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PGO G-MAX200 - User Manual

PGO G-MAX200
275 pages
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Manufactured by Motive Power Industry Co., Ltd

Table of Contents

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Summary

Preface

1.1 G-MAX 50 SPECIFICATION

1.2 G-MAX 125 SPECIFICATION

1.3 G-MAX 150 SPECIFICATION

1.4 G-MAX200 SPECIFICATION

1.5 G-MAX220 SPECIFICATION

1.6 G-MAX250 SPECIFICATION

II.Service information

(1)The operation notice

General guidelines for servicing and part handling during maintenance and repair.

(2)Locking torque value

Specifies torque values for various engine and chassis components for proper assembly.

(3)Lubrication instruction

Details oil types and quantities for engine lubrication and gearbox oil changes.

(4)Periodical Maintenance Table

Outlines scheduled maintenance checks and replacements based on time or distance.

(5)Troubleshooting

Provides diagnostic flowcharts for common engine starting, running, and performance issues.

3. Checking and Adjustment:

(1)Regular checking table

Lists routine inspection items for suspension, brakes, wheels, and chassis components.

(2)Battery

Covers battery inspection, recharging procedures, and electrolyte handling precautions.

(3)Clean air cleaner

Step-by-step guide for removing, cleaning, and reinstalling the air cleaner filter.

(4)The final reduction mechanism oil

Instructions for draining and refilling the final drive gear oil for the gearbox.

(5)Spark plug

Details on spark plug removal, inspection, cleaning, and specifications.

(6)Compression pressure measurement

Procedure for measuring engine compression pressure using a gauge.

(7)Ignition timing

Guidance on checking ignition timing using a timing lamp and related components.

(8)Throttle cables adjustment

Steps to check and adjust throttle cable clearance for proper operation.

(9)Idle adjustment

Procedure for adjusting engine idle speed and air/fuel mixture for stability.

(10)Front brake adjustment

Instructions for checking front brake lever clearance and fluid level.

(11)Rear brake adjustment

Steps to adjust the rear brake lever clearance for drum brakes.

(12)Tire

Guidelines for checking tire pressure, condition, and thread depth.

A. Plastic part dismantle Overview

B. G-MAX 50 Engine dismantle, maintenance, repair and assembly:

(1)Lubrication system

Details the lubrication system diagram and troubleshooting for the oil pump.

(2)Engine dismantling

Step-by-step instructions for removing the engine assembly from the chassis.

(3)Drive pulley, starter, clutch

Covers troubleshooting, measurement data, and dismantling procedures for CVT components.

(4)Cylinder and piston

Includes troubleshooting, operational notices, and detailed data for cylinder and piston inspection.

(5)AC Generator

Procedures for dismantling and installing the AC generator and flywheel assembly.

(6)Final transmission mechanism

Outlines troubleshooting, disassembly, checking, and assembly of the final drive.

(7)Crankcase, crankshaft.

Details troubleshooting, data, and procedures for dismantling and checking the crankcase and crankshaft.

(8)Carburetor, reed valve

Covers carburetor troubleshooting, dismantling, inspection, and cleaning procedures.

4. G-MAX 125;150 engine Dismantling, Maintaining, Repairing and assembling operation

(1) Lubrication system

Explains the lubrication system diagram and troubleshooting for oil pump components.

(2) Engine dismantling

Step-by-step guide for removing the engine assembly from the motorcycle chassis.

(3) Install Engine

Instructions for reinstalling the engine assembly, including checks and adjustments.

(4) Drive pulley, starter, clutch, driven pulley

Covers troubleshooting, measurement data, and disassembly for CVT components.

(5) Cylinder head and valve

Details troubleshooting, operational data, and procedures for cylinder head and valve servicing.

(6) Cylinder and piston

Provides troubleshooting, data, and inspection procedures for cylinder and piston components.

(7) AC generator

Instructions for dismantling and installing the AC generator and flywheel assembly.

(8) Final transmission mechanism

Covers troubleshooting, disassembly, checking, and assembly of the final drive.

(9) Crankcase, crank shaft

Details troubleshooting, data, and procedures for dismantling and checking the crankcase and crankshaft.

(10) Carburetor

Explains carburetor function, troubleshooting, dismantling, and adjustment procedures.

(D)Handle bar, front wheel, front brake and front fork:

A. Troubleshooting

Identifies common issues with handlebars, front forks, wheels, and front dampers.

B. Data

Provides standard and limit values for front brake pads, discs, and wheel swingness.

C. Change the speedometer cable:

Step-by-step guide for removing and installing the speedometer cable.

(D)Steering handlebar

Procedures for dismantling and assembling the handlebar components.

(E)Front wheel

Instructions for removing, assembling, and checking the front wheel and axle.

3.Front fork checking:

Guidance on inspecting the front fork for bends or cracks and replacing if necessary.

4.Front shock absorber checking

Procedures for checking the front shock absorber for damage or leaks.

5.Disassembling and assembling the front brake-disk.

Steps for removing and reinstalling the front brake disc assembly.

6.Checking the front brake-disk.

Specifications for checking front brake disc thickness and wear limits.

7.Checking the front brake-PAD.

Guidelines for checking front brake pad thickness and replacement criteria.

(E)Rear wheel, rear brake, rear damper:

A. Troubleshooting.

Identifies common issues with rear wheels, brakes, and dampers.

B. Data

Provides specifications for rear wheel swingness, brake lining, and pad thickness.

C. Disassembling and assembling the rear wheel.

Steps for removing and reinstalling the rear wheel assembly.

D. Checking the rear wheel

Procedures for checking rear wheel swingness and replacement limits.

E. Rear brake: (M2-50)

Details for checking rear brake hub and lining thickness for M2-50 model.

F. Rear absorber

Guidelines for checking rear absorber locking torque and oil leakage.

(F)Fuel supply

A. Troubleshooting.

Lists common fuel system issues preventing engine start or causing problems.

B. Fuel supply system diagram:

Illustrates the layout and flow of the fuel delivery system.

C. Dismantling and assembling Fuel Tank

Step-by-step guide for removing and reinstalling the fuel tank.

D. Oil tank disassembling diagram: (only available for M2-50)

Diagram showing the oil tank assembly for M2-50 models.

E.Dismantling and assembling oil tank: (only available for M2-50)

Procedures for removing and reinstalling the oil tank for M2-50 models.

V. Electric equipment:

(1)Troubleshooting

Detailed troubleshooting guide for electrical system issues like charging and ignition.

(2)Battery

Covers battery inspection, recharging procedures, and cable connection order.

(3)Recharge system

Explains the recharge system diagram and checks for AC generator and regulator.

(4)Ignition system

Guidance on checking spark plug, HV coil, and CDI unit for ignition system faults.

(5)Starting system

Procedures for checking wiring, starter motor, and starter relay for starting system issues.

6.2 Engine inspection data

CVT parts

Provides standard and limit values for inspection of Continuously Variable Transmission (CVT) components.

Camshaft & valves

Lists standard and limit values for inspecting camshaft, valves, and related components.

Piston & Cylinder inspection (200 CC)

Piston & Cylinder inspection (220 CC)

Crankshaft

6.3 Electric system

Carburetor model electric

General overview of electric systems in carburetor models.

General maintenance

Basic maintenance procedures for the electric system.

Engine Management System

Introduction to the Engine Management System (EMS) and its components.

6.5 Engine Management System (EMS)

EMS index

Table of contents for EMS sections: structure, units, and diagnostics.

Feature of PGO 2 nd-stage EMS

Highlights the key features and characteristics of the PGO 2nd-stage EMS.

EMS structure (A)

Diagram illustrating the components and connections within the EMS structure (Part A).

EMS structure (B)

Diagram showing the physical layout of EMS components on the vehicle (Part B).

EMS units

Identification and location of various EMS components on the motorcycle.

EMS diagnostic

Procedures for performing diagnostic checks and interpreting fault codes.

EMS system Repairing tool

Information on specialized tools required for EMS system diagnosis and repair.

EMS General Electric units

Overview of general electrical components related to the EMS.

PGO G-MAX200 Specifications

General IconGeneral
BrandPGO
ModelG-MAX200
CategoryScooter
LanguageEnglish

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