cap (Sealing Plug)162
Precaution for Handling Battery163
Recharging163
Battery Removal163
Recharge System Diagram for M2-50164
Recharge System Diagram for M2-125/150165
Check A.C. Generator166
Check Regulator166
Ignition System167
The Wiring of Ignition167
The Starting System168
Wiring Diagram for M2-50170
Wiring Diagram for M2-125/150171
Wiring Diagram for M2-150(4V)172
Wiring Diagram for M2-200173
Wiring Diagram for M2-22CEFI174
Wiring Diagram for M2-22CEFI (ECU)175
Wiring Diagram for M2-250176
GMAX-200/220 Characteristics , Dismantle & Inspection177
PGO-200/220 Engine Dismantle178
Cooling Cowl179
Cylinder Head Cover180
Chain Tensioner180
Recover the Chain Tensioner180
Camshaft Holder181
Cylinder Head181
Cooling Fan183
Generator Outer183
Generator Stator184
Starting Motor184
Right Crankcase Cover185
Starting Idle Gear185
One Way Clutch185
Sprocket of Oil Pump186
Oil Pump187
Right Crankcase187
Crankshaft187
Engine Inspection Data189
Piston & Cylinder Inspection (200CC)190
Electric System192
What Is Transistor Ignition?193
Electric System193
Major Components of Transistor Ignition194
Comparision of Transistor V.S. CDI Ignition195
G-MAX 200/220 Electric System196
Headlamp & Choke (Carburetor) Diagram196
Charging System Diagram197
Fuse Wire198
G-MAX 200/220 Electric Parts199
General Maintenance200
G-MAX 200/220 Specified Engine Oil (Synthetic 1000Ml)201
Engine Oil, Gear Oil202
Engine Oil Filling & Gauge203
Replace the 2Nd Oil Filter204
Air Element205
CVT Sponge206
CVT Dismantle207
CVT Install Notes208
Spark Plug209
Ignition Coil210
Front Brake System211
Replace the Front Pads212
Replace the Rear Pads214
Engine Management System (EMS)215
EMS Index216
Feature of PGO 2Nd-Stage EMS217
EMS Structure (A)218
EMS Structure (B)219
EMS Units220
Intake Pressure Sensor221
Throttle Position221
Important PIN No.# of ECU224
Function of Crank Speed Sensor226
Engine Temperature Sensor227
Measure Engine Temperature Sensor228
Throttle Position Sensor (TPS)229
Oxygen Sensor234
Injector236
Draining Cap of Injector238
Bleed the Air238
Drain the Gas238
Fuel Pump239
Fall down Sensor241
Isc(Idle Speed Control)243
ISC Initialization Timing246
Procedure of ISC Initialization247
EMS Fuses248
Main Purpose of EMS Fuses249
EMS Diagnostic250
Quick Diagnostic251
PC Diagnostic253
Quick Diagnostic Table256
Clear the Defect Code Memory257
EMS System Repairing Tool258
Pocket Tester Wiring259
Ignition Gauge260
Fuel Pressure Gauge261
Connect to the Vehicle262
General Electric Units263
Storage Light Controler264
Signal Flasher Relay (LED)265
Regulator266
Fuel Gauge267
Measure the Fuel Gauge268
Starting Relay269
Front Brake270
EMS Relays271
EMS Relays Wiring272
Control of Relays273
Measure the Relays274

PGO G-MAX 150 - Service Manual

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